February 19, 2018

Tomato Ketchup Production Process

Tomato Ketchup is made of whole lot of stuff going inside it from vegetables to tomatoes and spices to preservatives. Salt (sodium chloride), sugar, spices, spice extracts, vinegar, acetic acid, onions, garlic and chillies, and pectin and alginates as stabilizers.

Tomato Ketchup Production Flow Chart

Industrial Tomato Ketchup Production Video  

1. Pulping
The tomatoes are chopped and precooked, then pumped into pulping machines, or cyclones, which separate seeds, skins, and stems from the pulp. This pulp is filtered through screens and processed further into ketchup, and some is stored in a form of paste to use later in the year.

2. Adding ingredients and cooking
The pulp is pumped into cooking tanks or kettles and heated to boiling and kept at temperature above 80°C. Measured amounts of sweeteners, vinegar, salt, spices, and flavourings are added to the tomato pulp. To avoid evaporation of volatile oils they are not added early during the boiling with the spices, salt and sugar. Powders of onion or garlic are usually added which are procured from various firms which do the dehydration. The mixture is cooked for 30-45 minutes and is circulated by rotating blades installed in the cookers or kettles. The temperature is carefully regulated to insure absorption of the ingredients without overcooking.

3. Finishing
Once the cooking is completed, the ketchup mixture passes through a finishing machine. Finishers are used to remove excess fiber and particles they do so by the help of screens, creating a smoother consistency. The ketchup is sometimes milled at higher temperatures and pressures to achieve a smoother consistency.

4. Removing air
The ketchup is de-aerated to prevent discoloration and growth of bacteria. Excess air may cause unattractive air pockets and impede the closure process.

5. Filling
To prevent contamination, the ketchup passes from the receiving tanks to the filling machines at a temperature not lower than 190°F (88°C). The containers are filled with the ketchup and immediately sealed to retain the freshness of the product. Ketchup containers are available in various sizes and shapes.

6. Cooling
The containers are cooled to prevent flavour loss through stack burning, which occurs when ketchup stays at high temperatures after cooking is complete. Containers of ketchup are cooled in cold air or cold water.

7. Labelling and packing
Finally, the ketchup containers are labelled and coded with product information, including ingredients, date and location of manufacture, and shelf-life. The bottled ketchup may be inspected again before shipping. The entire process of ketchup manufacturing generally takes two to three hours.


How much Sodium and Sugar in Ketchup?
Sodium chloride which is the major source of sodium is used commonly as a food-flavouring condiment and sometimes as a food preservative. In tomato ketchup it is used as taste enhancer. The percentage of sodium chloride ranged from 1.84% to 2.58%. Similarly for sugars (sucrose) gives a natural taste and uniform texture to the product, in addition to thick density. The addition of sugar in ketchup is for balancing the taste of sourness of tomatoes. No limit or requirement has been set by the national standards. Sugar was found between 17.64% and 29.62%.

Viscosity Of Ketchup
Being a Non-Newtanion Fluid, it’s Viscosity is high and because of this only it’s hard to pour out the bottle. Viscosity of ketchup ranges from 50,000-70,000 Centipoises.


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