Lesson 1Washing systems: objectives, water quality, flow-through vs countercurrent washers, sanitizers and contact time controlCovers washing aims, dirt removal, and water needs for tomatoes. Looks at flow-through against against-flow washers, cleaner choice, amounts, time watch, plus checks for germs and chem leftovers.
Prewashing, destoning, and debris removalWater quality, filtration, and reuse optionsFlow-through versus countercurrent washer designSanitizer choice, dosing, and contact timeMonitoring residues and microbiological loadLesson 2Concentration options: vacuum evaporation, falling-film vs forced circulation evaporators, effects on solids, color and heat loadGoes over thickening tech for tomato puree, key on vacuum boiling off. Compares falling film and pushed flow types, changes to colour, taste, thickness, and ways to cut heat harm and build-up.
Objectives of concentration and Brix targetsFalling-film evaporator design and limitsForced circulation evaporators and foulingImpact on color, flavor, and viscosityEnergy integration and aroma recoveryLesson 3Aseptic packaging and filling: sterile environment, sterilized packaging (cartons/pouches), sterilant methods (H2O2, peracetic acid), laminar flow, filler typesLooks into germ-free filling lines, clean areas, and pack stuffs. Gives cleaner types and checks, smooth flow build, filler tops, and watches that keep clean from tank to shut carton or bag.
Aseptic zone design and overpressure controlPackaging material sterilization parametersH2O2 and peracetic acid application methodsLaminar flow hoods and air velocity targetsFiller types, CIP, SIP, and sterility testsLesson 4Blanching/heating: objectives (enzyme inactivation, skin loosening), steam blanchers, hot-water blanchers, typical conditions and design considerationsShows quick hot steps before clean-up or thicken. Covers killing work enzymes, loose skins, steam and hot water quick-hotters, usual time-heat setups, and builds to cut quality loss.
Pectin methylesterase and polyphenol oxidase controlSteam blancher design and residence timeHot-water blanchers and water managementTypical blanching time–temperature profilesQuality impacts and overprocessing risksLesson 5Refining and pulping: sieving, rotary drum pulpers, high-pressure screens, homogenization options and solids retention targetsKey on clean-up and pulping for wanted feel and seed out. Shows sieves, turn drum pulpers, press screens, optional smooth-mix, with note on yield, fibre keep, and smooth item.
Screen selection and open area designRotary drum pulper setup and speed controlHigh-pressure and static screen applicationsSolids retention, yield, and seed removalInline homogenization and texture tuningLesson 6Ancillary equipment and utilities: CIP systems, air handling/sterile filters, steam generation, deaeration equipmentStudies support setups for germ-free tomato work. Covers clean-in-place builds, air care and clean filters, steam make, air-out, and how services are sized, checked, and joined to process watches.
CIP circuits, detergents, and validation testsSIP procedures for aseptic equipmentAir handling units and sterile air filtersSteam quality, distribution, and condensateDeaeration systems and oxygen controlLesson 7Thermal sterilization vs high-temperature short-time (HTST) pasteurization for aseptic filling: aseptic UHT/sterilization unit designs (tubular, plate heat exchangers), holding sections, coolingCompares full kill heat and quick high-heat mild-heat for germ-free puree. Goes over UHT builds, tube and plate changers, hold pipes, cool parts, key on kill power, quality keep, build-up watch.
Target microorganisms and required F0 valuesTubular versus plate heat exchanger selectionHolding tube design and residence time controlRegeneration and product cooling strategiesFouling, cleaning frequency, and heat impactLesson 8Size reduction and crushing: crushers, hammermills, rotary pulpers — operating principles and particle size targetsGives details on machine size cut of tomatoes before clean-up. Tells of crushers, hammer mills, pulpers, work ways, and how bit size aims shape thickness, seed harm, down-line heat pass.
Crusher types and feed preparation needsHammermill design and operating parametersRotary pulpers and rotor screen interactionsParticle size targets for puree consistencyImpact on enzyme release and heat transferLesson 9Complete industrial process flow listing from reception to packaged aseptic puree with brief purpose for each stepGives step-by-step factory flow from tomato intake to germ-free packed puree. Sums each step aim, key watches, usual order, joining raw quality to end item safety and hold.
Reception, unloading, and sampling of tomatoesStorage, buffering, and feeding to processing lineCore processing steps from washing to refiningThermal treatment, concentration, and holdingAseptic filling, packaging, and palletizingLesson 10Sorting and trimming: manual and automated sorting (optical sorters, belt conveyors), removal of defects, foreign material controlCovers hand and auto sort of tomatoes with belts and light systems. Shows fault out, strange stuff watch, grade rules, and early pick-off guards down gear, yield, germ-free safety.
Raw tomato quality and acceptance criteriaManual sorting lines and ergonomic designOptical sorters and vision system settingsForeign material detection and rejection pointsDocumentation and traceability at sortingLesson 11Process layout and material flow: hygiene zoning, personnel flow, waste collection, and by-product routingTells clean plant setup for tomato puree, zones, item and worker paths, split raw and clean spots. Deals waste and side item flows to dodge dirt mix and aid good runs.
Hygiene zoning: raw, clean, and aseptic areasPersonnel entry, gowning, and traffic routesProduct, packaging, and utility flow mappingWaste, peel, and seed by-product routingCross-contamination and airlock strategies
