How is Tomato Sauce Mass-Produced?

Overview of Tomato Production

• The factory produces approximately 200,000 kilos of tomato sauce daily, requiring massive harvesters to collect millions of fresh tomatoes.

• California supplies 95% of the tomatoes harvested in the U.S. each year; warm days enhance their flavor and a thick-skinned variety is cultivated for efficient harvesting.

Harvesting Process

• Advanced technology has transformed tomato harvesting; a mobile harvester operated by four workers cuts roots and transports plants via conveyor belts.

• Metal spikes shake tomatoes free from vines while separating heavier fruits from waste, which is recycled as fertilizer for future crops.

Sorting and Transporting Tomatoes

• A laser scanner distinguishes ripe red tomatoes from unripe green ones, ensuring only quality produce enters the machine.

• Each truck carries exactly 22 tons of tomatoes with minimal damage during transport; up to 2.5 million tomatoes are delivered daily to the processing plant.

Initial Cleaning Process

• Tomatoes are washed using water jets that remove dirt before entering a clean channel where stones sink and are discarded.

• In large tanks, gentle agitation further cleanses the tomatoes while preventing bruising; they then proceed through an electronic sorting line.

Peeling and Cutting Tomatoes

• Damaged or unripe fruits are swiftly removed by pneumatic fingers in less than a second before being immersed in hot water to loosen skins.

• After peeling, remaining skins are washed away through rubber discs, ensuring no residue remains on the peeled tomatoes.

Processing into Sauce

• Peeled tomatoes move along conveyors towards cutting machines equipped with stainless steel blades capable of slicing four kilos per second.

• As cut pieces pass workers who check for quality, empty aluminum cans are prepared for filling at high demand rates.

Final Steps in Sauce Production

• Cans undergo ionized air blasts for cleanliness before being filled with crushed tomato puree made by specialized machines that blend ingredients efficiently.

• The puree is filtered to eliminate seeds and skin remnants, creating a smooth sauce essential for texture and flavor consistency.

Cooking Process

• Cooked in large stainless-steel pots heated by steam, the tomato mixture is continuously stirred to prevent burning; this process can take several hours.

How is Tomato Sauce Made?

Mixing Ingredients

• The process begins with mixing fried oil and other ingredients such as salt, sugar, spices, and vinegar. This step is crucial for achieving a uniform flavor in the tomato sauce.

• The mixture must be blended for 20 minutes to ensure good homogenization of all components.

• Approximately 200,000 kilograms of tomato sauce are produced daily in this factory.

Pasteurization Process

• After mixing, the tomato sauce is pumped through pipes to the pasteurization room where it is heated to high temperatures. This step kills any bacteria or microorganisms present.

• The heating process ensures a longer shelf life for the product by eliminating harmful pathogens before cooling it down for packaging.

Filling and Sealing Cans

• In the filling room, aluminum cans are lined up and filled with tomato sauce by an automated filling machine.

• The sealing process involves displacing air from the can using steam before placing a lid on it. This creates an airtight seal essential for preservation.

Packaging and Labeling

• Aluminum layers form a barrier that prevents oxygen contact with the product, allowing the sauce to have a shelf life of up to 9 months.