Lesson 1Washing systems: objectives, water quality, flow-through vs countercurrent washers, sanitizers and contact time controlCovers washing aims, dirt removal, and water needs for tomatoes. Looks at flow-through against against-flow washers, cleaner choice, amounts, and touch time checks, plus watching germ and chem 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 thickening tech for tomato puree, key on vacuum boiling off. Compares falling-film and pushed flow types, hits on colour, taste, thickness, and ways to cut heat harm and build-up.
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, and pack materials. Gives cleaner types and checks, smooth flow setup, filler tops, and controls keeping clean from tank to shut 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 considerationsShows quick-hot and heat steps before smoothing or thickening. Covers killing enzymes, loosening skins, steam and hot-water quick-hotters, usual time-heat 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 targetsSpotlights smoothing and pulping for wanted feel and seed take-out. Shows sieving, turning drum pulpers, pressure screens, and optional blending, minding output, fibre keep, and smooth finish.
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 equipmentStudies support setups for germ-free tomato work. Covers clean-in-place design, air care and clean filters, steam making, air removal, and how services are sized, checked, and fitted 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, coolingCompares full-kill heat and quick-hot pasteuring for germ-free puree. Reviews UHT setups, tube and plate exchangers, hold pipes, and cooling parts, stressing kill power, quality keep, and dirt 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 targetsGives details on machine size cutting of tomatoes before smoothing. Describes crushers, hammer mills, and pulpers, their ways, and how bit size aims hit thickness, seed harm, and later heat pass.
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. Rounds up each step's aim, key checks, and usual order, tying raw quality to end 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 systems. Shows fault take-out, strange stuff control, grade rules, and how early picking guards later gear, output, 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 plant setup for tomato puree, with zones, item and worker paths, and split of raw and clean spots. Deals with waste and side-product flows to dodge dirt mix 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
