Ing. A.Rossi

Purees natural and concentrate processing lines

Receiving

Receiving

TRANSFER YOUR PRODUCT AS

The modalities in which your product could arrive to our company are many: in 25 kg boxes, in 250 or 400 kg bins, or directly on the loading area of the trucks, and then to be discharged with hydraulic discharge. The Ing. A. Rossi receiving tankschannels and belts are suitable for any type of raw fruit conveyed, with different shapes and sizes depending on the type and quantity of product to be processed.

 

OUR SEPARATION SYSTEMS

We use screw or scraping systems for the separation of foreign materials in your product (stones, silt, sand, various objects). A further refinement in the elimination of foreign substances can be achieved by passing the discharging circuits at only one water to multiple water systems. According to the needs and capacities semi-automatic or automatic overturning bins systems can be provided.Specially designed for leaf vegetables processing, we use rotating baskets systems for coarse impurities separation from the product, as sand, earth, dry leaves, insects, etc.

Conveyors

Conveyors

TRANSPORT WITH HYDRAULIC CONVEYORS

During high production periods, or if the distance between the receiving or discharge area of the product and the selection and washing section is great, it is necessary to provide hydraulic conveyors for the transport of the product to the sorting tables. These conveyor systems can be installed underground so they do not interfere with moving vehicles in the service areas and can be built in stainless steel or in cement adequately coated.
Then to bring the product to other machines bucket or roller elevators can be used. In order to eliminate grassy residuals special weed removers can be used.

 

TRANSPORT WITH BELTS

For the handling of products for which hydraulic transport is not possible, we manufacture belt conveyors, suitably realized according to the specific needs of the Customer. The external structure of these systems is in stainless steel, whereas the conveyor belt can be either in canvas or in stainless meshes or in plastic material, according to the type of product to be transported.

Whashing machines and sorting tables

Whashing machines and sorting tables

ROLLER SORTING AND QUALITY CHECK

At the end of the receiving line the washing machines by spray or brushes and the roller sorting tables are placed. These stainless steel rollers allow the product both to move forward on the table and to rotate on its axis so that the employed personnel can carry out the quality check and verify the product integrity. A polypropylene waste conveyor with independent drive collects and removes the fruit deemed unsuitable.

 

SEPARATION WITH ROTATING BASKETS

A rotating basket system, consisting of a mesh cylinder entirely stainless steel made, allows heavy parts and impurities separation, as earth, dry leaves, stones and sand. The inclination of the basket allows the product progressing during the rotation, whereas all wastes are collected and removed by means of belts positioned under the basket itself.

Filtering systems

Filtering systems

THE QUALITY OF THE MANUFACTURING PROCESS IN RESPECT OF THE ENVIRONMENT

We, of Ing. A. Rossi, work thinking of getting maximum results with minimal environmental impact. In fact we use stainless steel drum filters in order to retain the impurities, which allow both the reuse of transport water and the limitation of water consumption. The impurities retained by the filter are removed by a scraper and by the auger.

 

WATER CYCLE

The filtered water is collected in a tank and can return to the line by pump or by exploiting the height difference between line and filters, generally placed on scaffolding a few meters high. Depending on the complexity of the receiving line you may generally have from 1 to 3 filters, one for each type of water present in the line: discharge water, the primary transport water and secondary transport water.

In line shredders and hammer mill ...

In line shredders and hammer mill choppers, presses, destoner machines, centrifuges units, decanters, enzymation and filtering, peeling and dicing

Ing. A. Rossi makes use of extensive processing for your product, adapting to your requirements and responding to specific needs.

  • IN LINE SHREDDERS OR HAMMER MILLS CHOPPERS
  • The in line shredder allows a rough chopping of the product, coarse or very fine, using different types of grilles. The product has easy access to the grilles, in order to facilitate the thermal exchange in the following stage of enzymatic deactivation, whether Cold Break Hot Break type. Another advantage of those choppers is that any grass filament escaped from the sorting inspections is chopped in order to prevent a partial or complete obstruction of the CB and HB groups exchanging pipes. The in line shredders are used for tomatoes and for some fruits without stones.
  • The floating hammer mills choppers of Ing. A. Rossi allow the treatment of apples, pears, carrots or peppers; fruits and vegetables, for which, immediately after the sorting stage, it is necessary to chop the product in order to allow the following processing operations.
  • PRESSES
  • They are necessary to obtain turbid or clarified juices from fruits such as apple.
  • DESTONER MACHINES AND STONE BRUSHING MACHINES BOTH WITH ROLLERS
  • For fruit such as peaches, plums, apricots or mango, for which it is necessary to separate the pulp from the stone and to recuperate the pulp that inevitably remains attached to it during the first separation stage.
  • CENTRIFUGATION GROUPS, DECANTERS, ENZYMATIC TREATMENT AND FILTRATION
  • Process accessories necessary for obtaining specific turbid and clarified fruit juices.
  • PEELING AND DICING
  • Required in case where the desired product is made from peeled or diced tomatoes.
Cold extraction

Cold extraction

COLD EXTRACTION FOR HIGH QUALITY PRODUCTS

In case it is necessary to obtain high quality and natural fruit or vegetable puree, Ing. A. Rossi offers alternatively to traditional hot extraction, a cold extraction to put before the enzymatic deactivation in the processing stages.
To ensure the maximum yield of the product, the cold extraction process consists of three different stages of chopping, separation and extraction. The fruit passes through a system so it simplifies the breaking of the pulp and the separation from the stones and finally arrives to the pulper where the peel, seeds and stones are removed.
All of extraction stages take place in a controlled environment, in order to avoid degradation of the product characteristics for the premature oxidation caused by the contact with oxygen.

Hot break

Hot break

HOT BREAK TREATMENT FOR TOMATO PROCESSING

The Hot Break treatment allows, thanks to the high temperatures reached (above 90°C), to stop the activity of the pectolytic enzymes responsible for the hydrolysis of the polysaccharides constituting the fruit structure and the resulting separation of the pulp from the serum.
The products treated with HB technology can be used, thanks to the high consistence of the juice thus obtained (in terms of Bostwick and the blotter), for the product production such as ketchup or pizza sauce.

 

HOT BREAK TREATMENT FOR FRUIT PROCESSING

Given the particularly sensitive nature of the fruit puree, such as apples, pears, peaches and apricots, Ing. A. Rossi has developed a technology in order to stop the activity of enzymes naturally contained in fruit and responsible for their structural disintegration.
The fruit HB groups with shorter high temperature permanence times thanks to holding pipes with lower volume. In this way the lower ratio between the circulating product and the inlet product reduces the thermal shock suffered by the pulp, allowing a more gradual transition to final temperatures, avoiding degradation in colour and taste.

Hot extraction

Hot extraction

SEPARATE PEELS AND SEEDS WITH HOT EXTRACTION

After the Hot Break and Cold Break enzymatic deactivation operations, it is necessary to separate the peels and seeds from the juice for concentration. Ing. A. Rossi offers a refined technology with over 60 years of experience, with different solutions depending on the requested capacities.
The Eureka turbo extractors for the hot extraction we work with have the following characteristics:

  • Single or double body with independent drive controlled by inverters;
  • Sieves of different sizes easily and quickly replaceable;
  • Removable paddles to allow an easy and economic replacement;
  • The distance between the paddles and the modifiable sieve with a simple adjustment also when machine is operating;
  • Automatisms for washing operations at regular intervals preset by water injections.
Double effect forced

Double effect forced

CIRCULATION EVAPORATORS (2D)

Completely made of stainless steel, the Ing.A.Rossi 2D series evaporators (double effect in two stages) represent the ideal solution for all situations in which the production capacity is between 150 and 500 T/day, or, when juice concentrates are the primary production (like apples, pears, peaches, apricots or other). The low temperatures allow maintaining a high quality of the final product colour. A feature much-sought in the fruit creamy products’ market.
All evaporators, both for tomato and for fruit, are coupled to pumps exclusively designed by Ing.A.Rossi, which are able to guarantee a perfect circulation of the product facilitating the thermal exchange and preventing the formation of black spots due to the overheating of the product inside the tube nests.

 

TRIPLE EFFECT (3T / ULTER)

Reaching a production capacity between 300 and 2.500 T/day, the 3T series evaporators (triple effect at 3 stages) and ULTER (triple effect at 4 stages) allow, compared to the 2D series evaporators, a reduced steam consumption while maintaining excellent results in all quality evaluation tests of the product obtained.
In the case of HB productions with capacities higher than 750T/day, such steam consumption is further reducible by inserting a flash tank upstream of the system.
Coupled to circulation pumps of exclusive design at 2 or 3 principles, the triple effect evaporators have stainless steel semi-barometric condensers for a production capacity up to 750 T/day and barometric condensers for larger sizes.
The low temperatures and the high exchanging surfaces give to the Ing.A.Rossi evaporators an advantage on the nominal capacities ranging between 12 and 20%, enabling users to cope with unexpected production peaks or to increase the production capacity of their installation without any additional cost.

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Hibrid evaporators

Hibrid evaporators

THOR PRE-CONCENTRATOR, OUR SOLUTION TO REDUCE CONSUMPTION

In recent years, it is increasingly requested to install pre-evaporation systems with mechanical vapour compression, to dramatically reduce energy consumption, both in terms of steam and power. Ing. A. Rossi, already capable to produce combined cycle systems (forced and falling film), has also studied and produced the THOR pre-concentrator in multiple copies and sizes designed according to the highest standards and capable of improving the finished product quality.

 

THOR, IDEAL IN THE TOMATO INDUSTRY

This technology has been specifically developed by Ing. A. Rossi to pre-concentrate a wide range of products having a intermediate viscosity difficult with fiber content and solid particles which have a moderate tendency to sediment on the exchanging pipes. THOR is widely used in the tomato industry, to concentrate natural tomato juice up to 10-12° Brix. The product obtained can be further concentrated in a forced circulation evaporators, or it can be used for the tomato puree production, as topping for peeled or diced and chopped tomatoes.
Thanks to its modular concept, the THOR pre-concentrator is able to cover a wide range of evaporation capacity, from 3 Ton/h up to 100 tons/h of evaporated water.

 

THE ADVANTAGES OF THOR PRE-EVAPORATOR

THOR is characterised with the following advantages:

  • 24H warranty for the entire tomato working season with semi-concentrated production of both for Cold and Hot Break;
  • High flexibility in the independent regulation of the evaporation capacity and of the juice inlet flow;
  • Delicate evaporation due to reduced temperature difference between the heating steams and the product;
  • Dwell time period highly reduced;
  • Machine in automatically stand-by mode without the need to replace the inlet product with water;
  • Easy transport of each evaporation module and reduced installation time at the Client's site;
  • Modest civil works to be carried out;
  • Possibility to visually monitor the operating parameters of each stage of the evaporation process.

 

MECHANICAL VAPOUR RECOMPRESSION: WITH A 360° SAVING

The THOR pre-concentrator has Mechanical Vapour Recompression (MVR). This technologically advanced device minimises the amount of steam required for its operation, thus allowing a significant savings in operating costs, a lower environmental impact and a reduction in the water requirements for the condenser.
The MVR involves the use of a centrifugal compressor driven by an external source of mechanical energy. This technology can enable to achieve a null consumption of heating steam with exceptional results in terms of savings, and it is often installed in conjunction with a steam turbine which drives the compressor and discharges low-pressure steam used at other points of the plant.

Tube in tube pasteurizers

Tube in tube pasteurizers

PASTEURIZATION TO INCREASE STORAGE TIMES

Once the production chain is completed, the elements responsible for product degradation must be inhibited in order to save the product preservation. Ing. A. Rossi uses a tubular pasteurizer with which the product to be packaged is brought to the pasteurization temperature. This type of processing is suitable for concentrated, semi-concentrated, fruit juice or fresh products, previously transformed to a direct packaging in glass, plastic, tinplate or brick.
The exchanger is composed of 4 concentric pipes in order to heat the product on two cylindrical surfaces and guaranteeing a uniform temperature inside. The thermo vector fluid is water heated by a direct steam injection.

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Tube in tube and scraped ...

Tube in tube and scraped surface sterilizers

STERILIZATION AND COOLING OF THE PRODUCT

In order to extend the preservation of treated products aseptic packaging, which consists in filling polifilm pre-sterilized bags with sterilized product at room temperature, is used. The product sterilization and cooling is obtained with tube in tube exchangers.
Composed of 4 or 2 concentric tubes, the exchangers include:

  • A product heating section with water overheated by a direct steam injection;
  • Up to the sterilization temperature, depending on the nature, pH, free water and previous treatments of the product;
  • A maintenance section at sterilization temperature and two cooling sections, the first generally cooled by tower water, and the second by refrigerated water or always by tower water.

Equipped with a washing and sterilization system with cooling constant pressure and with barriers in the dwelling and cooling sections (in order to prevent and avoid environmental contaminations), the Ing.A.Rossi sterilizers guarantee the right aseptic degree of the treated product and its preservation and stability in the warehouse.

SCRAPED SURFACE EXCHANGERS FOR COOLING

The presence of scraped surface exchangers allows the containing of circulation pressures , in periods when the high production of high-viscosity products and concentration that might affect at high temperatures the product texture (Bostwick and Blotter).
To avoid this, Ing.A.Rossi offers tube in tube heat exchangers for heating and temperature maintenance stages and scraped surface exchangers for cooling stages. This solution well suits tougher products in which concentration and viscosity are essential characteristics.
Completely scraped surface solutions may be developed for particular products with suspension ingredients or with particular viscosity such as ready sauces and purees, as well as in systems in which the great possibility of variations in the capacities would not be applicable to the pipe system.

Aseptic fillers

Aseptic fillers

SINGLE HEADED OR DOUBLE HEADED POLIPACK ASEPTIC FILLERS

The POLIPACK 200 M aseptic fillers are for 220 Lt (60 gl) bags and may be single-headed (model 1-200 M) or double-headed (model 2-200 M). Both models have loading and unloading rollers, a filling workstation area equipped with a mobile head, able to move vertically during the filling stage and a monitoring area.
 
A label printer and a jib crane to move full barrels and place them on pallets are provided too.  A system consisting of loading cells guarantees an accurate filling while steam barrels and various controlling instruments avoid the contamination of the product and of the filling environment.

EQUIPMENT AND PERFORMANCES

POLIPACK aseptic fillers can be combined with the small bags adapter (with capacities from 5 to 20 Lt), equipped with a continuous film bag supplier and discharge roller conveyor. The integration of the adapter’s operating parameters with the ones of the PLC filler allows the perfect compatibility of the two elements.

The aseptic fillers POLIPACK 200/4 - 1,000 M for bags having capacities of either 220 lt (60 gal) or 1.100 lt (300 gal) may be provided in a single-headed (1-200/4-1.000 M) or double-headed (2-200/4-1.000 M) model. Both models are equipped with motorized rollers conveyors for pallets/bins feeding and ejection, a mobile filling head, a monitoring workstation and a rotating roller conveyor underneath the filling head. This one allows the pallet rotation in order to place each of the 220 lt four bins right under the filling head. During the filling operation the head moves vertically to avoid the weight of the filled bag from causing laceration. An accurate filling is guaranteed by the presence of loading cells and flow meters, while steam barriers ensure an aseptic filling operation.

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