OMATO Cold and Hot Break Tomato Paste Lines
The Group and the History CFT (Catelli Food Technology), resulting from the merger of two historical brands in the field of food processing, Rossi & Catelli and Manzini, continues to be an undisputed leader for technological innovation, reliability and plant flexibility. Being a leading industry in tomato sector, CFT has developed complete lines, fully automated, for the production of Cold Break and Hot Break tomato concentrates and semi-concentrates. 22 million Tons of fresh tomatoes processed per year. 2
Tomato Paste Lines Designed to ensure the highest energy efficient production flexibility and an excellent preservation of the organoleptic characteristics of the treated product. The lines for tomato processing represent the confirmation of CFT s commitment to continuously surpass themselves through the constant search for more and more advanced technological solutions with which to obtain a high quality finished product, improve performances and lower production costs. 3
Cold Break tomato paste production The tomato paste obtained by Cold Break technology is a product with excellent organoleptic characteristics (good taste, good colour, sweet flavour), with not too high consistency values (>7 cm Bostwick), presence of syneresis. It is particularly suitable for direct consumption. In the production of Cold Break tomato paste, the sorted product is crushed and heated up to 65-70 C, a temperature that does not cause the complete inactivation of pectolytic enzymes, but guarantees an optimal performance in the following juice extraction and refining phase. Hot Break tomato paste production 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. 4
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 multiple effect evaporator, where the juice concentration takes place, or directly to the above mentioned evaporator. The tomato paste obtained is then submitted to a further phase of thermal treatment in heat exchangers, in order to achieve the pasteurization or sterilization temperature before being packaged. > The pasteurized product is destined to traditional packaging into cans of different types. > The sterilized product can be packaged in presterilized flexible bags, with capacities from 5 to 1500 l by means of aseptic fillers having one or more filling heads, 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 system which guarantees the sterility of the treated product. 5
Hot Break product 12-14 brix semi-tomato paste 16-18 brix semi tomato paste 22-24 brix tomato paste 28-30 brix double tomato paste Pizza sauce 22-24 brix Super Hot Break Cold Break product 12-14 brix semi-tomato paste 16-18 brix semi-tomato paste 22-24 brix tomato paste 28-30 brix double tomato paste 36-38 brix triple tomato paste 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 A Unloading and hydraulic transport system Chopping Juice extraction B Washing and sorting C D Pre-heating or Enzymatic inactivation E 6 Filtering and recirculating water group
I Pre concentration (optional) Sterilization and cooling Aseptic filling F H G Concentration H Pasteurization Hot filling Pasteurization Palletizing 7
A - Unloading and hydraulic transport system: SRH B - Washing and sorting C - Chopping Chopping pump: BT60 Product can be received in crates or bins (an automatic dumper provides for unloading of the raw material into the transport flume) or in bulk, too. In this latter case the unloading occurs by flooding the truck body by means of adjustable hoses. The product is separated from the water by one inclined grate or roller units, tomato is then collected into a grate separator tank, fed with cleaner water and equipped with a drag-chain conveyor to automatically remove stones, mud and foreign bodies. The product is then conveyed to the processing lines. Tomatoes sorting can be manually performed on roller tables in two phases: the first one, in which the roller table is inclined and where takes place the separation of the product from water, foreign bodies, etc., and then the washing by means of a sprayer series; the second one, in which the roller conveyor is horizontal, and tomato rotates on itself, in order to allow an accurate inspection by operators. The electronic sorting is performed by sensor optical sorters and/or by digital camera optical sorters manufactured by Raytec Vision. Washed and sorted tomatoes must be crushed in order to optimize the following phases of thermal treatment. The chopping pump model BT60, inserted both in the Cold-Break and the Hot-Break technological cycles, ensures a perfect, uniform and fine texture of the crushed product. In particular, as far as the Hot Break process is concerned, we can attain extremely low values in syneresis by means of break temperatures lower by almost 4 C, compared with the standard values, with a consequent energy saving. A Line Composition
D1 - Enzymatic inactivation: Eldorado D2 - Pre-heating: Cold Break E - Juice extraction: Giubileo For the production of Hot Break tomato paste the inactivator model Eldorado is used, which carries out the inactivation of pectolytic enzymes in order to preserve the pectins contained in the juice and obtain excellent consistency, colour and syneresis values. Thanks to its high recirculation flow-rate and the special geometry of its patented heat exchangers, the Eldorado system can run at its maximum efficiency over long periods of time even in the presence of foreign bodies (such as weeds, leaves, vines, etc.) in the product. Tomatoes destined to Cold Break tomato paste production are heated in the treatment unit model Cold Break, tube chest type, to perform a gradual heating of the product in order to preserve aromas and natural colours of tomato which distinguish this type of concentrate. Final product with various consistencies can be obtained by varying the treatment temperature. Crushed and preheated juice is sent to the extraction / refining phase which is carried out in the extractor model Giubileo using the principle of centrifugal separation by means of adjustable paddles and is able to remove the undesired parts of the fruit, as seeds and peels. The high efficiency of the separation process allows to obtain a high quality juice, to minimize the humidity of the waste and treat a wide range of products. C D11 B D21
G - Concentration: Venus H1 - Sterilization, Cooling: SFC Flash Cooler The refined juice, as it is or pre-concentrated at 9-10 Brix, is sent to the following concentration. The Venus plants are multiple effect evaporators with technology based on the patented principle of downward forced flow product circulation and positioning of the heat exchanger directly on top of the expansion chamber. Thanks to their structural characteristics it is possible to obtain very short product residence times inside the evaporator, the lowering of the average product circulation temperature, the elimination of all overheating phenomena to protect the quality of the finished product. SFC Flash Cooler represents the best solution for the treatment of big product volumes and for long running cycles. Product sterilization occurs by direct injection of culinary steam into the product and the cooling by vacuum expansion (flash). The SFC plant guarantees the highest processing safety, the aseptic conditions and integrity of the final product, and the preservation of product viscosity and initial quality. E F F - Pre-concentration: Apollo* 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.). 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 - Sterilization, Cooling: Olimpic The tomato paste is sterilized and cooled in the sterilizer Olimpic TC to be sent to the subsequent aseptic filling. The product is subject to a thermal cycle by means of indirect heat exchangers, concentric pipe type, with high production capacities and reduced amortization times, a maximum thermal exchange efficiency and process uniformity, and thanks to the constant product overpressure compared with the working fluids pressure, aseptic conditions are guaranteed during every single cycle phase. I - Aseptic filling: Macropak AF/2 The sterilized and cooled product is filled in presterilized flexible bags with different capacities by means of aseptic filling heads. The automation top level of Macropak fillers and the control system driven by a microprocessor with continuous monitoring of all working parameters ensure the packed product sterility. The packaged product weight control occurs by means of high precision load cells. Moreover, the machine uses steam both as a single sterilizing agent and for the spout washing after filling. G H1 I H2
Automation The supervision system of the lines allows to visualize all the process variables, file all the process data and carry out all operations required to achieve the best plant management. The line management is carried out through a touch screen colour Personal Computer connected with the PLCs. 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. 12
Characteristics > Dynamic block diagram, with visualization of every drive and valve status, piping 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. > Possibility to command and control every valve or drive in automatic mode. > Operating parameters setting. > Product parameters setting. > 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 up to 5000 t/day 13
> No product carry-over towards cooling towers. > Long non-stop production cycles. > Maximum yield, minimum production waste. > High quality of finished product, preservation of colour and organoleptic characteristics. > Water recirculation system, minimum consumptions. > High versatility in sterilizing solutions and aseptic filling. > Opportunity to produce more than one product by means of the same line simultaneously. Advantages and strong points > 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. > No pools or product holding points during the process phases. > Highest energy savings thanks to the most advanced technologies. > Complete supervision system of the line and control of all 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 > Capacity to obtain products with the required Bostwick consistency, on the same line. > Reduced syneresis in the finished product. Hot break > Capacity to obtain products with very high consistency (Bostwick 0) > Total absence of syneresis in the finished product. 14
After Sales Service Training Large resources are dedicated to improve the education of customers staff through training, by our specialized technicians, on the production lines. Technical assistance on site Important investments are constantly allocated in order to improve the on-site assistance methods, ensuring prompt interventions in the markets where the type of equipment installed and the service volumes require presence and availability. 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. Spare parts CFT pays a special attention to the constant supply of its stores in order to arrange shipments as quickly as possible. 15
CFT 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. www.cft-group.com