Tomato Sauce Ketchup

How Tomato Sauce Ketchup is made: Ketchup, a tangy, seasoned Tomato Sauce, is one of America's favorite condiments. Although Ketchup, is used primarily as a relish for hamburgers, hot dogs, and french fries, it is also a common ingredient for Sauces, Meatloaf, Beans, and Stews.

Raw Materials for Ketchup: The main ingredients of Ketchup are Tomatoes, Sweeteners, Vinegar, Salt, Spices, Flavorings, Onion, and 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. The white Vinegar, commonly 100-grain distilled, helps to preserve the Ketchup.

Ketchup is made up of five ingredients: Brine, Vinegar, Sugar, Tomato paste, and the secret Spices. The process is mainly about heating the ketchup and cooling it down. Afterwards, we fill it up into the bottles. The boxes with caps are emptied and transported upstairs.

Flavor: The Spices commonly used to enhance the flavor of the Tomatoes are all Spice, Cassia, Cinnamon, Cayenne, Cloves, Pepper, Ginger, Mustard, and Paprika. Some manufacturers believe that whole Spices produce a superior, more mild flavor than ground Spices or Spice oils.

Various Brands: of Ketchup have slightly different formulas, which vary primarily in the amounts of Spices or flavorings. Thicker consistencies require a greater ratio of Sugar and Spices relative to the Tomato juice. Occasionally formulas must be slightly adjusted according to variations in the acid and Sugar content of Tomatoes, which occurs with changes in growing conditions and types of Tomatoes.

The Manufacturing Process:
Developing quality Tomatoes: Ketchup manufacturers must seek out the best quality Tomatoes for their Product. Tomato varieties are developed which are superior in color, flavor, texture, and yield. Consistency is an important factor, as slight variations in Tomato characteristics could alter the flavor and color of the finished Product.

Preparing Tomatoes: Tomatoes are harvested mechanically between June and July. The fruit is commonly conveyed by water from the trucks into a flume, or an inclined channel. The water method washes the Tomatoes and protects them from bruising while they pass from the truck to the factory.

Pulping: The chopped and precooked Tomatoes are pumped into Pulping machines, or cyclones, which separate seeds, skins, and stems from the Pulp. The Pulp and juice are filtered through screens and processed further into Ketchup, though some may be stored in a Paste for use later in the year.

Adding ingredients: The Pulp is pumped into cooking tanks or kettles and heated to boiling. Foaming may occur if fresh Tomato Pulp is used, but can be corrected with anti-foaming compounds or compressed air. Precise amounts of Sweeteners, Vinegar, salt, Spices, and flavorings are added to the Tomato Pulp. Most Spices are added early in the cooking process. To avoid excessive evaporation, volatile Spice oils and Vinegar must be mixed in later. Onions and Garlic can be mixed in with the Spices, placed in a separate bag, or chopped and added to the Pulp.

Cooking: Salt and Sugar may be added at any stage of cooking though it is better to add Sugar later to prevent burning. The mixture cooks for 30-45 minutes and is circulated by rotating blades installed in the cookers. The temperature must be carefully regulated to insure absorption of the ingredients without overcooking, which creates a flat body.

Finishing: Once the cooking is complete, the Ketchup mixture passes through a finishing machine. Finishers remove excess fiber and particles through screens, creating a smoother consistency. The Ketchup passes to a holding tank before further processing. The Ketchup may be milled at higher temperatures and pressures to achieve a smoother consistency.

Removing air: The Ketchup must be de-aerated to prevent discoloration and growth of bacteria. Excess air might also create unattractive air pockets and impede the closure process.

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 come in various sizes and shapes, including 14-oz. bottles, No. 10 cans, pouch packs, room-service sizes, and single-serve packets.

Cooling: The containers must be cooled to prevent flavor loss through stack burning, which occurs when Ketchup stays at high temperatures after cooking is complete. Containers of Ketchup may be cooled in cold air or cold water. Labeling and packing

Quality Control: Some of the commonly used preservatives during the 19th century included benzoate of soda, borax salicylic acid, benzoic, and formaldehyde, all of which could pose health risks when consumed in large quantities. A series of Pure Food Laws beginning in 1906 banned the use of the harmful preservatives.

Ketchup: Oxidation of Ketchup can darken the color of Ketchup, but de-aeration of the Sauce during manufacture can prevent this problem. However, once the containers are opened, oxidation may still occur. Although the acidity of Ketchup preserves the Sauce, manufacturers recommend that once containers are opened they should be refrigerated to prevent deterioration of the Ketchup color, flavor, and quality.

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