Abstract:
A method of making chunk tomato pieces from tomatoes. The tomatoes are introduced into a tomato preparation system where they are cleaned, de-stemmed, peeled and chopped. This creates a mixture of tomato chucks, seeds and juice. The tomato chunks are separated from the seeds and juice. The juice is separated from the seeds and subsequently added back to the chunks in proper proportions.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     This invention relates generally to methods and systems for processing tomatoes, and more particular to methods and systems for processing tomato for the production of chunk products.  
         [0003]     2. Description of the Related Art  
         [0004]     Tomato processing for production of a chunk tomato product verses juice production is currently and has historically utilized a variety of different steps, including but limited to, peeling, cutting/chopping, thermal procedures, and packaging with seeds. Seeds are known to produce off flavors and are visually non-appealing to the end consumer. Over the years numerous attempts have been made to remove seeds from chunks after cutting. All attempts have been unsuccessful.  
         [0005]     With current methods of tomato processing, tomato essence is retained in the juice that is liberated during the cutting/chopping step. The tomato essence must be retained during the deseeding processes. However, methods employed to date to deseed reduce the amount of tomato essence. To be cost effective in the tomato industry mass flows are very high. Methods to date that have attempted to deseed have had a negative impact on the flow rate. Additionally, tomatoes are very sensitive to the introduction of unnecessary shear. Shear reduces product size and liberates excessive juice and tomato essence. Methods utilized to date for deseeding have not proven to be successful because they impact tomato product desirability, and reduce tomato essence.  
         [0006]     There is a need for improved methods and systems for producing seedless chunk tomato products. There is a further need for methods and systems for producing seedless chunk tomato products without effecting flow of product. There is yet another need for methods and systems for producing seedless chunk tomato products while preserving tomato essence and without introducing shear.  
       SUMMARY OF THE INVENTION  
       [0007]     An object of the present invention is to provide improved methods and systems for processing tomatoes.  
         [0008]     Another object of the present invention is to provide methods and systems for making chunks of tomatoes from tomatoes.  
         [0009]     Yet another object of the present invention is to provide methods and systems for the removal of seeds from tomatoes during processing of tomatoes into tomato chunks.  
         [0010]     A further object of the present invention is to provide methods and systems for producing tomato chunks while preserving tomato essence.  
         [0011]     Another object of the present invention is to provide methods and systems for making deseeded chunks of tomatoes from tomatoes during a continuous process.  
         [0012]     A further object of the present invention is to provide methods and systems for making deseeded chunks of tomatoes from tomatoes with minimal impact on the size and shape of the tomato chunks.  
         [0013]     Yet another object of the present invention is to provide methods and systems for making deseeded chunks of tomatoes from tomatoes with a seed removal of at least 90%.  
         [0014]     Another object of the present invention is to provide methods and systems for making deseeded chunks of tomatoes from tomatoes with an optimal balance of juice and chunks.  
         [0015]     These and other objects of the present invention are achieved in a method of making chunk tomato pieces from tomatoes. The tomatoes are introduced into a tomato preparation system where they are cleaned, de-stemmed, peeled and chopped. This creates a mixture of tomato chucks, seeds and juice. The tomato chunks are separated from the seeds and juice. The juice is separated from the seeds and subsequently added back to the chunks in proper proportions.  
         [0016]     In another embodiment of the present invention, a system is provided for making chunk tomato pieces from tomatoes. A preparation device includes a holding space for receiving tomatoes and a device to peel and de-stem tomatoes. A processing unit is coupled to the preparation device. The processing unit produces a mixture of tomato seeds, tomato juice, pulp and chunks. A separation device is coupled to the processing unit that removes the seeds from the tomato juice, chunks and pulp. A receiving device is coupled to the separation device. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0017]      FIG. 1  illustrates one embodiment of a system of the present invention for making chunk tomato pieces from tomatoes.  
         [0018]      FIGS. 2 and 3  illustrate embodiments of feed conveyors useful for the transport of the received tomatoes.  
         [0019]      FIG. 4  is a cross-sectional view of one embodiment of a a maceration processing unit of the present invention. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0020]     Referring to  FIGS. 1 through 4 , in one embodiment of the present invention, methods and systems are provided for making chunk tomato pieces from tomatoes. A processing system  10  includes a device  12  for receiving whole and/or partially crushed tomatoes, hereafter generally referred to as the “received tomato”.  
         [0021]     Processing system  10  peels, de-stems and then sends the received tomatoes to a maceration processing unit  14 . Maceration begins with the transport of the received tomatoes to various feed conveyors, generally denoted as  15 , including but not limited to surge bins.  
         [0022]     The received tomatoes are continuously feed into maceration processing unit  14  by the conveyors  15 . Feeding of the received tomatoes can be achieved in a variety of different manners, including but not limited to dropping the received tomatoes into maceration processing unit  14  in feed, and the like. Maceration occurs when the received tomatoes are exposed to a continuously moving cutting device. The cutting device reduces received tomato mass into chunks. Cutting device can also slice and/or dice, e.g., cube, the received tomatoes.  
         [0023]     Generally, maceration processing unit  14  produces tomato chunks, seeds and tomato juice. This mixture is then strained at a separating device  16  that removes the seeds and recycles the juice, chunks and pulp. The recycled juice, chunks pulp are then received at a receiving unit  18  and a suitable separating device  16  is employed.  
         [0024]     In another embodiment, illustrated in  FIG. 2 , the seeds are removed in the straining process and the remaining material is received at a high speed centrifugation device  20 . At centrifugation device  20  puree is further processed in order to create tomato paste. The remaining tomato chunks are then received at receiving unit  18 . In one embodiment, a Liquatex separator is utilized, which is commercially available from Rotex Inc., Cincinnati, Ohio.  
         [0025]     In various embodiments, the flow of chunks is diluted with tomato juice in order to create a diluted mass of chunks. The tomato juice can be received from processing apparatus  10 . The diluted mass of chunks can be passed across a rotex. The diluted mass of chunks can be sprayed with tomato juice. The spray can be delivered in the form of a water fall of tomato juice that cascades over the chunks.  
         [0026]     In one embodiment, the seeds, chunks and tomato juice are separated into three flows. The tomato juice can flow in a closed-loop system. At least a portion of the tomato juice that is separated from the chunks flows in a return path to spray the chunk and seed mixture. The tomato juice flows in a closed-loop pumping circuit within processing apparatus  10 . The closed-loop pumping circuit  22  can include a tomato juice reservoir  24  which can be pre-charged.  
         [0027]     Tomato juice can then flow from tomato juice reservoir  24  to a spray nozzle  26  that sprays the tomato chunks with tomato juice. Tomato juice reservoir  24  is filled with tomato juice prior to chopping the tomatoes. An equilibrium is created between the spray and the tomato juice reservoir. A tomato juice and tomato chunk balance without seeds is created.  
         [0028]     In one embodiment, the balance is in the range of 85% 60% tomato juice and 15%-40% tomato chunk. In another embodiment, the balance is about 75% tomato juice 25% tomato chunk. With certain embodiments of the present invention, methods and systems are provided for making deseeded chunks of tomatoes from tomatoes during a continuous process while maintaining a commercial rate of flow and with minimal impact on the size and shape of the tomato chunks. In one embodiment, the methods and systems of the present invention for a seed removal of at least 90%, at least 95% and at least 99%.\ 
       EXAMPLE 1  
       [0029]     In this example, apparatus  10  was utilized to separate tomato chunks from seeds. A modified Rotex unit, with liquid recirculation and a feed system was utilized. Four tests were performed. Tests were initiated with recovered and reconstituted juice. Testing occurred for a total of 61 minutes. Reject stream (seeds, juice and residual juice) was analyzed via placement on punch plate screen with 0.090″ openings. This allowed liquid (as compared to seeds and pectin) to drip free.  
         [0030]     Visually acquired data indicated significant reduction of seeds in finished product, as evidenced by the pulp feed and finished product. There was no discernable change in flavor profile pectin. Seed content of rejected stream was high with liquid reasonable low of about 1% of line flow on a mass basis. Pectin and seed were approximately 9 to 10% of total mass flow The actual total mass flow was 12,200 pounds for 61 minutes. Liquid reintroduction to pulp was successful with stationary weir functioning. Post test inspection revealed little if any build up on screen surfaces Table 1 summarizes the results.  
                                                                         TABLE 1                                       Recirculation   Recirculation               Mass Flow   Spray   Auger Deluge   pump Rate   pump       Test#.   lbs/hr Equiv   Bars Used   Used + Flow   in Hz   pressue   Observations                                                            15-Sep-03       Set Up       1, 2 &amp; 3       41.51       Initial start up juice                               is heat treated:                               120 deg F. @ 9 brix                               Dilute to 4.5                               Juice at approx. 100 deg F.                               Tomatoes at approximately                               100 deg F.                               Operated 10 minutes                               without product:                               4.2 lbs juice in seed                               discharge       1   Est. 50%   1 &amp; 2       41.51       Start Time is 8:09 AM           Lineflow                   Seeds, Pectin and Juice:                               25.3 pounds in 1′ 15″                               Visible reduction of seeds                               in pulp is very significant                               Pulp side tank must be                               modified to greater slope                               Decanting wier works                               amazingly well.       2   15823   1 &amp; 2   Valve @ 50%   41.51       Seeds, Pectin and Juice:   % lineflow                               25.3 pounds in 1′ 01″   10%                               203 cans in 4′ 20″ . . .                               90 ozs tomatoes/can or                               5.625 pounds/can                               Seed removal improved       3   13950   1   Valve @ 50%   41.51       Seeds, Pectin and Juice:                               24.6 pounds in 1′ 09″    9%                               40 second 15.2 pounds total   10%                               mass                               13.8 pounds seeds and pectin    9%                               1.4 pounds juice    1%                               Some increase in seeds in pulp                               124 cans in 3′ 00″       4   13900   1 &amp; 2   Valve @ 50%   41.51       Seeds, Pectin and Juice:                               40 second 17.5 pounds total   11%                               mass                               15.6 pounds seeds and pectin   10%                               1.6 pounds juice    1%                               End Test 9:10                  
 
         [0031]     While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention.