Tomato Processing

Tomato Processing
Dr. A.S. Kulkarni

Associate Professor
ADIT
Introduction
• Tomato (Lycopersicum esculantum) belongs to family Solanaceae.
• Tomato is one of the most popular and widely grown vegetable crops in the world.
It stands next only to potato in terms of production.
• India is fourth largest producer of tomato next only to China, USA and Turkey.
• In India, Bihar is the leader in terms of area under tomato crops, but Uttar Pradesh
leads is production as well as productivity.
• It is short duration vegetable crops and important cultivars of tomatoes grown in
India include Pusa ruby, Pant bahar, Pusa hybrid-1 & 2 and Arka Saurabh.
• Tomato is a very versatile vegetable for culinary purposes. Ripe tomato fruit is
consumed fresh as salads and utilized in the preparation of a large number of
processed products such as puree, paste, powder, Ketchup, sauce, soup and
canned whole fruit.
• The waste obtained after the juice or pulp extraction i.e. seeds and pomace is also
utilized for the extraction of tomato seed oil and lycopene, respectively.
Tomato Pulp and Juice Extraction
• Tomato juice and pulp are the major primary processed products of tomato which may
be utilized for the production of high value added products like puree, sauce, ketchup,
chutney, powder etc.
• All varieties of tomato are not suitable for processing point of view.
• The varieties which are used for juice and pulp manufacture must possess following
characteristics.
i. Deep red coloured varieties are preferred as yellow coloured pigments not only mask
the red colour in processed tomato products but these are also susceptible to oxidation
resulting in brown colouration.
ii. Firm but ripe fruits should always be used as they contain sufficient amount of pectin
which is essential for the consistency of the finished products like puree, sauce, ketchup
etc.
iii. Green coloured and sour varieties should not be used as they will affect the flavour and
colour of the resultant products.
iv. Tomatoes are also susceptible to microbial decay, hence any infected or diseased fruit
should never be used for the manufacture of products as they may pose health hazards.
Pulping or juice extraction
• Preliminary processing of tomato: After selection of
suitable fruits, they are washed in running water to remove all adhering dirt, dust,
foreign particles including fungal filaments and other microbes. On large scale
production plant, rotary washers or trough washers flitted with moving conveyer
belt and soft rubber brushes are generally employed.
• Trimming & sizing: Tomatoes are trimmed manually with the help of
knife to remove green, yellow coloured portion, decayed or infected parts and
stalks. The trimming losses may vary from 4 to 17% depending on the selection of
raw material. After trimming, tomatoes are cut into 4-6 small pieces of 0.4-0.6 inch
and crushed for juice extraction.
• Pulping or juice extraction: The tomato juice is probably one of the
most widely used juices. The juice extraction may be done either by hot pulping, or
cold pulping method.
Hot pulping
• Crushed tomatoes are boiled in their own juice in steam-
jacketed stainless steel kettles or aluminum pans for 3 to 5
minutes to facilitate pulping.
• The crushed or chopped tomato pieces are heated to at least
82OC for 15-20 seconds to inactivate pectic enzymes.
• On industrial scale heating is usually carried out in rotary coil
tanks followed by passing through a plate heat exchanger
(PHE) and holding tube to achieve a processing temperature of
104OC to retain at least 90% of the potential serum viscosity in
the original fresh tomato juice.
• At small scale crushed or whole tomatoes are pressure cooked
for 2-3 minutes.
Advantages
• Serum separation tendency in the product is checked, because of more
extraction of pectin present in skin and around the seeds. Heat treatment also
inactivates the enzymes (pectic enzymes specially polygalacturonase) that may
hydrolyze pectin and reduce the viscosity of the juice or
pulp. Polygalacturonase is highly heat resistance enzyme that cause splitting of
two adjacent galacturonic acid molecules and responsible for softening.
• Juice is quite viscous, heavy bodied and homogenous because of the
extraction of pectin and other soluble polysaccharides.
• Thermal treatment partially sterilizes the juice or pulp; thereby it decreases
the initial microbial load and product can be kept for longer period.
• Inactivation of oxidative enzymes i.e. ascorbic acid oxidase, prevent loss of
vitamin C.
• More juice yield as compared to cold pulping.
• Juice or pulp obtained by hot pulping process is deep red and attractive in
colour. It is because of the release of pigments located within the cell vacuoles
due to heating.
Cold pulping
• In cold pulping or cold break method tomatoes are scalded to
facilitate the separation of skin before chopping.
• Tomatoes are crushed or chopped at temperature less than 66 OC
and allowed to fall into a holding tank, where they remain for
few minutes.
• During this period the native cell wall hydrolyzing enzymes i.e.
pectinolytic enzymes of the tomatoes are liberated and catalyze
the various hydrolytic reactions to release the cellular
components.
• The cold break juice is better in terms of flavour, colour and
nutrients mainly vitamin C, but the juice is quite prone to
spoilage and quick processing of the extracted juice is necessary.
Disadvantages
• Extraction of juice from the interior of cell requires higher
pressure. Hence often juice yield become low, higher
pressure cause extraction as juice around the seeds, which is
more acidic and less sweet.
• Inferior colour (lighter) because of the less extraction of
pigments from the skin.
• Poor microbiological quality as comparison to hot break juice.
• Less nutrition due to oxidation of vitamin C resulting in loss.
• Cold extraction results in insufficient extraction of pectin and
other polysaccharides that may adversely affect the viscosity
or consistency.
Characteristics of tomato juice
• Juice should be free from skin, seeds and other
coarse parts of tomatoes.
• The product shall have pleasant taste and
flavour characteristic of tomatoes free from off
flavour and evidence of fermentation.
• The juice should have total soluble solids (TSS)
free of added salt to be not less than 5.0OBx.
• The pH of the tomato juice and pulp varies in
the range of 4.0 to 4.4.
Manufacturing of Tomato Puree and Paste
• The pulp which is obtained by hot or cold
break method is concentrated to manufacture
puree and paste.
• Fully mature and deep red coloured tomatoes
are preferred for the manufacture of tomato
puree and paste.
Tomato Puree
• Tomato juice or pulp as obtained by cold or hot
extraction method is concentrated to about 9.0 percent
to 12.0 percent total solids to prepare tomato puree.
• Commercial tomato puree can be defined as
concentrated tomato juice or pulp without skin or
seeds, with or without added salt and containing not
less than 9.0 percent salt free tomato solids, is medium
tomato puree.
• Further concentration to 12.0 percent solids will yield
heavy tomato puree.
Tomato Paste
• Tomato paste can be defined as concentrated tomato juice or
pulp without skin and seeds, and containing not less than 25
percent of tomato solids.
• If the tomato paste is further concentrated to a tomato solid
levels of 33 percent or more then it is called as concentrated
tomato paste.
• Tomato puree (A) and Tomato paste (B)

Process flow diagram for tomato puree or paste manufacture
Tomato Ketchup and Sauce
• As per FSSAI standards tomato ketchup and sauce means the
product prepared by blending tomato juice/puree/paste of
appropriate concentration with nutritive sweeteners, salt,
vinegar, spices and condiments and any other ingredient
suitable to the product and heating to the required
consistency.
• Tomato paste may be used after dilution with water suitable
for the purpose of maintaining the essential composition of
the product.
• The finished product should contain not less than 25.0
percent total soluble solids (salt free basis) and acidity not less
than 1.0 percent as acetic acid.
• Tomato ketchup and sauce can be made from freshly
extracted juice or pulp or using tomato puree or paste.
• Strained tomato juice or pulp along with spices, salt, sugar
and vinegar is cooked or concentrated to the extent that
ketchup and sauce contains not less than 12 percent
tomato solids, 25 percent total solids and minimum acidity
as 1% acetic acid.
• The TSS content in tomato ketchup should be 25-29 for
grade C, 29-33 for grade B and over 33 for grade A.
• Basically there is no difference between tomato ketch-up
and tomato sauce. Tomato sauce has thinner consistency
and it is blended with juice or pulp from other vegetable
sources including potato puree, cucumber juice or carrot
pulp.
Manufacturing of tomato ketchup
• Refer the lab manual.
Defects in Ketchup
• The two most common observed defects in ketchup are:
1. Serum separation: Due to cold pulping method.
2. Blackening specially around the neck: It is referred as Black neck
defect.
The tannins present in spices get extracted into the ketchup and
when these phenolic compounds come in contact with iron
leached out either from processing vessels or from the closure of
ketchup bottles, they form ferrous tannate.
This compound undergoes oxidation and form ferric tannate and
it is a black coloured compound. To check it one should not use
iron or copper utensils and headless clove should be used. The
inner lining of bottle cap should be of PVC.

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Tomato Processing

Dr. A.S. Kulkarni

• Tomato puree (A) and Tomato paste (B)

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