1. What is Hot Break Processing?
Hot Break is a tomato paste production method where freshly harvested tomatoes are heated rapidly to 85–100°C before crushing. This process is designed to:
- Inactivate pectinase enzymes
- Retain pectin structure
- Increase viscosity
It is the counterpart to Cold Break processing (typically at 60–70°C).
2. Standard Operating Steps for Hot Break Tomato Paste
| Step | Description | Key Control Points |
|---|---|---|
| 1️⃣ Selection | Choose ripe tomatoes (>85% ripeness) | Free from rot and disease spots |
| 2️⃣ Washing | Spray and brush cleaning | May add chlorine for disinfection |
| 3️⃣ Preheating | Rapidly heat tomatoes to 85–100°C | Hold for 1–3 minutes |
| 4️⃣ Crushing | Crush tomatoes while still hot | Temperature must stay >85°C |
| 5️⃣ Pulping | Remove seeds and skins using sieves | Typical screen size: 1.0mm & 0.8mm |
| 6️⃣ Evaporation | Concentrate to target Brix (e.g., 36–38%) | Vacuum evaporator preferred |
| 7️⃣ Sterilization | Use tubular or plate sterilizer at >90°C | Ensure >30s holding time |
| 8️⃣ Aseptic Filling | Fill into sterile bags or cans | Maintain aseptic environment |
3. Functions of the Hot Break Process
| Function | Explanation |
|---|---|
| Enzyme Inactivation | High heat inactivates pectinase, preserving pectin structure |
| High Viscosity | Intact pectin network creates a thick and stable paste |
| Stable Color | Slightly darker than cold break, but less prone to color fading |
| Ideal for High-Brix Paste | Good for producing 36–38 Brix products for export |
| Better Sterility | High temperature helps reduce microbial load early on |
4. Typical Test Results for Hot Break Paste
| Parameter | Typical Value | Notes |
|---|---|---|
| Brix (°Bx) | 28–38% | Depending on final concentration |
| Viscosity (Brookfield) | ≥6,000–12,000 mPa·s | High thickness and consistency |
| Bostwick (30 sec) | 3–6 cm | Lower flow distance = higher viscosity |
| pH | 4.1–4.4 | Suitable for food safety |
| Lycopene | 30–50 mg/100g | Slightly lower than cold break |
5. Recommended Applications
| Use Case | Reason |
|---|---|
| High Brix Export Paste | High viscosity suits 220L or 1000L drums |
| Canned Tomato Products | Maintains structure and color during retorting |
| Pizza Sauce / Thick Base | Excellent coating and flavor delivery |
| Export (Middle East / Africa) | Buyers prefer thicker texture in these markets |
6. Hot Break vs Cold Break (Summary Table)
| Item | Hot Break | Cold Break |
|---|---|---|
| Temperature | 85–100°C | 60–70°C |
| Viscosity | High (3–6 cm Bostwick / 30s) | Lower (6–9 cm Bostwick / 30s) |
| Color | Slightly darker but stable | Brighter but less stable |
| Nutrient Retention | Moderate | Higher retention |
| Paste Structure | Dense, gel-like | Thinner, more flowable |
| Ideal For | Cans, export, thick sauces | Juices, soups, light sauces |
