FOOD PROCESSING TECHNOLOGIES.
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
(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
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.
Blanching,Cooking and Cooling lines.
Frozen vegetables mixing.
French Fries lines.
Potato Chips lines.
Fresh vegetables preparation.
Vegetables puree and Carrot juice production lines.
Complete plants for processing of milk with outputs:
-Dried Milk Powder
Complete bakeries for all kind of bakering products.
Your inquiries go here.