What is Tomato Paste aseptic packaging?
Aseptic packaging is a process during which microorganisms are prevented from entering a
The canned bean production line includes the sections of bean preparation, pre-cooking (blanching), sauce preparation, packaging, and final cooking and sterilization. These steps can also be implemented for other legumes such as chickpeas and broad beans and even legumes such as green peas and … In fact, with a canned bean production line, the production of these products is also possible.
Simerco Industrial Group offers this production line with a daily capacity of 25,000 cans in a semi-automatic manner and a daily capacity of 50,000 cans per day in a fully automatic manner.
The most complex part of the canned bean production line is sterilization and final cooking, which is done by an autoclave. The high cost and sensitivity of autoclave operations have made this section one of the biggest concerns for manufacturers. By considering various solutions, Simerco has been able to provide an appropriate response to this concern of its customers.
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In the first step, the grains are emptied onto the sand belt. Due to the vibration and inclination of the belt of this device, the grains move forward and the soil and small aggregates pass through the grooves and are separated.
An elevator or lift is used to transport materials in different parts of this production line, such as delivering beans to the soaking tub, blancher, and filling hopper.
The beans are loaded into the soaking tanks by a lift and soaked in these tanks for a certain amount of time, depending on their type. A special valve is installed underneath the tub to change the water so that this can be done easily at specific intervals.
Inside the hopper of this machine, water is constantly circulating and the beans are poured into this hopper. The clean and soaked beans remain on the water and move towards the elevator, and the dirt, stones and waste settle and are removed from the tank. At this point, the clean beans reach the blancher for cooking.
This machine has a large cylindrical tank called a drum, which has several meshes on it through which hot water and steam flow. The beans soften when placed in this space, and so-called pre-cooking is performed. After being blanched, a shower of lukewarm water cools the beans, and finally the beans are directed towards sorting.
Before filling the can with beans and legumes, it is necessary to ensure the contents of the can. For this purpose, the cooled beans are poured onto an inspection belt and moved in front of the operator. The operators stand on the sides of the machine and inspect the beans to ensure that there are no bean shells or stones or debris left between the beans.
The operator removes the empty cans from the pallet and places them on the rotating tray of this machine. With each rotation, the rotating tray, with the help of the centrifugal force it creates, guides the cans to the side of the machine. The cans exit from an outlet built into one side of the tray and are placed on the conveyor belt of the next machine.
The cans must be sterilized before filling, by using nozzles to force steam into the empty cans. Eventually, the cans are dry and ready to be filled.
The beans are gradually placed on the bowl-type filling tray by the elevator. The filling tray has multiple bowls so that if there are beans on the tray, they are filled volumetrically. With each rotation of the tray, the beans are released into the bowls and poured into the empty can placed under the nozzle.
In the case of canned beans and mushrooms, the mushrooms must first be washed in special tubs that have air conditioners. These tanks are usually double-walled so that waste and sand are placed in the second wall. After soaking, the mushrooms are better washed by a blower that is responsible for air conditioning.
The mushrooms must be cooked before being filled into the can. This is done by a device called an industrial rotary cooking pot. The industrial cooking pot has two walls, the mushrooms are placed in the main tank and the steam flows through the second wall. In this way, the mushrooms are cooked with indirect heat.
After blanching, it is time to slice the mushrooms. To do this, the slicer device, with a vibrator and a groove on it, guides the mushrooms individually and parallel to the blades. Each device has multiple blades so that as the blanched mushrooms pass under the blades, the sliced mushrooms come out.
A formulation machine is used to mix and make sauces for beans and legumes. The formulation has one tank at the bottom and one or two tanks at the top. All of these tanks have a jacket (water vapor barrier) and a stirrer, with the difference that in the lower tank, the stirrer rotates at high speed to mix water, salt and other spices, but in the upper tanks the stirring speed is lower.
Two models of dispensers are used in canned food production lines: one is a shower dispenser that continuously pours the prepared sauce onto the ingredients inside the can, and the other is a pneumatic dispenser in which when the can is placed under the nozzles, the sensor sends a signal to the PLC and the device automatically stops the cans from passing and pours the sauce into them.
To remove the remaining air on the surface of the product inside the can, by passing the filled cans under the steam nozzles, the surface and internal temperature of the can increases, causing expansion and the air to escape from the can. If water vapor remains inside the can after the capping and cooling process in the autoclave, the water vapor turns into droplets and creates a vacuum.
The filled cans are transferred to the capping machine by a conveyor belt. When the sensor detects the can entering, a cap is placed on the rail and the can is guided by a screw on the pedal. At the same time, the can cap is placed on the body and when the pedal of the machine is raised, the can and the can cap are exposed to the sewing rollers. These rollers, with the neck around the can, form the edges of the cap in two stages (the first and second steps) and finalize the can seal.
Since the outer walls of the cans may become dirty during the sauce pouring stage, after the lid is sealed, the cans are washed again with hot water in this machine.
At the end of the process, the sealed cans are placed in an autoclave. This serves two purposes: the first is to finalize the contents of the can and the second is to sterilize it. If the autoclave is performed correctly, the product inside the cans will last for up to 24 months without the need for preservatives.
A jet printer is used to print production information, including the product’s manufacturing code in the factory, production date, expiration date, and product price. As the can is placed on the conveyor belt and passes under the nozzle, the jet printer detects its presence and automatically prints the desired information.
The cans are arranged by the operator on cardboard or short-edge plastic in multiples (12 or 16). Then, they are guided into the shrink pack by a front jack and wrapped in nylon. Inside the tunnel, the heat generated by the element forms the nylon and packs the cans.
SEAMERCO Industrial Group had the honor of participating in the launch of 170 domestic and 37 foreign factories so far.
Canned Legumes, Jam, Canned Fruit
Baked Beans
Canned Beans, Tomato Paste
Frequently asked questions about Canned Beans production line
In case of simultaneous exploitation of the canned beans production line, the type of exploitation and its production capacity should be determined. In general, 80% of non-meat canning machines are jointly operated. Only in the preparation section for cleaning and separation, initial cooking and filling, changes are made in the machine.
For example, to produce eggplant caviar, eggplant peeler, meat grinder, double-piston filling machine, rotary drum, and mushroom washing machine, mushroom blancher, and mushroom slicer should be added to the production line to produce canned beans with mushrooms.
A capacity that, in addition to justifying fixed and current costs, can introduce your product in the market.
The steps that are usually mentioned in standard phasing are:
The first phase: the founder’s understanding of the production process and familiarization with the relevant environment and the upcoming obstacles, obtaining solutions to overcome the upcoming obstacles, opportunities and challenges will be experienced in the first year.
The second phase: advertising and continuous presence and exploiting opportunities and providing sales offers with minimum profit and maximum circulation, distributors and sellers getting familiar with the product produced in the second year.
The third phase: diversity in products and reduction of business costs, reduction of production costs, focus on creating the target market according to the data obtained during these two years will be realized in the third year.
The fourth phase: appropriate response to customer requests according to business and sales feedback, establishment of internal and external representation, product production considering the environment and target market and customer order, competitive product export
Yes – Currently, many canned beans and legumes factories in Iran export most of the products for export to Afghanistan, Iraq, etc.
But it is necessary to study the food culture of those countries and consider the formulation of canned beans and legumes according to their taste.
By raising the quality of the final product and planning and setting goals and establishing representation and communication with foreign merchants, it is possible to export products according to the final price.
Yes, it will be possible to reduce the initial costs by changing the capacity and form of the production line. Cost reduction is generally done by two methods: reducing the capacity of machinery or buying second-hand machinery. Simerco company has considered various plans for the implementation of the canned beans and legumes production line, which includes industrial, workshop and overhauled types. Running a production line with overhauled machinery will usually reduce the initial investment by 40%.
For example, two-nozzle filling machines, fixed blanchers, and horizontal autoclaves are used in the low-capacity canned beans production line, which will reduce initial fixed costs by 50%.
The construction of a factory depends on the approach of the founder of the group in the way of marketing and selling the product (whether it is only a producer or a producer and seller). Larger sales are available with higher shipping costs. If the factory is far from the field of harvesting beans, the costs of supplying raw materials will be higher and access to the market will be better. But in some productions, the factory should be close to the field of harvesting beans, for example, to produce canned green peas, it is better to preserve them for less than 4 to 5 hours from the time of harvesting to the time of canning, otherwise the green peas will dry out and It is not suitable for canning.
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