Bertuzzi supplies performing and reliable ketchup and vegetable sauces production lines according to the most advanced technology and designed to meet the most stringent hygienic international requirements and to be extremely flexible being able to process various recipes: with or without thickeners, with or without vegetable particles, with or without preservatives, filling at cold or hot temperature, etc.
Ingredients preparation
Depending by the capacity of the plant and on the recipe requested by the customer, different ingredient preparation groups can be foreseen to allow automatic (or semiautomatic) dosing and loading into the blending section. These groups can be:
Tomato paste dilution group: the tomato paste is diluted to approx. 20 brix to be transferred in the blending line;
Process water heating group with buffering tank;
Sugar dosing system and syrup preparation group. The group can be completed with a dedicated pasteurizer;
Salt dosing system and brine preparation group;
Starch, thickeners or preservatives dosing system and dissolving group;
Aroma, flavours or spices (liquid or powdered) dosing group;
Other ingredients like vegetable or fruit intermediates (for example concentrated fruit purees) dosing group;
Vegetables rehydration, pasteurization and dosing unit to add vegetable pieces, after pasteurization of the ketchup.
All the ingredient preparation groups are fully customized based on the available recipes.
A dedicated room for the loading of salt, sugar and starch that will be sent to the dedicated preparation groups.
Dosing system for fruit purees.
A vegetables rehydration, pasteurization and dosing group for the preparation of vegetable pieces to be added in the finished product
A syrup pasteurizer to reduce bacterial load in the syrup.
an automatic tomato paste in drum unloading system to be considered in case of high capacity plant
An automatic dosing system for powdered ingredients
Blending section
Bertuzzi foresees a very efficient blending system based on special horizontal mixing tanks. In order to shorter the batch time, the system can be designed to receive all the prepared ingredients simultaneously thanks to an advanced dosing system automatically controlled by the general control panel of the line. This allow to have high performances with high reliability on the recipes.
The horizontal blending action allow a better and homogeneous mixing of all ingredients
The system is fully automatized to guarantee the highest flexibility and reliability on recipes
Deaeration, homogenization and pasteurization
The blended ketchup (or vegetable sauce) ready to be pasteurized is delivered to fully integrated system that allow the following phases:
preheating to the product up to the deaerating temperature;
deaeration, thanks to a deaerator specifically designed for viscous products, of the product in order to reduce the potential oxidation;
homogenizing at high pressure to reduce the product fibres sizes, resulting in an increase of product viscosity. In case of ketchup recipes with starch the homogenization can be bypassed;
pasteurization and cooling at filling temperature (depending by the filling characteristics) with tubular heat exchanger;
As an option the product can pass through a dedicated shear mixer in order to give the shine glaze effect to the ketchup.
Before the filling the prepared vegetable pieces can be automatically injected into the product for the production of ketchup with solids.
A complete integrated group including pasteurizer, deaerator and high pressure homogenizer specifically designed for ketchup
A high capacity pasteurizer for ketchup
Sauces with dices
for the production of dices Bertuzzi can supply the Cubomatic, a dicing machine with high capacity designed to peel and dice tomatoes in one only operation. It can produce tomato dices with size 14, 16 or 18 mm.
Cubomatic dicer
Cleaning of the plant
All Bertuzzi lines are designed according to the international food grade requirements and to be fully cleanable by exploiting integrated cleaning procedures and systems or centralized and fully automatic CIP system. The Bertuzzi CipMatic is specifically designed to guarantee a perfect and efficent CIP of the fruit processing plants.
The huge distribution system of Bertuzzi CipMatic 10.000/6x5
a Bertuzzi CipMatic 3.000/3 installed in a juice and milk reconstitution line