Commercial Tomato Ketchup Processing Line – Pasteurizing & High Viscosity Filling
This tomato ketchup processing line is specifically designed for viscous sauces including tomato ketchup, tomato sauce, and BBQ sauce, making it an ideal choice for condiment companies seeking standardized industrial production. The core process flow includes: raw material pretreatment, blending and mixing, colloid milling, vacuum deaeration, homogenization, tubular/scraped-surface sterilization, filling and sealing, labeling/coding, and secondary packaging. The process can be customized according to customer formulations.
The blending system incorporates a high-shear emulsifying tank with variable frequency mixing, rapidly and uniformly combining tomato paste base with sugar, salt, spices, thickeners, and other ingredients, preventing clumping and separation. The combination of colloid mill and homogenizer achieves product fineness below 20-50 microns, delivering smooth and delicate texture that significantly enhances product quality. The sterilization stage utilizes tubular or scraped-surface sterilizers specifically designed for high-viscosity and particle-containing sauces, ensuring thorough sterilization without compromising flavor structure. The filling system offers optional servo piston or rotary lobe pump fillers, compatible with glass bottles, PET bottles, and soft pouches, achieving filling accuracy of ±0.5% with capacities ranging from 500 to 20,000 bottles per hour.
The entire line is constructed of food-grade stainless steel, compliant with FDA and CE standards, and equipped with a CIP automatic cleaning system for convenient changeover between batches. The PLC control system can store up to 99 different sauce processing parameters, enabling one-touch recipe recall and reducing operator skill requirements. We provide end-to-end service including formulation advice, equipment selection, line layout design, installation commissioning, and production guidance. Our solutions are successfully deployed in tomato paste factories, condiment manufacturers, and fast-food supply chain operations. Send us your capacity requirements and raw material specifications, and we will provide a preliminary proposal and quotation within 24 hours.
Complete Production Process
FRESH TOMATO ⇒ CONVEYOR ⇒ WASHING ⇒ SORTING ⇒ CRUSHING ⇒ PREHEATING ⇒ PULPER & REFINER ⇒ EVAPORATING ⇒ STERILIZING ⇒ ASEPTIC FILLING ⇒ STORAGE OR BLENDING
Key Features
- Food-grade 304 stainless steel construction meeting FDA/CE standards
- Intelligent temperature control (±1℃ precision) for consistent quality
- Energy-saving design reducing operational costs by 25-30%
- Customizable capacity from 500kg/h to 10t/h
- PLC smart control system for automated operation
- Easy-to-clean structure with minimal maintenance requirements
- Versatile for various sauce types and packaging formats
Technical Specifications
| Product Name |
One-stop solution for tomato processing line |
| Fresh Fruit Input Capacity |
500kg per hour ~ 25 tons per hour |
| Raw Material |
Fresh tomato, tomato paste |
| End Product |
Tomato paste, tomato sauce or ketchup, tomato juice, etc |
| Final Product Brix |
28%~30%, 36%~38% |
| Main Machine Material |
Food grade SUS304 or SUS316 |
| Warranty |
12 months after commissioning |
This state-of-the-art tomato paste processing line integrates multiple operations, focusing on the complete tomato processing journey from initial raw material treatment to final product packaging. As a versatile production system, this line efficiently manufactures various tomato-derived products including tomato paste, tomato sauce, and tomato juice, spanning all essential processing stages.
Raw Material Preparation
The system includes comprehensive screening and cleaning components, where a vibrating screen eliminates flawed tomatoes and impurities while a high-pressure bubble cleaning machine with brush rollers thoroughly cleanses surfaces by removing mud, pesticide residues, and unwanted particles. Flexible conveying mechanisms prevent damage to tomato skins, establishing a pristine base for processing.
Crushing and Pulping
Following pretreatment, tomatoes are processed through a spiral crusher in low-temperature settings to retain nutrients and flavor. A double-stage pulping machine separates tomato pulp from peel and seeds, with the first stage eliminating larger impurities and the second stage providing fine pulping for desired consistency.
Concentration and Sterilization
Tomato pulp undergoes concentration in a vacuum concentration tank where excess water is extracted in a low-temperature vacuum environment (60-70°C). Solid content is concentrated between 10% to 30% as per specifications, preserving lycopene and essential nutrients. Concentrated pulp proceeds to tubular sterilizer using rapid high-temperature sterilization (121°C instant sterilization) to eradicate microorganisms while preventing flavor degradation.
Final Product Packaging
Sterilized tomato products are meticulously dispensed into packaging containers through an aseptic filling system maintaining an aseptic environment to prevent secondary contamination. Capping, sealing, labeling, coding, and boxing complete the packaging process, with some lines incorporating metal detection and weight detection systems to eliminate substandard products.
Final Products & Packaging
Available Packaging Options
- Aseptic bags
- Metal cans
- Sachets
- Stand-up pouches
- PP containers
- Glass bottles
- PET bottles
- Gable tops
Comprehensive Solutions
Technical Support
- Technical consultation
- Customized proposal design
- Equipment manufacturing
Implementation Services
- Installation, commissioning, and on-site training
- One-year after-sales guarantee
- Lifelong service
Additional Support
- Package design and purchasing support
- Marketing suggestions
- Factory building and design
After-Sales Service
- Debugging equipment
- Overseas technical support
- Overseas equipment maintenance
- English speaking engineers available
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