B2B - Industrial

When the fruit is received, the origin of each cargo of fresh tomato is identified by the Sugal Group Supplier Card and the Delivery Note describing the cargo (field, producer, variety, weight). 

That information is stored in a digital format for traceability purposes.

The tomato is then sent for weighing and grading (quality assessment). 

Based on a random sample taken from the cargo, all tomato entering our plants is evaluated according to the following quality parameters: degree of ripeness, colour, healthiness of the fruit, the presence of inert substances, brix and pH.

Only fruit that meets the quality criteria approved by the Sugal Group is accepted – the fruit must come from a Sugal Group approved supplier, be of an approved variety (registered and not genetically modified), be healthy, undamaged and perfectly ripe.

If the fruit does not meet the Sugal Group’s quality requirements the cargo will be rejected.

The tomatoes that comply with Sugal’s quality standards are unloaded at the unloading dock and carried to the production lines through channels with running water that carry the fruit and ensure it remains undamaged, while at the same time beginning the washing process.

The tomato is first washed, and then selected on a conveyer belt before being crushed.

Once the tomato has been crushed the enzymatic process begins; this has to be stopped in second, through heat to guarantee enzymatic inactivation.

The juice production stage is when the various manufacturing techniques are used to create products that vary in terms of consistency, texture and refining.

From the outset the temperatures reached in the heating stage vary in line with the desired consistency and type of product: 

– if the end product requires less consistency, a lower temperature is used and the output is called a COLD Break product

– if the end product requires more consistency, a higher temperature is used and the output is called a HOT Break product

– SEMI HOT BREAK or WARM BREAK products – These are intermediate products. 

– SUPER HOT BREAK products – These products have greater consistency.

(The different types of manufacturing processes usually call for different types of equipment.)

Once enzymatic inactivation has been guaranteed, skin and seeds are removed at a sieving or refining station where the tomato juice is drawn off.

As the name suggests, the tomato goes through a sieve – a filter with rotating blades that separate the skins and seeds from the juice.

The diameter of the sieve holes varies depending upon whether the end product should contain more or less skin and seeds:

         – Tomato paste and pulp products: sieves with 0.5mm to 1.5mm holes are normally used.

         – Crushed tomato or pizza sauce products: sieves with 0.8 to 4 mm holes are normally used (the largest hole allows some seeds and skin to pass).

Using a simple and highly automated method, water is drawn from the juice by applying vacuum and temperature.

The water is extracted as steam and condensation.

We are able to optimize the evaporation process by using more efficient and speedier equipment such as the pre-concentrator and the triple effect evaporator. 

By using the latest technology, we are able to be energy efficient and produce an end product that is:

• Quicker 
• More environmental-friendly 
• Fresher – since it has been less exposed to high temperatures – thus preserving its natural colour and flavour.

Concentration levels can range from 5% to 40% – degrees brix. 

At this stage the product is subjected to a high temperature for a period of time and then cooled quickly so that any bacteria are eliminated and the product is safe for human consumption.

This is a Critical Control Point.

The process ends with the filling and packing of the product.

Filling/packing is undertaken in a sterile chamber using aseptic bags (approved for use with foodstuffs), which are placed in metal or plastic containers.

The product is then stored in line with the type of packaging and shipped to the food industry or used to produce retail products in-house. 

We are always searching for new packaging methods that will ensure our products high quality and food safety.