Description

The tomato processing line is exceptionally efficient in transforming fresh tomatoes into a diverse array of final products. Among these processes, the Tomato Sauce Production Line stands out for its ability to convert fresh tomatoes into tomato paste, which is then packaged in drums using aseptic bags. This complex procedure encompasses crucial stages such as receiving fresh tomatoes, washing, sorting, pulp extraction, concentration, sterilization, and ultimately, filling the product into aseptic bags within drums, resulting in premium-quality tomato paste ready for distribution.

Moreover, the tomato paste stored in aseptic bags within drums can undergo additional processing to create a variety of products including 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 various other packaging formats.

The processing capacity for fresh tomatoes can be tailored to meet a wide range of production needs, spanning from 60 tons per day to 4000 tons per day, offering flexibility to customers.
Clients have the option to select between hot crushing or cold crushing methods for the tomatoes, allowing them to align with their preferences and specific requirements.
The brix level of the final tomato paste is adjustable to meet customer specifications, typically falling within the optimal ranges of 28-30% or 36-38% for desired taste and consistency.
The tomato paste is meticulously packaged in aseptic bags within drums, ensuring a shelf life of up to two years under regular storage conditions, guaranteeing freshness and quality.
All materials utilized in the production process are food-grade, with main components being either SUS 304 or SUS 316, meticulously chosen to adhere to hygiene and safety standards specific to the operation.
Aside from aseptic bag filling, we offer a variety of packaging options such as metal cans, small sachets, stand-up pouches, and PET/PP containers to enhance convenience and versatility.
Moreover, any surplus fruit or vegetables generated during production can be repurposed into fertilizer, endorsing sustainable practices and reducing environmental impact by efficiently utilizing resources.

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, alongside the primary tomato processing machinery, the following auxiliary equipment is crucial:

• Steam Boiler: Provides heating steam for tomato steamers and other steam-dependent equipment.
• Cooling Equipment: Rapidly cools tomato products or machinery to regulate 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 meet environmental standards.
• Odor Control Systems: Manage odors generated during processing to maintain plant air quality.

These auxiliary components are vital for ensuring the efficient operation and quality control of tomato product processing lines. The specific auxiliary equipment needed will vary based on production scale, product variety, and processing technology requirements.