A typical Tomato ketchup would be based on sieved or whole tomatoes, and/or Tomato paste. It would also contain water, sugar, vinegar, salt, and seasoning. Tomato ketchup is a condiment manufactured with similar ingredients, although paste is used rather than whole tomatoes.
Manufacture of Tomato Sauces
Tomato sauces are used in many products including frozen foods, pasta sauces, pizza toppings, etc. A typical Tomato sauce would be based on sieved or whole tomatoes, and/or Tomato paste. It would also contain water, sugar, vinegar, salt, and seasoning. The desired product viscosity would normally be achieved using a starch-based thickener.
Tomato ketchup is a condiment manufactured from similar ingredients, although paste is used rather than whole tomatoes. Premium quality ketchup with a high solids content derives its viscosity from a combination of water retention of the fibrous strands in the paste and the gelling effect of pectin found naturally in tomatoes. High-pressure homogenization is also used to obtain the desired viscosity. This is common with lower solids content ketchup, which may also contain starch-based thickeners.
The recipe, viscosity, and solids content of sauces and ketchup vary widely according to the end user. Typical process requirements are as follows:
1. Mixing apparatus must be capable of dispersing powdered ingredients into the water to form an agglomerate-free product.
2. If the product is made from whole peeled tomatoes, these require chopping and pulping before addition to the mix.
3. Insoluble particles in the tomatoes need to be fully dispersed and “milled” to obtain a smooth texture and even dispersion of the pigment (carotin) to give depth of color.
4. Fibrous strands in the tomatoes must be fibrillated (frayed) to raise the capacity for water retention, which increases viscosity.
5. Once mixed, the product may be passed through a high-pressure homogenizer or colloid mill to obtain the required consistency.
1. Dramatically reduced processing times
2. Rapid dispersion of thickeners and stabilizers
-Improved yield of ingredients
3. Smoother texture and improved product consistency
4. Improved color
5. The product fed to the homogenizer is uniform and of low particle size, allowing faster processing through the homogenizer and fewer passes required
6. Some sauces with low solids content may not require homogenization
7. Special “low shear” head available for processing whole tomatoes to eliminate the risk of milling pips
8. A Silverson mixer can be used as a “polishing step” after homogenization to improve texture, viscosity, and sheen to ketchup
See below for a full list of acknowledgments:
2) CAVALIERI SPA
3) Sica s.r.l.
4) CFT Group
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