NATIONAL AGRARIAN UNIVERSITY LA MOLINA

FACULTY OF FOOD INDUSTRIES

ACADEMIC DEPARTMENT OF FOOD ENGINEERING AND

AGRICULTURAL PRODUCTS (I.A.P.A)

Deliverable No. 4:

MEMBERS CODE

Carrasco Fidel, Luis 20170247

Gaspar Limache, Deyvi Cesar February 28, 2017
Mamani Olgado, Lizbeth Raquel 20170245
Rodriguez Diaz, Jamerccy Hylda Victoria 20170236

Professor: Mg. Elizabeth Villanueva Quejía

Course: Machinery for the Food Industry
Practice group: G/F Wednesday 2:00 - 4:00 pm.

2020-I
 I. INTRODUCTION

The tomato has important nutritional properties. It is one of the foods with
higher lycopene content, a pigment that gives it the characteristic red color and
what is a powerful antioxidant that helps reduce the incidence of
cancerous diseases, such as those of the lungs, prostate, and digestive tract, in addition to

cardiovascular diseases and others associated with aging. The tomato is

also rich in vitamins A, C, and minerals.
To make the paste, the tomatoes are ground to extract the pulp, which is
concentrated in evaporators. Additives and flavorings are added, it is homogenized.
and pasteurized, to finally be packaged. In this process, many of the
components are concentrates, which makes this product an excellent source of
lycopene and other nutrients.

II. PROCESS FOR AN INDUSTRIAL PLANT FOR THE MANUFACTURE OF

TOMATO PASTE

Description of the process

According to Rosero Velasco, D. & Ramirez Navas J., (2007) the process begins in the

receipt of the tomato, then it is weighed using a floor scale, then

the tomatoes are moved to a conveyor belt where they are washed and sorted from
according to the company's requirements, in this stage impurities such as are eliminated
like twigs, soil, leaves, etc.
The tomato is placed in a basket where it is taken to a hammer mill; it is there
where the whole tomato is introduced and the result will be in pieces not very small and
Subsequently, the tomato is transferred to the pulper where the seeds are removed.
and the skin of the tomato the result there will be a tomato pulp, then it is taken to
weigh to check the mass balance, then it is transferred to an evaporator which
concentrate the tomato paste here the concentration should be measured in degrees brix
in addition to the percentage of soluble solids since in evaporation the
excess water and that gives us new characteristics of the product. Subsequently the
Tomato paste is transferred to a pot where a series of products are added.
such as sugar, salt, among other species that are mixed to obtain the
desired flavors by the company, at the same time a process occurs of
pasteurization at 80°C for approximately 20 minutes is carried out to prevent the
proliferation of bacteria and other microorganisms, then the tomato paste is
taken to be bottled in glass jars that have been previously sterilized
this stage is performed at 80 °C for approximately two minutes, it is important to place
the lid quickly should then be allowed to cool to create a vacuum environment
which makes it have a longer lifespan, it will eventually be taken to
label and store in a low light environment.

2.1 Receipt of raw materials: Tomatoes must be received in containers.

clean and dry. The tomatoes must be ripe with a shape, color, and size
suitable.

2.2 Heavy: It consists of quantifying the tomato that will enter the process in order to be able to

determine yields later.

2.3 Washing and selection: The tomato is washed with non-chlorinated water and subsequently

they are selected manually. The tomatoes are selected according to the variety and their

degree of maturity.

2.4 Blanching and Peeling: Once the tomato is selected, it must be blanched to
to facilitate peeling them mechanically, in the blanching process the tomatoes are immersed in water

clean and heat to 90 to 95 °C for 5 minutes this operation has as

objective to destroy the enzymes responsible for color loss, in addition to reducing
the microbial load present and soften the tomatoes to facilitate the extraction of the
pulp.

2.5 Cutting and pulp extraction: The extraction of the pulp is carried out with a
blender or a juice extractor, in the second case, well the pulp must be strained or sieved
according to the type of mesh placed in the pulper to separate some remnants of the
skins and seeds.
2.6 Heavy: After removing the seeds and shell, it is necessary to quantify the
we are collecting data to be able to establish the parameters in the following
stages such as evaporation and pasteurization.

2.7 Concentration: It is carried out in an evaporator for a time of 30-45 minutes at

a temperature of 90-95°C while gently stirring and it must also be constant
cooking time is determined by the final concentration you want. Therefore
general between 25 and 30 °Brix at this point salt is added at a rate of 2% with
relation to the weight of the pulp, that is, for 100 kilograms of processed dough, it is necessary to

add 2 kg of salt, other seasonings such as garlic, oregano, and can also be added
basil. When juice is processed and concentrated, it is necessary to know the
final concentration of the sauce, which can be calculated by determining the
density, the refractive index, and the percentage of total solids. The latter two
They can be measured using the refractometer, it should be considered to reach a 34%
total solids which corresponds to a 1.385 refractive index and to a
density of 1.155.

2.8 Packaging: The packaging is done in glass jars or bottles that must be
previously sterilized. The sauce drips at a temperature of 85°C and for
to prevent air bubbles, the containers are gently tapped on the bottom.
As it gets filled, a space should be left unfilled equivalent to 10% of the
volume of the container, finally the lids are placed but not completely closed
it is also necessary to know that the sauce goes through a tank
receptor that has a stirrer and a steam jacket since the temperature must
It is close to the boiling temperature, from here it is discharged to the bottling machine.

(Perugachi, 2012)

2.9 Sterilized: This is carried out immediately after evaporation at a temperature of

80-85°C can eliminate the microorganisms that may have survived the
process temperatures and thus guarantee the product's shelf life, processing is done
heating the containers at 95°C for 10 minutes counted from when the water
It starts to boil at the end of the thermal treatment, and it ends by quickly closing the ...
jar lids.

2.10 Cooling: The bottles, once sterilized and packaged, are not immersed in
the cold water, if not rather they just go through a hot water bath to be
cleaned, then they are stacked avoiding the blows of cold air.

2.11 Labeling: It consists of attaching labels with the required information.

through the established regulations (Perugachi, 2012)

2.12 Storage: Once cooled, it is stored in boxes and must be

located in a cool, dry, and dark place until its distribution (Perugachi, 2012)
Below is the flowchart that outlines the operations above.
mentioned.
 Figure 1. Flowchart of tomato paste preparation.

III. TEAMS
Below is a general diagram that represents the teams and their flow line in
plant for the production of tomato paste.
 Figure 2. Tomato paste production plant
Source. Fbrelpo. com

3.1 Optical Sorter

After receiving, the raw material may go through a scraping system.
automatic (redler) to eliminate mud, stones, and other impurities that accumulate in
the bottom is also equipped with a water filtration system in
recirculation, which allows for keeping the water free of solid deposits in circulation.

After washing, the tomatoes are transported to conveyor belts.

selection through special channels and in the end they reach the selector
optics, which allows for the elimination of foreign bodies (Fbr [Link]).

Figure 3. Optical Selector

Source: [Link]

3.2 Washing machine

Machine designed for washing tomatoes in bunch or loose. They are composed of a
series of modules, configurable according to the client's needs: input belt,
módulo de lavado, módulo de aclarado, módulo de desinfectado, módulo de soplado,
drying module, polishing module, drying module and exit belt.
Depending on the capacity, they can be for medium productions, from 10 to 15 tons per.
Time. The washing is done with sanitized water and the drying can be at temperature
environment or with hot air.

They have systems for saving water, diesel, and detergent and a design that
minimize mechanical damage, avoiding shocks and the subsequent appearance of stains and
loss of product quality.

Figure 4. Washer for tomatoes

Source: [Link]

3.3 Passer - Refinisher

It is used for tomato juice extraction in 'Hot Break' with high content of
fibers, perfect for obtaining a final product with high viscosity. It is possible
mix said product with the juice obtained in the traditional way and achieve the
requested Bostwick consistency.

The stainless steel cylindrical rotor is divided into five parts, with fixed blades.
coated with special material and oriented opposite to the axis of rotation. The
the distance from the rotor to the sieve is minimal; the sieve and its relative reinforcement rings are
made of stainless steel. The machine, complete with an automatic washing system with
centrifugal pump, consists of a motor controlled by an inverter. The capacity
productivity reaches up to more than 50 t/h (Fbr [Link]).
 Figure 5. Passer-refiner
Source: [Link]

3.4 Forced Circulation Evaporator

For products with a lot of fibers or pastes that stick to the wall of the
exchangers, it becomes necessary to use another type of evaporator called
forced circulation, in this type, the product is pumped through a
heat exchanger in an upward direction, while being heated, upon its arrival at
the upper expansion deposit causes the instant evaporation of water,
achieving the concentration of the product.

In this type of evaporator, the product recirculation is about 100 times the flow rate.
of process in each effect, which is why large and powerful pumps are used.

The number of possible effects is limited by the viscosity of the obtained product.
Usually 3 or 4 at most are used, since in many cases the last effect
it must be a surface scraper exchanger.
 Figure 6. Forced circulation evaporator
Source: [Link]

3.5 Packer

Automatic linear filling machine

This automatic linear filling machine with a precision of +/- 0.5% is equipped
with 2 to 6 filling nozzles, allowing it to achieve filling rates of 3000
liters/hour depending on the product and the volume of the container to be filled. It adapts to
all viscosities (liquid, thick, and pasty) and all types of liquids for
its application in the most diverse sectors of activity: food processing
(vinegar, oil, mustard, sauce, fruit juices, etc.)
 Figure 7. Automatic linear filling machine
Source: [Link]

3.4 Autoclave
An autoclave is a hermetic container designed to withstand high pressures and high temperatures.
temperatures. It is used for commercial sterilization of glass and metal containers,
and adapted plastics, generally for the food sector, although
they are also used in bacteriological analysis laboratories.

Figure 8. Sterilizing autoclave

Source: [Link]

Figure 9. Sterilization and aseptic filling

Source: Fbr [Link]
IV. MATERIAL BALANCE

For the material balance, it was analyzed at each stage of the process with the
objective of determining their respective losses. In the reception stage, it is rejected
approximately 4% of the total tomatoes for not meeting the characteristics
desired in shape, color, and size. For the weighing stage, there is no loss of
raw material, as it consists of a quantification of the mass of the tomato. In the stage
of selection and washing, in the first operation the tomatoes are sifted therefore,
which there is no variability in weight; for the washing operation, the losses
the losses are 0.5% in reference to the weight obtained in the weighing operation.
For the scalding stage, it did not seem like a loss of mass; the opposite is the case.
peeled where the loss is 16% of the weight obtained during weighing. In the cutting.
we have a 9% loss compared to the mass of the previous operation, for the
pulp extraction a pulper was used where approximately 12% is lost in
husk, seed, peduncle. The concertation takes place in an evaporator, where
Simpson et al. (2008) indicates that for their analysis, the mass balance is used as
shown in Figure 3, to facilitate calculations, the system is considered as a
steady state, where the mass within the evaporator effect is controlled,
obtaining the equation shown in Figure 4.

Figure 3. Material balance equation

Source: Simpson, et al. (2008)

Figure 4. Material balance equation in steady state

Source: Simpson, et al. (2008)

For the mass balance of the partial, the total solids are taken as a reference in
°Brix, with the aim of determining its concentration when leaving the evaporator, for its
 analysis uses a partial mass balance as shown in Figure 5; where
the system is once again considered as a steady state. Having as
resulting in a concentrate at 25°Brix, where the steam removed by the equipment reduces the
weight is 41.5% of the weight of the previous stage,

Figure 4. Partial material balance equation in steady state

Source: Simpson, et al. (2008)

During packaging, up to 0.3% can be lost due to various equipment issues.

used. For the rest of the stages; sterilization, cooling, labeling, storage;
weight loss is null or has no effect on the final calculations. It is obtained a
final yield of 36.30% based on the initial weight of the tomatoes in kg.

V. BIBLIOGRAPHY

Direct Industry. Automatic filling machine K - Line. Retrieved from

:Unable to access content from the provided link.

Fbr [Link]. Line of tomato. Recovered of

The provided link does not contain any text to translate.

Intercompany virtual fair. Sterilizer autoclaves. Retrieved from:

The provided link does not contain any text to translate.
[Link]

Machinepoint Engineering. Equipment and technology. Retrieved from:

The provided text is a URL and cannot be translated.
ogy/[Link]

Mendez, R. (2013). Design of a tomato paste plant in Moche, Peru, as a

alternative to sustainable development. Science and Technology.

Pedrozo, D., Fonseca, J., De Angel, J. (2015). Preparation of Tomato Sauce.

Popular University of Cesar.

Perugachi, K. M. (2012). Improvement plan for the process of making tomato sauces
Mayonnaise in a food plant. University of the Americas. Ecuador.
 73p. Recovered
Unable to access external links or content.

Rosero Velasco, Diego Fernando; Ramirez Navas, J. S. (2007). Tomato Sauce Management
of solids and fluids. University of the Valley. Cali. Colombia, 7–10p. Retrieved
Unable to access the document content from the provided link.

Simpson, R., Almonacid, S., López, D., Abakarov, A. (2008). Optimum design and
Operating conditions of multiple effect evaporators: Tomato paste. Journal of Food
Engineering.

VI. INTERACTIVE LINKS

Washing machine of pasta of tomato

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Preparation of tomato paste in Argentina:

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