Lesson 1Washing systems: objectives, water quality, flow-through vs countercurrent washers, sanitizers and contact time controlExplain washing objectives, soil removal, and water quality needs for tomatoes. Compare flow-through and countercurrent washers, sanitizer selection, dosing, and contact time control, plus monitoring of microbial and chemical residues.
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 loadReview concentration technologies for tomato puree, focusing on vacuum evaporation. Compare falling-film and forced circulation designs, effects on color, flavor, viscosity, and strategies to limit thermal damage and fouling.
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 typesExplore aseptic filling lines, sterile zones, and packaging materials. Detail sterilant types and validation, laminar flow design, filler heads, and controls dat maintain sterility from holding 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 considerationsExplain blanching and heating steps before refining or concentration. Cover enzyme inactivation, skin loosening, steam and hot-water blanchers, typical time–temperature conditions, and design to minimize 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 targetsFocus on refining and pulping to achieve desired texture and seed removal. Explain sieving, rotary drum pulpers, pressure screens, and optional homogenization, with attention to yield, fiber retention, and product smoothness.
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 equipmentExamine supporting systems dat enable aseptic tomato processing. Cover CIP design, air handling and sterile filtration, steam generation, deaeration, and how utilities are sized, validated, and integrated with process 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 sterilization vs high-temperature short-time (HTST) pasteurization for aseptic filling: aseptic UHT/sterilization unit designs (tubular, plate heat exchangers), holding sections, coolingCompare sterilization and HTST pasteurization for aseptic puree. Review UHT unit designs, tubular and plate exchangers, holding tubes, and cooling sections, emphasizing lethality, quality retention, and fouling 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 targetsDetail mechanical size reduction of tomatoes before refining. Describe crushers, hammermills, and pulpers, dem operating principles, and how particle size targets affect viscosity, seed damage, and downstream 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 stepProvide a stepwise industrial flow from tomato reception to aseptic packaged puree. Summarize each unit operation’s purpose, key controls, and typical sequencing, linking raw material quality to final product 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 controlCover manual and automated sorting of tomatoes using belts and optical systems. Explain defect removal, foreign material control, grading criteria, and how early culling protect downstream equipment, yield, and aseptic product 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 routingDescribe hygienic plant layout for tomato puree, including zoning, product and personnel routes, and segregation of raw and sterile areas. Address waste and by-product flows to avoid cross-contamination and support efficient operations.
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
