Tomato Paste Production

In Partial Fulfillment of the Requirements for the Course

Plant Design

Submitted by:

Cusipag, Jonelou A

Lozano, John Harvey S.

Telan, Melody Mae B.

Submitted to:

Engr. Leonard D. Agana

March 2019
 Table of Contents
A. Process Description........................................................................................................... 1

B. Material Balance ............................................................................................................... 5

C. Energy Balance ............................................................................................................... 14

D. Modified Block Flow Diagram ...................................................................................... 19

E. Process Flow Diagram .................................................................................................... 20

F. References........................................................................................................................ 21
A. Process Description
WASHING

The tomato is washed with clean water using about 3times by weight of tomatoes. Water
is introduced as spray. The reception area comprises of unloading system which includes
recirculation pump, staff platform, sludge and dirt discharge, and an air water bubbling system.
(Tomato Processing Plant, Tomato Ketchup Plant, Tomato Processing Machine, Tomato
Ketchup Machine., 2014)

SORTING

The tomatoes then arrive at the sorting station, after having been rinsed under a clean water
spraying system (preferably drinking water). At the sorting station, the staffs remove the green,
damaged, discolored, and excessively small tomatoes which are placed on a reject conveyor
(or an auger) and then collected in a storage unit or directly inside a truck to be taken away.
(Tomato Paste Processing, n.d.)

CRUSHING
Tomatoes are carried to a crushing unit, where they are processed into small pieces,
resulting in a mixture composed of liquid and solid parts. Crushing system uses a mill
containing a rotor that spins and crushes the tomatoes at high speeds. The resulting paste is
pumpable and ready for thermal treatment. (Tomato Processing Plant, Tomato Ketchup Plant,
Tomato Processing Machine, Tomato Ketchup Machine., 2014)

PREHEATING (Hot Breaking)

In preheating, the crushed tomatoes are heated at temperatures ranging from 85 to 100°C. Hot
break increases the viscosity in the tomato paste by using heat, is technically identified as the
enzymatic inactivation procedure. (Fenco Food Machinery, 2014)

PULPING

The crushed tomato is fed into an electrically driven mechanical pulper. This separates the
juice from seeds and skins. The tomatoes are rubbed against a perforated drum by two brushes
which are fixed to the central shaft driven directly by the motor. The juice passes through the
perforated drum into the outer stationary drum and collected through an outlet. The remaining
seeds and skins are pushed out through an outlet connected to the inner perforated drum.

1
REFINING

At the refiner section, further juice is recovered from the seed and peels.

HOMOGENIZATION

The high pressure homogenization (HPH) technology consists of pressurizing a fluid to

flow through a narrow gap valve, which greatly increases its velocity, resulting in
depressurization with consequent cavitation and high shear stress. Thus the macromolecules
and suspended particles in the fluid (as cells and its fragments) are subjected to high mechanical
stress, which are twisted and deformed.

The tomato pulp contributes many relatively special particles, which are insoluble in water
and which must be reduced in size and uniformly dispersed throughout the product. If this is
done, a product with an excessively rough texture will result. Further, since the carotene
pigment is contained in these particles of pulp, failure to properly disperse them will result in
a product with poor uniformity and depth of color.

EVAPORATION

The juice in this storage tank is fed to the evaporator which automatically regulates juice
intake and finished concentrate. The juice inside the evaporator passes through different stages
(also called effects) where its concentration level will gradually increase until the required
density is obtained in the final stage or “finisher”. Here the tomato paste is automatically
extracted via a pump.

The entire concentration process (evaporation) takes place under vacuum conditions and at
low temperatures, significantly below 100°C. Product circulation inside the various concentric
tubular exchangers is carried out by special stainless steel pumps which are designed to ensure
that the product is conveyed inside the exchanger tubes at a speed of over 1.2 m/sec to avoid
“flash evaporation” thus avoiding to get burnt. This means it is possible to process for extensive
periods without having to shut down the machine.

Evaporator output is measured in liters of evaporated water per hour while concentrating
tomato juice with an initial 5°Brix concentration and producing tomato paste double
concentrate at 30° Brix. All the tomato juice evaporators are designed according to these
parameters. The evaporative capacity of tomato juice concentrators is greatly influenced by the
viscosity level. If the tomato paste has a low Bostwick value, then the concentrator’s output

2
level will also be low; on the other hand, a higher Bostwick value means an increased output
level.

STERILIZATION, ASEPTIC PROCESS TO PRODUCT STORAGE

The concentrate is sent from the evaporator directly inside the aseptic system tank. From
here it is pumped at high pressure inside the aseptic sterilizer-cooler and then to the aseptic
filler, where it is filled into pre-sterilized aseptic bags housed in metal drums. The sterilization
temperature and the holding time vary according to the product’s pH value. Generally speaking,
a product with a pH value equal to or less than 4.2 could have a sterilization temperature of
115°C measured at the end of the holding section, and a holding time of at least 60-90 seconds.
On the other hand, if the pH value is greater than 4.2, it is advisable to acidify the product in
order to bring it to about 4.1, improving taste and final product quality, thanks also to the
reduced sterilizing temperatures/time. The sterilized tomato paste is cooled down to about 35-
38°C before being piped into pre-sterilized aluminum bags housed in special metal or plastic
bins via a special aseptic filler. The packaged concentrate can be kept up to 24 months
depending on its pH value and ambient conditions. When storing for over 12 months, it is
however advisable to conserve it in refrigerated cells, more to reduce oxidization, which could
cause darkening than to protect the product’s aseptic quality.

3
Block Flow Diagram

4
B. Material Balance
Assumptions:
1. A basis of 100 kg/h feed flowrate was taken which was later reverted back to
original basis.
2. Steady-state operating conditions were assumed for each equipment.
3. Tomato is made up of 7% TS (Total solids) and 93% water.

WASHER
W1=300

F =100 kg
Washer X1
H2O = 0.93
TS = 0.07

W2=300

The tomato feed is washed 3 times by weight of water entering at stream W 1.

OMB: F  W1 W2  X1

Where: W1 = Input washing water

W2 = Output wastewater

F = Input tomato into washer

X1 = Output tomato from the washer

100 300  300  X1

X1 100 kg/h

5
SORTER

X1 = 100
H2O = 0.93 Sorter X1
TS = 0.07

Culls = 0.05X1
Assumption: 5% tomato is sorted as culls

OMB:
100  X 2x  0.05(100)
X 2  100  [0.05(100)]
X 2  100  5
X 2  95kg
Material in = material out for both crusher and preheater

PULPER

X2 = 95
Pulper X3
H2O = 0.93

Y1 = 0.065X2

Where: X2 = crushed tomatoes

X3 = tomato juice

Y1 = pomace

6
Assumption: 6.5% of the crushed tomato is pomace

Y10.065 (95)
Y16.175

OMB:
X 2 X 3 0.065 X 2
95  X 3  0.065 (95)
X 3  88.821
REFINER

Z1 =Y1 -Y2

Y1 = 0.065X2 Refiner Y1 = 0.065X2

Where: Y1 = pomace

Y2 = reduced moisture pomace

Z1 = moisture

Tomato pomace and skins are high-moisture products (often more than 80% moisture). Also
assumed refiner efficiency is 95 %.

OMB:

Y2  amount of moisture in pomace  efficiency of refiner

Y2  0.8(0.95)(6.175)  4.693

Y1  Y2  Z1
6.175  4.693  Z1
Z11.482

7
HOMOGENIZER

Y2

X3 X4
Homogenizer

X 4  X 3  Y2
X 4  88.82  4.69
X 4 93.51 kg

EVAPORATOR

100% H2O
Z2
0 % TS

93 % H2O 70 % H2O
X4 Evaporator X5
7 % TS 30 % TS

Where: X5 = tomato pace

Z2 = water evaporator

Component Balance:

93.5 (0.93)  Z2  X 5 (0.70)

93.5 (0.07)  0 X 5(0.70)
93.5 (0.07)
X5 
0.3
X 5  21.8 kg

8
Therefore the processing ratio

100 kg tomato feed


21.8 kg tomato paste
 4.6

This shows that the plant requires a processing ratio of 4.6 kg of raw tomatoes to give 1 kg of
tomato paste. This gives a better processing ratio of 5 to 7 kg of raw tomatoes to 1 kg of tomato
paste reported by FAO, 2009.

Z 2  93.51  21.8
Z 2  71.7 kg

With the actual processing ratio figured out, the following calculations are thereof the actual
production specifics of the process,

Actual Production

WASHER

W1=300

F =100 kg
Washer
H2O = 0.93
TS = 0.07

X1
W2=300

100 kg tomato feed F kg tomato paste


21.8 kg tomato paste 1800 kg
1800 tons  tomato paste
1 tons
F kg tomato feed  8256880.734 kg tomato feed
F kg tomato feed  8256.9 tons/day

9
OMB:
F  W1 W2  X1

tons tons tons

8256.9  300  300  X1
day day day
tons
X1  F  8256.9
day

SORTER

X1 = 8256.9
H2O = 0.93 Sorter X1
TS = 0.07

Culls = 0.05X1

8256.9  X 2  0.058256.9
tons
X 2  7844.055
day

Culls  0.058256.9
tons
Cullss  412.845
day

NOTE: material in  material out fo r crusher and preheater

PULPER

X2 = 7844.055 Pulper
Y1

X3, tomato pulp going to

homogenizer

10
 Y1  0.065 7844.055
tons
Y1  509.864
day

OMB:

X 2  X 3  0.065X 2
7844.055  X 3  0.0657844.055
tons
X 3  7334.19
day

REFINER

Y1 = 0.065X2 Refiner Y1 = 0.065X2

Y2, reduced moisture pomace going to homogenizer

OMB:
Y2  0.8 0.957334.19
 tons 
Y2  385.99  
 day 

Z1  Y1  Y2
tons
Z  (509.864  385.99)
day
tons
Z  123.874
day

11
HOMOGENIZER

X3 from pulper

Homogenizer Y2 from refiner

X4, homogenized

OMB:
X 4  X 3  Y2

X 4  7334.19  385.99
tons
day
tons
X 4  7720.18
day

EVAPORATOR

100% H2O
Z2
0 % TS

93 % H2O 70 % H2O
X4 X5
7 % TS Evaporator 30 % TS

Z2

12
Component Balance:
7720.18 (0.93)  Z 2  X 5 (0.70)
7720.18 (0.07)  0 X 5 (0.70)
7720.18 (0.07)
X5 
0.3
tons
X 5 1801.375
day
Substituting X5 in Equation 1:
Z 2  7720.18(0.93)  1801.375(0.70)
tons
Z 2  5918.805
day

13
C. Energy Balance
PREHEATER

Cpf = (specific heat capacity of tomatoes) =3.98 kJ/ºC

Tfin=30ºC

Tfout = 92ºC

Incoming steam: saturated at 110ºC

Condensation latent heat, obtained from saturated steam tables for saturated steam at 110ºC,

kJ
λ s  2229.7
kg

Energy Balance:

Q  m λ s  m f c pf Tfout  Tfin 
.

.  kJ   kg  kJ 
m 222.9    7844036.697  3.98 92  32 C
 kg   day  kgC 
. kg
m  868096.3786
day
. kg
m  868096.3786
day
. tons
m  868.096
day

EVAPORATOR

(Feedforward arrangement)
w1 w2 w3

ms

mf
Tf = 92o C
mp
Tp = 45oC

14
Assume (no BPE)

Temperature of Steam Overall Heat Transfer Coefficient

T1st effect = 110ºC U1 = 3000 W/m2K
U2 = 2000 W/m2K
T3rd effect = 45ºC U3= 1000 W/m2K
Temperature of Incoming Feed 92ºC
Temperature of Product 45 ºC

The boiling point of tomato juice is very small and it can be neglected.

For thermal Loads in each effect, that is Q1  Q 2  Q 3

U1A1ΔT1  U 2 A 2 ΔT3  U 3 A 3 ΔT3

or for equal areas in each effect;

U1 A1ΔT1  U 2 A 2 ΔT2  U 3 A 3 ΔT3

U1ΔT1  U 2 ΔT2  U 3 ΔT3
3000T1  2000T2  1000T3
2
ΔT1  ΔT2
3
ΔT3  2ΔΔ2

 ΔT  ΔT 1  ΔT2  ΔT3  383  318K  65K

2
ΔT2  ΔT2  2ΔΔ2  65K
3
195
ΔT2  17.727 or
11
130
ΔT1  11.818 or
11
390
ΔT3  35.455 or
11

15
 T1  383  11.818K  371.182K  98.182C; λ  2261.19952
kJ
kg

T2  371.102  17.727 K  353.455K  80.455C; λ  2306.8443

kJ
kg

T3  353.455  35.455K  318K  45C; λ  2394

kJ
kg

At

kJ
T1s  110C, λ  2229.7
kg
kJ
T3s  45C, λ  2394.
kg

W1  2261.19952x10 3  W2 x 2306.8443x10 3
 W3 x 2394x10 3
 Ws x 2229.7x10 3

W1  W2  W3  total water evaporated  5918.8049

 2261.19952 
W2  W1 x  
 2306.8443 
W2  0.9802W1

 2261.19952 
W3  W1 x  
 2394 
W3  0.9445W1

 2261.19952 
Ws  W1 x  
 2229.7 
Ws  1.014W1

tons
W1  0.9802W1  0.9445W1  5918.8049
day

W1 1  0.9802  0.9445  5918.8049

tons
day

16
 tons
W1  2023.7306
day
tons
W2  1983.7306
day
tons
W3  1911.6607
day
tons
Ws  2052.2652
day

2052.2652 tons
Steam consumptio n 
5918.8049 day
tons steam
 0.35
ton water evaporated

FCpf Tf  Tref   Qduty  PCpp (Tp  Tref )  Vλ fg

kg  kJ   kg  kJ  2052.265x1 03 kg  kJ 
7720180  3.98 98.182C  92C  Qduty  1800000  3.98 45C  92C   2229.7 
day  kgC   day  kg C  day  kg 
kJ
Qduty  4.0493x10 9
day

q 1  m s λ s  FC pf T1  Tf   W1 λ s
 tons  1000kg  kJ 
q 1   2052.2652   2229.7 
 day  1ton  kg 
kJ
q 1  4.5759x10 9  q2  q3
kg

q1  U1A1ΔT1
q1
A1 
U1ΔT1

kJ 1day 1h 1000J
4.5759x10 9 x x x
day 24h 3600s 1kJ
A1 
1 J 
 W   s
 3000 2 11.818K 
 m K   1W 
 
A 1  1493.817 m  A 2  A 3
2

17
STERILIZER


Q  m λ s  m f c pf Tfout  Tfin 
.

Tfin  45 C
Tfout  40 C

 kJ   kg  kJ 
m s  2229.7   1800000  3.98 40C  45C
 kg   day  kg C 
kg
m s  16064.94147
day
tons
m s  160.649x10 3
day

 tons  kJ  1000kg 
Q  160.649x10 3  2229.7  
 day  day  1ton 
kg
Q  35820000
day
kJ
Q  3.582x10 7
day

18
D. Modified Block Flow Diagram

19
E. Process Flow Diagram

20
F. References
Fenco Food Machinery. (2014). Retrieved from Equipment for Tomato Paste Production.

Gallaher, D. M. (1999). United States Patent No. US 415011 .

Tomato Processing Plant, Tomato Ketchup Plant, Tomato Processing Machine, Tomato
Ketchup Machine. (2014).

Tomato Paste Processing. (n.d.). Retrieved September 3, 2014, from www.tomatojos.net/08-

tomato-paste-processing

21
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