Tomato Paste Making Process: From Fresh Tomatoes to Thick Paste

Tomato paste is a widely used food ingredient known for its rich flavor, deep color, and long shelf life. It is produced by concentrating fresh tomatoes through a series of carefully controlled processing steps. From raw material selection to final packaging, each stage plays an important role in determining the quality of the finished tomato paste. Below is a detailed introduction to how tomato paste is made in a modern tomato paste processing plant

1. Raw Tomato Selection and ReceivingThe tomato paste production process begins with the selection of high-quality fresh tomatoes. Processing tomatoes are usually fully ripe, with high solid content, bright red color, and minimal defects. Tomatoes are harvested at peak maturity to ensure strong flavor and natural sweetness.

Once delivered to the factory, tomatoes are weighed, inspected, and unloaded into water channels or receiving hoppers. Damaged, unripe, or rotten tomatoes are removed at this stage to ensure consistent product quality.

2. Washing and SortingAfter receiving, the tomatoes are thoroughly washed to remove dirt, sand, leaves, and pesticide residues. Washing is typically carried out using bubble washers or spray washers with clean circulating water.

Following washing, manual or automatic sorting systems are used to further eliminate defective tomatoes. Modern processing lines may include optical sorting equipment to detect color defects and foreign materials, ensuring only qualified tomatoes move forward.

3. Crushing and PulpingClean tomatoes are then crushed into a coarse mash using a tomato crusher. This step breaks the tomato skin and releases the juice and pulp. The crushed mixture is fed into a pulping and refining system.

During pulping, seeds and skins are separated from the tomato flesh. The refined tomato pulp passes through fine screens, resulting in a smooth, uniform consistency that is ideal for paste production.

4. Preheating (Hot Break or Cold Break)Before concentration, the tomato pulp is preheated to control enzyme activity. There are two common methods:

Hot break process: The pulp is rapidly heated to a high temperature (around 85–95°C). This deactivates enzymes responsible for viscosity loss, producing a thicker paste with higher consistency.

Cold break process: The pulp is heated to a lower temperature (around 60–70°C). This method preserves a fresher tomato flavor but results in a thinner consistency.

The choice between hot break and cold break depends on the desired characteristics of the final tomato paste.

5. Evaporation and ConcentrationThe preheated tomato pulp is then concentrated using a vacuum evaporator. Under vacuum conditions, water is removed at lower temperatures, which helps preserve color, flavor, and nutrients.

As water evaporates, the tomato pulp gradually thickens into paste. The concentration level is usually measured in degrees Brix. Common tomato paste products include 28–30% Brix, 30–32% Brix, and even higher for industrial applications.

6. SterilizationOnce the desired concentration is achieved, the tomato paste is sterilized to ensure food safety and long shelf life. High-temperature short-time (HTST) sterilization is commonly used to destroy microorganisms while maintaining product quality.

Proper sterilization is essential to prevent spoilage and maintain the paste’s bright color and rich taste during storage.

7. Aseptic Filling and PackagingSterilized tomato paste is filled into aseptic bags, metal cans, glass jars, or drums, depending on the target market and customer requirements. Aseptic filling allows the paste to be stored at room temperature for extended periods without preservatives.

Large-scale producers often use aseptic bags-in-drum (200L or 220L) for export and industrial use, while smaller consumer packages are used for retail markets.

8. Storage and DistributionAfter packaging, tomato paste is stored in a clean, dry warehouse. Thanks to its low water activity and proper sterilization, tomato paste can be stored for up to two years under suitable conditions.

The finished product is then distributed to food manufacturers, catering businesses, or retail markets, where it is used to produce sauces, ketchup, soups, and many other tomato-based foods.

The transformation from fresh tomatoes to concentrated tomato paste involves a combination of advanced equipment and precise processing control. From washing and crushing to evaporation and aseptic packaging, every step contributes to the paste’s quality, flavor, and shelf life. With a well-designed tomato paste production line, manufacturers can efficiently convert fresh tomatoes into a valuable, versatile food product that meets global market demands.

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