Lesson 1Washing systems: objectives, water quality, flow-through vs countercurrent washers, sanitizers and contact time controlExplains aims of washing, removing dirt, water needs for tomatoes. Compares straight-flow and against-flow washers, choosing cleaners, amounts, 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 loadLooks at ways to thicken tomato puree, key on vacuum boiling off water. Compares thin-film falling and pushed circulation types, changes to colour, taste, thickness, ways to cut heat harm and sticking.
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, packing stuff. Details cleaners and checks, smooth air flow, filler parts, 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 hot treatment and heating before smoothing or thickening. Covers stopping enzymes, loosening skins, steam and hot water types, usual time-heat setups, 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 smoothing and pulping for right feel and seed removal. Explains sieves, turning drum pulpers, high pressure screens, optional blending, noting yield, fibre keep, 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 gear for germ-free tomato work. Covers clean-in-place designs, air handling and germ filters, steam making, air removal, sizing, checks, linking 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 kill heat and quick high heat pasteurizing for germ-free puree. Reviews UHT designs, tube and plate heaters, hold pipes, cooling, stressing kill power, quality keep, sticking 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 breaking tomatoes small before smoothing. Describes crushers, hammer mills, pulpers, how they work, size aims affecting thickness, seed harm, heat pass later.
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 arrival to packed germ-free puree. Sums each step's aim, key checks, usual order, linking raw quality to final safety and keep.
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 scanners. Explains cutting bad parts, strange stuff control, grade rules, early picking protecting 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 routingDescribes clean factory setup for tomato puree, zones, product and worker paths, splitting raw and clean areas. Handles waste and side product flows to avoid mixing bad and run smooth.
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
