Lesson 1Washing systems: objectives, water quality, flow-through vs countercurrent washers, sanitizers and contact time controlExplains washing aims, dirt removal, and water quality needs for tomatoes. Compares flow-through and countercurrent washers, cleaner choice, dosing, and contact time control, plus checking 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, color and heat loadReviews thickening tech for tomato puree, focusing on vacuum evaporation. Compares falling-film and forced circulation types, effects on colour, taste, thickness, and ways to limit heat damage 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, sterilized packaging (cartons/pouches), sterilant methods (H2O2, peracetic acid), laminar flow, filler typesLooks at germ-free filling lines, clean zones, and packing materials. Details cleaner types and checks, smooth flow design, filler heads, and controls keeping sterility from tank to sealed 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 considerationsExplains quick boiling and heating before refining or thickening. Covers enzyme kill, skin loosening, steam and hot-water blanchers, usual time–temperature 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, homogenization options and solids retention targetsFocuses on refining and pulping for right texture and seed removal. Explains sieving, rotary drum pulpers, pressure screens, and optional blending, noting yield, fibre keep, and 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 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 utilities are sized, checked, and linked to 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, coolingCompares full sterilizing and quick high-heat pasteurizing for germ-free puree. Reviews UHT unit designs, tube and plate exchangers, holding pipes, 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 of tomatoes before refining. Describes crushers, hammermills, and pulpers, their work principles, and how particle size goals affect thickness, seed harm, and later heat flow.
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. Summarises each step’s aim, key controls, 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 material control, grading standards, and how early picking protects later machines, 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 layout for tomato puree, including zones, product and worker paths, and splitting raw and clean areas. Handles waste and side-product flows to avoid 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
