Optimization Modeling of Water and Steam Consumption in Tomato Paste and Canning Factories Based on Green Productivity Indicators and Real Industrial Data

Abstract

Tomato processing industries are among the most resource-intensive sectors in the food industry due to their high dependence on water consumption and thermal energy systems. Steam-based operations such as washing, concentration, sterilization, and thermal processing significantly increase operational costs and environmental pressures in tomato paste and canning factories. Growing concerns regarding water scarcity, rising energy prices, and environmental sustainability have intensified the need for integrated optimization models capable of reducing resource consumption while maintaining production efficiency. The present study aims to develop an integrated optimization model for water and steam consumption in tomato paste and canning factories based on green productivity indicators and real industrial operational data. Operational datasets associated with water use, steam consumption, thermal efficiency, process intensity, and production performance were evaluated across different industrial sections including raw material washing, preheating, evaporation, sterilization, and packaging processes. A multi-objective optimization framework combined with green productivity indicators was employed to simultaneously improve energy efficiency, reduce water consumption, and enhance environmental performance. Statistical analysis, energy intensity indicators, water footprint assessment, and multi-criteria optimization functions were applied for process evaluation and modeling. The findings demonstrated that evaporation units accounted for the highest steam consumption, while raw material washing processes represented the largest share of industrial water use. Implementation of the proposed optimization model led to significant reductions in steam intensity, improvements in thermal process efficiency, and lower specific water consumption per ton of final product. Furthermore, green productivity assessment revealed that integrated management of water and energy resources can substantially reduce production costs and environmental impacts simultaneously. The proposed model can also be adapted for other thermal-based food processing industries and may provide an effective framework for sustainable industrial resource management.