What is Tomato Paste aseptic packaging?
Aseptic packaging is a process during which microorganisms are prevented from entering a
Tomato paste is one of the products that can be found in the food basket of every family, and considering the target market, it is offered in various packaging by producers. The most important types of packaging for this product are metal cans and glass jars.
The capacity of the tomato paste packaging line is measured by the number of cans and jars produced per day. This line has the ability to package between 15,000 to 50,000 products daily.
The pasteurization section of this line is designed to ensure the shelf life of packaged products in jars and cans for up to 24 months.
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The batch vaccum evaporator performs the dilution of the tomato paste on the packaging line.
After the paste is removed from the aseptic packaging and mixed with a specified percentage of water (depending on the Brix level of the packaging in the cans and jars), it must be re-cooked to prevent the water from separating from the paste or, in other words, from forming two phases. However, both the cooking time is shorter, and less vacuum is required.
After being drained into the storage tank and mixed with a specified percentage of water (usually 25 to 30 percent), the mixture is transferred to the batching concentration tanks by a mono pump. Once the tanks are filled, steam is introduced into the walls, and the pumps begin operating to create a vacuum. After a specified period, the dilution process of the final paste is completed, and the paste reaches the desired Brix level for packaging into containers, after which it is transferred to the next sterilization device.
Before the final filling and packaging of the tomato paste, it must be pasteurized.
The pasteurization of the paste at this stage is carried out for two purposes: to assist in hot filling (filling the product hot into the container to aid in exhaust) and to pasteurize the final product to reduce the microbial load before filling and increase the shelf life of the product.
The pasteurization device consists of transfer tubes for the paste, which are surrounded by steam tubes. This is done through both incoming and returning tubes to not only increase the duration of the pasteurization process but also to achieve a higher capacity of the product per hour.
Empty containers are removed from the pallet by the operator and placed on the rotating tray of this device. The rotating tray, with each turn, uses the centrifugal force it generates to guide the containers to the side of the machine. The containers exit from an outlet located on one side of the tray and are placed onto the conveyor belt of the next machine. This process is carried out for the continuous injection of containers into the packaging line.
It is suitable for various types of containers, including glass, cans, and PET, and the device can be adjusted according to the different dimensions of the containers.
Before the product is filled, the cans must be sterilized, which is done by the can sterilization machine, also known as the can washer.
Throughout the transfer path of the cans in the can washer, a steam pipe is installed so that when the cans are placed upside down during their transfer to the next machine (the filler), the compressed steam washes and sterilizes the inside of the cans. This process occurs multiple times as the cans pass over the steam outlet nozzle along the transfer path to ensure the cans are fully sterilized.
The rotary 8-piston filler has the capability to fill materials into various containers, including cans, glass jars, and PET bottles, for both thick and thin products.
In the design of rotary fillers, filling occurs without stopping the containers and is typically used for high-capacity packaging lines.
This machine allows for the filling of various products such as tomato paste, jams, different types of mayonnaise and ketchup, and diluted canned legume sauces.
By changing the size of the piston outlets, it is possible to fill different products into various glass containers with different openings and capacities, PET bottles in various shapes and sizes, and metal cans with differing openings and heights.
The metal can seaming machine performs the sealing of metal can lids onto the bodies of the cans based on the 1881 standard set by the National Standards Organization.
Common names for this machine include seamer, roller, simer, sealing, and capping. The operation of this machine is fully automated and does not require human intervention; the only action the operator needs to take is to fill the lid magazine, although automatic loading of the can lids into the machine is also possible.
Once the can enters the seaming machine, the sealing operation is carried out with precise and accurate functioning of the main components, including the entry star, automatic lid feeder, pedal, first roller, second roller, and exit star. To keep the components of this machine synchronized over long periods and with a capping speed of 80 to 200 cans per minute, all of them must be controlled by a single main mechanical axis.
Before the product is filled, the glass jars must be sterilized, which is done by the glass sterilization machine, also known as the glass washer.
Throughout the transfer path of the glass jars in the hot water washer, a hot water pipe is installed so that when the jars are placed upside down during their transfer to the next machine (the filler), the hot water washes and sterilizes the inside of the jars. This process occurs multiple times as the jars pass over the hot water outlet nozzle along the transfer path to ensure the jars are fully sterilized.
In many products, such as jams and certain sauces, the presence of water in glass jars or PET bottles exposes the product to mold growth and spoilage.
After washing the glass or PET containers, a heated air dryer is used to dry the hot water or steam present inside the containers.
This machine has a transport conveyor to move the containers, allowing the accumulated water inside the containers to be dried by warm air or the warm environment created during their transfer.
The glass capping machine is used to attach metal lids onto glass jars.
The automatic version of this machine features various heads to perform the capping of glass jars without operator intervention.
This machine is specifically designed for capping glass jars of various products such as tomato paste, whey, jams, olives, pickles, preserves, and more.
It can be adjusted for different glass jars with varying openings and diameters. Initially, this type of machine requires manual adjustments for a specific jar model with a desired opening, and thereafter, it does not require further adjustments as long as the jar’s opening and diameter remain unchanged.
The pasteurization tunnel carries out the final cooking and pasteurization processes for products after their final packaging.
Canned products in glass jars, metal cans, or PET bottles are directed to the pasteurization tunnel after being sealed, where the pasteurization operation is performed.
The mechanism of the pasteurization process in this machine is based on applying heat as the product passes through and the spraying of water at various temperatures onto the product.
Once the product enters the machine, it is transported by a conveyor belt through different zones with varying temperatures. Depending on the type of product, packaging, heat transfer mechanism, and microbial load, parameters such as the temperature of each zone and the duration of stay in that zone are adjusted.
In glass jar packaging, to ensure the final product is sealed by the manufacturing factory, a clear plastic label is used, which usually has the brand name printed on it.
The automatic sleeve applicator machine cuts a specially designed sleeve roll each time a jar passes under the sleeve applicator nozzle and places it over the sealed jar opening. Afterwards, the jar passes through a high-temperature sleeve tunnel along with a blower that shrinks the sleeve around the jar’s opening and lid. This process is done in such a way that it covers both the lid of the jar and part of the jar itself, indicating that the product has been sealed by its manufacturer.
The labeling machine applies labels to the bodies of products.
In many types of packaging, including glass jars, PET bottles, and cans, labels contain information about the factory, including the brand name, factory and headquarters address, contact information, a list of ingredients, usage instructions, standard and nutritional logos, barcodes, and promotional designs for the product.
The label design, tailored to the type of product and its information, is printed by the label manufacturer and provided to the factory in rolls. The produced roll is placed on the labeling machine, and each time a container passes in front of the optical sensor, one roll label is dispensed and applied to the container.
The jet printer is used to print production information on the body or lid of the final product.
Production information typically includes details such as the production date, expiration date, consumer price, and inventory or product codes.
Jet printers are available in laser, inkjet, or cartridge formats.
Each time a product passes under the printer nozzle, the desired information is printed on the product.
The jet printer has the capability to store product information in its memory, eliminating the need to re-enter this information each time.
The shrink pack machine wraps the final packaging of products that are arranged in multiples next to each other with shrink film or plastic.
The films placed over the packages are shaped and formed into the final packaging through the heat of the machine’s tunnel, preventing the products from shifting during transportation.
Typically, the shrink pack machine is one of the last devices used in the production line. After going through all stages of production and being prepared for storage in the warehouse, products are arranged in multiples (9, 12, 24) on a base made of cardboard or plastic to be wrapped and made ready for storage.
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Frequently asked questions about Tomato Paste Packaging Line
The technical experts at Simarco have gathered the most important questions arising from years of interaction with entrepreneurs active in the food production sector to find a model that addresses such concerns. According to Simarco’s proposed model for establishing a production line, entrepreneurs’ journey from the conception of an idea to the production of the final product includes the following steps:
The tomato paste factory can be divided into two sections: the production line and the packaging line. Most of the machinery in the production section, such as receiving, sorting, juicing, and concentration, can be placed outside in an open space, while the entire packaging section must be inside the buildings. Of course, everything depends on the production capacity, but generally speaking, to establish a standard tomato paste factory, about 800 square meters of building space and 3,500 square meters of land are needed.
This production line can also produce tomato puree. Interestingly, by adding an appropriate preparation section, the tomato paste production line can be utilized to produce other products, such as fruit purees, date syrup, and date concentrate.
Aseptic packaging is a process during which microorganisms are prevented from entering a
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Tomato paste is a versatile ingredient used in various cuisines worldwide due to