2TPH  20TPH tomato ketchup manufacturing equipment / tomato sauce processing plant

A "tomato sauce processing plant" is an industrial facility designed to convert fresh tomatoes into various types of tomato-based sauces, such as pasta sauce, ketchup, salsa, and pizza sauce. 

A turnkey project for a small to medium-sized tomato sauce plant would encompass the following components:

Project Feasibility and Planning:
• Market analysis to assess demand for different tomato sauce products, competition, and potential distribution channels.• Site selection, taking into account proximity to tomato suppliers, transportation links, utility infrastructure, and environmental regulations.• Preparation of a comprehensive business plan, including capital investment, operational costs, revenue projections, and marketing strategies.

Plant Design and Engineering:
• Customized layout design to ensure efficient material flow, worker movement, and adherence to food safety and hygiene standards (e.g., HACCP, GMP).• Detailed engineering drawings, equipment specifications, and utility requirements, covering: • Raw material receiving and handling (weighing, sorting, washing, destemming, crushing)• Juice extraction and clarification (pulping, screening, sedimentation, filtration)• Thermal processing (pasteurization, sterilization, evaporation)• Blending and seasoning (addition of spices, herbs, sugars, acids, stabilizers)• Packaging (filling, sealing, labeling, coding, palletizing)• Utilities and support systems (electricity, water, steam, compressed air, refrigeration)• Waste management (solid waste, wastewater, air emissions)

Equipment Supply and Installation:
• Procurement of high-quality, food-grade processing equipment, including crushers, pulpers, cookers, blenders, evaporators, fillers, and packaging machines.• Professional installation and commissioning of all equipment, ensuring seamless integration, optimal performance, and compliance with manufacturer guidelines and industry standards.

Utilities and Infrastructure:
• Construction or adaptation of buildings to accommodate processing lines, storage areas, laboratories, and office spaces.• Installation of electrical, plumbing, HVAC, and fire protection systems tailored to the tomato sauce plant's specific needs.• Implementation of waste management solutions, such as wastewater treatment, solid waste disposal, and air pollution control technologies.

Quality Assurance and Regulatory Compliance:
• Assistance in obtaining necessary permits, licenses, and certifications from local authorities and regulatory agencies, such as food safety inspections, product registrations, and environmental clearances.• Development and implementation of a robust Quality Management System (QMS), including Standard Operating Procedures (SOPs), sanitation programs, allergen management, and traceability systems.• Training of staff on Good Manufacturing Practices (GMPs), Hazard Analysis and Critical Control Points (HACCP), and other relevant food safety standards.

Training and Technical Support:
• Comprehensive operator training on the operation, maintenance, and troubleshooting of all installed equipment.• Ongoing technical assistance, including warranty coverage, spare parts supply, process optimization, and capacity expansion consultation.

A turnkey tomato sauce processing plant project offers investors a hassle-free approach to establishing a fully functional facility, minimizing project risks, reducing coordination efforts, and expediting time-to-market. 


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

Installing and debugging a tomato sauce processing plant involves a series of detailed steps to ensure that the equipment operates efficiently, meets food safety standards, and produces high-quality tomato sauce. Here's an overview:

Installation Process

1. Site Preparation:•Select a clean, well-drained site with proper utilities (electricity, water, gas, waste disposal).•Prepare the foundation for heavy machinery, ensuring it's level and can bear the load.

2. Equipment Delivery and Assembly:•Receive delivery of all components including receiving tanks, washers, peelers, cookers, pulpers, sieves, fillers, packaging machines, and storage tanks.•Assemble modular parts according to manufacturer instructions and using appropriate lifting gear.

3. Raw Material Handling:•Install conveyor belts and elevators for transporting tomatoes from reception to washing stations.•Set up grading and sorting systems to remove bad or unripe fruit.

4. Cleaning and Sanitation Systems:•Integrate CIP (Clean-in-Place) systems for automatic cleaning of process lines.•Ensure there are adequate facilities for manual cleaning and sanitation.

5. Processing Equipment:•Position and install steam peeling equipment, pulping machines, and cooking kettles with heat exchangers and temperature control systems.•Connect pumps, valves, and pipes between stages to transfer product fluidly.

6. Quality Control Stations:•Establish quality control labs for pH, Brix, viscosity, and color measurement.•Implement inline sensors where possible for real-time monitoring.

7. Product Treatment and Formulation:•Set up blending tanks for adding seasonings, spices, and other ingredients.•Configure pasteurization and sterilization equipment as required by the recipe and regulations.

8. Packaging Line:•Align conveyor belts, filling machines, capping devices, labeling machines, and sealing apparatus.•Install checkweighers, metal detectors, and X-ray machines for quality assurance.

9. Automation and Controls:•Program PLCs (Programmable Logic Controllers), SCADA (Supervisory Control and Data Acquisition) systems, and HMI (Human Machine Interface) panels to control and monitor the entire production process.•Configure alarms and interlocks for safety and efficiency.

Debugging and Testing

1. Electrical and Mechanical Checks:•Test all electrical connections, motors, and mechanical components for safety and functionality.•Calibrate instruments and sensors for accurate readings.

2. Process Validation:•Run tests on each piece of equipment independently to verify correct operation.•Conduct integrated runs through the entire line using water or simulated products before actual tomatoes.

3. Product Quality Assurance:•Analyze samples at various stages to confirm compliance with food safety standards and desired product attributes.•Optimize processing parameters based on test results.

4. Cleaning and Sanitization Verification:•Perform multiple CIP cycles and visually inspect cleaned surfaces to guarantee cleanliness.•Confirm sanitization levels through ATP swab testing or similar methods.

5. Line Efficiency Tests:•Measure cycle times, throughput rates, and reject rates to optimize the performance of the processing and packaging lines.

6. Alarms and Safety Interlocks:•Test all alarm systems and safety features to ensure they trigger appropriately in case of malfunctions or abnormalities.

7. Operator Training:•Train personnel on how to operate, maintain, and troubleshoot the new equipment.•Educate staff on hygiene protocols, GMP (Good Manufacturing Practices), and emergency procedures.

8. Documentation and Record Keeping:

•Document every step of installation and debugging, noting any adjustments made.

•Establish record keeping systems for traceability, maintenance logs, and regulatory compliance.After thorough installation and debugging, the tomato sauce processing plant should undergo a trial run using actual raw materials under close supervision. This will allow for final adjustments before moving into full-scale production. Regular maintenance, system checks, and continuous improvement initiatives are essential to ensure ongoing success and adherence to industry standards.


The products produced by tomato sauce processing plants usually include the following types:
1. Tomato sauce: This is the main product of tomato sauce processing plants. Tomato sauce is made from fresh or processed tomatoes through cooking, concentration, and seasoning processes. It has a rich tomato flavor and a rich mouthfeel, which can be used for seasoning, cooking, and consumption.
2. Tomato paste powder: Tomato paste powder is a powder product made by spray drying or freeze drying of tomato paste. It has a longer shelf life and a more convenient storage method, making it suitable for making instant drinks, seasonings, and instant noodles.
3. Tomato concentrate: Tomato concentrate is a product obtained by further concentrating tomato sauce. It has a higher concentration and a stronger tomato flavor, and is commonly used in making sauces, canned foods, and ready to eat products.
4. Tomato sauce: Tomato sauce is a type of sauce made from tomato sauce, with other seasonings and spices added. It can be used as dipping sauce, cooking sauce, or hamburger sauce, with a variety of uses and flavors.
5. Canned Tomatoes: Tomato sauce processing plants can also produce various canned tomato products, such as tomato slices, diced tomatoes, canned tomato sauce, etc. These canned products can be consumed directly or used to make various dishes and foods.

It should be noted that different tomato sauce processing plants may have different product combinations and characteristics, and the above is only the general product range. The specific product types and specifications may vary depending on the actual situation of different manufacturers.

 

Pre sales services