Examples of technological lines at the factory
Technological line of tomato paste production
Production of tomato paste:
Production of tomato paste is based on the tomatoes’ processing through their wiping out and deletes of air from the got mass. Ripe tomatoes, without a rot, with maintenance of dry matters no less than 4%, with acidity no more than 10% are accepted in processing. The special value for the increase of the productivity of line on tomatoes’ processing and receipt of tomato paste is sort of tomatoes supplied for processing. An output from the prepared product rises substantially with an enhanceable maintenance of dry matters in the tomatoes. The product got at a hot method is more viscid and in more stiff consistency, the product got in cold-process is less viscid and, accordingly, less thick. At hot method there is a rapid reaction of enzymes, saving natural viscidity of product thus.
Description of technological process:
Raw material enters at the raw material ground after determination of its high-quality and quantitative indexes. Tomatoes acting on an enterprise unload in a bunker and water is given. Amount of water there are more high-usage tomatoes approximately in three times. Tomatoes head for the line of the tomatoes’ processing by the hydro-conveyer. Washing in washings machines provides the complete delete of contaminations. During the tomatoes’ moving on a conveyer (2) raw material under the action of the revolved rollers is inverted, that allows also high-quality to carry out his washing, sorting and inspection. Examined raw material is rinsed with water on the washing area of conveyer, whereupon it's given at the nourishing shnek and typified in a heater. After this there is the double wiping out, tomatoes are skipped through a sieve with the diameter of openings of 0,8mm and sieve by the diameter of openings of 0,6 mm accordingly. The mass collected in collection is sent at the tomato evaporator. The valves of evaporator are adjusted so that to protect the key-in of tomato paste not passing the complete cycle of temperature treatment. The temperature of sterilization makes 115°S. A concentrate, sterilized thus, cools down to 35 – 38°S and packed up in aseptic B/Ss which take place in plastic barrels. B/Ss leave on storage for storage and get labels.
Description of tomato paste production line:
The line of sorting and washing of tomatoes is intended for formal acceptance and sorting of tomatoes, acting both in boxes and high-usage on a freight motor transport loading appearance. A receiving bunker is made from cement solution and steel constructions. Trays are made from steel constructions and have an oval bottom and walls. They are brought to the roller lift which deletes water. A roller lift is made from stainless steel and consists from the chain of drive rollers for the transporting of tomatoes with the guided abater of speed, bunker for unloading and load of tomatoes, nozzles-nebulizers of water under constraint for tomatoes’ washing. Productivity of line washing and sorting of tomatoes is 12,5 tons in an hour. It consists from roller lift with a sorting table, chain of drive of rollers, figured sheet for collection of water, nebulizers of water for washing of tomatoes under constraint. All knots are made from stainless steel. The system of heat treatment activates pectin enzymes, warms up the ground up product, which allows promoting making of the prepared products as compared to the traditional systems, to increase consistencies of the finished concentrated good by reason of the general activating of pectin additions. The system allows the immediate activating of pectin enzymes in a product, acting from a washrack and sorting table, sending a product in a hot stream which constantly circulates through warm-changers and capacity of maintenance of product in the hot state by means of pump with a centrifuge.
After necessary time of self-control a product is passed by pressing and transported at the cleaning. The system includes the pump of crusher, intended for growing and serve of initial product shallow in warm-changer, and then on a pipeline to turbo-extractor, warm-changer, intended for maintenance of temperature balance for the activating of enzymes, pipelines, settings of control of steam and sensors of control of level of product. Further there is a pressing of product in turbo- pressing, which executes three functions: crusher, purifier, turbo-press. There is a separation of seed, skin, sticks which go to wastes. A pressing consists of corps, rotor, motor, system of pipelines.
A product is sent in a capacity for subsequent direction in evaporator, with the purpose of two-phase evaporation of water. At the first stage temperature of process is 75 –77°S, at the second – 50 – 60°S. Centrifuge pumps are used for the forced circulation of product into the nests of the warm-changer's pipes, cylindrical booths for dissociating of steam from mixture of steam and liquid going out from the warm-changer, vacuum pump for taking the uncondensed gases from a condenser, pump for the delete of the prepared tomato paste, checking system, system of sensors and relay. All details of evaporator are executed from stainless steel. Water, going out from evaporator and used for condensation of fumes, enters into cooler, consisting of a few modules, intended for cooling. The prepared tomato paste is sent in a fluidizer for packing in aseptic B/Ss.
Chart of production of tomato paste:
Washing machine
Pulpier
Vacuum pan
Homogenization
Story capacity
Composition of line
Washing-bath
Conveyer washing
Conveyer is an inspection
Crusher
Heater of tomato mass
Pulpier
Homogenization
Vacuum evaporator
Package and packed semi-automatic device
Line on a production and pouring out of fruit juices:
Fruits processing: pears, apples, peaches, apricots, merry.
Receiving bunker with a cupelevator;
Sorting conveyer;
Filtration setting;
Hammer crusher;
Bearing frame;
No oxidant group of preparation and dosage;
Bunker with mono by a pump;
Tubular cellular heater;
Plating lift;
Stones’ selection machine;
Device for cleaning of stone;
Double group of extraction of juice;
Bearing frame;
Reservoir with a pump for collection of puree;
Control and control panel.
STERILIZATION and ASEPTIC SECTION of FILLING
Group of sterilization is self-control - cooling;
Aseptic device of filling dualheaded;
Control and control units;
Electronic printer;
Conveyer with sending rollers; platform.
Platform.
SECTION of PREPARATION of FRUIT JUICES
Pump for emptying of soft packages;
A reservoir is a depository of product with a pump;
Reservoir of dosage of ingredients with a batching pump;
Fluidizer dissolution of sugar;
Horizontal mixer reservoir;
A reservoir − a depository of product;
Electric closet.
Sterilizer of fruit puree, to 3000 kg/hour
Setting is intended for the rapid heating, sterilization and cooling of fruit puree in the closed stream. Productivity, l/hour (smooth regulation) to:
- puree of 12% s.v., juices with pulp, fluid liquids
- jam of 60% s.v.
3000
1500
3000
1500
Temperature of sterilization (set) to 105 – 115
Temperature of going out product from setting (after cooling) 25 – 30
Temperature of output of product on homogenization 65 – 70
Time of self-control at the temperature of sterilization 60 - 120sec
Sizes of setting, mm
3700 х 4000 х 3500
Mass of setting, provide 1600 kg
Devices of control and adjusting of setting:
• automatic maintenance and temperature temporal record of the mode of sterilization of product;
• automatic maintenance and temperature temporal record of the mode of cooling of product;
• possibility of work of setting in the automatic and hand modes on the technological stages: initial stage, pre-sterilization, cooling, production, washing;
• possibility of adjusting of serve of product a pump by a frequency transformer within the limits of 1500 - 5000 l/hour, steam, air)
A closet drying, work-load 300 kg
Intended for drying of food products (chopped green-stuffs and fruit, pastas, herbares, expecting, berries et cetera) with possibility of programming and maintenance in the process of parameters' of temperature and humidity optimum drying.
Base acquisition:
Closet (with the stainless steel inside)
Cart platform (3 sht.)
Tray for product’s drying (78 sht.)
System of taking of air
Capacity for storage of products:
