English — Industrial food & beverage lines
Tomato Paste Rework Line — Drum Unloading, Mixing, Pasteurization & Filling
A rework line does not process fresh tomato: it re-processes bulk concentrate already stored in aseptic bags, 220 L drums or 1000 L IBCs, and converts it into retail product — passata, standardized paste, ketchup, pizza sauce — packed in glass, cans, sachets or pouches. It is the fastest way to add value without owning a campaign plant: it runs 250–300 days a year instead of 90, it needs no growing basin under contract, and CAPEX is one order of magnitude lower than a full evaporation line. MCF Technology supplies the complete rework line — drum and bag emptying, ingredient preparation, continuous in-line standardization to target °Brix, pasteurization, filling and closing — with installation, commissioning and operator training worldwide.
What MCF Technology supplies
- Aseptic bag-in-drum and IBC emptying station with piston or hydraulic press discharge, hot-water jacket for high-viscosity paste
- Ingredient preparation: sugar, salt, vinegar, starch, spices — weighing, hydration and powder-into-liquid mixing under vacuum
- Buffer and pre-mix tanks with side-scraping agitators and load cells
- Continuous in-line standardization: dilution water, mass-flow and refractometer control to the target °Brix (± 0.2)
- Deaeration and homogenization for ketchup and smooth sauces
- Tubular or scraped-surface pasteurizer with validated holding section (92–98 °C)
- Filling in glass jars, tinplate cans, sachets, doypacks or bottles, with capping / seaming and steam-vacuum control
- Pasteurization tunnel or cooling tunnel, labelling and end-of-line packing
- Automatic CIP, utilities skid, SCADA recipe management and traceability per batch
Typical outputs
- Standardized tomato paste 22–28 °Brix in glass or cans
- Passata and pizza sauce in bottles and jars
- Ketchup and seasoned sauces in bottles, sachets and doypacks
- Tomato paste sachets 50–400 g for retail and food service
- Re-packed aseptic bulk (bag-in-box) for industrial clients
Reference configuration
Tomato paste rework line — 3,000 kg/h
This is the configuration MCF Technology quotes most often for rework projects: aseptic bulk paste in, retail cans and glass out, running 250–300 days a year. Use it as the baseline and scale it to 500, 1,000, 2,000 or 5,000 kg/h.
Customer requirement
- Convert aseptic tomato paste at 36–38 °Brix, stored in bags, drums or IBCs, into finished retail product all year round.
- Fill 400 g and 830 g cans, 2–5 kg catering cans and glass jars on the same line, with recipe change and CIP in between.
- Guarantee a stable finished specification (°Brix, colour, viscosity) independently of the inbound bulk batch.
- Full traceability per batch and a documentation package suitable for financing and food-safety audits.
Technical data
| Capacity | 3,000 kg/h finished product (500 / 1,000 / 2,000 / 5,000 kg/h also available) |
|---|---|
| Product | Tomato paste, passata, pizza sauce, ketchup and seasoned sauces |
| Input | Aseptic drums 220 L, IBC 1,000 L, bag-in-box — 36–38 °Brix |
| Output | 400 g / 830 g / 2–5 kg cans + glass jars (sachets and doypacks optional) |
| Standardisation | Continuous, mass-flow loop with inline refractometer, ± 0.2 °Brix at steady state |
| Thermal treatment | Tubular or scraped-surface pasteurizer, 92–98 °C, validated holding section |
| Automation | PLC + SCADA with recipe management, batch traceability and remote assistance |
| CIP | Automatic, dedicated skid with caustic and acid circuits and conductivity control |
| Operating days | 250–300 days/year — bulk concentrate, not a seasonal campaign |
| Installation | Worldwide: erection, commissioning, FAT/SAT and operator training included |
- — Two alternating unloading stations are specified above 3,000 kg/h so the line never waits for a drum change.
- — Ketchup adds vacuum powder induction, deaeration and a 100–200 bar homogenizer before pasteurization.
- — Utilities envelope for this size: steam 8–10 bar, chilled water, compressed air and treated dilution water.
Reference configuration for budgeting and layout discussion. Final specification, utilities and performance are confirmed in the feasibility study on your product, packaging formats and site conditions.
Process flow
- Aseptic tomato paste (36–38 °Brix)
- Drum / IBC unloading
- Mixing
- Recipe preparation
- Standardisation
- Thermal treatment
- Buffer tank
- Filling
- Pasteurization tunnel
- Packaging
- Palletizing
Download — PDF
tomato paste rework line — technical datasheet
A real engineering datasheet, not a brochure: the same data published on this page, formatted for your technical and financial review.
Technical data & process
Reference configuration, specifications, step-by-step process
Dimensions & layout
Footprint, clear height, functional zones, utilities and manning
CAPEX & payback
Indicative capacity / CAPEX / EBITDA / payback grid with assumptions
MCF Project Studio
From idea to commissioned plant, in one engineering path
Every commercial page on this site is connected to the same working method: process engineering, capacity sizing, CAPEX and a bankable financial plan over 3–10 years are produced together, not in sequence by different suppliers.
01 · Idea
Is this factory feasible in my country, with my product and my formats?
Start from the guided configurator02 · Engineering
Which capacity, process and utilities does my line actually need?
Compare technologies and lines03 · Investment
What does it cost, what does it return, and is it bankable?
Run the ROI simulator04 · Purchase
Who engineers, installs and services it worldwide?
Request the technical-financial dossier
Rework process, step by step
From aseptic bulk concentrate to packed retail product. Every step below is sized on the finished output in kg/h and on the packaging formats chosen, from 500 to 5 000 kg/h.
- 1
Bulk reception and drum / IBC emptying
220 L bag-in-drum or 1 000 L IBC · 2–4 min per drum
The aseptic bag is opened in a hygienic enclosure and emptied by hydraulic press or piston pump into a jacketed hopper. Above 3 000 kg/h two stations alternate so the line never waits for a drum change.
- 2
Ingredient preparation
Sugar, salt, vinegar, starch, spices · vacuum powder induction
Powders are weighed and hydrated under vacuum to avoid lumps; liquids are dosed by load cells or mass flow. This is the step that separates a passata line from a ketchup line.
- 3
Continuous standardization
36–38 → 22–28 °Brix · inline refractometer ± 0.2 °Brix
Treated dilution water and concentrate are mixed in a mass-flow controlled loop; the refractometer closes the loop on the recipe set point, so the finished specification does not depend on the inbound batch.
- 4
Deaeration and homogenization
Vacuum deaerator · 100–200 bar homogenizer (ketchup, smooth sauces)
Air removal protects colour and shelf life, homogenization sets viscosity and prevents serum separation in the jar. For rustic passata this stage is bypassed.
- 5
Pasteurization
Tubular or scraped-surface · 92–98 °C · validated holding
The product is heated in a wide-gap tubular or scraped-surface exchanger, held for the validated time, then delivered hot to the filler for hot filling, or cooled when the format requires it.
- 6
Filling and closing
Cans 400 g–2.2 kg · jars · sachets 50–400 g · doypack
Volumetric or weight filling with steam-vacuum control, then seaming or capping. Format changeover is managed by recipe on the SCADA, with tooling kits per container size.
- 7
Cooling, coding, packing
Cooling tunnel · lot and expiry coding · case packing
Containers are cooled to storage temperature, coded with lot and expiry data (Arabic or Latin script as required) and packed in cases or shrink packs.
- 8
CIP and recipe traceability
Automatic CIP · batch records per recipe
Caustic and acid circuits clean the whole path between recipes; every batch keeps the inbound bulk lot, °Brix, pasteurization curve and filled quantity for audits and customer complaints.
Capacity → CAPEX → payback
Rework line — capacity, CAPEX, payback
A rework line is sized in kg/h of finished product, not tonnes of fresh tomato. The grid below is what MCF uses to screen a project before any quotation.
| Capacity | Turnkey CAPEX | Annual output | EBITDA | Payback | Commissioning |
|---|---|---|---|---|---|
| 500 kg/h finished product | €0.6 – 0.9 million | 1 500 – 2 200 t/year packed | 12 – 18% of revenue | 3 – 4.5 years | 7 – 9 months contract-to-commissioning |
| 1 000 kg/h finished product | €0.9 – 1.4 million | 3 000 – 4 400 t/year packed | 14 – 19% of revenue | 3 – 4 years | 8 – 10 months contract-to-commissioning |
| 2 000 kg/h finished product | €1.5 – 2.3 million | 6 000 – 8 800 t/year packed | 15 – 20% of revenue | 3 – 4 years | 9 – 12 months contract-to-commissioning |
| 3 000 kg/h finished product | €2.2 – 3.2 million | 9 000 – 13 000 t/year packed | 16 – 21% of revenue | 2.5 – 4 years | 10 – 13 months contract-to-commissioning |
| 5 000 kg/h finished product | €3.4 – 4.8 million | 15 000 – 22 000 t/year packed | 17 – 23% of revenue | 2.5 – 3.5 years | 12 – 15 months contract-to-commissioning |
Assumptions behind the figures
- 250–300 working days per year, 16–20 productive hours per day: the feedstock is stored aseptic concentrate, not seasonal fresh tomato.
- Inbound bulk paste at 36–38 °Brix in 220 L bag-in-drum or 1 000 L IBC, standardized in line to 22–28 °Brix.
- Finished product filled in tinplate cans, glass jars or sachets, with pasteurization and end-of-line packing included.
- CAPEX is turnkey scope: emptying station, mixing, standardization, pasteurizer, filler, closing, CIP, automation, installation, commissioning and training; civil works, land and bulk paste stock excluded.
- EBITDA and payback assume retail or food-service pricing of the packed product and no financing cost inside the operating margin.
From range to committed scenario
Indicative engineering ranges used by MCF Technology for budget screening of rework projects, not a quotation and not the audited result of a specific plant. Final figures are fixed in the feasibility study, once inbound °Brix, packaging formats, utilities cost and working hours are confirmed.
Related processes
Explore related tomato paste rework line technologies
A complete tomato paste rework line project typically integrates pasteurization, sterilization, homogenization and aseptic filling. Follow the internal links below to deep-dive into each upstream and downstream stage engineered by MCF Technology.
- tomato paste processing plant with evaporationThe upstream campaign plant that produces the aseptic bulk a rework line consumes.
- tomato paste rework line in EgyptUtilities, water treatment, packaging formats and customs documentation for an Egyptian installation.
- tomato paste rework line 3000 kg/hEquipment list, utilities, footprint and output per shift for the 3 t/h configuration.
- tomato paste rework line 500 kg/hEntry configuration with batch mixing: lowest CAPEX step into retail packing.
- tomato paste rework line 1000 kg/hContinuous standardization with ± 0.2 °Brix control and two filling formats.
- tomato paste rework line 5000 kg/hParallel filling lines and 24-hour thermal section for 15 000–22 000 t/year packed.
- tomato paste sachet production lineMulti-lane form-fill-seal for 50–200 g sachets, the dominant format in Africa and MENA.
- tomato paste canning lineHot filling, seaming with steam-vacuum control and pasteurization tunnel or retort.
- tomato paste line for cans and glass jars400 g and 830 g tins, 2–5 kg catering cans and 314/720 ml glass, with changeover times.
- turnkey tomato paste plant in AfricaWeak grids, water treatment, 40–45 °C ambient design, local formats and financing.
- industrial pasteurizer for sauces and pasteTubular and scraped-surface pasteurization at 92–98 °C with validated holding.
- filling machine for jars, cans and sachetsVolumetric and weight filling with steam-vacuum control and format changeover by recipe.
- homogenizer for ketchup and smooth saucesViscosity and serum separation controlled at 100–200 bar.
Technical FAQ
Frequently asked questions
What is a tomato paste rework line?
It is a line that re-processes concentrated tomato paste already produced and stored aseptically (36–38 °Brix in bags, drums or IBCs) into a finished retail or food-service product: drum emptying, dilution and standardization to the target °Brix, recipe dosing, pasteurization and filling. No fresh tomato, no evaporation section.
Which capacities does MCF supply?
500, 1000, 2000, 3000 and 5000 kg/h of finished product. Below 1000 kg/h the line is usually semi-automatic with batch mixing; from 2000 kg/h upwards MCF supplies continuous in-line standardization with mass-flow and inline refractometer control.
How is the target °Brix controlled?
Bulk paste at 36–38 °Brix is diluted with treated water through a mass-flow controlled loop; an inline refractometer closes the loop on the set point, typically 22–28 °Brix for retail paste, with a tolerance of about ± 0.2 °Brix at steady state.
How does the aseptic drum unloading station work?
The aseptic bag is opened under hygienic conditions and emptied by a hydraulic press or piston pump; jacketed hoppers and heated pipework keep viscous paste flowing. Typical discharge is one 220 L drum in 2–4 minutes, so a 5000 kg/h line needs two stations working alternately.
Can the same line produce ketchup as well as passata?
Yes, with recipe management: ketchup requires vinegar and sugar dosing, powder hydration under vacuum, deaeration and homogenization before pasteurization. MCF specifies the extra units at design stage so both recipes run on the same skid with CIP in between.
How many days a year does a rework line operate?
250–300 working days, because the raw material is stored concentrate and not seasonal fresh tomato. This is why payback is usually shorter than for a campaign plant, even with a lower gross margin per tonne.
What does MCF include besides the machines?
Layout and utilities engineering, mechanical and electrical installation, hot commissioning with capacity and °Brix verification, operator and maintenance training, spare-parts kit, and the technical-financial dossier used for bank or development-fund financing.
Next step
Request a feasibility study for your tomato paste rework line
MCF Technology delivers worldwide — engineering, installation, commissioning and after-sales service on every continent. Send us your throughput target and destination country and we will reply with a preliminary sizing and quote.