Tomato processing line full automatic tomato paste making machine
The fully automated tomato processing production line is a highly integrated system designed to automate the entire process from raw material processing to finished product packaging. This production line not only improves production efficiency, but also ensures consistency in product quality, and reduces human errors and labor costs. The following is an introduction to the main components and functions of a typical fully automated tomato processing production line:
1. Raw material reception and cleaning
Unloading equipment: used to unload freshly picked tomatoes from transportation vehicles.
Pre washing tank: preliminary removal of surface dust, dirt, and other impurities.
• Lift conveyor belt: Transport tomatoes to the next process.
Drum cleaning machine: Thoroughly clean tomato skins with a rotating brush.
Spray device: Rinse off residue with clean water.
2. Grading selection
Visual Sorting Machine: Using a camera to capture images and automatically classify them based on factors such as size and color.
Weight sorter: further screen products that meet the standards based on weight differences.
3. Peel and remove seeds
• Steam peeling machine: The skin is relaxed by brief heating and immediately cooled for easy peeling.
Seed crusher: Crush the fruit and separate the seeds and fiber parts.
4. Concentrated extraction
Preheater: Heat the material for subsequent operations.
Evaporator: Using multi effect evaporation technology to reduce moisture content and obtain high concentration juice or sauce.
• Condensed water recovery system: Collect and recycle the condensed water generated during the evaporation process.
5. Sterilization filling
Pasteurization machine: kills harmful microorganisms while maintaining the original flavor of the product through gentle heating.
Aseptic filling machine: Inject finished products into bottles or other containers in a sterile environment.
• Capping machine: Quickly and accurately seal containers to prevent contamination.
Labeling machine: Automatically paste product labels including brand name, ingredient list, and other information.
• Stacking robot: neatly stack the loaded boxes for shipment.
6. Warehousing and Logistics
Intelligent warehouse management system: Real time monitoring of inventory status to optimize storage space utilization.
AGV car: Unmanned vehicles are responsible for handling goods in the factory area to improve work efficiency.
7. Control system
PLC controller: As the core control unit, it manages the operation logic of the entire production line.
Human Machine Interface (HMI): Provides an intuitive operating interface for staff to view status and adjust parameters.
Data collection and analysis platform: records key indicators and supports remote monitoring, fault diagnosis, and other functions.
The above is the general composition of a complete fully automatic tomato processing production line. The actual configuration may vary depending on specific needs. Please let me know more details about your project (such as expected production volume, target market positioning, etc.) so that I can provide you with more accurate information.
Process flow
Raw material:
Fresh tomato--Washing--Sorting--Crushing--Pre-heating--Refining--Vacuum evaporation---Sterilizing--Drum filling (Finished product)
SALIENT FEATURES ARE:
High yield up to 90% of juice
Low energy cost.
Low temperature evaporation resulting improved quality of products.
User friendly.
Semi-automatic as well as fully automatic system available.
Machine list with Technical parameter
| No |
Code |
Equipment Name |
capacity |
Parameter |
| 1 |
A . fresh fruit(tomato) washing unit |
| 2 |
A-1 |
Clapboard elevator |
6T/h |
Height * width: 5500*1000, motor of 2.2KW and adjustable geared motor 20~100RPM, pitch 38.1 anti-corrosion roller chain |
| 3 |
A-2 |
air-blow washer and sorting machine |
6T/h |
stainless steel centrifugal pump ; oxygen pump; lifting speed can be adjustable,size of elevator and sorting roller platform is φ51, sorting table with guardrail, platform is made of stainelss steel anti-skidding checkered plates |
| 4 |
A-3 |
Clapboard elevator |
6T/h |
motor 2.2KW and speed reducer 20~100RPM, stainless steel plate, 4500 x 1000mm |
| 5 |
|
subtotal: |
|
|
| 6 |
B. Pulping unit |
| 7 |
B-1 |
Crusher |
6T/H |
SUS304, power is about: 18.5KW |
| 8 |
B-2 |
Tempoary storage tank |
1000L |
SUS304, single, installed on the top of the lamp hole mirror, CIP cleaning ball, bottom flange type outlet, with low level, four adjustable legs |
| 9 |
B-3 |
Screw pump |
6T/H |
Manual speed control, outlet pressure 0.6Mpa |
| 10 |
B-4 |
Tubular heat exchanger heater |
6T/H |
Food sanitation, tube heating , with the inlet steam pressure system, automatic control temperature with a outlet thermometer, |
| 11 |
B-5 |
Double beater |
6T/H |
SUS304, first mesh 0.8mm , secondary mesh 0.4mm, power 37KW |
| 12 |
B-6 |
Buffer storage tank |
1000L |
SUS304, single, circular, half open, bottom flange outlet, high and low level, pure water inlet |
| 13 |
B-7 |
Screw pump |
6T/H |
Manual speed control, outlet pressure 0.6Mp |
| 14 |
B-8 |
crusher platform |
|
carbon steel frame, stainless steel checkered plate, size: 5000mm×2500mm, central draining |
| 15 |
B-9 |
pulping operation platform |
|
Carbon steel bracket,stainless steel checkered plate, size:3500mm×2500mm, central draining |
| 16 |
|
Subtotal |
|
|
| 17 |
C .Evaporator and concentrating unit |
| 18 |
C-1 |
Buffer storage tank |
5000L |
SUS304, PU insulation, conical head, pull rod valve at bottom discharge , sealed manhole, ladder,high and low level, sampling valve, the top offset vertical mixing, anti-vortex plate, digital thermometer, CIP cleaning ball, adjustable support legs |
| 19 |
C-2 |
Centrifugal pump |
10T/H |
Food grade, mechanical seal, ABB motor, 36M lift |
| 20 |
C-3 |
Double-effect forced circulation evaporator |
4T/H |
SUS304, automatic PLC control, the British Spirax Sarco steam pressure regulating valve system, inlet temperature sensor, pressure sensor, tower water cooling. |
| 21 |
C-4 |
Batch storage tank |
5000L |
SUS304, single layer, digital thermometer, sampling valve, sealed manhole, ladder, top offset vertical mixing, high and low liquid level sensor, adjustable legs |
| 22 |
C-5 |
Rotor pump |
3T/H |
Food grade rubber seal, variable frequency speed regulation |
| 23 |
|
Subtotal |
|
|
| 24 |
D. Sterilizing and filling system |
| 25 |
D-1 |
Tube-in-tube
UHT sterilizer |
1T/H |
SUS304, Tube-in-tube type, automatic PLC control, tower water cooling , the British Spirax Sarco steam pressure regulating valve, sterilization temperature 110 ºC, 60S |
| 26 |
D-2 |
Filling machine |
1T/H |
|
| 27 |
|
Subtotal |
|
|
| 28 |
E CIP system |
| 29 |
E-1 |
Semi automatic single circuit CIP |
2T×3 |
SUS304 outer cladding, inner shell SUS316, 3000L acid and alkali tank, 3000L hot water tank, coil tube heating inside the tank, automatic temperature control, single circuit, United States of America concentrated acid and alkali adding system, with two 200L concentrated acid and alkali tank, 2pieces of centrifugal pump (20T/h, head of 24m) |
| 30 |
R |
CIP return pump |
20T/H |
Food grade, self-sucking, mechanical seal |
The following are some application cases about tomato sauce production lines, which demonstrate their practical applications in different aspects:
1. Large scale production
1.1 Case background
Client: A large food processing company in the United States
• Product: Classic Tomato Sauce
• Capacity: Daily production of 100 tons
1.2 Application Scenarios
Raw material reception: Receive a large amount of fresh tomatoes from the farm for preliminary cleaning and screening.
• Preparation: Peel and seed the tomatoes, cut them into small pieces.
• Cooking: Put the cut tomatoes into a pot, add water, salt, sugar, spices, etc., and cook.
• Concentration: Concentrate the cooked tomato juice to the desired concentration through an evaporator.
• Cooling: Cool the concentrated tomato sauce to the appropriate temperature.
• Filling: Fill the cooled tomato sauce into a bottle or bag.
Sealing: Seal the filled bottle or bag.
Quality inspection: Conduct quality inspections on finished products to ensure compliance with standards.
• Storage and transportation: Store qualified tomato sauce in the warehouse and arrange transportation.
1.3 Key equipment
Cleaning machine: used for cleaning tomatoes.
Peeling and Seed Removal Machine: Used for peeling and removing seeds from tomatoes.
Slicer: used for slicing tomatoes.
Cooking pot: used for cooking tomatoes.
Evaporator: used for concentrating tomato sauce.
Cooling system: used for cooling tomato sauce.
Filling machine: used for filling tomato sauce.
Sealing machine: used for sealing bottles or bags.
Quality inspection equipment: used for quality inspection of finished products.
• Refrigerated warehouse: used for storing finished products.
Transport vehicles: used for the transportation of finished products.
2. High end customized production
2.1 Case Background
Client: A high-end food brand from France
• Product: Organic Tomato Sauce
• Capacity: Daily production of 10 tons
2.2 Application Scenarios
Raw material reception: Receive fresh organic tomatoes from organic farms for preliminary cleaning and screening.
• Preparation: Peel and seed the tomatoes, cut them into small pieces.
• Cooking: Put the cut tomatoes into a pot, add organic salt, organic sugar, organic spices, etc., and cook.
• Concentration: Concentrate the cooked tomato juice to the desired concentration through an evaporator.
• Cooling: Cool the concentrated tomato sauce to the appropriate temperature.
• Filling: Fill the cooled tomato sauce into a glass bottle.
Sealing: Seal the filled bottle.
Quality testing: Conduct quality testing on finished products to ensure compliance with organic standards.
Packaging: Exquisite packaging design to enhance product quality.
• Storage and transportation: Store qualified tomato sauce in the warehouse and arrange transportation.
2.3 Key Equipment
Cleaning machine: used for cleaning tomatoes.
Peeling and Seed Removal Machine: Used for peeling and removing seeds from tomatoes.
Slicer: used for slicing tomatoes.
Cooking pot: used for cooking tomatoes.
Evaporator: used for concentrating tomato sauce.
Cooling system: used for cooling tomato sauce.
Filling machine: used for filling tomato sauce.
Sealing machine: used for sealing bottles.
Quality inspection equipment: used for quality inspection of finished products.
Packaging equipment: used for exquisite packaging of products.
• Refrigerated warehouse: used for storing finished products.
Transport vehicles: used for the transportation of finished products.
3. Seasonal production
3.1 Case Background
• Customer: A seasonal food producer in Italy
• Product: Seasonal specialty tomato sauce
• Production capacity: The daily production during the summer peak period reaches 50 tons, and during the winter trough period, the daily production reaches 10 tons
3.2 Application Scenarios
Market research: Conduct regular market research to understand consumers' preferences for seasonal products.
• Raw material procurement: Purchase corresponding characteristic raw materials according to seasonal changes, such as fresh tomatoes in summer and dried tomatoes in winter.
Product development: Based on market research results, develop seasonal specialty tomato sauce products.
Flexible production: Adjust the production line flexibly according to market demand to ensure efficient production.
• Promotional activities: Carry out various promotional activities during peak season to increase sales.
Inventory management: Reasonably manage inventory to avoid waste.
Quality inspection: Conduct strict quality inspections on finished products to ensure product quality.
3.3 Key Equipment
Cleaning machine: used for cleaning tomatoes.
Peeling and Seed Removal Machine: Used for peeling and removing seeds from tomatoes.
Slicer: used for slicing tomatoes.
Cooking pot: used for cooking tomatoes.
Evaporator: used for concentrating tomato sauce.
Cooling system: used for cooling tomato sauce.
Filling machine: used for filling tomato sauce.
Sealing machine: used for sealing bottles or bags.
Quality inspection equipment: used for quality inspection of finished products.
• Refrigerated warehouse: used for storing finished products.
Transport vehicles: used for the transportation of finished products.
4. Environmentally friendly production
4.1 Case Background
Customer: An environmentally friendly food brand from Canada
• Product: Environmentally friendly tomato sauce
• Capacity: Daily production capacity reaches 30 tons
4.2 Application Scenarios
Green raw materials: Choose organic and sustainable materials to reduce environmental impact.
Energy saving equipment: Adopting energy-saving production equipment to reduce energy consumption.
Wastewater treatment: Install a wastewater treatment system to ensure that wastewater meets discharge standards.
• Waste recycling: Establish a waste recycling mechanism to reduce the generation of waste.
Degradable packaging: Use biodegradable packaging materials to reduce plastic pollution.
Quality inspection: Conduct strict quality inspections on finished products to ensure product quality.
4.3 Key equipment
Cleaning machine: used for cleaning tomatoes.
Peeling and Seed Removal Machine: Used for peeling and removing seeds from tomatoes.
Slicer: used for slicing tomatoes.
Cooking pot: used for cooking tomatoes.
Evaporator: used for concentrating tomato sauce.
Cooling system: used for cooling tomato sauce.
Filling machine: used for filling tomato sauce.
Sealing machine: used for sealing bottles or bags.
Wastewater treatment system: used for wastewater treatment.
Waste recycling equipment: used for waste recycling.
Quality inspection equipment: used for quality inspection of finished products.
Success factors
Equipment selection: Choose high-quality equipment that is suitable for production needs.
Process optimization: Continuously optimize the production process to improve production efficiency and product quality.
Quality control: A strict quality control system ensures product quality at every stage.
Environmental protection: Take measures to reduce environmental pollution and achieve sustainable development.
Market research: Conduct regular market research to understand consumer needs and develop new products.
Employee training: Regularly train employees to improve their operational skills and safety awareness.
Tomato Juice Processing Key Operational Points
Fresh Tomato pretreatment
The system is including the cleaning and sorting of fresh tomatoes,crushing them into 3-5mm tomato pieces,and then preheating them through a tubular preheater.The selection and cleaning process is of great significance to the quality and stability of the final tomato juice.The preheating and crushing processes are important processes that affect the consistency of tomato juice and the yield of juice.There are two crushing methods:hot break and cold break.Due to the low temperature of the cold-breaking sauce,the endogenous enzymes(mainly pectin tertiary enzymes)are not completely inactivated.The pectin is enzymatically hydrolyzed into short chains,and the viscosity will be low,but the flavor and color are good.The hot break enzyme is inactivated thoroughly,the pectin is less damaged,the viscosity is good,the flavor and color are poor.
Tomato squeezing and juicing
Squeeze the crushed fruit pulp after heating,while removing the peel and seeds,it also adjusts the pulp particles.Generally,it can be operated by a screw juicer or a beater.The screw juicer squeezes the crushed pulp between the screw and the sieve to extract the juice,and the beater extracts the juice by impact,and the aperture of the sieve is about 0.4mm.The squeezing rate of good varieties of tomato juice is 75%-80%.
Tomato juice blending and seasoning
As a seasoning for tomato juice,we can add wine vinegar,table salt,white sugar,lemon juice,etc.
Degassing,homogenization and sterilization of tomato juice
In the process of tomato crushing and blending,the air is inevitably mixed in,so after the juice is squeezed and blended,the tomato juice needs to be deaerated.At the same time,in order to refine the pulp particles and increase the consistency,a homogenizer can be used to make the tomatoes have a smooth feel through homogenization.Tomato juice contains pulp,which makes it a relatively viscous liquid.Therefore,it needs to be sterilized before filling.The HTST sterilization process is usually used(90-95ºC for 40-60S).The sterilized tomato juice is orange-red,the sugar content is 4.3%,and the PH value is 4.4.
Filling and sealing of tomato juice
The containers used for tomato juice are metal cans,glass bottles or PET bottles.The pre-sterilized tomato juice is filled into a clean container.In order to prevent oxidation,it is necessary to quickly cool the sterilized tomato juice to 85-89ºC and fill it into the container immediately.To prevent oxidation of the product,this filling method is called hot filling.It should be sealed immediately after filling.
Secondary pasteurization and packing of the tomato juice
After the filling is completed,for the sake of safety,the tomato juice needs to be sterilized twice,and the filled container is transported to the pasteurization tunnel or retort for secondary sterilization.The sterilization process is 90-95ºC for 15-20min.Then use cooling water to quickly cool the temperature of tomato juice to below 35ºC for subsequent packaging.
We offer turnkey projects for tomato processing plants,include process concentrated tomato paste,tomato puree,tomato sauce,ketcup,tomato powder and other tomato products.
The process of customizing a tomato paste production factory involves multiple steps, from initial planning to final production. The following is the detailed customization process:
1. Requirement analysis and preliminary consultation
Project objective: Clearly define the goals you hope to achieve, such as production scale, product types (such as concentrated tomato sauce, seasoned tomato sauce, etc.), expected market, etc.
Budget evaluation: Determine the overall budget of the project, including equipment procurement, construction costs, operating costs, etc.
Regulatory requirements: Understand local food safety regulations, environmental standards, and other relevant laws and regulations.
2. Feasibility Study
Market demand analysis: Conduct research on the tomato sauce demand, consumption habits, taste preferences, etc. of the target market.
Technical feasibility: Evaluate whether existing technologies and processes can meet your production needs.
Economic benefit analysis: Conduct a return on investment analysis to ensure the economic feasibility of the project.
3. Design phase
Conceptual design: Based on the results of requirement analysis, propose a preliminary conceptual design plan.
• Detailed design:
Process flowchart: Design a complete process flow from raw materials to finished products, including raw material receiving, cleaning, crushing, preheating, evaporation, homogenization, sterilization, filling, etc.
Equipment layout diagram: Reasonable layout of various functional areas, such as raw material storage area, cleaning area, crushing area, evaporation area, homogenization area, sterilization area, filling area, packaging area, etc.
Pipeline system diagram: Design the layout of refrigerant, water, steam and other pipeline systems.
Equipment selection: Choose suitable processing equipment, such as:
Raw material receiving equipment: unloading platform, conveyor belt, etc.
Cleaning equipment: cleaning machine, peeling machine, etc.
Crushing equipment: crushers, pulping machines, etc.
Preheating equipment: preheaters, heaters, etc.
Evaporation equipment: Multi effect evaporator, thin film evaporator, etc.
Homogenization equipment: homogenizer, etc.
Sterilization equipment: high-temperature instantaneous sterilizer, etc.
Filling equipment: automatic filling machine, sealing machine, etc.
Packaging equipment: automatic packaging machines, labeling machines, etc.
Environmental Impact Assessment: Conduct an environmental impact assessment and submit it for approval by relevant departments.
4. Construction and installation
Site selection and land preparation: Choose a suitable geographical location for land leveling and foundation construction.
Construction: Construct the main structure of the factory building, including production workshops, storage areas, office areas, etc.
Installation of public facilities: Install systems for electricity, water supply, drainage, ventilation, fire protection, etc.
Equipment installation: The installation, debugging, and trial operation of the equipment are carried out by a professional team.
5. Establishment of Quality Management System
HACCP system: Implement Hazard Analysis and Critical Control Points (HACCP) system to ensure food safety.
GMP standards: Adhere to Good Manufacturing Practices (GMP) to ensure hygienic conditions during the production process.
ISO certification: Apply for and obtain relevant ISO standard certification to enhance the credibility of the enterprise.
6. Personnel training
• Operation training: Provide training to operators on equipment operation, maintenance, and other aspects.
• Safety training: Conduct safety production education to ensure that employees understand safety regulations.
Quality management training: Provide professional training to quality inspectors to ensure product quality.
7. Trial operation and optimization
Single machine debugging: Test the performance of each device one by one to ensure its normal operation.
Linkage debugging: Connect all devices together to perform linkage debugging of the entire production line, ensuring coordination and consistency in all aspects.
Simulated production: Conduct small-scale simulated production to test product quality and production line stability.
Problem rectification: Rectify and optimize the problems found during trial operation.
8. Formally put into operation
Full production: After confirming everything is normal, it is officially put into production.
Market promotion: Develop a marketing plan, establish sales channels, and start selling products.
9. Continuous improvement
Feedback collection: Collect customer feedback and market information to continuously improve products and services.
Technological innovation: Introducing new technologies and processes to improve production efficiency and product quality.
Management optimization: Conduct regular internal audits and continuously optimize management processes.
10. After sales service and support
• Equipment maintenance: Provide regular equipment maintenance and upkeep services.
• Technical support: Provide continuous technical support to solve problems encountered during the production process.
Customer Relationship Management: Establish good customer relationships and improve customer satisfaction.
Specific precautions
• Raw material quality: Select high-quality fresh tomatoes as raw materials to ensure the taste and quality of the product.
Temperature control: Strict temperature control is required during evaporation and sterilization processes to maintain the color and nutritional content of the product.
• Aseptic environment: The filling process should be carried out in a sterile environment to prevent contamination.
Formula development: Develop various flavors and types of tomato sauce products to meet the needs of different consumers.
Through the above steps, you can gradually complete the customization of a tomato sauce production factory that meets your needs. Each step needs to be carefully planned and executed to ensure the success of the project. If you have more specific needs or require further assistance, please let me know and I will provide you with more support.
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FAQ
1 ) Q: How can we visit your factory?
A: If you come from abroad, air to shanghai airport, then we can pick you up at airport.
2) Q: How do you ensure the quality of your products?
A: Our Company is a state owned enterprise with more than 16 years experience , strict operation policy is performed, advanced processing machines guarangtee the precision of all components, workers with operation license, parts get multiprocessing, transmission& electrical parts are of international famous brand. Series of test and inspection are done in the whole producing state.
3) Q: What payment methods your company accept?
A: We accept most of the payment methods , but mainly accept T/T, L/C at sight .
4) Q: How long is the warranty time for your products?
A: Our officially promised warranty time is 12 months after commissioning .
5) Q: I am new in this field,can you supply us turnkey services?
A: YES.We can supply all the system including Market Analysis/Product Analysis/Location Choice/Processing Flow Design/Equipment Layout Design/Building Design direction/Equipment mode selection/Equipment Manufacturing/Equipment Mounting/Equipment Debugging/Worker Training.
6) Q: What ' s the shipment terms and delivery time of your company?
A: Well, the delivery time depend on the quantity of your order. Usually is 20 days . For some customized machine 30 days is necessary.
7) Q: Can you supply OEM services?
A: Yes,we have our R&D team,and we have more than 400 workers with workshop area 75000 square meters.
8) Q: Do you give any Discount?
A: I will surely try my best to help you get those by the best price and good service at the same time.
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