Blog Post | GEM Foodtech

Common Problems in Tomato Processing Machinery and How to Fix Them

Tomato processing machinery is essential for producing high-quality products like puree, paste, and sauces. However, like any industrial equipment, these machines can experience issues that affect productivity and product quality. Here are some common problems in tomato processing plant machinery and how to fix them.

Common Problems Faced in a Tomato Processing Plant in India

Clogging in Crushers and Pulpers

Problem: Over time, tomato skins, seeds, and pulp can accumulate in crushing and pulping machines, causing blockages and reducing efficiency.

Solution: Regular cleaning and maintenance are essential. Installing a self-cleaning filter or adjusting sieve sizes can help prevent clogs. Operators should also inspect the machine frequently to remove buildup before it becomes a major issue.

Inconsistent Pulp Quality

Problem: Variations in pulp texture and consistency can affect the quality of the final product, leading to customer dissatisfaction.

Solution: Check the blade sharpness and screen perforations in pulping machines. Dull blades or incorrect sieve sizes may cause inconsistencies. Additionally, ensure that tomatoes are processed at optimal ripeness to maintain uniformity.

Excessive Water Loss During Evaporation

Problem: When producing concentrated tomato paste or puree, excessive water evaporation can lead to reduced yield and inconsistent viscosity.

Solution: Proper calibration of evaporators is necessary. Adjusting temperature and pressure settings can help maintain the right concentration. Regularly check for leaks or faulty vacuum seals that may disrupt the evaporation process.

Overheating in Sterilisation Machines

Problem: Excessive heat in sterilisation machines can lead to burnt or altered tomato flavors, affecting product taste and quality.

Solution: Monitor and control temperature settings to avoid overheating. Ensure that the heat exchangers are functioning correctly and perform routine maintenance to prevent overheating issues.

Faulty Filling and Packaging Equipment

Problem: Packaging machines may experience issues like improper sealing, inaccurate filling, or leaks, leading to product wastage and contamination risks.

Solution: Regularly calibrate filling equipment to ensure accurate portioning. Check sealing elements for wear and replace them if necessary. Automated inspection systems can help detect defects before the products leave the facility.

Proper maintenance and timely troubleshooting of tomato processing machinery are crucial for smooth operations and high-quality products. A lot of these problems emerge from the low quality of tomato processing plant equipment. If you are looking for high-grade and quality tomato processing machinery, get in touch with GEM Foodtech. We can provide you with quality equipment for your tomato-processing needs.

Cleaning and Maintaining A Tomato Processing Plant – How Professionals Do It?

Cleaning a tomato processing plant is essential to ensure good quality processed products that meet health regulations. Moreover, a clean tomato processing plant will optimise the production level. If you keep the machine clean and maintained when it will last for a long time without incurring any repairing expenses. Thus, regular cleaning of the tomato processing plant is essential to improve productivity and prevent contamination of processed products. Companies manufacturing tomato processing plants in India provide guidelines to the users regarding the professional cleaning process.

Here’s an insight into the professional cleaning process that the manufacturing companies follow.

How Should Tomato Processing Plants be Cleaned and Maintained?

Establish a Cleaning Schedule

In order to clean the tomato processing plant properly, the companies need to establish a well-scheduled cleaning plan. This should include daily, weekly and monthly cleaning tasks to ensure that every part of the processing plant has been cleaned thoroughly. Daily cleaning focuses on the surfaces of the machine. Weekly cleaning addresses the drainage system, plumbing lines and the movable parts of the machine. Monthly cleaning involves a deep cleaning process where all the parts are removed, cleaned and inspected.

Clean all Parts Separately

During the monthly cleaning, all the parts are removed and cleaned separately. Before cleaning, the machinery is disassembled. Parts like hoppers, blades, and conveyors are cleaned separately to prevent contamination of tomato juice or pulp from the machine. The specialists use food-safe detergents to remove the tomato pulp and juice left over from the machine’s parts. The stuck residues are also cleaned with the help of a high-pressure water system.

Sanitise the Facility

Once the machine and its parts have been cleaned, proper sanitisation is conducted on the floor and the premises to ensure complete food safety. While cleaning and sanitising, proper attention should be paid to the areas where bacteria can accumulate. A proper inspection is done to check mould or fungal growth in and around the machine.

Clean and Inspect Plumbing Lines

When the cleaning is over, timely inspection should be ensured to ensure proper maintenance of the processing plant. During inspection, some of the moving parts are lubricated while others are replaced. The temperature control points and the plumbing lines connected with the processing plant are also checked to ensure that the processing plan maintains food safety throughout the process.

GEM Foodtech offers high-quality tomato processing plants, which are widely used by companies in the food processing industry. Our machines and processing units are made with high-end technology for better-processed products.

How is Mango Pulp Processing Work Done with Pulp Machines?

People love mango because it is the most rich tropical fruit in India that is rich in fat, protein, and sugar. It also includes vitamin, minerals and other high content of carotene. As one of the best tropical fruits, mango wins the hearts of fruit lovers. This is also known as the King of Tropical Fruits. Along with relieving thirst and fluid from the body, mango can prevent heat and vessel disease.

It can also moisten your skin. To manage the Mango Pulp Processing Line, a process is needed that can help in processing mango juice and pulp for deriving various products made of mango.

How does Mango Pulp Making Machine Works?

Mango can be processed in various types of products such as dried mango, mango juice, and mango pulp. Pulp processing is the most prevailing process to develop high nutrition products that are based on high yielding.

The mango pulp processing includes selecting, cleaning, pitting, peeling, pulping, pre cooking, concentrating, blending, sterilisation, filling, and cooling. The pre-treatment includes spray and brush cleaning, sorting, destoning, mango peeling, and other procedures.

Processing Flow of Mango Pulp

The mango customisation process involves the management of the exact functionalities on the basis of high-quality and high efficiency pulp maintenance. Have a look at the processing of mango pulp:

Raw Material Treatment

In this process, you can separate qualified, superior, and defective mangoes with the help of the fruit sorting machine. For making mango pulp, the acid and pectin content should be around 1%. If the raw materials do not reach the level, then the cleaning process can help in dealing with the pesticide and purification residue process.

Mango Pulping

Under the centrifuging and crushing of mangoes, you can use the mango pulping machine that can help in forming the fluid form of the mangoes.

Pulp Pre-Cooking Process

The crude mango pulp needs heating and softening the mango. The mangoes are cooked for 10 minutes at high temperature. When the colour becomes dark, then the processing is done.

Blending with Batching

After the batching and the heating process, you can use the mango pulp with a certain proportion of batches added. It is important to increase the volume with agar, pectin, and citric acid to maintain the acidic content.

GEM Foodtech follows a mango pulp processing line to produce various products made of mangoes such as jam, jelly, pickles, juice, squash, etc.

Ways to Enhance the Performance of your Dehydration Equipment

Dehydration is a critical process in the food processing industry. It preserves food by removing moisture. The demand for dehydrated products is high in India. So, investing in efficient dehydration equipment is essential. Proper maintenance and optimisation can improve the performance of these machines.

Understanding Dehydration Equipment Performance

Dehydration equipment is designed to extract moisture from food items, retaining their nutritional and aesthetic qualities in the process. To achieve optimal results, it’s important to focus on factors that directly affect its performance.

How to Take Care of Dehydration Equipment

Here are some practical ways to enhance the performance of your dehydration equipment:

Regular cleaning and maintenance: Accumulation of food particles and residues can reduce the efficiency of your dehydration equipment. Regular cleaning prevents blockages, ensures smooth airflow, and maintains hygiene standards. Scheduled maintenance also helps identify potential issues early. This reduces the downtime during operation.
Optimise airflow and temperature settings: The efficiency of dehydration equipment largely depends on proper airflow and temperature control. Ensure that air circulates evenly across all trays or racks. Calibrate temperature settings to suit the type of food being processed. Overheating or uneven airflow can result in inconsistent drying or product damage.
Use quality pre-treatment techniques: Pre-treating food before dehydration consists of several steps. These include blanching, slicing uniformly and applying anti-oxidants. These can improve dehydration efficiency and the quality of the final product. Consistent sizes and textures ensure even drying. Thus, you can prevent unneeded strain on the equipment.
Upgrade to energy-efficient components: Invest in modern energy-efficient fans, motors, and heaters. It can notably enhance equipment performance and lower operating costs. Retrofitting older equipment with energy-saving components is a cost-effective solution. It improves efficiency without investing in entirely new systems.
Monitor and document performance metrics: Regularly monitoring key performance indicators is essential. Look into the drying time, energy usage, and product quality to identify inefficiencies. Documenting these metrics can guide adjustments to processes and settings. This guarantees better performance over time.

Improving the performance of dehydration equipment is about more than just extending its lifespan. To buy quality equipment, you should contact a trusted source like GEM Foodtech. We are a trusted dealer of dehydration equipment in India. They are suited for vast applications in different industries. With proper maintenance, you can operate our equipment for a long time. For more information, you can visit our website today.

How to Choose the Right Equipment for Your Mango Pulp Processing Line

Choosing the right equipment for a mango pulp processing line is crucial. A suitable choice can ensure efficient production, high-quality output, and long-term profitability. A wide variety of machinery is available on the market. Understanding the factors influencing the selection process can make all the difference for manufacturers.

How to Select the Best Mango Pulp Processing Equipment?

Here are some key considerations when choosing equipment for your mango pulp processing line:

Production Scale and Capacity: The first step is determining the production scale. Whether you are setting up a small-scale operation or a large industrial plant, the capacity of each piece of mango pulp processing line equipment in India must align with your expected output. For smaller operations, compact machinery with lower capacity might be sufficient. However, for larger-scale operations, investing in high-capacity equipment is necessary. It can significantly increase throughput and reduce processing time.
Quality and Type of Mangoes Being Processed: Different varieties of mangoes may require specific handling. It is needed to retain the best flavour and quality. Consider equipment that can handle the particular variety you are processing. Consider vital factors like pulp consistency, fibre content, and sugar levels. Some machines are adjustable to accommodate these differences. It ensures the final product meets the desired standards.

Technology and Automation Level: Modern mango pulp processing lines offer a range of technology options. These include manual machinery and fully automated systems. Automation can enhance efficiency, reduce labour costs, and ensure consistent product quality. Automated equipment like sorting machines, pulpers, pasteurisers, and filling machines can streamline the process. However, manual options might be better for small-scale producers with more budget constraints.
Ease of Maintenance and Durability: High-quality, durable equipment can minimise downtime. It ensures a smooth operation of the processing line. Opt for machinery made from stainless steel and other food-grade materials. These are resistant to corrosion and easy to clean. Regular maintenance is essential so equipment that is easy to disassemble. Proper servicing can save both time and money in the long run.
Energy Efficiency and Sustainability: Energy-efficient machinery not only reduces operational costs. It also aligns with sustainable production practices. Look for equipment with energy-saving features. These include low-power motors and efficient heating systems for pasteurisation. Additionally, some equipment manufacturers offer eco-friendly designs. It will reduce water usage and waste and become a better choice for environmentally conscious producers.

Choosing the right equipment for a mango pulp processing line is vital. For a better choice, you can visit GEM Foodtech. We are a leading name for mango pulp processing equipment in India. Our tools offer efficiency and optimum functionality. For more details, visit our website today.

What Are The Costs Involved in Establishing a Tomato Processing Plant?

Tomatoes are a widely accepted vegetable which is a common ingredient in almost all Indian dishes. Apart from cooking, soups, sauces and tomato purees are a few forms of tomato pastes which are being widely used worldwide. To meet the growing demand for tomato pastes, food processing companies have resorted to using tomato processing plants.

These plants have the capability of squeezing the tomato puree out of the vegetable, grinding the same and converting it into a usable paste. However, the manufacturing and establishment cost of a tomato processing plant involves a lot of factors.

What are the Expenses Involved in the Establishment of a Tomato Processing Plant?

Cost of Equipment and Machinery

For processing of the tomato advanced and specialised machinery and equipment are necessary. The cost of equipment includes the cost of the washers, peelers, crushers, sorters and the evaporators as well. Companies that use high-quality automated machines for more production, have to bear high equipment costs.

Cost of Labour and Training Expenses

Labour cost is an ongoing expense for all tomato processing plants. Tomato processing plants are complex, hence the companies generally need extensive labour sources to operate these machineries. Hence this adds to the labour and training expenses of the company. Again adequate training programs are also required to ensure that the workers can operate the plants safely.

Cost of Raw Material

Tomatoes are the primary raw material which is used in the processing plant. However, the availability of tomatoes is subject to seasonal variations. Especially during summers getting tomatoes can be expensive. For raw material procurement, companies are required to negotiate with tomato growers and invest in the raw material procurement process.

Cost of Quality Control Process

Processing is not the end step. The companies need to invest in the quality control process as well. Expenses associated with quality control include labour charges, certifications, regular tests, checking shelf life and safety process and regulation expenses.

Cost of Packaging and Distribution

Expenses involved in packaging materials and the distribution process of the processes tomato play a significant role in determining the total cost of the tomato processing. Moreover, the packaging expenses also include the costs of the cans, glass jars, pouches and plastic containers where the processed tomato is being stored. Along with packaging distribution costs are also included in the same.

Get in touch with GEM Foodtech a leading manufacturer and exporter of tomato processing plants for the best quality tomato processing units.