Manufacturing Tomato Ketchup (2024)

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Tomato ketchup is a condiment made by mixing concentrated tomato paste with water, sugar, vinegar, salt and seasonings. The tomato paste is typically manufactured using the “Hot Break” method. With this method, pulped tomatoes are heated to 200˚F (90˚C). This preserves the pectin that is found naturally in tomatoes, but some of the aroma and color are lost. Premium quality ketchup with a high solids content derive their viscosity from a combination of water retention of the fibrous strands in the paste and the gelling effect of the pectin, which is released via high-pressure hom*ogenization. Lower solids content ketchup may also contain starch-based thickeners or gums.

The Process

The recipe, viscosity and solids content of ketchups vary widely. Typically tomato paste is blended with water and the other ingredients and the manufacturing process continues in one of two ways:

  • When utilizing the pectin present in the paste as a thickening agent, fibrous strands in the tomatoes must be fibrillated (frayed) to raise capacity for water retention, which increases viscosity.
  • Once mixed, the product is passed through a high-pressure hom*ogenizer to obtain the required consistency.
  • This method can also be used to increase yield as a thicker product can be achieved with a lower solids content.
  • With the second processing method high-pressure hom*ogenization is not used and thickening agents such as xanthan gum, pectin or starch (including modified starches) are used to obtain the required viscosity in the finished ketchup.
  • With either method mixing apparatus must be capable of dispersing powdered ingredients into water to form an agglomerate-free product.

The Problem

A number of problems can be encountered when using conventional agitators:

  • Long mixing times are required to dilute tomato paste into water, as agitators cannot easily blend liquids of widely differing viscosity.
  • Additives designed to thicken the product tend to form agglomerates which agitators cannot easily break down.
  • Partially hydrated ingredients can build up on the vessel wall and parts of the mixer.
  • Long mixing times are required to achieve complete dispersion.
  • A uniform pre-mix is required by the hom*ogenizer. This is not easily achieved using agitators.
  • hom*ogenization and other handling can dull the finish of ketchup.

The Solution

A Silverson high shear mixer can solve these problems and eliminate the need for additional processes such as pre-dispersion of the starches or thickeners and in some cases hom*ogenization. Where a hom*ogenizer is used, the high shear mixing action will improve pre-mix quality and consistency. Operation is as follows:

Manufacturing Tomato Ketchup (1)

Stage 1

The vessel is charged with water and the Silverson mixer is started. The powdered ingredients are then added. The high-speed rotation of the Silverson mixer creates a powerful suction which draws the liquid and powders into the workhead. The materials are subjected to intense shear within the workhead.

Manufacturing Tomato Ketchup (2)

Stage 2

Agglomerates are broken down between the ends of the rotor blades and the stator wall. The product is forced out through the stator and returned to the mix. Fresh materials are simultaneously drawn into the workhead, maintaining the mixing cycle. The circulatory mixing pattern ensures that hydration of the thickening agents is rapidly completed.

Manufacturing Tomato Ketchup (3)

Stage 3

The tomato paste is then added and dispersed in the same manner. A hom*ogenous mixture is rapidly obtained.

Stage 1 Stage 2 Stage 3

  • Stage 1

    Manufacturing Tomato Ketchup (4)

    Stage 1

    The vessel is charged with water and the Silverson mixer is started. The powdered ingredients are then added. The high-speed rotation of the Silverson mixer creates a powerful suction which draws the liquid and powders into the workhead. The materials are subjected to intense shear within the workhead.

  • Stage 2

    Manufacturing Tomato Ketchup (5)

    Stage 2

    Agglomerates are broken down between the ends of the rotor blades and the stator wall. The product is forced out through the stator and returned to the mix. Fresh materials are simultaneously drawn into the workhead, maintaining the mixing cycle. The circulatory mixing pattern ensures that hydration of the thickening agents is rapidly completed.

  • Stage 3

    Manufacturing Tomato Ketchup (6)

    Stage 3

    The tomato paste is then added and dispersed in the same manner. A hom*ogenous mixture is rapidly obtained.

The Advantages

  • Dramatically reduced processing times.
  • Rapid dispersion of thickeners and stabilizers.
  • Improved yield of ingredients.
  • Smoother texture and improved product consistency.
  • Improved color.
  • Ketchup with low solids content do not require hom*ogenization and the entire process can be completed using the Silverson mixer.
  • The product fed to the hom*ogenizer is uniform and of a low particle size, allowing faster processing through the hom*ogenizer and fewer passes required.
  • A Silverson mixer can be used as a “polishing step” after hom*ogenization to improve texture, viscosity and sheen of ketchup.

The type of product, batch size and viscosity of the end product determine which mixer from the Silverson product line is most suitable:

High Shear Batch Mixers

  • Suitable for batches of up to 150 US gallons
  • Larger batches can be processed with additional in-tank agitation
  • Easily cleaned
  • Can be either vessel mounted or fitted to a mobile hydraulic floor stand

More about this Mixer

High Shear In-Line Mixers

  • Ideal for larger batches
  • Aeration free
  • Easily retrofitted to existing plant
  • Self-pumping
  • Can be used to discharge vessel
  • Designed to be Cleaned-In-Place
  • Multistage units available for greater degree of shear resulting in finer particle size and faster processing times
  • Tomato paste dilution can be carried out on a continuous basis as shown
  • High Viscosity models available

More about this Mixer

Silverson Flashmix

  • Ideal for larger sauce batches
  • Capable of rapidly incorporating starch, sugar, salt and spices
  • Minimized aeration
  • Minimized cleaning requirements
  • Suitable for higher viscosity mixes
  • Suitable for operation at higher temperatures
  • Minimum operator input required

More about this Mixer

Related videos

How to Manufacture Sauces and Dressings
How to Blend Liquids of Varying Viscosities
What Is hom*ogenization?

Manufacturing Tomato Ketchup

Manufacturing Tomato Ketchup (2024)

FAQs

Manufacturing Tomato Ketchup? ›

These tomatoes are harvested, washed, and processed to eliminate impurities. Tomato pulp is then cooked and mixed with sweeteners, vinegar, salt, spices, and flavorings. After achieving the desired consistency, the ketchup is de-aerated, cooled, and packaged for distribution.

Why avoid Heinz tomato ketchup? ›

It contains high quantities of sugar, salt, fructose, preservatives and corn syrup. All of these ingredients when combined together have an adverse effect on the body.

Who is the largest producer of ketchup in the world? ›

Who is the largest manufacturer of Tomato Ketchup Market worldwide?
  • Lee Kum Kee Company Limited.
  • General Mills Inc.
  • The Kraft Heinz Company.
  • Del Monte Food Inc.
  • Unilever Plc.
  • Premier Foods plc.
  • Conagra Brands Inc.
  • Bolton Group S.r.l.
Nov 1, 2023

Why is tomato ketchup in short supply? ›

High temperatures, heat waves and hydric stress are hindering the crop of different fruits and vegetables, and the optimization of resources is causing fewer tomatoes to be planted or to be ultimately replaced by other more profitable crops.

What are the raw materials for tomato ketchup? ›

The main ingredients of ketchup are tomatoes, sweeteners, vinegar, salt, spices, flavourings, onion, and/or garlic. The types of sweetener used are usually granulated cane sugar or beet sugar. Other sweeteners include dextrose or liquid sugar in the form of corn or glucose syrup.

What are the five main ingredients of ketchup? ›

Ketchup recipes vary, but it's made from a core set of ingredients including tomatoes, sugar, salt, and vinegar. This explains the sweet but tangy flavor it packs. Spices like allspice, cloves, coriander, and even cinnamon or ginger may be added too.

What are the bad ingredients in tomato ketchup? ›

High levels of sugar, salt, fructose, preservatives, and corn syrup are also present. When combined, all of these chemicals have harmful effects on the body. Here's what tomato ketchup contains that you should know about: Distilled Vinegar and Sugar.

Is ketchup bad for your gut? ›

“Tomato ketchup, being an acidic food, due to the presence of acids such as malic acid and citric acid can trigger acidity and heartburn. Thus, those who have digestive problems such as digestive stress or gastroesophageal reflux disease (GERD) should avoid tomato ketchup,” suggests Ms Palan.

What is the healthiest ketchup brand? ›

Sir Kensington's Classic Ketchup

Made with fresh tomatoes (rather than paste or concentrate), a variety of seasonings and spices, and organic cane sugar, Sir Kensington's ketchup is a go-to for nutritionist Robin Werner, RD. It has a uniquely spicy, tangy vibe.

Why is there a 57 on Heinz ketchup? ›

“Although the number itself technically has no real purpose, and even back then there were more than 57 varieties, the number has stuck around for over 100 years of Heinz branding, making it synonymous with the Heinz brand.

What ketchup does McDonald's use? ›

In particular, McDonald's ketchup isn't a commercially-available brand like Heinz or Hunt's, it's their own proprietary blend -- and that makes all the difference. You might think this means they add something unique to the mix, but you'd be wrong.

What's the difference between catsup and ketchup? ›

As it turns out, they're the same thing!

Ketchup and catsup are both Westernized terms for a condiment that has origins in China: fish sauce. Ketchup as we know it today is a modernized version of fish sauce, which was made in port towns on the South China Sea with salted and fermented anchovies.

Why not refrigerate ketchup? ›

In addition, Sargent adds, to the preservative natures of the vinegar, salt, and sweeteners, “the acidity of the tomatoes prevent it from requiring refrigeration, but the flavor and texture will be better maintained if kept under refrigerated conditions.”

Is a food shortage coming in 2024? ›

The February 2024 Agricultural Market Information System (AMIS) Market Monitor highlights that in early 2024, global commodity markets have maintained relative stability, with wheat, maize, and soybean export prices hitting their lowest in two years, although rice prices are almost one-third higher than a year ago ...

What is the tomato ketchup trick? ›

He demonstrated the trick by holding the bottle from the bottom then swinging it around in a circular motion for a few seconds. The centrifugal of the rapid movement shifts the remaining ketchup to the top of the bottle where the cap is.

What is the main ingredient in tomato ketchup? ›

What Is Ketchup? Ketchup is a tomato-based condiment that's primarily used for dipping or spreading, though it's also commonly featured as an ingredient in other sauces and dressings. It's usually made with tomatoes, vinegar, sugar, and spices and seasonings.

Does Heinz ketchup grow their own tomatoes? ›

OUR TOMATOES

Our high-quality, non-GMO tomatoes are grown by passionate farmers whom we're proud to call our partners. To keep freshness and flavor in, Heinz tomato fields are within an average of four hours from harvest to unloading. This also keeps our carbon footprint low, and our quality high.

What is the profit margin on tomato sauce? ›

However, for consumers, the end price is at approximately 120 – 160 rupees a kilo with a profit margin of 20-30%. Conclusion: Thus, a tomato ketchup manufacturing business is a low investment and high profitability business.

What is the process of manufacturing tomato sauce? ›

PROCESS OF MANUFACTURE

Ripe and matured tomatoes are washed and graded. The graded tomatoes are then boiled in steam kettles. The boiled tomatoes are then pulped and the juice is filtered out from seeds, fiber and solid waste. Spices and condiments like ginger, garlic, clove, pepper, salt, sugar, vinegar etc are added.

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