Tomato processing plant
We offer automatic and semi-automatic tomato processing equipment. Tomato ketchup plant , tomato paste, tomato powder, and tomato paste are common forms of tomato processing.
The capacity of the equipment ranges from 500 kg per hour to 20,000 kg per hour of tomatoes.
There is a word that companies often overuse: leader. It comes from the Old English word "lædan" meaning "to go as a guide". When we talk about tomato processing, we are not afraid to say that Wahal Process Technologies is a real leader.
We have offered a wide range of tomato processing machines and complete lines: from production to bottling or canning of tomato products such as tomato paste, puree, sauce, chopped tomato pulp, or peeled tomatoes.
WAHAL ENGINEERS PROCESSING PHASES
Machinery uses for Tomato processing plants as:
High Shear homogenizer
In Tank Homogenizer
Enclosed Shaft Homogenizer
Inline Homogenizer
1. HYDRAULIC UNLOADING AND TRANSPORTATION
In the tomato processing line, the product can be received in crates or containers, and the raw material is unloaded into the transport channel via an automatic dump truck. Alternatively, in case of the arrival of bulk product, unloading is done by flooding the bin using adjustable pipes. The product is separated from the water by an inclined grate or roller conveyors, and the tomato is then collected in a separation tank, filled with cleaner water, and equipped with a chain conveyor for automatic removal of stones, mud, and foreign bodies. At this point, the product is then transported to the processing lines.
2. WASHING AND SORTING
Tomato sorting can be done manually on roller conveyors in two stages: the first, in which the roller conveyor is tilted and where the product is separated from water, foreign bodies, etc., and then washed with a series of sprayers; the other in which the roller conveyor is horizontal and the tomato rotates on its own to allow precise control by operators. Sorting can also be done electronically thanks to optical sorting sensors and/or optical sorters with a digital camera manufactured by our Raytec Vision company.
3. Chopping
Washed and sorted tomatoes need to be mashed in order to optimise the subsequent stages of heat treatment. The BT60 chopper pump, embedded in the Cold-Break and Hot-Break technological cycle, guarantees a perfect, uniform, and fine consistency of the crushed product. In the Hot Break process, in particular, extremely low synergistic values can be achieved using breaking temperatures that are almost 4°C lower than standard values, a factor that also allows significant energy savings.
4A. ENZYME INACTIVATION (HOT BREAK)
Eldorado inactivator, which inactivates pectolytic enzymes, is used to make Hot Break tomato paste to preserve the pectins contained in the juice and obtain excellent values of consistency, colour, and synergy. Thanks to the high recirculation flow and the special geometry of its patented heat exchangers, the Eldorado system can work with maximum efficiency for a long time even in the presence of foreign bodies (such as weeds, leaves, creepers, etc.).
4B. PREHEAT (COLD BREAK)
Tomatoes intended for the production of Cold Break tomato paste are heated in a special tube-type unit to gradually heat the product and preserve the natural flavours and colours of the tomatoes that characterise this type of concentrate. By changing the processing temperature, a final product of different consistencies is obtained.
5. JUICE EXTRACTION
The preheated tomato juice is sent to the extraction/refining phase, which is carried out in the Giubileo extractor on the principle of centrifugal separation using adjustable paddles. This operation is able to eliminate unwanted parts of the fruit such as seeds and peel. The high efficiency of the separation process makes it possible to obtain high-quality juice and minimises moisture in the waste.
6. PRELIMINARY CONCENTRATION (OPTIONAL)
The refined tomato juice can be sent to the initial concentration stage – from 4.5 to 12° Brix – in the Apollo pre-concentrator, which is a mechanical vapour recompression (MVR) falling film evaporator. MVR technology enables the concentration of tomatoes with up to 98% steam savings thanks to the mechanical recompression of acid vapours. Thanks to the reduced residence time and maximum ΔT of 6 °C between the heating vapours and the product, the organoleptic properties of the outgoing product are of excellent quality.
7. STERILISATION AND COOLING
The SFC Flash Cooler represents the best solution for processing large volumes of products and for long operating cycles. Sterilisation takes place by direct injection of cooking steam into the product and cooling by vacuum expansion (lightning). The SFC system guarantees maximum processing safety, aseptic conditions, and the integrity of the final product.
Alternatively, the tomato puree can be sterilised and cooled in the Olympic TC steriliser. The product is subjected to thermal cycling using indirect concentric tube-type heat exchangers with high production capacity, maximum heat exchange efficiency, and process uniformity.
8. ASEPTIC FILLING
The sterilised, cooled product is filled into pre-sterilized flexible bags of various sizes using aseptic filling heads. The high degree of automation of Macropak filling machines and the control system controlled by a microprocessor with continuous monitoring of all working parameters guarantee the sterility of the packaged product. The weight of the packaged product is checked using highly accurate load sensors. The machine uses steam both as the only means of sterilisation and for washing the spout after filling.
WAHAL ENGINEER TOMATO PASTE STRENGTH
Long uninterrupted production cycles
Maximum yield, minimum production waste
High quality of the finished product, preservation of colour, and organoleptic properties
Water recirculation system, minimum consumption
Considerable versatility in sterilising solutions and aseptic filling
The possibility of producing multiple products on the same line at the same time
Less thermal stress on the product due to lower temperatures in the evaporator finisher
Maximum energy savings thanks to the most modern technologies
The complete supervisory control system of the line and control of all process steps
Recording, viewing, and printing of daily production data
TOMATO PASTE PRODUCTION LINE
This plant contains the following machinery:
PREPARATION:
Dishwasher (for washing tomatoes thoroughly)
Inspection conveyor (for manual inspection and sorting of tomatoes)
Elevator (for supply to the hot brake system)
Hot Break System (crushing and immediate heating of crushed tomatoes to preserve pectin)
Pulper (to remove seeds and obtain fine pulp as output)
PROCESSING SECTION
Standardisation tanks (for adding ingredients needed to prepare ketchup/sauce)
Vacuum evaporators (for concentration in vacuum)
Pasteurizer (for pasteurising tomato paste/sauce / ketchup)
FILLING AND PACKAGING
Aseptic bag filling (for filling tomato puree in aseptic bags)
Automatic can filling (for filling tomato paste or tomato paste in cans)
Bottle filling (for filling tomato sauce or tomato ketchup in glass or PET bottles)
