Production line of tomato puree Tomato ketchup making machine making machines tomato cans

Production line of tomato puree Tomato ketchup making machine making machines tomato cans

A tomato puree production line is a sophisticated industrial process that transforms fresh tomatoes into high-quality tomato puree. The entire manufacturing process typically involves the following stages:

1. Receiving and Sorting: The process starts with receiving raw, freshly harvested tomatoes at the factory. They are then sorted to remove any spoiled or unripe fruits.

2. Washing and Destemming: The selected tomatoes are thoroughly washed to remove dirt, dust, and other impurities. A destemmer machine is used to detach stems and leaves from the tomatoes.

3. Crushing and Pulp Extraction: Tomatoes pass through crushing equipment such as hammer mills or pulpers to break them down into a slurry. This step also separates some of the skin and seeds from the pulp.

4. Preheating: The crushed mixture is preheated to initiate enzymatic inactivation and facilitate better extraction of juice and color.

5. Juice Extraction: The tomato pulp goes through a series of presses or centrifuges for efficient separation of the juice from the solid waste (skins, seeds, and pulp).

6. Evaporation and Concentration: The extracted juice is heated under vacuum conditions in an evaporator to reduce its water content, increasing its concentration to form a thick puree.

7. Pasteurization and Sterilization: The concentrated tomato puree undergoes pasteurization to eliminate harmful bacteria and extend shelf life. Depending on the product's specifications, this can be done using direct steam injection, plate heat exchangers, or UHT (Ultra High Temperature) processing.

8. Homogenization: To ensure a smooth texture and consistent quality, the puree may be homogenized, which breaks down any remaining lumps and emulsifies the fat content.

9. Seasoning and Standardization: At this stage, the puree is standardized for acidity, Brix levels, and flavor by adding ingredients like salt, sugar, or spices as per the recipe.

10. Cooling and Storage: The processed tomato puree is rapidly cooled and stored in temperature-controlled tanks before packaging.

11. Filling and Packaging: Using automated filling machines, the cooled puree is filled into cans, jars, pouches, or other containers, then sealed and labeled according to industry standards and regulations.

12. Quality Control: Throughout the entire production line, there are stringent quality control measures in place to monitor critical parameters such as pH, viscosity, color, and microbial activity, ensuring the final product meets all safety and quality standards.

Modern tomato puree production lines often feature advanced automation, including PLC controls and robotics, for increased efficiency, precision, and food safety.

Tomato juice processing plant high lights

1. Sustainable Raw Material Handling: A state-of-the-art tomato juice processing plant begins with efficient raw material management, often sourcing tomatoes from local farms or trusted suppliers. The facility may feature automated systems for sorting and grading tomatoes based on size, ripeness, and quality.

2. Advanced Washing and Pre-processing: High-tech washing equipment uses minimal water while effectively removing dirt and contaminants. Cutting-edge peeling and dicing machines ensure precise sizing to optimize juice extraction efficiency.

3. High Yield Extraction Technology: The heart of the plant houses powerful and efficient juice extractors that can handle large volumes while maximizing yield and preserving the natural taste and nutritional value of the tomatoes.

4. Ultra-Filtration Systems: Utilizing advanced filtration technology such as membrane ultrafiltration, which separates solids, seeds, and pulp from the liquid, resulting in a clear and smooth tomato juice without compromising flavor or nutrients.

5. Customizable Blending & Flavoring: In-house blending capabilities allow for creating a variety of tomato juice products with different flavor profiles by adjusting the sugar content, adding spices, herbs, or other ingredients according to market preferences.

6. Precision Pasteurization: Using either traditional heat pasteurization or more innovative methods like high-pressure processing (HPP) to ensure product safety while maintaining freshness and minimizing nutrient loss.

7. Automated Filling & Packaging: Modern filling lines are capable of bottling or canning tomato juice at high speeds with precision dosing. They incorporate advanced technologies for cap sealing, labeling, and coding to meet strict food safety regulations.

8. Quality Control & Traceability: Comprehensive quality control measures include real-time monitoring of pH, Brix levels, color, and microbial activity throughout the production process. Additionally, robust traceability systems track each batch from farm to shelf, ensuring compliance and consumer confidence.

9. Energy-Efficient Operations: Sustainable practices are integrated into the plant's design, including energy-efficient lighting, HVAC systems, and waste reduction strategies. Some plants may also employ renewable energy sources like solar power to minimize their environmental footprint.

10. Flexible Production Capacity: The plant is designed with scalability in mind, allowing for adjustments in production volume to accommodate seasonal fluctuations in tomato availability or changes in market demand.

Overall, a modern tomato juice processing plant combines cutting-edge technology, stringent quality standards, and environmentally conscious practices to produce top-quality tomato juice products.

The process of installing and debugging a tomato juice processing factory involves multiple stages to ensure correct equipment installation, smooth system operation, and product quality compliance. The following are the main steps:

1. Planning and on-site preparation: • Conduct detailed planning and layout design based on the factory scale and production process requirements Ensure that the construction site is level and complete the preparation work for the connection of water, electricity and other infrastructure.
2. Equipment installation: According to the design plan, the equipment for each link of raw material reception, cleaning, crushing, juice extraction, filtration, sterilization, blending, filling, sealing, packaging, and automated conveying should be in place one by one Accurate positioning and stable installation of large-scale equipment such as juicers, sterilization kettles, filling lines, etc.
3. Pipeline and circuit connection: • Connect all material transportation pipelines, compressed air pipelines, and power lines between equipment to ensure smooth material flow and safe and reliable electrical control systems.
4. Equipment individual debugging: • Conduct independent startup debugging on each device, including but not limited to operational performance testing, sensitivity inspection of control systems, and verification of safety protection functions.
5. Linkage debugging: After the individual equipment debugging is normal, conduct a linkage test of the entire production line, simulate the actual production process, ensure that the coordination between various links is correct, and the production capacity meets expectations.
6. Process parameter optimization: Adjust various process parameters (such as temperature, time, pressure, etc.) according to the actual trial production situation to achieve the best tomato juice extraction rate, color, taste, and nutritional value.
7. Quality control and testing system settings: • Install and debug online or offline quality testing equipment, such as turbidity meters, pH meters, sugar meters, etc., to ensure product quality meets food safety and enterprise standards.
8. Employee training: • Provide comprehensive training to operators to familiarize them with the operation methods, maintenance points, and emergency response procedures of new equipment.
9. Acceptance of Environmental Protection Facilities: • Acceptance of whether environmental protection facilities such as wastewater treatment, exhaust gas emissions, and noise control meet national environmental standards, ensuring green and environmentally friendly production processes.
10. Overall operation test and acceptance: Conduct a certain period of continuous production test, collect data for analysis, and evaluate the stability and reliability of the entire tomato juice processing production line.

After strict operational testing and confirming that all indicators are qualified, relevant departments are organized to conduct the final acceptance of the project. Through the careful implementation of the above steps, a complete tomato juice processing factory can be successfully put into production and operation.