FOOD PROCESSING TECHNOLOGIES.

Tomato processing.

Normally  tomato ketchup is being  produced   from  existing  tomato paste  during  the  off  season,  rarely is produced  on-line  from  fresh tomatoes.

Tomato  paste at 30/32°Brix Hot Break type is being pumped  from  aseptic  storage tanks  or  from  200 L  aseptic bags-in-drums  into  the  first mix tank.   Drinkable/softened   water is being  added  in  a volume  such to reduce  the  solids content down  at  15 –16 °Brix.

Soon  after  vinegar one or two types of liquid sugar (glucose or fructose)  shall be  added into the first mix tank according  to  volumes  specified  by the  recipe.

Cold mix now at  about  25-35°C for  5 minutes   then  add  spices  and  essential oils  according to the recipe and  mix  again for   5 minutes.  Makes a second batch while  discharging  from  first mix tank.  The process  can be made  a continuous blending  process  but  it requires  complicated  controls  and  in consideration of  costs involved  it might be convenient only for  large  processing  capacities.

The  final mixture  (ketchup)  can now be pumped through  a tube-in-tube   heat exchanger in order to be heated up to  77-87°C,   temperature  control and  diversion line  shall be provided  in case  this temperature is not  obtained,  only when  set temperature is reached  ketchup  will go through  the homogenizer  or high shear  mill  performing  at least  180 – 200 bar working pressure.

After the homogenization process  ketchup shall be  pasteurized  at  99-104°C  into  a tube-in-tube  heat exchanger or  by steam injection device, in both cases  temperature control and diversion line shall be provided  in order to make sure that the set temperature has been obtained.

Pasteurized  ketchup shall now be  desaerate into  an under vacuum  deaerator  from  which  product   will come out  at  about  87-93°C  ready for hot fill into  the final  container  (glass bottles, plastic bottles,  aluminum bags,  etc).

 

If the  chosen  container for final product  cannot be hot filled  at  87-93°C  cold filling  process shall then  be used.  In this case  ketchup from  deaerator  shall be  cooled  down  at  32-37°C   by an aseptic  tube-in-tube  heat exchanger  then pumped to the  “clean room”  for  filling  into  the  appropriate  containers.

It is recommended that all  heat exchangers  are made of  special  stainless steel  of titanium alloy or  high molybdenum  content  due to the severe corrosion  properties of  the ketchup.

There are  a lot of   different  recipes  for ketchup, we  can provide   custom made  recipes  to its clients according to the taste  of consumers  of that  particular market.

 

FILLING  OF  PLASTIC  CONTAINERS  provided with  dispenser

 

Two containers  are normally  available for  tomato ketchup:

(a)  mono layer  polyester  containers, cheaper, but  cannot  accept  filling temperatures  higher than  75°C;

(b)  multi layer  polyester/polypropylene   containers,  more  expensive, but  performing  better  filling temperature  up to  95°C  and  providing  better oxygen  barrier  particularly if mould with an intermediate layer of EVAL.

 

In case of  containers  (a)  i.e. mono layer polyester, is not possible to pasteurize  the  container thus  chemical preservatives  shall be added to the product in order to have  reasonable long  shelf live. In any case,  being such type of container  permeable to oxygen  the product  gets a color degradation very rapidly thus at the end the product’s  shelf live is reduced at 5 – 6 months  only.

In case of containers (b) i.e. multi layer polyester / polypropylene,  it is possible to hot fill the product at  90°C while  the better oxygen  barrier provided by  such types of containers allows  a shelf life up to 18 months without adding any preservative.  Furthermore,  whenever  production volume  exceed  5 millions pieces it will be very convenient to  manufacture such plastic bottles  at the plant itself  directly from the polypropylene granulate.  Equipment for  production  of  plastic bottles  is not  really very expensive. kinds  of  plastic

In case of  ketchup hot fill at 90°C  into the appropriate plastic bottles,  it is recommended that  full bottles  are hold  at about  80 – 85°C  for   7 – 8 minutes into a tunnel  then  cooled  at  45°C and dried ready for labeling  and/or final packaging

 

 

Fruit processing.

 

We supply complete technology lines for processing of all kinds of fruits as Apples,Peaches,Nectarines,Oranges,Strawberrys etc.Also various types of final products are available.

You have to know capacity of required processing machinery and what will be final product,packing-glass,paper,PE,PET etc.

 

Vegetable processing.

 

Blanching,Cooking and Cooling lines.

Frozen vegetables mixing.

French Fries lines.

Potato Chips lines.

Fresh vegetables preparation.

Vegetables puree and Carrot juice production lines.

 

Milk processing.

 

Complete plants for processing of milk with outputs:

-Dried Milk Powder

-Butter

-Dried Whey

-Cheese

-Kasein

-Whey Cheese

 

Bakeries.

 

Complete bakeries for all kind of  bakering products.

Your inquiries go here.

 

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