Report on Tomato/Juice Line

Subject:
Student READY Experiential Learning Programme II (FPO-472)

Semester: 7th

Submitted by:
Tatvik Patel (3070920028)
Vandana Pavra (3070920029)
Rakesh Kumar Saini (3070920031)
Manas Savaliya (3070920034)
Sounak Biswas (3070920039)

Submitted to:
Dr. A. V. Ravani
Assistant Professor
Department of Food Plant Operations

College of Food Processing Technology and Bio-Energy

Anand Agricultural University, Anand-388110

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Introduction:
Tomato (Lycopersicon esculentum) is grown in our country in abundance; both in summer and
winter seasons, but those grown in winter are superior in quality because they contain more total
solids. They are a good source of vitamin C. Fresh tomatoes are very refreshing and appetizing
but cannot be stored for a long period. It is estimated that a loss of about 25% of the produce
occurs due to lack of post-harvest handling operations in India. Under this situation, production,
storage/transport of an intermediate product would help in reducing the huge post-harvest losses
and would be highly beneficial to the development of processing industry. But, sophisticated
technology for bulk storage of tomato pulp, has limited application in Indian, due to higher costs
involved. The intermediate products which would help the farmer to get more profit from the
crop. Often they are sold at distress prices during the peak harvest season and huge percentage of
the produce is spoiled due to mishandling. Such losses can be avoided by converting tomatoes in
to delicious products.

Nutritional Benefits of Tomato:

Tomato is a warm season crop and ranked highest in comparison of crops and its contribution of
nutrients to the diet. Tomatoes also provide potassium, iron, phosphorus, and B vitamins and are
good source of dietary fiber. The ripe tomatoes are red in color because they contain lycopene and
other natural antioxidants are carotene, anthocyanin, ascorbic acid (vitamin C), vitamin E,
phenolics, flavonoids. Antioxidants have anti-inflammatory, anti-allergic and anti-thrombotic
properties and beneficial in lowering the incidence of cardiovascular problems, cancer and
neurological pathologies. Water comprises 90% of the fresh weight of tomato fruit and the size of
the fruit is influenced by the availability of water to the plant. The presence of large amount of
water in the fruit makes it perishable. As the tomato fruit develops, starch decreases while
carbohydrates such as sucrose and reducing sugars increase. Sugars are mostly found in ripe fruit
and starches in unripe fruit. In a ripe tomato, solids form about 5-7% of the total fruit weight.
About half of the solids comprise sugars and one eighth is acids. The main sugar in tomatoes is
glucose. Citric acid is the main acid in tomato juice; and the pH of fruit is normally between 4.0
and 4.5.

Nutritional Value of Tomato:

Tomato is rich in nutrition and per 100 gram contains:-
Calories: 16
Fat: 0.2g
Sodium: 5mg
Carbohydrates: 3.5g

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 Fiber: 1.1g
Sugars: 2.4g
Protein: 0.8g

Importance of Tomato Processing:

Tomato is one of the important crops used as fresh vegetables and for preparing a variety of
processed products like tomato juice, ketchup, sauce, canned, puree and paste. In advanced
countries, nearly 80% of the fresh tomatoes are processed. In India, although tomato production is
increasing the growth of tomato processing industry is slow, mainly due to the lack of constant
supply of good quality and cheaper raw material to the processing centre. In India, tomato sauce
and ketchup are very popular and are being manufactured on an increasingly large scale, mostly in
small units. As tomatoes are available practically throughout the year there is scope for setting up
large-scale processing units. The quality of a tomato product is judged by its colour, which is
dependent on the redness of the tomatoes used. In fact, the red pigment (lycopene) can be used as
an index of the amount of tomato actually present in a product. High quality tomato products can
be prepared only by:
i) Using plant – ripened uniformly red tomatoes as the yellow and greenish portions not
only mask the red colour but also cause browning due to oxidation
ii) Avoiding prolonged heating, and cooling the product quickly after preparation
iii) Not using iron and copper equipments at any stage of processing. Lycopene (Self-
oxidizing isomer of carotene) turns brown when it comes into content with iron. Iron
also forms black compounds with the tannin in the tomatoes and the spices used.
Equipments used should be glass-lined or made of stainless steel.

Processing and Value Addition of Tomato:

Tomato production is a growing worldwide as consumers demanding a wider range of innovative,
value-added products. This results in high demand on mixing technology for production and
processing. Tomato processing industry is huge. A large part of the world tomato crop is
processed into tomato paste/puree, which is subsequently used as an ingredient in many food
products, mainly soups, sauces and ketchup. India has been exporting processed tomato in the
form of tomato paste and ketchup. Tomato sauce is being used with snacks like rolls, cutlets,
samosas, chops, soup, chowmin and other continental as well as chinese dishes. Bright mixture
made from tomato is used as important items with all modern food/snacks. The only ketchup and
sauce market in India is pegged at Rs 1,000 crore and growing at around 20% year-on-year. There
is a big market for the processed tomato products. Tomato products are one of the chief
ingredients in ready-to-eat or fast food products.

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Points to be considered while processing of tomato:
(i) Use only plant-ripened red tomatoes as far as possible. The yellow and greenish
portions not only mask the red colour of the fully ripe tomatoes, but also turn
brown due to oxidation.
(ii) Avoid use of iron equipment during processing. Lycopenes turns brown when it
comes in contact with iron. Iron also forms black compounds with the tannin of the
tomatoes or of the spices used.
(iii) Avoid prolonged heating and cool the product quickly after preparation of tomato
based processed products like ketchup, sauce, chutney and soups.
(iv) Mere rinsing of tomatoes in water is not enough, because mould filaments and
other microorganisms found in the cracks, wrinkle, folds and stem cavities, are not
easily removed by gentle washing alone.
(v) After filling tomato products in bottle it is better to pasteurize to avoid
fermentation.
(vi) Filling hot sauce at a temperature not less than 85°C temperature.
(vii) Leaving minimum headspace in bottles (the more the air than greater is the
blackening).

Processing of tomato puree:

Commercial tomato puree can be defined as concentrated tomato juice or pulp without skin or
seeds, with or without added salt. Tomato puree has diluted flavor and is thinner in consistency.
Tomato puree contains between 11 and 14 percent TSS.

Fig. Tomato Puree

Processing Flowchart of Tomato Puree:

Tomatoes (Fully ripe and red)



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 Washing using portable water

Sorting and Inspection

Blanching at 90C for 3 to 5 min

Pulping and Straining

Cooking to desired consistency (Double jacketed steam kettle)

Judging of end-point TSS for puree (12%) (Tomato solids by hand refractometer)

Filling hot in to bottlesat 82 to 88C

Sterilization in boiling water for 20 minutes

Cooling

Storage at ambient temperature (In cool and dry place)

2. Processing of Tomato Ketchup:

Tomato ketchup is one of the most popular among fruit and vegetable products manufactured in
our country. Tomato ketchup is the commercial product made either from fresh tomato by
converting them into juice/pulp or by using tomato puree or tomato paste. It is made by
concentrating tomato juice or pulp without seeds and skin. Spices, salt, sugar, vinegar, onion,
garlic etc. are added to the extent that the ketchup contains not less than 12% tomato solids and
minimum of 25 % total soluble solids (w/w). The juice or puree prepared earlier can be used for
preparation of tomato ketchup.

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 Fig. Tomato Ketchup

Process Flowchart of Tomato Ketchup:

Tomatoes (Fully ripe, red)


Washing

Sorting and Trimming

Cutting and Chopping

Blanching at 80 to 90C for 3 to 5 minutes (to soften)

Pulping or Extraction of juice/pulp (Mechanically or by sieving)

Straining Tomato Pulp/Juice

Cooking pulp with one-third quantity of sugar

Putting spice bag in pulp and pressing occasionally

Cooking to one-third of original volume of pulp/juice

Removal of spice bag (after squeezing in pulp)


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 Addition of remaining sugar

Cooking

Judging of end-point (tomato solids by hand refractometer)

Addition of vinegar / acetic acid, salt and preservative

Filling hot in to bottles at about 88C

Crown Corking

Pasteurization (at 85 to 90C for 30 minutes)

Cooling

Storage at ambient temperature (in cool and dry place)

Equipments:
1. Washing Unit:

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Washing Unit is used to remove dust particles from outer surface of fruits and vegetables using
potable water and rotating action of washing unit.

Fig. Washing Unit

2. Sorting and Inspection Belt:

Sorting and Inspection Belt is used to sort and inspect for damaged and spoiled fruits and
vegetables before processing.

Fig. Sorting and Inspection Belt

3. Blancher:
Blancher is used to carry out blanching process which inactivate enzymes which otherwise cause
loss of flavor, color and texture. In addition, blanching removes some surface dirt and
microorganisms, brightens color and helps slow vitamin losses.. It is also used for the removing of
skins in fruit and vegetable processing.

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 Fig. Blancher

4. Bucket conveyor:
Bucket conveyor is used to convey blanched tomatoes to the pulper machine.

Fig. Bucket Conveyor

5. Pulper and Pulp tank:

Pulper is used to obtain pulp from the tomatoes and it also separates the seeds from the tomatoes.
Further, the tomato puree is obtained from the pulp in the pulp tank.

Fig. Pulper Fig. Pulp tank

6. Steam Jacketed Kettle:

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Steam-jacketed kettles are often used to rapidly and uniformly heat food and agricultural products
to processing temperatures. Steam is injected into a thin jacket that surrounds the bowl of the
kettle.

Fig. Steam Jacketed Kettle

7. Crown Corking Machine:

This is a table top hand operated Crown Corking Machine. Light weight and easy to use. Most
useful for small scale manufacturers for crowning glass Juice Bottles /sauce Bottles.

Fig. Crown Corking Machine

8. Weighing Balance:
Used to accurately weigh the raw materials and the
finished products.

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 Fig. Weighing Balance

9. Display Refrigerator:
It refers to equipment that is used to store and display food/drinks in commercial establishments.
It is a way of keeping produce in low temperatures whilst giving clear visibility to customers of
what you have on offer.

Fig. Display Refrigerator

Formulation and Cost Calculation of Tomato Ketchup:

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Sr. No Ingredients Quantity (gm) Price (Rs.)
1. Xanthan Gum 20 140
2. Spice Mix 7.46 97
3. Sodium Benzoate 43.48 150
4. Acetic acid 184.67 135
5. Modified Starch 270.39 140
6. Tomato Puree 36170 660
7. Salt 810.62 40
8. Sugar 7822.81 350
9. Paprika 12.36 188
Total price (27 kg) = Rs.1900
Processing cost (25%) = Rs. 475
Net price (27 kg) = Rs. 2375
Net price (210g) = Rs. 19
Selling price (profit 59%) = Rs. 30

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Processing of Bael Squash:
Introduction:
Bael, (Aegle marmelos), important member of plant family Rutaceae, native to Eastern
Ghats and Central India, is widely utilized in traditional medicines due to its excellent
therapeutic characteristics. Although being a subtropical tree it can grow well in tropical
climates too at an altitude of 1200 m. Bael is widely distributed throughout Indian
Peninsula and grows in most of the southeast Asian countries. The bael fruits exhibit a
diverse range of shape from round, oval, pyriform, or oblong and are 5–25 cm in
diameter, also the seeds can be from 10 to 50 in number having flat-oblong shape and 1
cm long. Although having high moisture content of nearly 61%, bael fruits have high
nutritional composition as it contains minerals (phosphorus, potassium, calcium,
magnesium, iron, copper, zinc, chromium), fat, fiber (hemicellulose, cellulose, lignin,
pectin), protein, carbohydrate, vitamins (B1, B2, B3, C), amino acids (threonine, valine,
methionine, isoleucine, leucine, lysine), and fatty acids.

Process Flowchart of Bael Pulp:

Ripe fruits

Breaking of shell

Removal of pulp with seed and fibre

Mixing with water

Passing through pulper

Pulp

Note: Pulp can also be obtained by heating the mixture of pulp and water a little,
followed by straining through a thick cloth.

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Bael Squash:
It contains at least 25 per cent pulp, 40 to 50 percent total soluble solids, about 1.0 percent
acid and 350 ppm sulphur dioxide or 600 ppm sodium benzoate. It is diluted before
serving.

Fig. Bael Squash

Process Flowchart of Bael Squash:

Bael pulp

Addition of sugar syrup (78 °B)

Addition of citric acid

Heating

Addition of menthol

Cooling

Bottling and Capping (80 °C)


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 Storage

Formulation and Cost Calculation of Bael Squash:

Sr. No Ingredients Quantity (gm) Price (Rs.)
1. Bael pulp 15920 3500
2. Sugar 11940 501.48
3. Menthol 45 348.75
4. Citric acid 79.6 62.884
5. KMS 31.84 10.793
Total Price = Rs. 4423.907
Processing Cost (20%) = Rs. 884.7814
Net Price (28.5 kg) = Rs. 2972.5
Net Price (750 gm) = Rs. 79
Selling Price (750 gm) (Profit 28%) = Rs. 110

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