Tomatoes will be arriving at the factory to be processed. First, the tomatoes need to be washed to remove any excess material that could contaminate the finished product. Then we will first need to choose the seedbed and green, unripe tomatoes from the high-quality tomatoes in order to produce high-quality tomato sauce after the fresh tomatoes have been cleaned by the bubble cleaning machine. After purchasing clean, high-quality fresh tomatoes, we will be using a tomato crusher to reduce them to 3-5 mm pieces.
We will then move the crushed tomatoes to a two-stage beater to create 0.4 to 0.6 mm tomato paste, however, using a tubular type before beating will increase the production of the juice.The tomato pulp is heated to 60°C in the preheater for 15 minutes. About 90% of the two-stage beater’s tomato pulp output is tomato pulp. The tomato pulp and seeds are removed from the tomato pulp after pounding. To prepare tomato puree, we employ a tubular preheater. Two procedures exist.
One method involves heating tomato paste that has been crushed and heating the tomato puree to 85–90°C for 10-15 minutes; the alternative involves cold-crushing tomato pulp and heating to 55–60°C for 10-15 minutes. Improve pulp yield, guarantee product viscosity, and soften tomato pulp so it is easier to separate and destroy pectinase activity to conserve more pectin. Raw tomato pulp (which is around 12 Brix) can be evaporated into tomato paste (which is either 28 Brix or 36 Brix), and then the tomato paste is heated in a tube sterilizer to remove the tomato paste.
The normal sterilizing method is 108-110C to maintain 1205. Bacteria get lengthy shelves. The tomato is placed into a sterile bag using a sterile filter after being treated in the sterilizing kettle. At a temperature of around 40°C, the sterilizing procedure is carried out in a sterile setting. The filling chamber will be steam sterilized and all procedures will take place in a full environment to ensure aseptic conditions. The tomato paste has a two-year shelf life in the sterile bag.
Tomato paste processing
In a tomato processing line, an automatic dumper unloads crates or bins. Adjustable pipes dump loose products from bins. The tomato is collected in a separation tank filled with purified water and connected with a chain conveyor to remove stones, dirt, and other elements. The product is processed.
Tomato sorting can be performed manually on roller conveyors in two phases: the first, in which the roller conveyor is inclined and the product is separated from water, foreign bodies, etc., and then washed; the second, in which the roller conveyor is horizontal and the tomato rotates on itself to allow accurate operator checking. Raytec Vision develops digital camera optical sorters and optical sorting sensors. Before squashing tomatoes, wash and sort them.
The BT60 chopping pump ensures perfect, homogenous, and fine product consistency in Cold-Break and Hot-Break cycles. By breaking at 4°C lower than typical in the Hot Break technique, energy can be saved. Eldorado inactivator inactivates pectolytic enzymes in Hot Break tomato paste to maintain pectins in the juice and improve consistency, color, and synaeresis. The Eldorado system can function at optimal efficiency even in the presence of foreign contaminants because of its high recirculation flow rate and sophisticated heat exchangers (such as weeds, leaves, vines, etc.).
Cold Break uses tomatoes. Cooking tomato puree in a tube preserves tastes and colors. Changing treatment temperature produces different products. The Giubileo extractor uses adjustable blades and centrifugal separation to extract warmed tomato juice. Fruit seeds and peel are removed. Separation generates high-quality juice and eliminates waste. Apollo pre-concentrator, a falling film evaporator with MVR, concentrates tomato juice to 4.5 to 12° Brix (MVR). MVR technology saves up to 98% steam during tomato concentration.
The organoleptic properties of the leaving product are excellent due to a reduced residence period and a maximum T of 6°C. The SFC Flash Cooler handles large volumes and long cycles. Sterilization by steam infusion and vacuum expansion (flash). SFC ensures product safety, asepsis, and integrity.
Olimpic TC can chill tomato paste. High-capacity indirect concentric tube heat exchangers with optimum heat exchange efficiency and process homogeneity thermally cycle product. The sterilized, refrigerated product is put into aseptic flexible bags. Macropak’s filling machine and microprocessor-guided inspection system maintain sterility. High-precision load cells weigh packaged products. After filling, steam cleans and sterilizes the spout.
What is tomato paste
Yes, but what precisely is tomato paste? Appropriate question! In essence, tomato paste is the result of cooking tomatoes for a very long time while squeezing out as much water, seeds, and skin as you can. Simply said, the tomato is quite concentrated. Tomato paste that has been double-concentrated is, in fact, significantly more concentrated. This is advantageous since less paste can impart the same taste as more chopped canned tomatoes, which is handy.
When fresh tomatoes aren’t in season, aren’t accessible, or take up too much room for another reason, it’s extremely useful. It may thus be used as a convenient tomato-based component in a variety of tomato-based recipes. Tomato paste is a powerful flavoring agent that can turn any dish into a tasty and delicious meal. Whether it’s a soup, a stew, or any other dish the tomato paste will give it a savory flavor. Tomato paste can also be used to make all kinds of tomato based sauces, such as ketchup, pasta sauce, spaghetti sauce, etc.
How is tomato paste made
Unexpectedly simple to produce is homemade tomato paste. All you need is a food processor, tomatoes, salt, olive oil, and a taste for an authentic Italian flavor. Also, time. It has a rich, smooth, caramelized flavor that is completely in contrast to the tinny flavor of canned tomato paste. I also produce the Roma tomato, therefore I use these two species to prepare my paste in addition to the delicious Marmande variety.
The flavor of homemade tomato paste is rich, mellow, and caramelized, as opposed to the acidity of store-bought tomato paste. It completely transforms your favorite recipes when applied. Depending on the type, I core and cut my tomatoes into quarters, but you may just do that and remove the stem end.
The tomatoes are first washed thoroughly to remove anything that can contaminate our paste, then they should be cut in half, there are many ways to pulp the tomatoes so you just need to find the method that is the most suitable and easy for you, after pulping the tomatoes with a blender or a food mill or a sieve, put them in the pot and bring them to a boil on medium high heat, then let it simmer until most of the water content has been evaporated and the liquid inside the pot is simmering slowly and loudly then turn off the heat and let the paste cool down. Now you can pour it into the desired containers and refrigerate or freeze it.
How is tomato paste made in a factory
The unloading location is reached by the trucks carrying fresh tomatoes. To allow the tomatoes to flow out of the aperture at the end of the trailer, an operator uses a special tube to inject a large amount of water into the pickup truck. The tomatoes may be transferred safely by using water. To move the tomatoes onto the roller elevator, rinse them, and then deliver them to the sorting station, water is continuously pumped. Materials other than the tomatoes are eliminated from the sorting station along with any green, discolored, or damaged tomatoes.
Although automated sorting technology is available in certain sites, this is mostly done by hand. The perfect tomatoes are pumped to the place where they will be sliced, the chopper area. The pulp is pre-heated to 85–95°C for hot break processing or 65–75°C for cool break processing. Juice removal: After the pulp, which consists of fiber, juice, pores, and skin, and seeds, is pumped through a removal unit comprised of a pulper and a refiner, two sizable sieves, it is then filtered.
These sieves enable the pulp to become either coarser or smoother, depending on the needs of the consumer. 95 percent of the pulp typically passes through both sieves. The remaining 5%, which consists of fiber, seeds, and skin, is regarded as trash and is sent from the station to be sold as animal feed. The improved juice is gathered in a huge holding tank, which continuously supplies the evaporator with food. The stage that requires the greatest energy in the production of tomato paste is evaporation.
The water is drained from the juice, which is still only 5% solid, at this point, turning the juice into tomato paste that is 28–36% concentrated. The operator simply needs to set the Brix value on the control panel for the desired amount of concentration since the evaporator automatically controls juice intake and final concentrate output.
Aseptic Filling: Most facilities use aseptic bags to package the finished product, ensuring that it never comes into contact with air before being delivered to the client. The concentrate is piped directly from the evaporator into an aseptic container before being put into large, pre-sterilized aseptic handbags at the aseptic filler. This process is known as aseptic filling. The concentrate can be stored for up to two years after being packaged.
Tomato paste can
Various tomato paste packaging methods are marketed in numerous magazine articles, at trade shows, in product flyers, etc. The most popular system is the tapered 220 l steel drum, which is available from most local drum manufacturers and is used throughout Europe and the Mediterranean tomato paste-producing regions.
IBCs, or intermediate bulk systems, have also been utilized for a long time, but on a much smaller scale. In this regard, aseptic barrier bags and plywood 1.200-kg containers have been widely used in the U.S.A. since their inception. While the 220 l steel tapered drum is essentially the norm in Europe, the 1.200 kg plywood box is the standard in the United States, although 200 l units are also commonly used there.
The usage of tomato paste comes with potential health risks. The packaging is primarily to blame for this. Because of the packaging that tomato paste is supplied in, Nigerians have come to refer to it as “Tin tomato.” Few manufacturers provide their products in sachets. Using tomato paste is about equivalent to purchasing fresh tomatoes and producing your own pastes.
However, they alter in composition when they are put into tins and cans. The linings of cans and the majority of plastic objects are coated with the hazardous chemical Bisphenol-A, which is the reason for this. This substance has the potential to contaminate food and endanger your health. The following list includes some of the risks associated with using tomato paste that has been packaged in cans or tins coated with bisphenol-A:
- Hormonal disruption: If bisphenol-A leaks into the tomato paste that will be used in cooking, it may affect human hormones. We are often in danger as a result of how long tomato paste is kept in tins or cans covered with this dangerous toxin.
- Risk of miscarriage: Without boring you with the details of this dangerous chemical’s chemistry, you run the risk of miscarriage if tomato paste contained in cans lined with it dissolves in your body and leaks into the bloodstream.
- Increased chance of cancer: There is a strong likelihood that some of the frequent customers may get cancer, just like with any processed product that has been packaged for an extended period of time. Consuming this product is not very healthy because the BPA chemical increases the risk of cancer and tomatoes are high offenders due to their high degree of acidity.
- Malfunction of organs in children: Although the country’s dire economic conditions have compelled many households to improvise and use tomato paste more frequently, this may not seem like a healthy option for the kids, especially if the tomato pastes are in cans and tins. As a result, they run the danger of ingesting the chemical Bisphenol-A (BPA), which may cause some of their organs to malfunction.
- Sperm defects: The chemical bisphenol-A has the capacity to impair male sperm growth. This indicates that regular consumption of this compound through the usage of tin tomato might decrease male fertility. BPA harms stem cells by mimicking the actions of estrogen.
