Tomato processing plant

 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)

Product Details:

Minimum Order Quantity	1 Plant
Capacity	500 kgs per hour to 20,000 kgs per hour
Automation Grade	Automatic/Semi-Automatic
Material of Construction	SS 304, SS 316L
End Packaging	Aseptic Drums, Glass bottles, PET bottles, Canned, Pouches
Brand	Wahal Engineers

Colour Coated Granulation Machine

 Colour Coated Granulation Machine Product 

Description:

We are committed to manufacturing and supplying a wide range of granulators to meet the needs of plastic processing in various application areas. These are designed according to international standards and a detailed description is given below. 

Specifications: Palletizer for product pallets. 

The stainless steel cooling tank in which a temperature controller Cylinder heating controls Heating by an energy-saving heater Rugged helical gearbox with built-in thrust housing Cooling system accessories for accurate temperature control The drive from the main AC motor to the auger is rubber It is done via a belt, pulley, and gear unit with Fully nitrated, hard chrome plating.

PLASTIC SCRAP GRINDER MACHINE-16 

Depending on your requirements, we will offer you the most competitive offer of "WAHAL ENGINEER-Heavy Duty Plastic Scrap Grinder Machine".

Feature:

1.  'WAHAL ENGINEER' Heavy Duty Plastic Crusher consists of m.s body & amp. 

2. There is a rotor bar. 

• Engine: -15 HP (standard production) 

• Blades: Two blades are fixed. 

• Blade size is 16 inches (inch) processing capacity: -90 to 100 kg / hr. 

• Power Required 15HP (11.25 kW) 

• Screen Area 3350cm² 

• Floor Area (L&W) (mm) 1200 x 1050 

About Aggregator: 

Aggregate Base

1. The base is made of heavy and heavy channels. Mild Steel plate, top of the base is a heavy-duty plate mount AC induction motor housed in the base Thrust housing

2. Constructed ruggedly of cast iron to hold the base plate vertically With high tension screws Equipped with a heavy flange, it has two camps. 

3. Gaskets are provided to limit the ingress of raw materials into the housing. 

4. All bearings are standard manufacturers. 

• main drive…

• AC motor with V-belt connected... 

• control panel…

• The control panel design is M.S. CRC seat

The plate is powder coated. All switching devices are standard voltmeters with a voltage selector switch for the input voltage. 

Coagulator Specifications 

• MODEL HEAD-30 

• TANK SIZE 760M.M. X 760 mm (ms)

• Blade Material HCHC

• Manufacturing Process Nitride Polishing 

• Special Heat Treatment 120 h \ rH.R.C 65 ~ 68º 

• Blade Size 16m. m. x100mm x215mm 

• Main drive 30 HP-AC MOTOR WITH STARTER ROTATING BLADE FIXED 

• POWER REQUIRED 30 HP (approx) 

• PRODUCTION CAPACITY (KGS PER HOUR) * *(*10%+ - depending on material) 80 TO 100 Suitable for: HM/LD/LLDPE/HD/PP & PVC film.

Expo Paint and Coatings 2022: New Delhi, India

 Expo Paint & Coatings 2022 is a comprehensive Paint & Coatings Exhibition providing platform to the needs of every facade of the coating industry right from raw materials, formulation, application, technology, finishing, quality assurance, recycling and disposal. The Exhibition will feature a wide range display of products, Raw Materials, Application systems, Machines, Tools, current trends, development & innovations shaping future of coating industry

Over the years, paint mixing technologies have faced various challenges. Each challenge leading to a more effective solution. The breaking down of pigments to form agglomeration and dispersing of the solids into a homogenous mixture was achieved with the help of High Shear disperser. The development of the high speed disperser (HSD) blade, paved the way to faster processing of paints and coatings. In spite of its advantages these machines were unable to meet the Industrial requirement of the desired level of size reduction. They were incompetent in terms of production time, as the process demands higher processing time leading to slow production time. In a way affecting its productivity.

Wahal Engineer’s High Shear Mixer & high speed disperser for Paint and Coatings Industries, Paint Manufacturing Process advantages machines.

Emulsified Vaccines

 Emulsified Vaccines: Manufactured with Water-In-Oil (W/O)

Adjuvants are substances that enhance the body's response to antigens used in vaccines. When added to antigens (viruses, bacteria, peptides, etc.), adjuvant - especially oily adjuvant - can improve immune response. An appropriate adjuvant from appropriate are oily products ready for use, each specially formulated for a single type of emulsion (W / O, O / W, W / O / W). The adjuvant and emulsion types depend on the target pathology and types. For pathologies such as Foot and Mouth Disease (cattle, swine), Avian Influenza or Newcastle Disease (chicken), Water-water adjuvants can improve performance policy by introducing a strong and long-lasting drug. Non-infection.

In the case of cancer treatment with immunotherapy, Water-In-Oil adjuvants have been shown to provide an effective immune response and a long-lasting effect on the depot.

Important Points

Vaccine production should be done in an open area to avoid contamination during production or storage. Final sterilisation of emulsified injections is technically impossible, so an aseptic procedure is required.

After construction, the goals should be:

• Barren and Stable - up to 2 years at 39 ° F, no mixing, limited decay and oil release.

• Consistency - from one group to another to ensure uniformity of immune defences due to the repetitive process.

The process

To produce a stable emulsified W / O vaccine with immunosuppressive properties, the production process must reach tiny emulsion droplets (<1 µm) with monomodal dispersion and small particle size. The use of the high shear power provided by the Wahal Engineer rotor/stator mixer is required to achieve this goal.

The process must be improved to reduce droplet size, prevent soil erosion over time, and avoid over-slipping and waterlogging as it may affect the safety and effectiveness of the policy.

The infertility of the vaccine is confirmed by the aseptic process using the first seed material (smoke closure) and auxiliary substances (filtration). Process equipment must meet several requirements, depending on both design and construction:

• Clean construction (UHS or UHLS).

• Requirement-Cleaning-Area (CIP) and Interest-in-Area (SIP).

• The storage areas are as close to zero as possible.

• Specific features of the emulsification process containing appropriate adjuvants

The standard process of W / O emulsions containing appropriate adjuvants involves two steps:

• Pre-emulsion - mixing under low shear movements of the liquid phase and oily adjuvant to form evenly large droplets to improve the droplet size of the homogeneity vaccine. 

• High Shear emulsifying with Wahal Engineer High Shear Mixer - excessive emulsion drops with a high shear head of Wahal Engineer mixer (Collection or In-Line). 

• The production vessel is subject to the shear rotation if necessary for the same purpose.

Solution

High Shear emulsifying with Wahal Engineer Mixer - This step works in a four-phase mixing cycle as follows:

Stage 1

After the pre-emulsion step, large droplets are drawn by rotating high-speed rotor blades in the centre of the work head.

Stage 2

The droplets are driven towards the work surface by centrifugal force when under the action of grinding in a small space between the rotor blades and the inner wall of the stator.

Stage 3

The droplets are then under additional shear strength by being forced at high speed through the stator tubes.

Stage 4

The tiny droplets are dissolved by dispersing the head of the work into an emulsion mass. The mixing cycle continues until the intended droplet size and stability are achieved.

Benefits

Wahal Engineer’s rotor/stator high shear alloys are commonly found in the field to adjust Water-In-Oil targets in various batch sizes. For more than 30 years, An appropriate helped vaccine manufacturers develop processes in their existing Wahal Engineer compounds or provide investment recommendations.

The length of the pre-emulsion process and the high shear step depends on the size of the batch and the adjuvant used.

For specific recommendations on your application, please contact your appropriate sales representative.

High Shear Batch Mixers

• Recommended volumes of less than 1 - 3 US litres

• It can be considered medium volumes

Top High Shear In-Line Mixers

• Recommended for volumes more significant than 13 US gallons

• It can be considered medium volumes

• In-Line mixer with 2.75 "rotors or less:

To use:

• At higher frequencies, there is a standard power supply (70 - 120Hz)

• With Fine Emulsion Screen (FEMSC)

• In-line mixtures with 4.25 "or more rotors:

Can be used:

• At expected frequencies (50 or 60Hz)

• With Standard Emulsion Screen (EMSC)

mixing raw fruits and vegetables

 How to manufacture a smoothie using the Wahal’s Machinery 

Smoothies are made by mixing raw fruits and vegetables with water, fruit juice, and milk. It may also contain other ingredients such as grains, herbs, and proteins.

In general, smoothies are more viscous than juices due to their high solid content and the natural thickening effect of some ingredients such as bananas and mangoes.

Process

1. smoothies are manufactured in a variety of batch sizes, from the single food service industry to mass production.

2. Some manufacturers use whole fruits and vegetables, while others buy and mix ready-made purees. As a result, there are many different ways to make smoothies, and many different types of equipment are used. However, the processing requirements are about the same.

3. When making a smoothie from puree and juice, the mixing system must be able to mix liquids of different viscosities.

4. When processing whole fruits and vegetables, especially when using frozen solids, hard or fibrous raw materials, various equipment may be required to chop the solids into the puree. 

5. The mixing system must be able to disperse all powdered ingredients, such as milk powder and other dietary supplements.

6. After the initial disintegration stage, further processing may be required to achieve the required smooth texture and mouthfeel.

Problem

There are many problems with the manufacturing process.

1. The small mixing plant widely used in this process does not have comparable production. Therefore, duplication of results from laboratory or pilot production can be very problematic during scale-up. 

2. Reproducibility between lots is difficult to achieve.

3. Inadequate treatment can result in inadequate texture and mouthfeel.

4. Traditional stirrers cannot easily mix liquids with very different viscosities.

5. Long mixing times may be required to achieve uniform mixing.

6. Powdered materials can be difficult to formulate and disperse, especially when added to high-viscosity smoothies.

Solution

These problems can be overcome with Wahal Engineer's high shear mixer. The high shear of the rotor/stator workhead allows for quick shredding and shredding of fruits and vegetables of all shapes and sizes, including hard solids. The operation is as follows:

Liquid Power Mixer (Powder Induction Mixer) LPM

Stage 1

The tank is filled with liquid and the mixer starts. Fruits and/or vegetables are placed in the hopper and pulled into the rotor/stator workhead, where they are rapidly shredded.

Stage 2

Centrifugal force pushes the material around the workhead, applying strong high shear in the gap between the rotor and stator walls. The product is extruded from the stator and radially returned to the body mix .

Stage 3

At the same time, new material is sucked into the workpiece head. In one short mixing cycle, all materials pass through the work head many times to achieve a smooth and uniform mixing.

Benefits

• Rapid shredding and shredding of solids and incorporation of powder components.

• Can mix liquids with different viscosities.

• Replaceable work head. Available from coarse shredder heads to ultra-fine sieves, users can achieve their desired consistency.

• Consistent and reproducible results.

• Wahal Engineer scalable results across the product range

The batch size, formulation, ingredient type, and viscosity of the final product will determine which Wahal model is best suited to your processing needs:

high shear mixer homogenizer

• Manufactured with the same tolerances as the production model, it provides a simple and accurate product. 

• Function Duplex assembly available for solids collapse

High shear batch mixer

• Suitable for batches up to 300 US gallons

• Can be used on mobile floor stands

• Duplex mixer available for larger solids collapse

High shear In-line Homogenizer 

• For larger batches than ideal

• Suitable for mixing puree through a distributor just before the inlet

• Gives uniform consistency to the product

• Easy retrofit to existing equipment

• Self-pumping

• Aeration Free

• High Viscosity Model Available Designed for

• Cleaning In Place

Wahal Blending Plant

• A complete system that can be decomposed as large as this lid without pretreatment

• Bottom Entry Mixer provides initial softening of solids

• Inline Mixer further refines the product to achieve the required smooth consistency