Lesson 1Washing systems: objectives, water quality, flow-through vs countercurrent washers, sanitisers and contact time controlExplains washing objectives, soil removal, and water quality needs for tomatoes. Compares flow-through and countercurrent washers, sanitiser 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, colour and heat loadReviews concentration technologies for tomato puree, focusing on vacuum evaporation. Compares falling-film and forced circulation designs, effects on colour, flavour, 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, sterilised packaging (cartons/pouches), sterilant methods (H2O2, peracetic acid), laminar flow, filler typesExplores aseptic filling lines, sterile zones, and packaging materials. Details sterilant types and validation, laminar flow design, filler heads, and controls that 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 considerationsExplains blanching and heating steps before refining or concentration. Covers enzyme inactivation, skin loosening, steam and hot-water blanchers, typical time–temperature conditions, and design to minimise 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 refining and pulping to achieve desired texture and seed removal. Explains sieving, rotary drum pulpers, pressure screens, and optional homogenisation, with attention to yield, fibre 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 equipmentExamines supporting systems that enable aseptic tomato processing. Covers 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 sterilisation vs high-temperature short-time (HTST) pasteurisation for aseptic filling: aseptic UHT/sterilisation unit designs (tubular, plate heat exchangers), holding sections, coolingCompares sterilisation and HTST pasteurisation for aseptic puree. Reviews UHT unit designs, tubular and plate exchangers, holding tubes, and cooling sections, emphasising 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 targetsDetails mechanical size reduction of tomatoes before refining. Describes crushers, hammermills, and pulpers, their 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 stepProvides a stepwise industrial flow from tomato reception to aseptic packaged puree. Summarises 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 controlCovers manual and automated sorting of tomatoes using belts and optical systems. Explains defect removal, foreign material control, grading criteria, and how early culling protects 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 routingDescribes hygienic plant layout for tomato puree, including zoning, product and personnel routes, and segregation of raw and sterile areas. Addresses 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
