Aseptic Tomato Paste Packaging Line

Tomato paste Aseptic line video

Aseptic Tomato Paste Packaging Line

The aseptic packaging process is optimal for making sterile and sustainable canning in the food industry. Tomato paste is one of the most essential products packaged with the aseptic method. Unlike disinfection or sterilization within the container, in aseptic, the product and package are sterilized independently by optimal processes in which microbial inactivation (enzyme brie) and degradation of the degrading factor are carried out simultaneously. Aseptic packaging is the process of filling commercial sterilized products in pre-sterilized containers. Containers are sterilized using one of four techniques: heat, mechanical, irradiant, or chemical.

Heat: hot air, steam, etc.
Mechanical: water, brushing, and so on.
Radiation: Infrared radiation, ultraviolet radiation, etc.
Chemicals: hydrogen peroxide, chlorine, etc.

Aseptic Tomato Paste Packaging Line machinery

Aseptic Tank:

Aseptic storage tank is an all-automatic device to buffer liquid foods such as milk, yogurt, rice pudding, sauces, and tomato paste. This device ensures the health of safe food and is used as an independent unit or as part of an integrated production and packaging line of tomato paste. Aseptic tanks are designed and manufactured in different types for products with various viscosity and volume. This system is used in aseptic filler machines after evaporation and before the final sterilization of tomato paste to increase production sequence, reduce crop loss, and improve efficiency.

Aseptic storage tanks are made using stainless steel and are usually mounted vertically and cylindrically, with plate bottoms or tapered shapes, equipped with cooling jackets. These tanks are created and checked to ensure their performance at predetermined pressure and under a vacuum. If the product is to be disassembled, the tanks may also be equipped with a stirrer installed at the bottom.

Before production starts, aseptic tanks are sterilized with steam and then cooled by circulating water in the cooling jacket. At this stage, sterile air enters the tank, which prevents the vacuum from forming and keeps the tank under pressure. During production, sterile air fills the area above the product surface of the tank. The tanks have a valve cluster module and a control panel that guides product flow, cleaning fluids, sterile air, and steam. During production, a vapor barrier protects from pollution.

Advantages of Aseptic Storage Tanks:

Filling and sterilizing a food product is a feature of aseptic storage tanks. Tanks also offer:

Flexibility in production planning by eliminating the necessity of returning additional sterilized products from aseptic filler to sterilizer.
Safety of storage between processing and packaging, minimizing any product loss.
Maintains a cleaning mechanism along with production monitoring to increase efficiency.
Use stimulants or cooling jackets to improve the safety and quality of custom processing.

Aseptic Sterilization Machine:

An aseptic sterilization system has the ability to sterilize liquid, beverage, and canned products such as tomato paste. The system can sterilize both packaging and product separately in several different ways. Aseptic sterilization, compared to another model sterilizer, has the following characteristics:

High heat, 90% Amy can use and reduce the temperature after heating and material exit.

2. The system is fully automatic and can automatically control the sterilization of the lobe and material.

It has precise and reliable control over the temperature required for sterilization and can automatically control the sterilizing temperature system, such as vapor pressure, flow, and material flow.
Aseptic sterilization system uses all techniques, including microwave, heating, high voltage discharge, and ultra-high pressure.
Aseptic sterilization in sanitation involves various steps that fill the product and contents in complete safety and health in the packaging and also take care of the packaging in all stages of distribution and distribution of goods:

Sterilize the products before filling.
Sterilize the package before filling.
Sterilization of aseptic installations before operation.
Sterilize the product after packaging until it is delivered to the consumer.

Aseptic Filling:

The aseptic filling machine is specifically designed to fill large volumes of aseptic bags, with the features of covering small floor space, high stability, and easy operation. Aseptic filler is widely used in liquid aseptic packaging, such as fruit juice, pulp, and jam. At room temperature, the product can be stored for more than one year, saving the cost and the risk of cold storage transportation. The aseptic filling machine can be directly connected to a sterilizing device, and UHT sterile products can be filled directly into an aseptic bag. An aseptic bag is a laminated aluminum plastic bag that can effectively separate sunlight and oxygen, maximizing the product quality.

The bag-in-box aseptic filling machine (BIB) is designed to fill aseptic bags prepared from craters with sterile liquids such as natural fruit juice, concentrate, vegetable juice, fruit syrup, fruit jam, magma drink, dairy, and pharmaceutical products.

Aseptic filler receives a drum or bucket through roller conveyors. Containers can be drums in one line, drums in one pallet (4 drums), and buckets. The operator puts the bag in the container, and the drum and the kit are automatically shipped to the filling piston. The prefabricated bag is manually placed under the aseptic chamber in a sterile environment saturated by maximum-pressure steam. The operator presses the start cycle, and the cap is automatically removed, and the bag full of the product is sterilized and then sealed. At the end of the filling cycle, the roller conveyor conveys the containers to the outlet.

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FAQs

Frequently asked questions about Tomato Paste production line

With what capacity should we start the production of tomato paste in aseptic packaging?

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 is the founder’s knowledge of the production process and familiarization with the relevant environment and the obstacles ahead, obtaining solutions to overcome the barriers, opportunities, and challenges ahead are experienced in the first year.
In the second phase of advertising, continuous presence, exploitation of opportunities, and offering sales offers with minimum profit and maximum circulation, distributors and sellers familiarize themselves with the product produced in the second year.
The third phase is diversification in products and reduction of business costs, reduction of production costs, and focus on creating a target market according to the data obtained over two years.
The fourth phase is an appropriate response to customer requests according to business and sales feedback, the establishment of internal and external representation, product production considering the environment and target market and customer order, and competitive product export.

Can the performance of the tomato paste production line be changed in aseptic packaging?

Yes – with changes in machines and adding machines related to the type of exploitation, it will be possible to produce fruit concentrate.

What kind of tomato products will succeed in the market?

As these issues have already been mentioned, some things should be considered for this purpose, some of which are:

Product supply and demand, easy access to raw materials, access to the sales and consumption market, and considering the production costs in proportion to the initial investment are all things that will be of great importance in determining the type of manufactured product.

What kind of assistance does SEAMERCO offer to the customer to set up a tomato paste factory in aseptic packaging?

Some of the services of Seamerco Industrial Group are as follows.

Consulting in the field of feasibility, location of the factory, market supply and demand analysis, financial and time estimates, and presentation of charts, machines, and equipment.
Factory design, including design and presentation of civil, architectural, electrical, and mechanical plans.
Implementation of infrastructure including septic tank, engine house, electricity, steam, water and water purification, wind.
Design and manufacture of machines or their overhaul.
Installation and operation of machines and trial production of products.
Training on the operation of machines, supply and maintenance of production line equipment and machines, formulation, periodic support and Or case, 18-month warranty, and ten years after-sales service.
Introduce the commercial and expert sales team and the final product to domestic and foreign merchants.

Where should we start?

Based on Seamerco’s proposed model for starting a production line, the path of entrepreneurs from the time of the formation of an idea to the production of the final product includes the following.

The first step is expert consultation and an initial feasibility study.
The second step is presenting a justification plan and obtaining an establishment license.
Third step: designing and manufacturing machinery.
Fourth step: Implementation of infrastructure and production line launch.
The fifth step is trial production of the product and obtaining an operating license.
The sixth step is obtaining health permits.
Seventh step: training and counseling.
Eighth step: final production, marketing, and sales of the product.