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T O M AT O Cold and Hot Break Tomato Paste Lines


The Group

and

the History

Tomato Paste Lines

CFT (Catelli Food Technology), resulting from the merger of

Designed to ensure the highest energy efficient

two historical brands in the field of food processing,

production flexibility and an excellent preservation

Rossi & Catelli and Manzini, continues to be an undisputed leader for technological innovation,

of the organoleptic characteristics of the treated product.

reliability and plant flexibility. The lines for tomato processing represent the confirmation of Being a leading industry in tomato sector,

CFT’s commitment to continuously surpass themselves through

CFT has developed complete lines, fully

the constant search for more and more advanced technological

automated, for the production of “Cold

solutions with which to obtain a high quality finished product, improve

Break” and “Hot Break” tomato concentrates

performances and lower production costs.

and semi-concentrates.

22

million 2

Tons of fresh tomatoes processed per year. 3


Finisher

and

thermal treatments

The juice obtained both and Cold Break or Hot Break technology is collected into a storage tank and sent to a preconcentrator and subsequently to a “finisher”

“Cold Break”

multiple effect evaporator, where the juice concentration takes place, or

tomato paste production

directly to the above mentioned evaporator.

The tomato paste obtained by Cold Break technology is a product with

The tomato paste obtained is then submitted to a further phase of thermal

excellent organoleptic characteristics (good taste, good colour, sweet

treatment in heat exchangers, in order to achieve the pasteurization or

flavour), with not too high consistency values (>7 cm Bostwick), presence

sterilization temperature before being packaged.

of syneresis. It is particularly suitable for direct consumption. In the production of Cold Break tomato paste, the sorted product is

> The pasteurized product is destined to traditional packaging into

crushed and heated up to 65-70 °C, a temperature that does not cause

cans of different types.

the complete inactivation of pectolytic enzymes, but

guarantees

> The sterilized product can be an

packaged in presterilized flexible bags,

optimal performance in the

with capacities from 5 to 1500 l by means

following juice extraction and

of aseptic fillers having one or more filling heads,

refining phase.

depending on the working capacity required by the line, or be stored in aseptic rooms. Both systems are equipped with a high automation and control

“Hot Break”

tomato paste production

system which guarantees the sterility of the treated product.

The tomato paste obtained by Hot Break technology is a product rich in fibres, with a very high consistency (<5 cm Bostwick) and a very low syneresis; this product is a semifinished product, particularly suitable for the production of sauces, ketchup and meat sauces. In the production of Hot Break tomato paste, the sorted product is finely crushed and heated at the temperature of complete enzymatic inactivation or higher (up to 105 °C); the pulp obtained is subsequently submitted to the refining process.

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5


Hot Break product

Cold Break product

12-14° brix semi-tomato paste

12-14° brix semi-tomato paste

16-18° brix semi tomato paste

16-18° brix semi-tomato paste

22-24° brix tomato paste

22-24° brix tomato paste

28-30° brix double tomato paste

28-30° brix double tomato paste

Pizza sauce

36-38° brix triple tomato paste

22-24° brix Super Hot Break

Pizza sauce

28-30° brix Super Hot Break 6-8° brix strained pulp 8-10° brix strained pulp 10-12° brix strained pulp

Line Composition Quality control

I Pre concentration (optional)

F

Sterilization and cooling

Aseptic filling

H

A Unloading and hydraulic transport system

B

Juice extraction

Chopping

C Washing and sorting

D

G

E Pre-heating or Enzymatic inactivation

H Pasteurization

6

Filtering and recirculating water group

Concentration

Hot filling

Pasteurization

Palletizing

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A - Unloading and hydraulic transport system: SRH

C - Chopping Chopping pump: BT60

B - Washing and sorting

D1 - Enzymatic inactivation: Eldorado

D2 - Pre-heating: Cold Break

E - Juice extraction: Giubileo

G - Concentration: Venus

H1 - Sterilization, Cooling: SFC Flash Cooler

H2 - Sterilization, Cooling: Olimpic

I - Aseptic filling: Macropak AF/2

The tomato paste is sterilized and cooled in the sterilizer Olimpic Product can be received in crates or

Tomatoes

sorting

can

be

manually

Washed and sorted tomatoes must

For the production of Hot Break tomato

Tomatoes destined to Cold Break tomato

Crushed and preheated juice is sent to the

The refined juice, as it is or pre-concentrated

SFC Flash Cooler represents the best solution

TC to be sent to the subsequent aseptic filling. The product is

The sterilized and cooled product is filled in presterilized flexible

bins (an automatic dumper provides for

performed on roller tables in two phases:

be crushed in order to optimize the

paste the inactivator model Eldorado is

paste production are heated in the

extraction / refining phase which is carried

at 9-10 °Brix, is sent to the following

for the treatment of big product volumes and for

subject to a thermal cycle by means of indirect heat exchangers,

bags with different capacities by means of aseptic filling heads.

unloading of the raw material into the

the first one, in which the roller table

following phases of thermal treatment.

used, which carries out the inactivation of

treatment unit model Cold Break, tube

out in the extractor model Giubileo using

concentration. The Venus plants are multiple

long running cycles. Product sterilization occurs

concentric pipe type, with high production capacities and

The automation top level of Macropak fillers and the control

transport flume) or in bulk, too. In this latter

is inclined and where takes place the

The chopping pump model BT60,

pectolytic enzymes in order to preserve the

chest type, to perform a gradual heating

the principle of centrifugal separation by

effect evaporators with technology based on

by direct injection of culinary steam into the

reduced amortization times, a maximum thermal exchange

system driven by a microprocessor with continuous monitoring

case the unloading occurs by flooding

separation of the product from water,

inserted both in the Cold-Break and the

pectins contained in the juice and obtain

of the product in order to preserve aromas

means of adjustable paddles and is able

the patented principle of downward forced

product and the cooling by vacuum expansion

efficiency and process uniformity, and thanks to the constant

of all working parameters ensure the packed product sterility.

the truck body by means of adjustable

foreign bodies, etc., and then the

Hot-Break technological cycles, ensures

excellent consistency, colour and syneresis

and natural colours of tomato which

to remove the undesired parts of the fruit,

flow product circulation and positioning

(flash). The SFC plant guarantees the highest

product overpressure compared with the working fluids pressure,

The packaged product weight control occurs by means of high

hoses. The product is separated from

washing by means of a sprayer series; the

a perfect, uniform and fine texture of

values. Thanks to its high recirculation

distinguish this type of concentrate. Final

as seeds and peels. The high efficiency of

of the heat exchanger directly on top of

processing safety, the aseptic conditions and

aseptic conditions are guaranteed during every single cycle

precision load cells. Moreover, the machine uses steam both as

the water by one inclined grate or roller

second one, in which the roller conveyor

the crushed product. In particular, as far

flow-rate and the special geometry of its

product with various consistencies can

the separation process allows to obtain a

the expansion chamber. Thanks to their

integrity of the final product, and the preservation

phase.

a single sterilizing agent and for the spout washing after filling.

units, tomato is then collected into a

is horizontal, and tomato rotates on itself,

as the Hot Break process is concerned,

patented heat exchangers, the Eldorado

be obtained by varying the treatment

high quality juice, to minimize the humidity

structural characteristics it is possible to

of product viscosity and initial quality.

grate separator tank, fed with cleaner

in order to allow an accurate inspection

we can attain extremely low values in

system can run at its maximum efficiency

temperature.

of the waste and treat a wide range of

obtain very short product residence times

water and equipped with a drag-chain

by operators. The electronic sorting

syneresis by means of break temperatures

over long periods of time even in the

products.

inside the evaporator, the lowering of the

conveyor to automatically remove stones,

is performed by sensor optical sorters

lower by almost 4 °C, compared with

presence of foreign bodies (such as

average product circulation temperature, the

mud and foreign bodies. The product is

and/or by digital camera optical sorters

the standard values, with a consequent

weeds, leaves, vines, etc.) in the product.

elimination of all overheating phenomena to

then conveyed to the processing lines.

manufactured by Raytec Vision.

energy saving.

protect the quality of the finished product.

C A

D11

E

F

G

H1

F - Pre-concentration: Apollo*

B

The refined juice can be sent to an initial concentration phase - from 4,5 to 9-10° Brix – in the Apollo pre-concentrator, which is a falling film evaporator with Mechanical Vapour Recompression (M.V.R.).

Line Composition

D21

This system allows an energy saving up to 40% with a subsequent reduction of operating costs. Thanks to the reduced residence time of the product and a 6 °C maximum

ΔT between heating vapours and

product, the organoleptic characteristics of the product have a particularly high quality level. * Optional

H2

I


Characteristics > Dynamic block diagram, with visualization of every drive and valve status, piping

Automation

colour according to the fluid contained in the same during every working step. > Indication of all working steps, with directions for the personnel. > Dynamic visualization of all controllers with real time trend.

The supervision system of the lines allows to visualize all the process

> Possibility to command and control every valve or drive in automatic

variables, file all the process data and carry out all operations required to

mode.

achieve the best plant management. The line management is carried out

> Operating parameters setting.

through a touch screen colour Personal Computer connected with the PLCs.

> Product parameters setting.

The supervision system is a 32 bit application based on an open software architecture, operating

with

the

Windows

operating system. It is possible to provide centralized control rooms for the management of one or more complete production lines.

> Process variables recording and graphic visualization. > Alarms recording and visualization. > Production data recording and visualization. Data can be exported directly from the ethernet network. > Possibility to print the historical data from a remote station and export them. > Remote assistance service, if required.

Construction features Working capacity for each line from

300 t/day

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up to

5000 t/day

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Advantages and strong points > No product carry-over towards cooling towers. > Long non-stop production cycles. > Maximum yield, minimum production waste.

After Sales Service

> High quality of finished product, preservation of colour and organoleptic characteristics.

Training

> Water recirculation system, minimum consumptions. > High versatility in sterilizing solutions and aseptic filling. > Opportunity to produce more than one product by means of

Large resources are dedicated to improve the education of customersâ&#x20AC;&#x2122; staff through training, by our specialized

the same line simultaneously. > Total absence of syneresis and black specks in the finished product. > Opportunity to obtain products with different viscosity values. > Lower thermal stress onto the product thanks to lower temperatures in the evaporator finisher.

technicians, on the production lines.

Technical assistance on site Important investments are constantly allocated in

Remote technical assistance 24/7 telephone assistance service, for the northern hemisphere during the processing season.

Upgrade Continuous technical update service for machines and existing lines.

order to improve the on-site assistance methods,

Spare parts

> Highest energy savings thanks to the most advanced technologies.

ensuring prompt interventions in the markets where

CFT pays a special attention to the constant supply

> Complete supervision system of the line and control of all

the type of equipment installed and the service

of its stores in order to arrange shipments as quickly

volumes require presence and availability.

as possible.

> No pools or product holding points during the process phases.

processing phases. > Recording, visualization and printing of daily production data. > Storage and keeping in aseptic rooms of semi-finished products, available for secondary processing.

Cold break

Hot break

> Capacity to obtain products with the required

> Capacity to obtain products with very high

Bostwick consistency, on the same line.

consistency (Bostwick 0)

> Reduced syneresis in the finished product.

> Total absence of syneresis in the finished product.

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C F T S.p. A Via Paradigna, 94/A - 43122 Parma - Italy

Twitter: @CFT_spa Facebook: CFTspa Google+: +CFTParmaspa Instagram: @CFT_spa LinkedIn: cft-s.p.a.

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