Name: Lorven Jane B. Flores Yr.

/Course/ Section: 3BSABE-C

Instructor: Engr. Loradel Llenado Date: 03/05/2023

Module 2: AB Products Processing and Storage

Activity 1. List Post-Harvest Operations of a specific commodity of the Philippines staple

products and give at least 1 by-product and provide factors that can affect its production.

I. Choose a commodity
Tomatoes are an essential part of our diets and are widely consumed globally.
Post-harvest management is an important step in ensuring the quality of tomatoes
and their safe consumption. Post-harvest operations refer to all activities that take
place after harvesting and includes sorting, grading, packaging, storage, transport,
and marketing (Harsh et al., 2018). Proper post-harvest management practices
help to maintain the quality of the produce, ensure food safety, and improve
market access and value (Debrah et al., 2016). This article will discuss the
importance of post-harvest operations for tomatoes, discuss current practices, and
suggest best practices.
Tomatoes (Solanum lycopersicum) are one of the most important crops in the
Philippines. According to a study published in the Philippine Journal of Crop
Science, tomato production in the Philippines has been increasing steadily since
the 1980s and is now among the top 10 vegetable crops in the country,
contributing greatly to the livelihood of Filipino farmers (Aquino, et al., 2018).
Tomatoes are grown in various parts of the Philippines, including the rainfed
lowlands, irrigated plains, and upland areas, making them a versatile crop suitable
for various agro-ecologies. Tomatoes are also highly nutritious, containing a wide
array of vitamins and minerals, making them an essential part of a balanced diet
(Ekpu, et al., 2018).

II. List of post-harvest operation

MANUFACTURING PROCESS
Industrial Scale
(Tomato Ketchup Production Process)

Developing quality tomatoes

1. Ketchup manufacturers must seek out the best quality tomatoes for their
product. Tomato varieties are developed which are superior in color, flavor,
texture, and yield. Consistency is an important factor, as slight variations in
tomato characteristics could alter the flavor and color of the finished product.
Preparing tomatoes
2. Tomatoes are harvested mechanically between June and July. The fruit is
commonly conveyed by water from the trucks into a flume, or an inclined
channel. The water method washes the tomatoes and protects them from
bruising while they pass from the truck to the factory. The U.S. Department of
Agriculture or state inspectors approve and grade tomatoes to meet initial
requirements. The tomatoes are sorted, washed, and chopped. Next,
precooking, or scaling, in stainless steel vats preserves the tomatoes and
destroys bacteria.
Pulping
3. The chopped and precooked tomatoes are pumped into pulping machines, or
cyclones, which separate seeds, skins, and stems from the pulp. The pulp and
juice are filtered through screens and processed further into ketchup, though
some may be stored in a paste for use later in the year.

Adding ingredients and cooking

4. The pulp is pumped into cooking tanks or kettles and heated to boiling.
Foaming may occur if fresh tomato pulp is used, but can be corrected with
anti-foaming compounds or compressed air. Precise amounts of sweeteners,
vinegar, salt, spices, and flavorings are added to the tomato pulp. Most spices
are added early in the cooking process. To avoid excessive evaporation,
volatile spice oils and vinegar must be mixed in later. Onions and garlic can be
mixed in with the spices, placed in a separate bag, or chopped and added to the
pulp. Salt and sugar may be added at any stage of cooking though it is better to
add sugar later to prevent burning. The mixture cooks for 30-45 minutes and is
circulated by rotating blades installed in the cookers. The temperature must be
carefully regulated to ensure absorption of the ingredients without
overcooking, which creates a flat body.
Finishing
5. Once the cooking is complete, the ketchup mixture passes through a finishing
machine. Finishers remove excess fiber and particles through screens, creating
a smoother consistency. The ketchup passes to a holding tank before further
processing.
6. The ketchup may be milled at higher temperatures and pressures to achieve a
smoother consistency.
Removing air
7. The ketchup must be de-aerated to prevent discoloration and growth of
bacteria. Excess air might also create unattractive air pockets and impede the
closure process.

Filling
8. To prevent contamination, the ketchup passes from the receiving tanks to the
filling machines at a temperature not lower than 190°F (88°C). The containers
are filled with the ketchup and immediately sealed to retain the freshness of
the product. Ketchup containers come in various sizes and shapes, including
14-oz. bottles, No. 10 cans, pouch packs, room-service sizes, and single-serve
packets.
Cooling
9. The containers must be cooled to prevent flavor loss through stack burning,
which occurs when ketchup stays at high temperatures after cooking is
complete. Containers of ketchup may be cooled in cold air or cold water.
 Labelling and packing
10. Finally, the ketchup containers are labeled and coded with product
information, including ingredients, date and location of manufacture, and
shelf-life. The bottled ketchup may be inspected again before shipping. The
entire process of ketchup manufacturing generally takes two to three hours.

III. By products
1. Tomato Juice:
Tomato juice processing is a complex process that begins with
harvesting the ripe and juicy tomatoes and ends with packaging and labeling
the finished product. This process has been industrialized over the years to
ensure a safe, high-quality product for consumers.

The harvesting process begins with the selection of the tomatoes. The
tomatoes are chosen based on their size, color, and firmness. Once the
tomatoes have been selected, they are washed and sorted. The tomatoes are
then chopped and crushed to extract the juice. The juice is then strained to
remove any solids.

The juice is then heated to a temperature between 180-185 degrees

Fahrenheit for about two minutes. This is a process known as heat-
pasteurization. This process kills any bacteria present in the juice and also
deactivates any enzymes that can cause the juice to spoil. The juice is then
cooled to a temperature of 45 degrees Fahrenheit.

The juice is then filtered and blended to create a homogenous product.

This process also removes any solids that may still be present. The juice is
then clarified to remove any remaining solids. The clarified juice is then
 concentrated through the process of evaporation to remove the water and
create a more concentrated product.

The juice is then packaged into cans, bottles, or cartons. The containers
are sealed to keep the juice fresh. The cans, bottles, or cartons are then labeled
with the product name, ingredients, and nutrition facts. The containers are also
labeled with expiration dates and other relevant information.

Finally, the juice is placed on the shelves of grocery stores and ready
for consumers to purchase. The entire process of harvesting, processing,
packaging, and labeling ensures that consumers get a safe, high-quality
product.

2. Tomato Paste:
Tomato paste is a processed food item made from tomatoes that have
been cooked and concentrated down to a thick, paste-like consistency. The
process of industrializing the production of tomato paste is a complex one that
begins with harvesting the tomatoes and ends with packaging and labeling the
finished product.

The first step in industrializing the production of tomato paste is

harvesting the tomatoes. This is typically done by hand, although some
commercial operations may make use of machines to speed up the process.
The tomatoes are then washed and sorted according to size and quality. The
tomatoes are then crushed, either by machine or by hand, and the juice is
separated from the solids. The juice is then filtered and clarified to remove
impurities and then concentrated by boiling to reduce the volume and increase
the solids content.

Once the tomatoes are concentrated, they are further processed to make
the tomato paste. The concentrated tomato mass is cooked at high
temperatures to break down the cell walls and soften the tomatoes. The cooked
mass is then strained to remove the seeds and skins and is then passed through
a series of filters and screens to homogenize the product. The filtered tomato
paste is then poured into a large heated holding tank where it is further cooked
and homogenized. The resulting paste is then cooled and packaged into cans
or jars.

Finally, the tomato paste is labeled and packaged for sale. The product
is typically labeled with information such as the nutritional value, ingredients,
and the manufacturing and expiration dates. The packaging is also labeled
according to the size and type of product, such as whole, diced, or pureed.

Industrializing the production of tomato paste is an important part of

the food processing industry as it allows for a consistent, high-quality product
to be produced quickly and in large quantities. With the appropriate equipment
and processes in place, companies are able to produce a product that is safe,
nutritious, and of a consistent quality.
3. Tomato Sauce:
Tomato sauce is an incredibly popular condiment that is used in a
variety of dishes. It is typically made from tomatoes, salt, garlic, and various
spices. The production of tomato sauce starts with the harvesting and
collection of tomatoes. Depending on the area, tomatoes may be grown in
greenhouses, fields, or hydroponically. After the tomatoes are harvested, they
are then sorted, graded, and washed. At this stage, any spoiled tomatoes are
discarded. Once the tomatoes have been cleaned, they are then chopped up
into smaller pieces (Kalpana, 2018).

The chopped tomatoes are then put through an industrial processing

system. This process involves blanching, cooling, and then straining the
tomatoes to remove the skins and any large pieces of seeds. The processed
tomato pieces are then cooked in a large kettle and the juice is extracted. The
extracted juice is then heated and cooked further until it reaches the desired
consistency (O’Rourke, 2003).

Once the tomato sauce has been cooked, it is then cooled and poured
into containers or jars for packaging. The jars or containers are labeled with
the ingredients, nutritional information, and any other information necessary.
The containers are then sealed and sealed with a label.

The last step in the industrial processing of tomato sauce is the

labeling. Labeling includes expiration dates, nutrition facts, ingredients, and
other pertinent information. The labeling also includes the name of the
company producing the product and any relevant logos or trademarks (Baker,
2003).

After the labeling is completed, the containers are shipped to various

stores or restaurants where they are available for purchase. The containers are
then stored in the appropriate area until they are purchased by the consumer.

In summary, the industrial processing of tomato sauce involves the

harvesting of tomatoes, sorting and grading, washing, chopping, blanching and
cooling, straining, cooking, cooling, packaging, labeling, and finally shipping
to stores or restaurants where they are available for purchase. This process
ensures that only the highest quality tomato sauce is made available to
consumers.
4. Sun-Dried Tomatoes:
Sun dried tomatoes are a delicious and nutritious food that has been
beloved by cultures around the world. This popular product is made by
harvesting and drying tomatoes under the direct sunlight until most of their
moisture content has been removed. Sun drying tomatoes is a traditional
method of preserving the vegetable and allowing it to be used for a longer
period of time. The industrialized processing of sun dried tomatoes involves a
number of steps from harvesting to packaging and labeling.

Harvesting of sun dried tomatoes begins with the selection of the best
quality tomatoes from the field. The tomatoes are then washed and inspected
for any imperfections or rot. After the tomatoes are inspected, they are cut into
slices and placed on drying trays. These trays are then placed in direct sunlight
and left for several days or weeks depending on the desired level of drying
(Konstantinou et al., 2021). During this time, the tomatoes are regularly
inspected and turned to ensure that they are evenly dried.

Once the tomatoes have been sufficiently dried, they are removed from
the trays and placed on sorting trays. At this stage, any remaining
imperfections or rot is removed and the tomatoes are sorted based on their size
and shape. The sorted tomatoes are then placed into a blanching machine
which helps to preserve the nutrition and flavor of the tomatoes (Tzortzakis et
al., 2017). After the tomatoes are blanched, they are placed into a cooling
chamber and then into a dehydration chamber. This process helps to further
reduce the moisture content of the tomatoes and helps to preserve the tomatoes
for a longer period of time.

The next step of the industrialized processing of sun dried tomatoes is

packaging and labeling. After the tomatoes are dried and cooled, they are
placed into food grade packaging containers. The containers are then labeled
with the name of the product, the nutrition facts, and any other relevant
information. The packaging containers are then sealed and placed on a shelf
where they can be sold in stores or online (Tzortzakis et al., 2017).

Finally, sun dried tomatoes are subject to quality control tests. The
tomatoes are tested for any potential contaminants and for their nutritional
content to ensure that they meet the standards for food safety and quality.
Once all of the tests have been completed, the tomatoes are approved and
ready to be sold (Konstantinou et al., 2021).

In conclusion, the industrialized processing of sun dried tomatoes is a

complex process that involves a number of steps from harvesting to packaging
and labeling. This process ensures that the tomatoes are safe, nutritious, and of
the highest quality.
5. Tomato Powder:
Tomato powder is a popular and convenient form of tomato that can be
used in a variety of dishes. The process of industrializing the production of
tomato powder involves several steps from harvesting to packaging and
labeling.

Harvesting is the first step of the process and is the most crucial step in
producing high-quality tomato powder. Tomatoes are typically hand-picked
when they are ripe and then placed in crates. The tomatoes are then taken to
the processing facility where they are washed, sorted, and inspected for any
defects or damage. After this, the tomatoes are cut into uniform sized pieces
and then blanched. Blanching is a process that involves briefly immersing the
tomato pieces in boiling water to kill any bacteria and to make them more
pliable for further processing.

The next step is the drying process. The tomato pieces are placed in a
continuous dryer that uses hot air to evaporate the moisture from the tomatoes.
Once the tomato pieces have been dried, they are then milled or ground into a
fine powder. At this stage, the powder may be sieved to remove any large
pieces and to ensure a uniform texture.

The next step is the addition of other ingredients. Depending on the

desired flavor, a variety of ingredients such as spices, herbs, and salt may be
added to the tomato powder. These ingredients are mixed thoroughly with the
powder and then it is ready for packaging.

The last step is packaging and labeling. The tomato powder is typically
packaged in air-tight containers to preserve its freshness and shelf life. The
containers are then labeled with information such as the name, ingredients,
and nutritional facts. The product is then ready to be shipped and sold in
stores.

In conclusion, the process of industrializing the production of tomato

powder involves several steps from harvesting to packaging and labeling. The
tomatoes are first hand-picked and then washed, cut, and blanched. They are
then dried, milled into a powder, and seasoned before being packaged into air-
tight containers and labeled with information. This process helps to produce
high-quality and flavorful tomato powder that is safe to consume.
IV. Factors to be considered to extend shelf life of Sugar
1. Use of modified atmosphere packaging (MAP) techniques: Modified atmosphere
packaging (MAP) techniques can effectively extend the shelf life of tomatoes by
preserving their quality and extending the storage time (Kabata-Pendias, 2010).

2. Use of edible coatings: Edible coating technology can be used to extend the shelf
life of tomatoes by reducing water loss and controlling the respiration rate of tomatoes
(Ioannou et al., 2013).
 3. Temperature control: Temperature control is an important factor to consider when
trying to extend the shelf life of tomatoes. Tomatoes should be stored at temperatures
between 5°C and 10°C in order to preserve their quality and extend their shelf life
(Kumar et al., 2008).

4. Post-harvest treatments: Post-harvest treatments such as hot water treatment, wax

coating and ozone treatment can help extend the shelf life of tomatoes (Kumar et al.,
2010).
V. Possible losses
Post-harvest sucrose losses are driven by two factors, both of which result in limited
sugar recovery.
1. Mechanical damage: Mechanical damage is one of the most common factors
causing postharvest losses in tomato fruit. Physical damage to the fruits during
harvesting, handling and transportation can cause tomato fruit to rot, leading
to losses in quality and quantity (Hussain et al., 2017).
2. Microbial spoilage: Microbial spoilage is a major cause of postharvest losses
in tomato. Different microorganisms, such as fungi and bacteria, can cause the
fruits to rot and deteriorate (Salam et al., 2018).
3. Water loss: Water loss is a major factor that can affect the quality and shelf
life of tomato fruits. During storage, the fruits can lose water, resulting in
weight loss, shriveling and a decrease in quality (Rice and Schaffer, 2019).
4. Environmental conditions: Environmental conditions, such as temperature and
humidity, can affect the rate of postharvest losses in tomato fruits. Extreme
temperatures and high humidity can cause the fruits to spoil quickly (Bari et
al., 2018).
5. Physical Damage: Physical damage to tomatoes can occur during harvest,
transport and storage. Common methods of physical damage include bruising,
cracking and splitting. For example, tomatoes may be damaged by machinery,
rough handling and exposure to extreme temperatures (Kumar et al., 2018).
6. Pathogenic Infection: Pathogenic infection is a major cause of post-harvest
tomato losses. Bacterial and fungal diseases, such as black rot and gray mold,
can lower the quality and market value of tomatoes (Kumar et al., 2018).
7. Insect Infestation: Insects can cause post-harvest losses of tomatoes by feeding
on the fruit and spreading diseases. Common pest species include fruit flies,
weevils and aphids (Kumar et al., 2018).
8. Mechanical Injury: Mechanical injury is another cause of post-harvest losses
in tomatoes. This type of damage is usually caused by improper handling and
packaging of the fruit (Kumar et al., 2018).
9. Water Loss: When tomatoes are stored for prolonged periods of time, they can
suffer from water loss. This can lead to a reduction in size, weight and
nutritional value of the fruit (Kumar et al., 2018).
10. Sunburn: Sunburn can occur when tomatoes are exposed to direct sunlight for
extended periods of time. This can cause the skin of the fruit to become
discolored and reduce its market value (Kumar et al., 2018).
11. Heat Damage: Heat damage can occur when tomatoes are stored at high
temperatures for extended periods of time. This can cause the fruit to become
soft and reduce its market value (Kumar et al., 2018).
12. Cold Damage: Cold damage can occur when tomatoes are stored at low
temperatures for extended periods of time. This can cause the fruit to become
discolored and reduce its market value (Kumar et al., 2018).
13. Ethylene Damage: Ethylene is a naturally occurring plant hormone that can
cause post-harvest losses in tomatoes. High levels of ethylene can cause the
fruit to ripen prematurely and reduce its market value (Kumar et al., 2018).
14. Nutrient Loss: Nutrient loss can occur when tomatoes are stored for extended
periods of time. This can lead to a reduction in nutritional value and
marketability of the fruit (Kumar et al., 2018).
15. Shrinkage: Shrinkage is a common cause of post-harvest losses in tomatoes.
This occurs when the fruit loses water, which can reduce its size and weight
(Kumar et al., 2018).
16. Oxidation: Oxidation can occur when tomatoes are exposed to air for extended
periods of time. This can cause the fruit to become discolored and reduce its
market value (Kumar et al., 2018).
17. Decay: Decay is a common cause of post-harvest losses in tomatoes. This can
occur due to fungal and bacterial infections and reduce the quality and
marketability of the fruit (Kumar et al., 2018).
18. Desiccation: Desiccation is a common cause of post-harvest losses in
tomatoes. This occurs when the fruit loses water, which can reduce its size and
weight (Kumar et al., 2018).
19. Chilling Injury: Chilling injury is a common cause of post-harvest losses in
tomatoes. This occurs when the fruit is stored at temperatures that are too low,
which can reduce its quality and market value (Kumar et al., 2018).
VI. Diagram

Figure 1. Traditional Making of Tomato Ketchup at Industrial Scale

Figure 2. Present way of Making Tomato Ketchup

Ketchup manufacturers continue to improve the quality of ketchup by

developing tomato strains that are superior in color, flavor, and firmness. Tomato
hybrids are also engineered to improve resistance to disease and rot, thus decreasing
the reliance on chemical pesticides.
In the 1990s, in response to consumer demand for more healthful foods,
ketchup manufacturers created low-calorie, low-salt ketchup alternatives. The
increasing popularity of Spanish salsas and marinades also influenced manufacturers
to develop salsa-style ketchups which were lower in sugar content. Packaging
technology continues to improve as consumers demand safer, more convenient, and
recyclable containers

Schematic Diagram for the Production of

Tomato Ketchup in an Industrial Scale
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