Automatic Tomato Paste Production line
Tomato paste is one of the most widely used food seasonings worldwide. As
The complete tomato processing line includes the following sections: unloading, washing, sorting, pre-heating, extraction, and evaporation.
This production line is capable of receiving and processing 50 to 1500 tons of fresh tomatoes per day, and the Brix of the produced tomato paste can be adjusted in the range of 24 to 36.
The separation section is designed so that the moisture of the waste remaining from the tomatoes is a maximum of 2%, and the amount of this waste will be less than 3.5%. The falling film technology in the evaporator allows for the complete preservation of the color, flavor, and aroma of the raw materials, producing tomato paste with the best texture.
The crushed tomatoes are get to 85-95°c in pre-heater then in 2 steps the tomato juice is concentrated (double-concentrated) in evaporators. The hot break processing is used for products with higher viscosity and denser, and Brix 28-30 like ketchup
The crushed tomatoes are get to 75°c in pre-heater and in 3 steps tomato juice is concentrated (triple-concentrated) in evaporators. The cold beak processing is used for production packing tomato paste and products with brix 36-38%.
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The tomato unloading and washing tank allows for the discharge of tomatoes in both basket and bulk forms, and the washing process occurs in two stages.
In the first stage, the tomatoes are soaked, and the dirt is removed. In the second stage (the second tank), a blower creates turbulence in the water, facilitating better washing of the tomatoes. Finally, with the pressure from the circulating water pump, the tomatoes are directed to the sorting conveyor.
After entering the sorting conveyor, the tomatoes are continuously moved forward by a rotating roller conveyor, and during this transfer, a final wash is applied using water compression nozzles. Workers stationed on the viewing platform separate unhealthy tomatoes and waste materials that are transported with the tomatoes, placing them on the waste return conveyor.
On both sides of the sorting conveyor, a metal platform is designed at a height of 1.5 meters to allow production line workers to have a clear view for inspecting and sorting the tomatoes.
To control and reduce water consumption in the tomato unloading, washing, and sorting conveyor sections, which are the highest water consumers in this system, physical water filters are responsible for separating leaves, stems, and dirt that accompany the tomatoes to the production line.
The physical water filters enable the recycling of water back into the washing cycle in the tomato unloading tank. Many factories use specialized purification systems or settling tanks (septic tanks) anticipated below the unloading tank to improve water conditions.
The primary tomato crusher is a device where tomatoes enter after passing through the sorting conveyor and are crushed.
The crusher features a hopper for collecting tomatoes from the input chute and a blade screw for transferring and crushing the tomatoes.
In this device, the tomatoes are divided into small pieces to facilitate their transfer. However, due to the potential clogging of the pre-heater pipes in the next machine, the tomatoes must be divided into even smaller pieces, which is carried out by the crusher.
The screw in this device is entirely made of stainless steel and coated to prevent blade corrosion during the crushing process.
To prevent pieces of tomatoes from getting stuck during the pre-cooking and separation stages, and to achieve higher efficiency in water extraction through the sieve, the crusher further reduces the size of the chopped tomatoes using a screw pump.
The secondary crusher performs the task of chopping the tomatoes into even smaller pieces after the primary crusher, allowing for easier movement through the pre-cooking pipes. This results in greater water yield and less pulp during the water extraction process with the turbo sieve.
After the initial chopping, the tomatoes are fed into the crusher under pressure from the screw pump (primary tomato crusher). The crusher utilizes counter-rotating gears and coated sharp blades to divide the chopped tomatoes into smaller pieces.
To achieve better water extraction from the chopped tomatoes and to deactivate enzymes, a pre-heater device is used.
The pre-heater consists of a series of material transfer pipes covered by a steam chamber. As the chopped tomatoes pass through these pipes, they are exposed to steam, which raises the temperature of the chopped tomatoes. This process not only deactivates enzymes but also facilitates the separation of water from the tomato pulp, including the skin and pulp, in the sieve.
The pre-cooking and enzyme deactivation of the chopped tomatoes in the pre-heater is accomplished using two methods: cold break and hot break. In the cold break method, the product temperature reaches between 65 to 75 degrees Celsius, while in the hot break method, it reaches 85 degrees Celsius.
The function of the tomato juice separator is to separate the juice from the skin, pulp, and residue of the tomatoes. The heated tomato juice from the pre-heater enters the separator, which contains specially designed meshes that, through rapid rotation around a central shaft and using centrifugal force, separate the tomato residue, including the firm tissue, seeds, and skin, from the pure tomato juice, which is then directed to the concentrators for final cooking.
The efficiency of this device is crucial to the overall process, and it depends on factors such as the rotation speed of the retort, the shape of the retort, the type of sieve, the variety of tomatoes, and the temperature of the pulp. Under normal conditions, the efficiency of this device is 95%.
The tomato juice obtained from the previous stages, which has been separated by the turbo sieve, is stored in a special cylindrical tank to continuously supply the required tomato juice for concentration.
The batch concentrator is used in the tomato paste production line, jam production line, and generally in all food industry production lines where a concentration process is required. Other important applications of the batch machine include its use in the concentration process for grape syrup and date syrup production lines.
This device, sometimes referred to as a vacuum cooking kettle, is designed with a double-wall structure and performs the cooking process through indirect heating and under vacuum conditions. The vacuum cooking mechanism results in a gentle cooking process, preventing burning and producing a product that preserves its original texture and higher quality.
The continuous concentrator, also known as a multi-effect evaporator, gradually introduces the tomato juice obtained from the extraction section of the production line through the vacuum created in the device. This process allows for two or three stages of concentration to reach the desired consistency, and the resulting paste is then extracted using special pumps.
The continuous concentrator, referred to as an evaporator, is a device used for concentration operations in food industry production lines. It is designed to carry out the concentration process in multiple stages, continuing until the product reaches the desired thickness. The most common applications of the continuous concentrator in the food industry include its use as a concentrating machine in tomato paste production lines, jam production lines, and fruit concentrate production lines.
SEAMERCO Industrial Group had the honor of participating in the launch of 170 domestic and 37 foreign factories so far.
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Technical experts at Simrko have compiled the most important questions arising from years of interaction with entrepreneurs active in the food production sector, aiming to find a model that can address such concerns. Based on the proposed model by Simrko for setting up a production line, the path for entrepreneurs from the inception of an idea to the final product includes the following steps:
Step One: Specialized consultation and initial feasibility assessment
Step Two: Providing a feasibility plan and obtaining establishment permits
Step Three: Designing and manufacturing machinery
Step Four: Implementing infrastructure and launching the production line
Step Five: Conducting trial production and obtaining operating permits
Step Six: Acquiring health licenses
Step Seven: Training and consulting
Step Eight: Final production, marketing, and selling the product.
The tomato paste factory should be divided into two sections: the first section is the production line, and the second section is the packaging line. Most of the machinery in the production section, such as receiving, sorting, dewatering, and concentration, can be placed outside the building in an open space, while the packaging section is entirely inside the buildings. Of course, everything depends on the production capacity, but generally speaking, it can be said that setting up a standard tomato paste factory requires 800 square meters of building and 3,500 square meters of land.
This production line can also produce tomato puree. However, the interesting point is that by adding an appropriate preparation section, the tomato paste production line can also be used to produce products such as fruit puree and date syrup and concentrate.
Tomato paste is one of the most widely used food seasonings worldwide. As
The tomato paste is a paste-shaped material produced if you cook tomatoes for
Tomato paste is one of the most popular food seasonings in the world,