The production of ketchup begins long before packaging lines and sterilization equipment are put into operation. It starts with a critical decision that determines the final texture, flavor, viscosity, and application potential of the product: cold break or hot break.
Understanding Cold Break vs. Hot Break in Tomato Processing
What is Cold Break Processing?
Cold Break processing involves heating crushed tomatoes to a relatively low temperature — typically between 65°C and 75°C (149°F–167°F) — immediately after pulping. This method preserves certain enzymes that affect flavor but results in a lower viscosity paste. It is ideal for products like tomato juice, ketchup, or sauces where a thinner consistency is desirable.
What is Hot Break Processing?
Hot Break processing heats the tomatoes quickly to a higher temperature, usually between 85°C and 100°C (185°F–212°F). This rapid high-temperature treatment inactivates pectin-degrading enzymes, thus preserving the pectin and resulting in a thicker, more viscous paste. It is typically used for triple-concentrated tomato paste, pizza sauce, and products that require a dense texture.
Equipment for Cold Break and Hot Break Processing
1. Cold Break Equipment Setup
- Cold Break Crusher/Pulper: Tomatoes are first crushed at ambient temperature to separate juice and pulp from skins and seeds.
- Preheater (Cold Break type): Gently heats crushed tomato to 65–75°C. It operates at controlled residence times to avoid enzyme denaturation.
- Holding Tube or Enzyme Reaction Tank: Maintains temperature long enough to allow natural pectinase enzymes to function.
- Evaporator: Concentrates the juice to the desired Brix level (commonly 28–30° Brix for cold break paste).
- Finisher & Refining Equipment: Separates fine pulp and removes seeds or skin remnants.
- Aseptic filler and sterilizer: Guarantee the finished product’s shelf stability and microbiological safety.
Design Features:
- Emphasis on gentle heating to preserve flavor.
- Heat exchangers with precise temperature control.
- Easy integration with enzymatic treatment lines.
Hot Break Equipment Setup
- Hot Break Crusher/Pulper: Designed to work with preheated or rapidly heated tomatoes.
- Hot Break Preheater: A high-efficiency unit that raises the temperature to 85–100°C quickly, usually with direct or indirect steam injection.
- Holding Section: Maintains the high temperature for up to 5 minutes to stabilize pectin.
- Evaporator: Multi-effect evaporators are used to concentrate the product to higher Brix levels (30–36° Brix or higher).
- Finisher & Refining Equipment: High-capacity finishers with multiple screens to refine pulp consistency.
- Sterilizer and Aseptic Filler: Final sterilization before aseptic packaging in drums, bags, or containers.
Design Features:
- Robust build for high temperatures.
- Equipped with steam injection or plate/tubular heat exchangers for rapid thermal response.
- Prioritizes enzyme inactivation and pectin preservation.
Key Differences in Equipment Design
| Feature | Cold Break Equipment | Hot Break Equipment |
| Preheating Temperature Range | 65–75°C | 85–100°C |
| Heating Method | Gentle heat via tubular exchangers | Rapid heating, often with steam injection |
| Pulp Consistency | Lower viscosity | Higher viscosity |
| Evaporator Integration | Moderate Brix output (28–30° Brix) | High Brix output (30–36° Brix) |
| Ideal for Products | Juice, ketchup, and sauces | Tomato paste, pizza sauce |
| Enzyme Activity | Enzymes remain partially active | Enzymes inactivated |
| System Control Complexity | Standard process control | Higher complexity with temperature/hold time |
Which One to Choose?
Choose Cold Break If You Need:
- Bright Color and Fresh Tomato Flavor
Cold Break paste retains more volatile aromatics, resulting in a brighter, fruitier taste preferred in table sauces and juices.
- Lower Viscosity Product
Ideal for thinner products like tomato juice or ketchup, where pourability is crucial.
- Flexible Secondary Processing
Cold Break paste is often used as a base material for derivative sauces with added thickeners or flavors.
- Export to Regions with Cold Break Preference
Cold Break paste is more popular in European and North American food processing industries.
Choose Hot Break If You Need:
- High-Viscosity, Stable Paste
Suitable for industrial and commercial cooking where texture retention and minimal syneresis are required.
- Longer Shelf-Life Applications
High-temperature processing helps achieve better microbial safety and thermo-stable texture during storage and reheating.
- Product Integrity in High-Temperature Cooking
Hot Break paste performs well in recipes like pizza sauce, where thickening and stability during baking are essential.
- Export to Africa, the Middle East, and Asia
These markets tend to prefer Hot Break triple concentrate paste due to its application versatility and shelf life.
Production Scale Considerations
- Small/Medium Factories: May opt for Cold Break due to lower energy costs and simpler equipment.
- Large-Scale Plants: Favor Hot Break systems, especially with continuous flow production lines and multiple-effect evaporators for high-volume paste output.
Economic and Operational Comparison
| Criteria | Cold Break | Hot Break |
| Initial Equipment Cost | Lower | Higher (due to heat exchangers & control) |
| Energy Consumption | Lower | Higher (due to rapid heating & evaporation) |
| Maintenance Requirements | Moderate | Higher (more wear at high temperatures) |
| Operator Skill Requirement | Basic process knowledge | Requires skilled technicians |
| Customization & Modularity | More adaptable for mixed production lines | Best for dedicated paste production lines |
Cold Break + Hot Break Combo Lines
Many modern processing facilities incorporate both Cold Break and Hot Break units within the same production line, allowing flexibility in processing depending on the desired product. These hybrid systems use:
Switchable preheaters with adjustable temperature settings.
Shared crushers and evaporators for cost efficiency.
Programmable Logic Controllers (PLC) to automate process changes based on product formulation.
This hybrid approach benefits manufacturers who want to diversify product offerings without investing in two separate processing lines.
Equipment Supplier Considerations
- When sourcing Cold Break or Hot Break equipment, consider the following:
- Material Quality: Stainless steel with food-grade finishes is essential.
- Modular Design: Supports future upgrades or conversion between CB and HB.
- Automation & Control System: PLC/HMI interfaces improve process stability and reduce labor costs.
- Cleaning in Place (CIP): Look for automated cleaning systems to reduce downtime.
- After-Sales Service: Strong technical support ensures smooth installation, commissioning, and operator training.
Some of the world’s leading tomato processing equipment suppliers provide turnkey tomato paste lines, including crushers, preheaters, evaporators, sterilizers, and aseptic fillers — fully customized based on CB or HB needs.
Choosing between Cold Break and Hot Break equipment depends on product type, market needs, capacity, and cost. Cold Break suits thinner, flavor-rich products; Hot Break fits thicker, shelf-stable pastes.
Modular lines that handle both methods offer flexibility and efficiency for diverse production goals.
