Description

The tomato processing line is highly efficient in converting fresh tomatoes into a wide range of final products. Among these processes, the Tomato Sauce Production Line stands out, as it turns fresh tomatoes into tomato paste that is packaged in drums using aseptic bags. This intricate process includes key stages like receiving fresh tomatoes, washing, sorting, pulp extraction, concentration, sterilization, and ultimately, filling the product into aseptic bags within drums, creating high-quality tomato paste ready for distribution.

Furthermore, the tomato paste stored in aseptic bags within drums can undergo further processing to produce various products such as 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 range 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 undergone enhancements primarily focused on optimizing the labor-intensive task of unloading fresh tomatoes from delivery trucks. A specially tailored discharge platform has been developed for this specific purpose. Equipped with water guns, this platform efficiently unloads tomatoes from trucks, transports them to the processing line, and conducts initial washing of the fresh tomatoes, thereby boosting the efficiency of the initial production phases.

Key Components of the Tomato Sauce Production Line:
Discharge Platform with Water Guns:
The discharge platform, featuring water guns, efficiently unloads and transfers fresh tomatoes from trucks to the processing line while facilitating preliminary washing.

Elevator/Conveyor System:
This system plays a crucial role in moving fresh tomatoes from external delivery points into the processing facility.

Washing:
Thorough washing of fresh tomatoes before crushing is essential. Bubble washing and spray washing machines are utilized for this purpose, with options for additional washing phases incorporating techniques like ultrasonic and ozone cleaning for heightened cleanliness standards.

Sorting:
Following washing, manual visual inspection takes place to eliminate any substandard tomatoes.

Crushing:
The crusher operates at 1470 r/min to ensure complete crushing of fresh tomatoes.

Preheating:
The pre-heater raises the product's temperature post-crushing, typically adjustable between 45°C to 85°C, enhancing juice extraction rates and maintaining the color and flavor of the final tomato paste.

Pulper and Refiner:
Operating at 1470 r/min, these machines use centrifugal force and screens for refining, often employing a dual-stage configuration with varying screen sizes.

Evaporation:
A Forced Circulation Vacuum Evaporator concentrates the tomato paste under vacuum and low temperatures, preserving taste and nutrients while achieving paste with brix levels of 28-30 and 36-38.

Sterilization:
Tube-in-tube type sterilizers are used for paste sterilization, with adjustable temperature and holding time, typically heating the paste to around 115°C for 30 seconds before rapid cooling to retain taste and nutrients.

Aseptic Filling:
An aseptic filling machine operates within a closed cycle system with the sterilizer, maintaining an aseptic environment through steam for cavity sterilization.

Storage or Blending:
The processed tomato paste can be stored for future use or directed to blending processes as required.

In an industrial ketchup production line, in addition to the primary tomato processing machinery, the following auxiliary equipment plays a vital role:

Steam Boiler: Supplies heating steam for tomato steamers and other steam-dependent equipment.
Cooling Equipment: Quickly cools tomato products or machinery to control processing temperatures.
Pumps and Conveyors: Transport tomato pulp, juice, etc., between processing machines.
Steam Sterilizers: Steam sterilize containers, pipes, etc., ensuring product cleanliness before filling.
Packaging Machinery: Includes automated packaging and sealing devices for packaging finished tomato products.
Water Treatment Systems: Treat processing wastewater to adhere to environmental standards.
Odor Control Systems: Manage odors produced during processing to uphold plant air quality.
These auxiliary components are essential for the smooth operation and quality maintenance of tomato product processing lines. The specific auxiliary equipment required will vary depending on production scale, product diversity, and processing technology needs.