Overview of Tomato Puree and Ketchup Manufacturing
Tomato puree processing is a critical segment of food manufacturing, especially within the food processing consultant and food factory design domains. A significant volume of raw tomatoes is required to produce tomato paste or puree. Since tomatoes contain approximately 95% water and 5% solids (Brix), around 5.6 kg of fresh tomatoes with 5% sugar are needed to produce 1 kg of tomato paste at 28% Brix.
There are two primary types of tomato paste used in manufacturing:
- Hot Break (HB) Paste: Used for tomato ketchup and sauces (Brix 28–30)
- Cold Break (CB) Paste: Used for triple concentrate paste (Brix 36–38)
A consistent supply of fresh tomatoes is essential for continuous operations. Any disruption may require complete system shutdown for cleaning, leading to production inefficiencies.
Key Steps in Tomato Puree Processing
1. Fresh Tomato Selection
For food industry consultants and food manufacturers, quality control starts here. Tomatoes must be:
- Fully ripe and deep red
- Free from blemishes and rot
- High in total soluble solids (TSS) and pectin
These factors directly impact flavor, shelf life, and finished product quality.
2. Unloading and Washing
Tomatoes are unloaded using:
- Automatic dumpers
- Inclined grids or roller conveyors
They are then washed in a tank with clean water and chain conveyors to remove foreign matter. This stage is crucial in ensuring GMP-compliant food plant operations.
3. Sorting Station
Tomatoes are transported via water and sorted to remove:
- Discolored, green, or damaged tomatoes
- Foreign materials
While manual sorting is common in small-scale units, large food factories use automated optical sorting systems.
4. Chopping
Sorted tomatoes are conveyed to choppers to prepare them for heat treatment.
5. Heat Treatment (Hot Break or Cold Break)
Depending on the desired final product:
- Cold Break (CB): Tomatoes are heated to 65–75°C for flavor and color retention
- Hot Break (HB): Tomatoes are heated to 85–100°C for higher viscosity
Advanced tube nest heat exchangers are used for enzymatic inactivation
6. Juice Extraction
The pulp is passed through:
- A pulper and refiner system
- Two sieves (coarse and fine)
7. Holding Tank
The refined juice is collected in a large stainless-steel holding tank, which supplies the evaporator continuously.
8. Evaporation and Concentration
This is the most energy-intensive stage. Juice (initially 5% solids) is concentrated to:
- 28% Brix for paste
- Up to 36% Brix for concentrate
Modern vacuum evaporators ensure energy efficiency and operate below 100°C, preserving quality. Operators can simply set the desired Brix level via control panels—essential for automated food factory design.
9. Aseptic Filling
Final product is:
- Transferred directly to aseptic bags
- Packaged in pre-sterilized containers
- Stored safely for up to two years
This method ensures zero air exposure, preventing microbial contamination and ensuring food safety compliance.
Addition of Essential Ingredients
During processing, spices and essential oils are added to enhance flavor:
- Common spices: Clove, black pepper, cinnamon, cumin
- Essential oils preserve taste and do not alter the color
These ingredients are adjusted based on the specific end-product like ketchup, sauces, or concentrates
Manual vs Automated Units: Scale Considerations
- Small-Scale Food Processing Units: Often involve manual sorting and chopping
- Large-Scale Tomato Ketchup Factories: Use fully automated lines with electronic control systems
Regardless of scale, hygiene and quality control are paramount in ensuring safe and premium-grade products—a core concern for any food manufacturing consultant or food business consultancy.
✅ Conclusion
Setting up a tomato puree processing unit requires strategic input from food consultants, food technology experts, and engineering consultants. From raw tomato intake to final aseptic packaging, each step demands technical precision, regulatory compliance, and a deep understanding of food factory operations.
Whether you're planning a turnkey tomato paste plant or upgrading an existing facility, consultancy for food industry projects ensures operational efficiency, product safety, and regulatory compliance.
5. Reference
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