KWAME NKRUMAH UNIVERSITY OF SCIENCE AND TECHNOLOGY, KUMASI

COLLEGE OF ENGINEERING

CENG 291 ENGINEERING SOCIETY

TOPIC: PROCESSING FRESH TOMATOES INTO USEFUL PRODUCTS AS A WAY

OF EXTENDING THE SHELF LIFE OF FRESH TOMATOES

NAME: OWUSU SOLOMON

INDEX NUMBER: 8357319

DATE: OCTOBER 2020

 ACKNOWLEDGEMENT

First, I would like to thank the Almighty God for his guidance and seeing me through this
project. I would also like to express my appreciation to our supervisor and his teaching
assistants, not forgetting all the lectures who despite this covid-19 pandemic made it possible
through their various virtual lectures and tutorials which really prepared me for this project, Mrs.
Ella Kwao Boateng, Mrs. Mizpah Rockson, and Mr. Awarikabey for their effort in ensuring all
students in the department were well resourced to undertake this project.

DEDICATION AND DECLARATION

I dedicate this project to God for his knowledge and wisdom given to me, to my lovely mother
Kwarteng Grace for proving for all my educational needs, my family and to the good people of
Mampong and it neighbouring communites, hoping this project in the future will help solve the
problem of short shelf life of raw tomatoes.

I hereby declare that during this project no known act of scholastic theft and plagiarism was
commited. Consulted materials used during this project has being referenced accordingly.

TABLE OF CONTENTS

CHAPTER ONE:

INTRODUCTION................................................................................1

1.1 COURSE BACKGROUND.............................................................1

1.2 COURSE OBJECTIVE....................................................................1

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1.3 ABSTRACT....................................................................................1

CHAPTER TWO:

METHODOLOGY...............................................................................2

2.1 PROBLEM IDENTIFICATION ...................................................2

2.2 PREPARATION OF MAP. ...........................................................3

2.3 DATA COLLECTION ...................................................................4

CHAPTER THREE:

DISCUSSION OF RESULTS................................................................5

3.1 OVERVIEW OF THE ASANTE MAMPONG COMMUNITY...........................5

3.1.1 THE SETTING OF MADINA .............................................................................6

3.1.2 CULTURE AND SOCIAL STRUCTURE.............................................................7

3.1.3 ECONOMY ............................................................................................................7

3.1.4 VEGETATION .......................................................................................................8

3.1.5 CLIMATE ................................................................................................................8

3.2 NATURE AND CHARACTERISTIC OF THE PROBLEM ....................................8

3.2.1 INTRODUCTION............................................ .......................................................8

3.2.2 THE SHORT SHELF LIFE OF FRESH TOMATOES AS A PROBLEM IN ASANTE

MAMPONG …...9

3.2.3 CAUSES OF THE SHORT SHELF LIFE OF FRESH TOMATOES ................11

3.2.4 EFFECTS OF THE SHORT SHELF LIFE OF FRESH TOMATOES TO

CONSUMERS ......................12

3.2.5 LOCAL METHODS OF EXTENDING SHELF LIFE OF FRESH

TOMATOES. ................13

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3.2.6 LIMITATIONS OF THE LOCAL METHODS OF PRESERVATION IN THE
COMMUNITY….......15

CHAPTER FOUR:

CHEMICAL ENGINEERING.......................................................................................16

4.1 CHEMICAL ENGINEERING AS A PROGRAM OF STUDY ...............................16

4.2 DUTIES OF A CHEMICAL ENGINEER.................................................................17

4.3 SCOPE OF CHEMICAL ENGINEERING................................................................17

CHAPTER FIVE:

PROBLEM SOLUTION....................................................................................................18

5.1 PRODUCTION PROCESS.................................................................................................18

5.2 METHOD:............................................................................................................................19

CHAPTER SIX............................................................................................................................24

6.1 CONCLUSION......................................................................................................................24
6.2 RECOMMENDATION ..........................................................................................................24

CHAPTER SEVEN.......................................................................................................................25
7.1 REFERENCES........................................................................................................................25

7.2 APPENDICE..........................................................................................................................26

7.2.1 QUESTIONNAIRE SAMPLE 1 ......................................................................................26

7.2.2 QUESTIONNAIRE SAMPLE 2 ........................................................................................27

7.2.3 GLOSSARY AND ACRONYMS .......................................................................................28

7.3 OTHER MAPS.......................................................................................................................30

7.4 INTRODUCTORY LETTER.................................................................................................31

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TABLE OF FIGURES

FIGURE 1: DISTRIBUTION SHOWING MAJOR PROBLEMS FACING IN THE ASANTE

MAMPONG COMMUNITY.............. 3

FIGURE 2: THE MAP OF ASANTE MAMPONG AND ITS NEIGHBORING

COMMUNITIES ........................................... 7

FIGURE 3: IMAGE OF RAW GARDEN EGGS(TOP LEFT), CARROT (TOP RIGHT), RED
PEPPER (BOTTOM LEFT), TOMATOES(BOTTOM RIGHT)....................................... 9

FIGURE 4: HOUSEHOLD POPULATION IN COMMUNITIES IN ASANTE

MAMPONG.......................................................................................................................................
........ 13

FIGURE 5: IMAGE OF STEM SCAR OF TOMATO. THE BLOSSOM END IS DIRECTLY

OPPOSITE OF THE STEM SCAR......................................... 14
FIGURE 6: IMAGE OF LOCAL PACKAGING MATERIALS I.E PLASTIC CRATES AND
WOODEN BOXES.............................. 14

FIGURE 7: KNUST CHEMICAL ENGINEERING DEPARTMENT

LOGO............................................... 16

FIGURE 8: BLOCK DIAGRAM FOR PRODUCTION OF TOMATO PASTE FROM RAW

TOMATOES................................................ 19

LIST OF TABLES

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TABLE 1: VARIOUS PROBLEMS FACING THE ASANTE MAMPONG COMMUNITY
AND THEIR CORRESPONDING LEVEL OF
CONCERN............................................................................................................ 5

TABLE 2: TYPES OF PERISHABLE COMMODITIES AND THEIR RELATIVE SHELF

LIVES.................. 8

TABLE 3: DISTRIBUTION OF HOUSEHOLDS ENGAGED IN CROP FARMING BY TYPE

OF CROP AND POPULATION ENGAGED………………….10

TABLE 4: HOUSEHOLDS BY AGRICULTURAL ACTIVITIES AND

LOCALITY………………………………………………11

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CHAPTER ONE: INTRODUCTION

1.1 COURSE BACKGROUND

Engineering is the creative application of science, mathematical methods and empirical evidence
to the innovation, design, construction, operation and maintenance of structures, machines,
materials, devices, systems, processes and organizations in a bid to solving real life problems.

Engineering in society, CENG 291, is a first year course of engineering students in the Kwame
Nkrumah University of Science and Technology that teaches how to use chosen field of
engineering in solving societal problems. The objectives for the introduction of this course are
to:

• Equip students with the basic knowledge of identifying engineering problems around
them.

• Introduce students to engineering research methods.

• Enact into students the ways of analysing and solving everyday engineering problems in
their societies by drawing a link between problems and the chosen field of study.

1.2 COURSE OBJECTIVE

The course generally aims at imbibing into students the notion that the essence of engineering is
to solve problems in our society.

The course also seeks to act as a driving force to propel students to be innovative and apply their
field of engineering to the development of the nation. At the end of the course, the students
should have had a deepened interest in their discipline of engineering and come to appreciate the
extent to which their field of engineering can contribute to the various areas of their life.

1.3 ABSTRACT

The purpose of this study is to identify a major challenge confronting the Asante Mampong
community and deduce realistic solutions to solve the problem. Two approaches were embraced.

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First, questionnaire surveys, interviews, and field investigation supported by quantitative
analysis were employed to identify the short shelf life of perishable crops most especially

tomatoes as one of the most startling concern of the 42,067 households (according to the 2012
Population Census data) living in the community. The second approach, based on the estimated
data, required to ascertain the current measures the indigenes in the community were using to
manage the problem at hand and possible ways by which it could be improved. The outcome of
the in-depth analysis of the problem provided the necessary information required to design a
production process. The anticipated outcome of this production process is to extend the shelf life
of tomatoes commonly available in the community.

CHAPTER TWO: METHODOLOGY

2.1 PROBLEM IDENTIFICATION

Surveys of several forms were carried out in the rural parts of Asante Mampong community to
assess the needs and problems facing the community. 10 Study samples each were randomly
taken from four selected localities in the community namely; ‘Asaam’, ‘Kofiase’,
‘Naama’,’Butoku’ and ‘Abuontem’ respectively to perform the exercise. None of the study
samples taken from the rural areas of the community was literate so they had to go through one-
on-one interviews to ascertain their problems in the poor recycling of waste, poor hygienic
conditions, poor roads, the short shelf life of tomatoes available in the community and little job
opportunity.

Among these problems, 46.15% of the study samples from both the rural and urban areas shared
common concern for the short shelf life of tomatoes made available in Asante Mampong as a
major challenge confronting them either as producers, traders or consumers.

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 Series 1
50
45
40
35
30
25
20
Series 1
15
10
5
0

as
te ns ds oe
s
w itio r oa at
f nd or m
ngo co po f to
cli ic eo
cy ig en lif
re hy lf
or he
po or t s
po or
sh

Figure 1: Distribution showing major problems facing the Asante Mampong community

Upon further field investigations, visits were once made again but to specific targets; the small
scale farmers (producers), traders and consumers in the community. This was to discuss the
extent to which the short shelf life of tomatoes was affecting them and current measures they
were taking to manage the situation.

The opinions of the people listed above were used to substantially identify the short shelf life of
tomatoes as a major problem facing the people living in Asante Mampong.

2.2 PREPARATION OF MAP.

A digital format of the map of the Asante Mampong community was procured from ‘Google
Earth’. The layout of the community was acquired for the use of this report under the service of
Wikipedia.

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2.3 DATA COLLECTION.

The primary source of data used to support this report was mainly obtained through qualitative
means. Questionnaires, interviews and observation were the key forms of survey used during the
field investigation to collate data. The survey was structured in two forms to solicit, as much
needed information as possible from its respondents.

During the first survey, the study samples were given the opportunity to identify two major
problems that were confronting them in their locality. These data were used to draw a table
showing the problems facing the community at large. This was relevant in bringing out the short
shelf life of perishable tomatoes as a prevailing problem in the community.

The second survey was carried out in the forms of questionnaire and interview to produce data
on how they were managing the problem and ways they wished the problem could be solved.

Three main sections of people in the community were identified for the administration of the
second form of survey are namely: the farmers, the traders and the consumers.

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 Problems RURAL LOCALITIES
facing the Asaam Kofiase Naama Butoku Abuontem Total Total
community (30) (100%)

Poor 2 3 0 0 0 5 7.69
recycling
of waste
Poor 3 2 1 1 0 7 10.77
hygienic
conditions
Poor roads 6 7 5 2 3 23 35.38
Short shelf 8 7 5 4 6 30 46.15
life of
perishable
tomatoes

Table 1: Various problems facing the Asante Mampong community and their
corresponding level of concern

Secondary data were obtained from; the Asante Mampong Municipal analytical report provided
by Ghana statistical service and other government publications, electronic format of published
journals articles and books.

CHAPTER THREE: DISCUSSION OF RESULTS

3.1 OVERVIEW OF THE ASANTE MAMPONG

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3.1.1 THE SETTING OF ASANTE MAMPONG

Figure 2: The map of Asante Mampong and its neighboring communities

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Asante Mampong is a small town in the Mampong Municipal of Ashanti and serves as the
administrative capital of Mampong Municipal. Asante Mampong has a population of 42,037
people. Mampong is also the center of the new Anglican Diocese of Asante Mampong,
inaugurated in 2014. The Mampong Municipal Assembly, formerly the Sekyere West District is
one of the twenty-seven (27) districts in the Ashanti Region of Ghana. It covers a total land
surface area of 2,345 square kilometers km2 (905 square miles)

3.1.2 CULTURE AND SOCIAL STRUCTURE

One important characteristic about the Municipality is its ethnic diversity. Settlements within the
Municipality are made up of various ethnic groups from across the country and the sub-region.
Each group has a unique culture in terms of building styles, physical appearances and the type of
food. The population is however dominated by Akans who constitute 92.6 percent and the other
ethnic groups constitute 7.4 percent. Christians constitute about 87.6 percent of the population
whilst Muslims and traditionalists constitute about 10.9 percent and 1.1 percent respectively. The
Mampong Traditional Area is famous for the celebration of the Kontonkyi Adaekesie, which
traces the migration of the Mampong people to their present location

3.1.3 ECONOMY AND VEGETATION

Agriculture is the main economic activity within the Municipality and employs about 67.3
percent of the entire labour force. However, production is at the subsistence level, which needs to
be improved to ensure higher agricultural productivity for local consumption and export to
generate income and foreign exchange for the inhabitants and the country as a whole. Major
crops cultivated are carrots, tomatoes, maize, yam and groundnuts. The Service Sector is the
second economic industry and absorbs about 17.2 percent of the population while Commerce
constitutes 8.5 percent. Manufacturing however absorbs about 8.9 percent while 3.2 percent are
absorbed by other income generating activities.

3.1.4 VEGETATION

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The Mampong Municipality lies within the wet semi-equatorial forest zone. Due to human
activities like charcoal production, lumbering and bush fires, the forest vegetation particularly
the North-eastern part, has been reduced to Savannah. Vegetation of primary origin can only be
found within a reserve known as the Kogyae Natural Forest Reserve, which has a total land area
of 115 square kilometres.

3.1.5 CLIMATE

The Municipality has an average annual rainfall of 1,270mm and two rainy seasons. The major
rainy season starts in March and ends in August whiles the minor is between September and
November. The remaining months spans the harmattan dry season. The average annual
temperature is 270C with variations in mean monthly temperature ranging between 220C - 300C
(Meteorological Service, Mampong, 2010).

3.2 NATURE AND CHARACTERISTIC OF THE PROBLEM

3.2.1 INTRODUCTION

Shelf life is the length of time that a product, especially food, can be kept in a shop before
it becomes too old to be sold or used. Perishable foods available in Asante Mampong include
from fresh tomatoes, carrots, pepper, garden eggs etc.

Perishable Commodities Expected Storage Life

Tomatoes 5days
Carrots 4-5 weeks
Pepper 1 week
Garden eggs 8 weeks

Table 2: Types of perishable commodities and their relative shelf lives

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Figure 3: Image of raw garden eggs(top left), carrot (top right), red pepper (bottom left),
tomatoes(bottom right)

These products are liable to deteriorate, perish or spoil rapidly and become inedible because of
decay, various forms of fermentation.

3.2.2 THE SHORT SHELF LIFE OF RAW TOMATOES AS A PROBLEM IN ASANTE

MAMPONG

The shelf life of raw tomatoes is an essential indicator of the economic viability in the section of
the private informal sector which involves in the commerce of these perishable goods. Also,
78.5 percent of the agricultural activity in Asante Mampong is crop farming, followed by
livestock rearing (21.5%). Therefore, there is a large number of the employed sector of the
community that depend on the extent to which commodities like tomatoes, carrots, maize,
banana, pine apple, water melon, cabbage etc. can last without spoilage or deterioration in order
to make profits.

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 Type of Households Population in occupied units Population in agricultural activities
crops Total Male Female Total Male Female
Households 11,404 59,125 29,053 30,072 20,525 10,588 9,937
engaged in
crop farming
Tomatoes 1,158 6,728 3,494 3,234 2,438 1,373 1,065
Carrot 698 3,456 1,950 1,506 1,368 963 405
Yam 3,398 19,184 9,245 9,939 6,381 3,041 3,340
Plantain 3,592 19,231 8,971 10,260 6,648 2,860 3,788
Maize 5,973 32,664 16,571 16,093 11,352 6,246 5,106

Table 3: Distribution of households engaged in crop farming by type of crop and

population engaged

The Table indicates that 60.9 percent of the households in the Mampong Municipal engaged in
agriculture. In terms of distribution by localities, 78.6 percent of the total rural households and
42.4 percent of urban households are engaged in agriculture. Almost all the agricultural
households in the Municipality (97.5 percent) are engaged in crop farming. In terms of localities,
96.9 percent of the urban agricultural households as well as 97.8 percent of the rural households
are engaged in crop farming. Tree planting is not popular in the Municipality as less than 2
percent of the households in the Municipality (including rural and urban households) are
engaged in tree planting. With regards to Livestock rearing, 30.4 percent of the agriculture
households in the Municipality were engaged in livestock farming.

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 Type of Total Urban Rural
activity Number Percent Number Percent Number Percent
Total 19,203 100.0 9,388 100.0 9,815 100.0
Households
Households 11,698 60.9 3,982 42.4 7,716 78.6
engaged in
Agriculture
Crop 11,404 97.5 3,858 96.9 7,546 97.8
Farming
Tree 114 1.0 46 1.2 68 0.9
Planting
Livestock 3,556 30.4 826 20.7 2,730 35.4
Rearing
Fish 6 0.1 1 0.0 5 0.1
Farming

Table 4: Households by agricultural activities and locality

3.2.3 CAUSES OF THE SHORT SHELF LIFE OF TOMATOES

Tomato (Lycopersicon esculentum Mill.) is one of the most widely cultivated and extensively
consumed horticultural crops in Ghana. Tomatoes have the tendency to decay over a short period
of shelf life.

Tomatoes like other fruits are highly perishable. The rate of biological deterioration in harvested
tomato fruits depends on various environmental (external) factors and some biological causes.

Biological causes of deterioration

• Metabolic changes (respiration, ethylene production and reaction, compositional changes).

• Mechanical injuries (cuts, bruise, puncture, abrasion and compression etc.).

• Incidence of physiological disorder.

• Pathological breakdown.
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1.3 Environmental factors of deterioration

• Temperature

• Relative humidity

• Ventilation

• Concentrations of ethylene, oxygen and carbon dioxide.

The rate of biological deterioration in the fruit is highly influenced by the biological factors.

The relative importance of the internal and external factors depends on

• The cultivars

• The handling and storage system used.

• The time between harvest and consumption.

3.2.4 EFFECTS OF THE SHORT SHELF LIFE OF TOMATOES TO CONSUMERS

The short shelf life of tomatoes is not only a huge concern to those who make a living from
selling them. It is also a problem affecting the 42,067 households in the community. In homes,
tomatoes are mostly for immediate consumption needs, resulting in wastage of food surpluses
during the short harvest periods and scarcity during postharvest periods. Even though most
houses implore the use of fridges and freezers for storage of tomatoes once purchased from the
market or mall, it does not indefinitely store the tomatoes till the time of need. It simply slows
down the growth of bacteria and the tomatoes shelf life is extended a little longer. Inevitably, the
tomatoes gets spoilt. Some people prefer cooking their tomatoes immediately after purchase. It is
true that this method, cooking, has been approved scientifically to be a good mode of controlling
heat, moisture and pH in the tomatoes. Hence, inhibiting spoilage by preventing microbial
growth and slowing down the food’s natural breakdown process. But what most people are in the
dark about is the fact that this process permanently eliminates the action of enzymes only.
Although, bacteria and fungi are killed during the cooking process, they re-infect the cooked

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food when measures are not taken to prevent their return. It is evident that the current extent of
this problem has totally outpaced the capacity and measures of the people to manage the
situation.

Figure 4: Household population in communities in Asante Mampong

3.2.5 LOCAL METHODS OF EXTENDING SHELF LIFE OF TOMATOES

Due to the short shelf life of the tomatoes, most people in the community have now adopted a
system of trading in seasonal commodities. When the season of the tomatoes comes, the
tomatoes are in abundance so its easily perishable nature is ignored as there is more than enough
to do business with. But when its season passes, the tomatoes become scarce. The quantity left
after the fresh tomatoes are consumed by the people is the quantity that is preserved for

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consumption during the months when the tomatoes are not available. People resort to local
methods of preserving tomatoes extend the shelf life of the tomatoes namely:

 Store tomatoes away from direct sunlight with the scar facing up to reduce softening and
darking of tomatoes.

Figure 5: Image of stem scar of tomato. The blossom end is directly opposite of the stem
scar
 Sorting, cleaning and grading of tomatoes immediately after harvest. It is essential to
separate the bad fruits from the wholesome ones.
 Using packaging materials and methods that would not impact physical damage to the
tomatoes e.g. ventilated paper cartons, smooth wooden boxes and plastic crates.

Figure 6: Image of local packaging materials i.e plastic crates and wooden boxes.

3.2.6 LIMITATIONS OF THE LOCAL METHODS OF PRESERVATION IN THE

COMMUNITY.

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Also ignorance of the farmer in the packaging method (packing rotten and fresh fruits together)
ignorant of the farmers to process their produce and lack of modern storage facilities, result in
incidences of losses.

. Open container and mesh bags showed accelerated fruit decay frequency (complex infection)
due to faster fungal sporulation and mycelial spread.The physical damage observed in wooden
crates was due to improper fixing of wooden pieces with iron nails. The open container
irrespective of the nature of packing material is harmful.

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CHAPTER FOUR: CHEMICAL ENGINEERING

Figure 7: KNUST Chemical Engineering department logo

4.1 CHEMICAL ENGINEERING AS A PROGRAM OF STUDY

Chemical engineering is a broad discipline dealing with processes (industrial and natural)
involving the transformation (chemical, biological, physical) of matter or energy into forms
useful for mankind, economically and without compromising the environment, safety or finite
resources. This branch of engineering is concerned with the design, construction, and
management of factories in which the essential processes consist of chemical reactions. It is the
task of the chemical engineer to select and specify the design that will meet the particular
requirements of production and the most appropriate equipment for the new applications.
Chemical engineers use chemistry, physics and mathematics along with engineering tools to
solve problems relating to the production and use of chemicals. This includes things like refining
gasoline and other fuels from petroleum, purification of drinking water, treating waste,
recovering raw materials, and processing food, etc. chemical engineering graduates will
understand and be able to analyze entire chemical processes, learn independently, and participate
effectively in-group discussion, design, effectively perform laboratory experiments and analyze
and interpret results. Chemical engineering also works with fields such as nanotechnology and
bioengineering.

4.2 DUTIES OF A CHEMICAL ENGINEER

A chemical engineer:

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Conducts research to develop an improved manufacturing process

Provides safety measures for those working with dangerous chemicals

Works on making products like food, and drinks

Helps in managing world’s resources.

Protect the environment by providing health and safety standards.

4.3 SCOPE OF CHEMICAL ENGINEERING

Chemical engineer work in offices as well as laboratories. They find employment at industrial
plants, refineries and locations where they monitor or direct chemical operations. They usually
work with design professional and technicians or work on-site. The industries that employ
chemical engineers are as follows:

Architectural, engineering, and related services.

Basic chemical manufacturing

Scientific research and development services

Resin, synthetic rubber, and artificial synthetic fibers and filaments manufacturing

Petroleum and coal products manufacturing

Biotechnology and pharmaceutical companies

Business service

Health-care industries

Food manufacturing unites

Electronic and energy manufacturers.

Chemical engineering branch has many characteristics of a core branch of engineering.it is more
or less an evergreen branch. Chemical industry is showing no signs of slowing down. Actually, it

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is expanding and with this expansion, new job opportunities are also being generated.
Government and private sector jobs are available for graduates in ample amounts. Graduates may
bag following roles in the above mentioned sectors-

Plant managers

Production engineer

Purchase and quality control executive

Safety management officer

Chemical engineer

Plant designer

CHAPTER FIVE: PROBLEM SOLUTION

5.1 PRODUCTION PROCESS

A production process is concerned with transforming a range of inputs into those outputs that
are required by the market. A production process which can turn the fresh tomatoes into useful
product so as to extend the shelf life of tomatoes could solve the problem at hand in the
community. Packaging is one of the traditional methods used in the community to preserve fresh
tomatoes because the use of plywood boxes has the merit of providing a continuous smooth
surface which minimizes physical damage to packaged perishable tomatoes. The present studies
suggest the redesigning of paper material which should be shock proof, non-insulator and
appropriated aeration. Paper material would be better than the rest because least physical damage
would be noticed in this case. In this production process, measures are put in place using
knowledge from chemical engineering to address these limitations hence, extending appreciably
the shelf life of these fresh tomatoes longer than any of the traditional methods without
destroying desirable traits from the tomato.

METHOD

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Block Diagram for Production of Tomato Paste from Raw Tomatoes

Production of tomato paste from fresh tomato, the selected process routes is described below.
The selected route was arrived at by comparing alternative process routes. The justification for
the selected route is that it possesses the capacity of further processing wastes obtained from the
juice extractor to recover more juice. Also unlike existing routes which are most likely suited for
small scale processing, the selected route handles large volume of tomato paste product.

Fresh
Water

Fresh 1 2 3 4 5
Tomato
6

10 9 8 7

11

12

Tomato
Paste

Figure 8: Block Diagram for Production of Tomato Paste from Raw Tomatoes

LEGEND:

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 1. Washing

2. Sorting

3. Crushing

4. Preheating (Hot Breaking)

5. Pulping

6. Refining

7. Homogenizing

8. Evaporation

9. Sterilization

10. Aseptic tank

11. Finishing

12. Product Storage

2.3 Process Description of the Selected Process Route

From figure 2.1, the process for the processing of tomatoes into tomato paste follows the
following stages:

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.
(SSP, 2014).

SORTING

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Automatic fruit sorting use either image processing, computer vision or machine learning. For
tomatoes, factors considered are size and colour. This system involves the following process:
Firstly, fruits are collected in a chamber. From the chamber they move through escalators safely
where the weight of the fruits are estimated. It moves toward another chamber where the image
of fruit is captured by more than one camera in different angles. For detecting fruit growth (raw
or ripped), smell of the fruit is detected by sensors of wireless various algorithms network. Image
is then processed where different algorithms are applied for finding expected feature like size,
depth, 3D model, texture and colour. Based on the decision drawn after the process above, the
fruit is classified into different categories like big, small, medium sized, ripe/unripe or
defectives. Finally automatic packing system packs the fruit according to the categories
provided. (Naik and Patel, 2003).

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. (SSP, 2014)

PREHEATING

In the preheating unit, the crushed tomatoes undergoes enzymatic inactivation. Hot break is
recommended for high viscosity product. It inactivates completely the pectin enzymatic activity,
increasing the consistency and viscosity of the mixture. Hot break temperature is between 85-
95oC (Fenco, 2014).

PULPING

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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. (Practical Action,
2015)

REFINING

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

HOMOGENIZING

High pressure homogenization is an entirely mechanical process, the tomatoes products are
forced through the homogenizing valve producing changes in the particle structures:

 Single cells production.

 Disaggregation of agglomerates.

 Reduction of oil globules size.

 Cutting effect on fibers, seed and others.

These mechanisms relate to the changes in the structure of an aqueous tomato dispersion caused
by the application of mechanical energy.

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

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contained in these particles of pulp, failure to properly disperse them will result in a product with
poor uniformity and depth of colour. (GEA, 2015)

EVAPORATION

This involves the removal of water from the juice and serves two main purposes:

 Improve microbiological stability with reduction of water activity, which is the

predominant factor in most organic degradation processes;

 Reduce transportation, packaging, distribution and storage costs by minimizing

volume and weight.

STERILIZATION

The sterilizer has 4 layers tubular structures, the inner two layers and the outside layer will go
through with the hot water and the middle layer will be running with the product. The product
will be heated by the hot water to the setting temperature and then hold the product under this
temperature for few times to completely sterilize the product and then cool down the product by
the cooling water or chilled water. The sterilizer consist of product tank, pump, heat exchange,
holding tubes and control system.

ASEPTIC TANK

In aseptic process technology, product safety takes top priority. Food processors use sterile tanks
as storage or buffer tanks. Aseptic storage prevents contamination of the product and helps to
ensure a long shelf life and stability. Sterile tanks can perform a buffer function in the process
upstream of the filling line (GEA, 2015)

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PACKING, LABELING AND STORAGE

The product is the packaged, labeled all stored for sales.

8.1 CONCLUSION
The need to establish a tomato paste plant in Nigeria cannot be overemphasized. The plant
promises to eliminate glut experienced by tomato producers in periods of increased supply. It
also possesses the prospect of boosting the gross domestic products of the country. The design of
the plant being carried out indicates that it is technically feasible to construct the plant because
the equipment is available, the process route is feasible, and the process conditions attainable. It
was also shown from HAZOP studies that the safety and operability concerns of the plant can be
taken care of by proper engineering control, environmental control and personal protection.

in one plant (Tomato Paste, Tomato Powder, and Lycopene) should be designed and constructed
– this will encourage the utilization of waste which will increase the annual income for the plant

8.2 RECOMMENDATION

From the results obtained in this plant design exercise, it is recommended that investment should
be that make it possible made to set up this plant. More investment should be put into cultivation
of raw tomato which will help to reduce the price of tomato raw material. Tomato plant should
not be constructed for only tomato paste but a three for the plant to double its profit margin. A
technology should be developed for the plant which will re-inject heat produced in the process to
serve utility purposes thereby lowering the total production cost of the plant.

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CHAPTER SEVEN

7.1 REFERENCES

Abdulmalik I., Amonye, M., Ambali, A., Umeanuka, P. and Mahdi, M. (2014): Appropriate
Technology for Tomato Powder Production. Volume 3, Issue 8. Nigeria:
International Journal of Engineering Inventions
Ghana Statistical Service (2012), 2010 Population and Housing Census, National Analytical
Report
Adegbola J., Awagu, F., Adu, E., Anugwom, U. Ishola, D., and Bodunde, A. (2012):
Investment opportunities in tomato processing in kano, Northern Nigeria. Nigerian
Stored Products Research Institute, PMB 3032, Kano, Nigeria
Fellows, Dr. Ouaouich (2004). Small scale fruit and vegetable processing and Products.
Electronic document. Retrieved from http://www.unido.org>Publications>Pub_free/. Accessed 3
June 2017.
D.F.P. Silva, Salomao, lopes de siquiera, P.R. Cecon, Aline Rocha (2009). Potassium
permanganate effects in postharvest conservation of the papaya cultivar Sunrise Golden, Pesq.
Agropec. Bras., Brasilia. v.44, n.7, p.669-675

Group three - 2014 plant design (iii) (che 522) “plant design for the production of 1800 tonnes
of tomato paste per day from fresh tomatoes”

Atherton, J. and Rudich, J. (1986): The Tomato Crop. London: Chapman and Hall
Catelli, R. (2012): “Strategic Aspects in Tomato Processing: Efficiency, Flexibility, and
Reduction in Fixed Costs”. 12th ISHS Symposium on the Processing Tomato. 10 th World
Tomato Congress. Beijing. www.cft-group.com

CBN (2011): Integrating Nigeria’s Agricultural and Financial Value Chains: The Role of
NISAL

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J. Aked, Cranfield University at Silsoe (2002). Maintaining the post-harvest quality of fruits and
vegetables. Woodhead Publishing Ltd and CRC press, LLC.
CP Africa (2013): www.cp-africa.com. Accessed 3/3/2015
Dike, A. and Atchley, A. (1986): Handbook of Proximate Analysis Tables for Higher Plants.
Florida: CRC Press Inc.
Engineering Toolbox (2015):www.engineeringtoolbox.com/specific-heat-capacity-
food_295.html (Accessed, 10/02/2015): The Engineering Toolbox
FAO (2009): “Fruit and Vegetable Processing. Agribusiness Handbook. Italy: FAO Investment
Centre
Farahnaky, A. and Hill, S. (2007): The effect of salt, water and temperature on wheat dough
rheology. J. of Texture Studies, 38, 499-510.
Feedipedia (2015): www.feedipedia.org/node/689 (Accessed, 05/02/2015)
Fenco (2014): Tomato Paste Processing. www.fenco.it/eng/tomato-paste-processing.asp
Accessed 24/09/2014. Fenco Food Machinery

7.2 APPENDICE

7.2.1 QUESTIONNAIRE SAMPLE 1

Name: ……………………………………………………………

1. Which locality in Asante Mampong do you reside in? Please tick below

2. How many years have you lived in your locality? ………………

3. What do you do for a living? ....................................

4. State any two major problems confronting you and your household as a whole in Asante
Mampong.

(i) ………………………………………………………………………………………

(ii) ………………………………………………………………………………………

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7.2.2 QUESTIONNAIRE

SAMPLE 2

Name: ……………………………………………………………

1. Which of the following categories below can you classify yourself under? Tick one only

Primary producer (farmer)

Vendor (trader)

Consumer (you neither sell nor cultivate crops)

2. How long have you been in this community? …………….

3. Do you agree that the short shelf life of perishable foods is a major challenge confronting you
in this community? ……………..

4. How has it affected you in the community?

………………………………………………………………………………………………
………………………………………………………………………………………...........

5. Do you have any idea on what might be the cause of this problem? if yes, please state
them………………………………………………………………………………………… ...........
.....................................................................................................................................

6. In what ways have the Government been able to help with the situation?
………………………………………………………………………………………………
………………………………………………………………………………………………

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7. In what ways have you been able to manage the situation until now
………………………………………………………………………………………………
……………………………………………………………………………………………....

8. Do you have any suggestions on what must be done in the community to tackle or solve the
problem better? (i) Yes/ No

(ii) If yes, please state below:

………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………

7.2.3 GLOSSARY AND ACRONYMS

Enzymes natural proteins in food that cause change to colour, flavor, texture

in the food.

Sorting is any process of arranging items in some sequence and/or in different

sets, and accordingly,

Pulping crush into a soft, wet, shapeless mass.

Refining remove impurities or unwanted elements from (a substance), typically as

part of an industrial process.

Homogenizing to reduce to small particles of uniform size and distribute evenly usually in
a liquid.

Sterilization refers to any process that removes, kills, or deactivates all forms of life (in
particular referring to microorganisms such as fungi, bacteria, viruses,
spores, unicellular eukaryotic organisms such as Plasmodium, etc.) and
other biological agents like prions present in a specific surface, object or
fluid.

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Micro-organism tiny forms of life, invisible until they are in large numbers, moulds,

yeast and bacteria.

Shelf life the time that a food product can be stored before changes in

texture, colour, flavor, or the number of microorganisms make it

unacceptable.

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7.3 OTHER MAPS.

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7.4 INTRODUCTORY LETTER

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