Tomatoes are a cornerstone of food processing and culinary innovation worldwide. With rising consumer demand for value-added tomato products, food manufacturers and food processing consultants are exploring new ways to transform this perishable crop into shelf-stable, flavorful, and commercially viable offerings. This article delves into various novel tomato products, their manufacturing processes, and how food consultants and engineering experts play a pivotal role in enabling their production.
1. Tomato Chilli Sauce: A Spicy Twist to Classic Tomato Ketchup
Tomato chilli sauce is a popular condiment similar to tomato ketchup but with greater potential for product diversification in the food processing industry. Indian markets feature innovations like Tom-Chi (Tomato-Chilli Sauce) and Tom-Imli (Tomato-Tamarind Sauce). These sauces are designed to utilize excess tomato production and appeal to all age groups.
Key Features:
- Higher acetic acid (1.6%) for extended shelf life
- Increased sugar content (15–23%) to balance acidity
- Less spice than ketchup
- Modified viscosity using cereal or vegetable starch
Processing:
Green chilies are hot-break processed and pureed. Sugar, acid, and pungency are balanced for a pleasant taste profile. In tamarind-based varieties, tamarind pulp is combined with tomato puree to balance acidity.
2. Dried Tomato Products: Long Shelf-Life, High Utility
2.1 Dried Tomato Slices
Dried tomato slices are a ready-to-use ingredient with multiple culinary applications. They help minimize tomato waste and offer year-round usability.
Manufacturing Steps:
- Wash and blanch tomatoes in 2.5% salt solution
- Cut into 1.5 cm slices
- Dip in gelatinized starch + potassium meta-bisulphite
- Dry in tray dryer at 65–70°C until 4.5% moisture is reached
These can be powdered or packaged for bulk use.
2.2 Tomato Powder
Tomato powder is a versatile food ingredient used in sauces, soups, chutneys, and dry mixes.
Key Processing Techniques:
- Spray drying
- Foam mat drying
- Tray drying
Enhancement Additives:
- Maltodextrin (10%)
- Silicon dioxide (1%)
Best tomato varieties for powder:
- High pectin
- Thick walls
- Rich in solids & red pigments
Optimizing feed rate, air temperature, and atomization speed ensures high lycopene retention and minimal heat damage.
2.3 Whole Tomato in Sauce
This unique product offers whole, intact tomatoes preserved in sauce—a new niche in value-added tomato processing.
Steps Involved:
- Wash and select defect-free tomatoes
- Blanch and rapidly cool
- Pre-soak in brine/sugar solutions
- Add calcium salts to improve firmness
- Package in glass jars and thermally process at 80–85°C
Maintaining firmness and vibrant color is crucial for consumer appeal.
2.4 Whey-Tomato Soup: Nutrient-Rich Functional Food
Combining whey—a by-product of cheese and paneer manufacturing—with tomatoes creates a nutritionally rich soup base with added market value.
Steps:
- Blend vegetables in whey
- Add cooked corn flour
- Heat and package in retort pouches
- Process at 85–90°C for 30 minutes
Cheese whey is preferred over paneer whey due to its lower acidity. Whey proteins increase soup viscosity and reduce the need for additional salt and fats.
Conclusion
The development of novel tomato products—such as tomato chilli sauce, dried tomato slices, tomato powder, whole tomatoes in sauce, and whey-tomato soup—demonstrates the potential of food processing consultancy and engineering services to revolutionize traditional food products. These value-added products are ideal for food business consultancy services aiming to support startups, processors, and large-scale manufacturers in expanding product lines.
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