Lesson 1Washing systems: objectives, water quality, flow-through vs countercurrent washers, sanitisers and contact time controlExplains washing aims, dirt removal, and water needs for tomatoes. Compares straight-flow and against-flow washers, sanitiser choice, dosing, and contact time checks, plus watching germ and chemical 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, colour and heat loadReviews thickening tech for tomato puree, key on vacuum boiling off. Compares falling-film and pushed-flow designs, hits on colour, taste, thickness, and ways to cut heat harm and clogging.
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, sterilised packaging (cartons/pouches), sterilant methods (H2O2, peracetic acid), laminar flow, filler typesLooks at germ-free filling lines, clean zones, and packing stuff. Details sterilant kinds and checks, smooth flow design, filler heads, and controls keeping clean from tank to sealed box 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 considerationsExplains quick boiling and heating before smoothing or thickening. Covers enzyme kill, skin loosening, steam and hot-water blanchers, usual time-heat setups, and design 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, homogenisation options and solids retention targetsFocuses on smoothing and pulping for wanted feel and seed removal. Explains sieving, turning drum pulpers, pressure screens, and optional blending, noting yield, fibre keep, 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 germ-free tomato work. Covers clean-in-place design, air handling and germ filters, steam making, air removal, and how services are sized, checked, and fitted with controls.
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 sterilisation vs high-temperature short-time (HTST) pasteurisation for aseptic filling: aseptic UHT/sterilisation unit designs (tubular, plate heat exchangers), holding sections, coolingCompares sterilising and quick high-heat pasteurising for germ-free puree. Reviews UHT unit designs, tube and plate exchangers, hold tubes, and cooling, stressing kill power, quality keep, and clog 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 breaking down of tomatoes before smoothing. Describes crushers, hammer mills, and pulpers, their work ways, and how bit size aims hit thickness, seed harm, and later heat move.
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's aim, key checks, and usual order, linking raw quality to final safety and steadiness.
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 machine sorting of tomatoes with belts and light systems. Explains fault removal, strange stuff control, grading rules, and early picking protects later gear, yield, and 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 routingDescribes clean factory setup for tomato puree, with zones, product and worker paths, and split of raw and clean areas. Handles waste and side-product flows to dodge dirt 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
