Lesson 1Washing systems: objectives, water quality, flow-through vs countercurrent washers, sanitizers and contact time controlExplains washing goals, dirt removal, and water quality for tomatoes. Compares flow-through and countercurrent washers, sanitizer choices, dosing, contact time control, and monitoring for germs and chemicals.
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 loadLooks at concentration methods for tomato puree, focusing on vacuum evaporation. Compares falling-film and forced circulation types, effects on colour, taste, thickness, and ways to reduce heat damage and buildup.
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 typesCovers aseptic filling lines, sterile areas, and packaging materials. Details sterilant types and checks, laminar flow setup, filler heads, and controls keeping sterility from tank to sealed carton or pouch.
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 considerationsExplains blanching and heating before refining or concentration. Includes enzyme stoppage, skin loosening, steam and hot-water blanchers, usual time-temperature setups, and designs 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 targetsFocuses on refining and pulping for texture and seed removal. Covers sieving, rotary drum pulpers, pressure screens, optional homogenization, yield, fibre keeping, and smooth product.
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 equipmentLooks at support systems for aseptic tomato processing. Includes CIP design, air handling and sterile filters, steam making, deaeration, and utility sizing, checks, and process control links.
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 sterilization and HTST pasteurization for aseptic puree. Reviews UHT designs, tubular and plate exchangers, holding tubes, cooling, stressing kill power, quality keep, and buildup control.
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 targetsDetails mechanical size cutting of tomatoes before refining. Describes crushers, hammermills, pulpers, principles, and particle size effects on thickness, seed harm, and later heat transfer.
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 industrial flow from tomato receipt to aseptic puree pack. Summarises each operation's role, key controls, sequencing, linking raw quality to final safety and stability.
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 manual and auto sorting of tomatoes with belts and optics. Explains defect removal, foreign material control, grading, and early reject to guard equipment, yield, and aseptic 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 routingDescribes clean plant layout for tomato puree, zoning, product and staff paths, raw-sterile split. Handles waste and by-product flows to stop cross-mixing and aid smooth work.
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
