Description

The tomato processing line excels in transforming fresh tomatoes into a diverse range of final products. Among the most popular processes is the Tomato Sauce Production Line, which converts fresh tomatoes into tomato paste aseptically packaged in drums within aseptic bags. This thorough process involves key stages such as receiving fresh tomatoes, washing, sorting, pulp extraction, mixture concentration, sterilization, and ultimately filling the product into aseptic bags within drums, resulting in high-quality tomato paste ready for distribution.

Furthermore, the tomato paste in aseptic bags within drums can undergo further processing to produce various products like tomato ketchup, sauces, and juice. These products can be conveniently packaged in sachets, stand-up pouches, metal cans, PP containers, bottles, gable top cartons, and a variety of other packaging formats.

• The processing capacity for fresh tomatoes is customizable, ranging from 60 tons per day to 4000 tons per day to meet varying production needs.
• Customers can choose between hot crushing or cold crushing processes for the tomatoes, depending on their preferences and specific requirements.
• The brix level of the final tomato paste can be adjusted to align with customer specifications, typically falling within the ranges of 28-30% or 36-38% for optimal taste and consistency.
• The tomato paste is carefully packaged in aseptic bags within drums, ensuring a shelf life of up to two years when stored at regular temperatures, guaranteeing product freshness and quality.
• All materials used in the production process are food-grade, with the primary materials being either SUS 304 or SUS 316, carefully selected based on the unique demands of the operation to maintain hygiene and safety standards.
• In addition to aseptic bag filling, we provide diverse packaging options such as metal cans, small sachets, stand-up pouches, and PET/PP containers for added convenience and versatility.
• Furthermore, any waste fruit or vegetables generated during the production process can be repurposed into fertilizer, promoting sustainable practices and minimizing environmental impact through efficient resource utilization.

Advantages

The Tomato Sauce Production Line from Shanghai Gofun machinery company is running with high effective, water saving, high extracting rate, safety quality control for final product, safety control for operators, etc.

Flowchart

FRESH TOMATO ⇒ CONVEYOR ⇒ WASHING ⇒ SORTING ⇒ CRUSHING ⇒ PREHEATING ⇒ PULPER & REFINER ⇒ EVAPORATING ⇒ STERILIZING ⇒ ASEPTIC FILLING ⇒ STORAGE OR BLENDING

The Tomato Production Line has been enhanced with a focus on optimizing the labor-intensive task of unloading fresh tomatoes from trucks upon delivery. An innovative discharge platform has been specially designed for this purpose. This platform, equipped with water guns, efficiently unloads tomatoes from trucks, transports them to the processing line, and performs pre-washing of the fresh tomatoes, streamlining the initial stages of production.

Key Components of the Tomato Sauce Production Line:

Discharge Platform with Water Guns:
The discharge platform, featuring water guns, effectively unloads and conveys fresh tomatoes from trucks to the processing line while facilitating pre-washing.
Elevator/Conveyor System:
This system is pivotal in transferring fresh tomatoes from external delivery points into the processing facility.
Washing:
Comprehensive washing of fresh tomatoes pre-crushing is vital. Bubble washing and spray washing machines are employed for this purpose. Additional washing phases can be integrated for stringent cleanliness standards, utilizing techniques like ultrasonic and ozone cleaning for enhanced effectiveness.
Sorting:
After washing, manual visual inspection is conducted to remove any substandard tomatoes.
Crushing:
The crusher operates at 1470 r/min to ensure thorough crushing of fresh tomatoes.
Preheating:
The pre-heater elevates the product's temperature post-crushing, typically adjustable between 45°C to 85°C. This step enhances juice extraction rates and preserves the color and flavor of the final tomato paste.
Pulper and Refiner:
These machines operate at 1470 r/min, utilizing centrifugal force and screens for refining. A dual-stage configuration with varying screen sizes is commonly utilized.
Evaporation:
A Forced Circulation Vacuum Evaporator concentrates the tomato paste under vacuum and low temperatures, retaining taste and nutrients and achieving paste with brix levels of 28-30 and 36-38.
Sterilization:
Tube-in-tube type sterilizers are employed for paste sterilization. The temperature and holding time are adjustable, typically heating the paste to around 115°C for 30 seconds before rapid cooling to preserve taste and nutrients.
Aseptic Filling:
An aseptic filling machine functions within a closed cycle system with the sterilizer, ensuring an aseptic environment through steam for cavity sterilization.
Storage or Blending:
The processed tomato paste can either be stored for later use or directed to blending processes as needed.

In an industrial ketchup production line, along with the primary tomato processing equipment, the following auxiliary equipment may be essential:

• Steam Boiler: Provides heating steam for tomato steamers and other steam-requiring equipment.
• Cooling Equipment: Rapidly cools tomato products or machinery to regulate processing temperatures.
• Pumps and Conveyors: Transport tomato pulp, juice, etc., between processing equipment.
• Steam Sterilizers: Steam sterilize containers, pipes, etc., ensuring product hygiene before filling.
• Packaging Machinery: Includes automatic packaging and sealing machines to package finished tomato products.
• Water Treatment Systems: Treat processing wastewater to meet environmental regulations.
• Odor Control Systems: Manage odors generated during processing to maintain plant air quality.

These auxiliary components are crucial in tomato product processing, ensuring the production line runs smoothly and maintains product quality. The specific auxiliary equipment necessary will vary based on production scale, product variety, and processing technology requirements.