The Single-Stage Continuous System is a modern and efficient method in the production of tomato paste in factories. The system is designed to increase production speed, reduce costs and maintain the quality of the end product. In this way, tomatoes are constantly and non -stopped at various stages of processing to eventually become tomato paste.
The main steps of processing in the single -stage Conteinius system:
Receive and prepare tomatoes:
Receipt: Fresh tomatoes are transferred to the factory and discharged in special ponds.
Washing: The tomatoes are thoroughly washed to remove any contamination, soil and external material from their surface. Ummays and water spray systems are commonly used.
Sortation: The tomatoes are categorized by quality, color and size. Inappropriate tomatoes (damaged, cow or overcrowded) are separated. In some factories, automatic sorting systems are used using cameras and color and size sensors.
Crushing: Healthy tomatoes enter the crusher to become smaller parts. This facilitates the process of heat and dewatering.
Heat and Enzyme Deactivation: Heat and Enzyme Deactivation:
Chopped tomato puree enters the heating system. The purpose of this step is to disable the enzymes in the tomatoes (especially pectinase enzymes), which can reduce the viscosity and final quality of the paste.
There are two main methods for heating:
Hot Break (HB): Rapid puree heating up to 95-95 ° C. This method results in higher viscosity paste and is suitable for producing ketchup and other sauces.
Cold Break (CB): Heating puree to 75-65 ° C. This method will better preserve the color and taste of the tomatoes and are suitable for the production of high concentration (38-38 brix) paste).
Juice Extraction and Concentration:
The heat puree enters the Extractor. These devices usually include one or two filter stages, which separate the skin, seeds and fibers of the tomato and obtain tomato juice.
The obtained tomato juice enters the evaporator. Using heat and vacuum, these devices evaporate the excess water in the tomato juice and increase the concentration of soluble solids (Brix) to reach the desired tomato paste (usually 28-36 Brix). Concentrations are usually performed in several stages (Multi-Stage Evaporators to maintain product quality and optimize energy consumption.
Sterilization and Packaging:
Concentrated tomato paste is sterilized to eliminate potential microorganisms and increase shelf life. Continuous heating methods are usually used.
Sterilized tomato paste is packaged in a variety of containers (cans, glass, aspactic envelopes). Filling and automatic door filler devices are used at this stage.
Benefits of Single -Step Contestinus System:
Increasing production efficiency: The continuous and non -stop process results in the production of a higher volume of paste per unit of time.
Reducing Human Resources Costs: High automation in this system reduces the need for labor.
Improvement of product quality: More precise control of temperature and time at different stages of processing guarantees more uniform quality.
Waste Reduction: Modern systems minimize waste by reducing errors and process optimization.
Energy and Water Save: Optimal design of thermal and evaporative systems can reduce energy and water consumption.
Higher health: The closed and automatic process reduces the likelihood of product pollution.
Possible Disadvantages of Single Container System:
High initial cost: Initial investment in purchasing and installing equipment of this system is usually high.
Need for Technical Specialty: Operation and maintenance of these systems requires specialized and trained personnel.
Reducing flexibility in production: Changes in product type or process settings may be time consuming and complex.
The possibility of stopping the entire production line in the event of a problem arises in one section: Since the process is continuous, failure in a device can stop the entire production line
