General Introduction of the whole line:
1. Tomato paste Processing Project Overview
| Raw material |
Fresh tomato |
| End product |
Tomato paste |
| Processing capacity |
From 20 T/day to 3000 T/day |
| Fruit consistency |
4-6Brix |
| Semi-finished products |
Tomato paste in aseptic bag 220L, 1000L |
| Product consistency |
28-30%, 30-32%, 36-38% |
| Output |
Can be calculated |
2. Tomato paste project description
Tomatoes are usually processed for paste and the processing line mainly includes five parts: fresh tomato receiving, pre-washing and sorting section; extracting section; concentrating section; pasteurizing or sterilizing section; aseptic filling section. It is mainly composed of discharge system, hydraulic convey system, bucket elevating, washing and sorting system, crushing system, pre-heating system, pulping and refining system, evaporating& concentrating system, sterilizing system, aseptic filling system. Tomato paste in aseptic drum can be further processed to ketchup, sauces, juices in tin can/bottle/pouch, etc.
3.Different package for tomato paste:
4. Process flow for tomato paste processing line:
5. Key machines' description per tomato paste processing line:
| Key machines |
Descriptions |
| Tomato receiving system |
Fresh tomatoes arriving at the plant in trucks are unloaded into a collection channel (also known as flume), a stainless steel or cement duct into which a quantity of water 3 to 5 times higher than the amount of unloaded tomato is continuously pumped. For example, a 10 tons/hour rate requires at least 30m3/hour of water. |
Bucket Elevator |
1. Smooth bucket structure against clamping fruits, suitable for tomato, strawberry, apple, pear, apricot, etc.
2. Running stably with low noise, speed adjustable by transducer.
3. Anticorrosive bearings, double sides seal. |
Tomato washing machine |
1 Used to wash fresh tomato, strawberry, mango, etc.
2 Special design of surfing and bubbling to ensure a through cleaning and lessening the damage to the fruit as well.
3 Suitable for many kinds of fruit or vegetables, such as tomatoes, strawberry, apple,mango,etc. |
| Tomato Crushing machine |
used to crush the tomato into pieces and for further pulping |
| Preheating machine |
Preheater increases the temperature of the tomato pulp by steam so that to soften the pulp and deactivate the enzymes.The temperature is regulated at 65-75°C for Cold Break processing or to 85-95°C for Hot Break processing |
| Tomato pulping machine (turbo refiner) |
The heated tomato pulp (fiber, juice, skin and seeds) is then conveyed to an extraction unit composed of two operating stations: a pulper and a refiner, equipped with two sieves having different sized meshes. The first sieve processes solid pieces up to 1 mm, while the refiner processes solid pieces up to 0.6 mm, depending on the type of sieve fitted on the machine (the manufacturer can supply sieves with different sized holes if necessary). Two products therefore come out of the extraction unit |
| Tomato pulp evaporator |
The unit is composed of tubular heater, vacuum evaporation chamber, condenser, pumps, PLC control system, valves, meters& gauges, operation platform, etc.
SS304 for main, Special structure (forced circulation) for concentration of tomato paste and precisely control the brix |
Tube-in-tube sterilizer for tomato paste |
1. The united is consisted of product receiving tank, superheated water tank, pumps, product dual filter, tubular superheated
water generate system, tube in tube heat exchanger, PLC control system, Control cabinet, steam inlet system, valves and sensors,
etc.
2. Incorporated Italian technology and conform to Euro-standard
3. Great heat exchange area, low energy consumption and easy maintenance
4. Adopt mirror welding tech and keep the smooth pipe joint
5. Auto backtrack if not enough sterilization
6. CIP and auto SIP available together with aseptic filler
7. Liquid level and temp controlled on real time |
Tomato paste aseptic filling machine |
1.Applicable to aluminum foil (Bag-in-drum&Bag-in-box)compound aseptic bag from 5L-220L.
2.Consisted of aseptic filling head,accurate electronic balance,PLC control system,steam barrier and protection system,operation
platform
3.Keep the filling chamber sterilized all the time by steam protection.
4.Full auto SIP and CIP available |
6.Related machines' pictures per tomato paste processing line:
7. Features of Tomato Processing Line
High yield up to 90% of juice
Low energy cost design because of patent heat-recovery system
Low temperature evaporation resulting improved quality of products.
User friendly, Siemens PLC HMI equipped.
Semi-automatic as well as fully automatic system available.
Both hot break and cold break systems available.
8. History tomato paste processing project site view :
When we talking about tomato paste processing, we mainly means in two ways:
1. tomato concentrate processing line
from ( fresh tomato) to (220L aseptic bag in steel drum)
including:
fresh tomato lifting system
cleaning system, sorting system
crushing system
preheating and enzyme deactivation system
pulping and refiningsystem
vacuum concentration system
sterilizing system and aseptic filling system
Knowledge about tomato paste:
we can help smallholder farmers make more money and smooth out the bumps in their incomes, since tomatoes that would otherwise rot will be used to make a value-add product.
The great thing about tomato paste is that it requires a lot of tomatoes to make. Usually, tomatoes contain approximately 95% water and 5% solids/sugars. Next time you reach for that can of tomato puree, check the concentration percentage. Most likely, the label will read "double concentrate" and the product will contain about 28% solid material (also known as Brix). So if you're making paste, you will need 5.6kgs of tomatoes with a 5% sugar content to make 1kg of tomato paste at 28% Brix.
There are two types of tomato paste - Hot Break and Cold Break - and they are used to make different end products. To make Hot Break (HB) paste, the fresh tomatoes must be heated immediately after chopping to a very high temperature (ranging from 85 to 100°C). Cold Break (CB) paste requires the fresh, chopped tomatoes to be heated at a lower temperature (ranging from 65 to 75°C). HB paste is usually used for ketchup and different types of tomato sauce requiring a 28-30° Brix, while CB paste is mainly used for triple concentrate paste at 36-38° Brix, packaged for domestic use.
Tomato paste processing facilities require a constant supply of fresh tomatoes, and it is vitally important that the tomato processing line constantly operates at maximum capacity. If capacity drops below a certain threshold, or even worse, if paste cannot be made all day every day, then production has to stop completely while all the machinery is cleaned. This can lead to a lot of wastage, both of the fresh tomatoes waiting in trucks outside, and the tomatoes in the facility in various stages of processing.
So what exactly has to happen to make tomatoes into paste? It isn't rocket science! In fact, it turns out that there hasn't been a whole lot of innovation around processing over the past four decades!
Receiving: Fresh tomatoes arrive at the plant in trucks, which are directed to the offloading area. An operator, using a special tube or boom, pipes a vast quantity of water into the truck, so that the tomatoes can flow out from the special opening at the rear of the trailer. Using water allows the tomatoes move into the collection channel without being damaged.
Sorting: More water is continuously pumped into the collection channel. This water carries the tomatoes into the roller elevator, rinses them, and conveys them to the sorting station. At the sorting station, staff remove material other than tomatoes (MOT), as well as the green, damaged and discolored tomatoes. These are placed on a reject conveyor and then collected in a storage unit to be taken away. In some facilities, the sorting process is automated
Chopping: The tomatoes suitable for processing are pumped to the chopping station where they are chopped.
Cold or Hot Break: The pulp is pre-heated to 65-75°C for Cold Break processing or to 85-95°C for Hot Break processing.
Juice Extraction: The pulp (consisting of fiber, juice, skin and seeds) is then pumped through an extraction unit composed of a pulper and a refiner - these are essentially large sieves. Based on customer requirements, these mesh screens will allow more or less solid material to pass through, to make a coarser or smoother product, respectively.
Typically, 95% of the pulp makes it through both screens. The remaining 5%, comprised of fiber, skin and seeds, considered waste and is transported out of the facility to be sold as cattle feed.
Holding Tank: At this point the refined juice is collected in a large holding tank, which constantly feeds the evaporator.
Evaporation: Evaporation is the most energy-intensive step of the whole process - this is where the water is extracted, and the juice that is still only 5% solid becomes 28% to 36% concentrated tomato paste. The evaporator automatically regulates juice intake and finished concentrate output; the operator only has to set the Brix value on the evaporator's control panel to determine the level of concentration.
As the juice inside the evaporator passes through different stages, its concentration gradually increases until the required density is obtained in the final "finisher" stage. The entire concentration/evaporation process takes place under vacuum conditions, at temperatures significantly below 100°C.
Aseptic Filling: Most facilities package the finished product using aseptic bags, so that the product in the evaporator never comes into contact with air until it reaches the customer. The concentrate is sent from the evaporator directly to an aseptic tank - it is then pumped at high pressure through the aseptic sterilizer-cooler (also called a flash cooler) to the aseptic filler, where it is filled into large, pre-sterilized aseptic bags. Once packaged, the concentrate can be kept up to 24 months.
Some facilities choose to package their finished product under non-aseptic conditions. This paste must go through an additional step after packaging - it is heated to pasteurize the paste, and then kept under observation for 14 days before being released to the customer.
The process of creating tomato paste is energy and capital intensive. So next time you reach for that bottle of ketchup or that slice of pizza, you now know a little more about how it got to the dining table!
2.
Ketchup packing production line
from (tomato paste concentration) to ( small package, in sachet/ can/ botle etc.)
The extraction pump - formulations tank - sterilizing machine - can (bottle) washing machine - filling machine - capping machine (Capper) - tunnel spray sterilizing machine - drying machine - printer - packing
Flowchart:
Kind reminder to dear customer:
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please kindly understand that the tomato paste production line is a highly customized product. Our company is capable to design a processing line with capacity 10T-1500T per day. The machine configuration also will be varied based on the automation degree and the final products type you want to get.Therefore,If you need a quotation proposal from us, please contact our staff and offer the following data to serve you better:
1.What's the estimated capacity? Namely, How many fresh tomatoes you plan to process per day?
2.What will be the final package of your tomato paste? in drum, in tinplate or in pouch or in bulk?Will your products facing wholesale market or retail market?
3.When and where you want to start this project?
4.Will this project be cost-oriented or quality-diven?
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About Us:
Our company is the first company to manufacture complete food&beverage processing line in China and we are keeping leadership position in the tomato paste processing line for 30 years since 1986 when China introduce technique from Italy/German and start to manufacture.Till now, we have set up 46 tomato processing factory in domestic and oversea market.
We has independent intellectual property rights of several equipment, including: large vacuum evaporation concentrating equipment (1000L-60000L/H), large sterilization equipment (tube and tube in tube type 1T/H-50T/H), large drying equipment (water evaporation quantity 100-10000T/H), aseptic filling equipment, and many advanced pre-treatment equipment for different fruits. Among them, the concentrated equipment for juice and jam, with its high performance and ultra-low temperature , has gained high reputation in this industry; And large tube-in-tube sterilization equipment have gain major breakthrough in energy saving, saving 30% energy compared with the industry standard, which has owned the national patent (Patent No.: ZL 201120565107.2); Various types of advanced juicing and beating equipment have been ranking first for continuous 7 years regarding their quality and sales volume.
We are the best choice for tomato sauce processing in Turnkey Solution!
Thoughtful After-sale services:
1). We make accurate factory layout design according to customer's factory size; if the customer needed, we could make workshop design.
2). After receiving firm order and down payment, we start to apply for the Visa to your country immediately; while the machines arrives your factory, our engineers are ready to start for the commissioning service.
3). 1-2 of our engineers will go to your factory to install and adjust the processing line to realize normal production at shortest time.
4). Our engineers have responsibility to teach the workers how to operate, clean, maintain and repair all the machines, until the workers could well operate the processing line.
5). Our engineers can provide basic formula for the production, and help the customer to produce good quality food according customer's detailed formula
6). It normally costs 10-14 days for the commissioning service, and we supply 1 year guarantee from the date of completion of commissioning service.
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Contact Us:
To get more information of tomato sauce production line, please feel free to contact our engineer:
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