Tell us about your production challenge

It all begins with tons of tomato paste that is mixed and heated together with sugar, vinegar, and spices in a cooking kettle. After cooking, any remaining fibers and particles are filtered out. Once it reaches the right viscosity, your tomato ketchup production process is finished and ready for packaging and transport.

What ketchup equipment do you need?

Ketchup filling and capping monobloc

Spillage and overfilling are common problems in most production lines for bottled prod...

Standard FFS machine for spreads and sauces in mini portions

In the food industry, from a microbiological point of view,...

Batch vacuum mixer for ointment

The production of creams or ointments can be either be a water in oil (w/o) or oil in water ...

Automatic filling machine for sauce

Traditional sauce filling units can struggle to maintain a high quality of output in ca...

Craft beer pasteurizer

Pasteurization of craft beers in breweries is very important to ensure the maintenance of taste and ex...

Vacuum based homogenizer

When producing liquid and viscous products such as mayonnaise, sauces, dressings and ketchup it’s vi...

Universal mixer and cooker for sauces

Sauce cookers and mixers have traditionally been designed to suit one process. This c...

Modular HFFS Machine

A large range of sizes and types is available, with traditional horizontal form fill and seal machines b...

HFFS machine with servo-control system

Traditional HFFS machines use mechanical cams to drive the production path through t...

High Speed Premade Pouch Packaging Machine

Pre-made pouches can be problematic for traditional cam-driven mechanical HFS m...

Retort Pouch Packaging Machine

A wide variety of products that were previously canned are now able to more economically pack...

Colloid mill

For creating extremely fine emulsions and high quality dispersions a high pressure homogenizer is often chosen.  ...

High-pressure homogenizer

When processes call for homogenized emulsions with extremely fine particle sizes the traditional t...

Stickpack Machine

If you are looking to pack your product into stick packs from 17 x 40 mm to 100 x 200 mm in size, you may b...

Sachet Machine

If you want to pack into eye-catching 4-side sealed sachets between 40×50 mm and 250×200 mm in size, ...

Temperature-treatment mixer for bakery & gastronomy

The production of creams, sauces, ragouts, ready-to-bake, and sim...

GMP homogenizing system

Manufacturers need production mixing equipment that is capable, flexible, and easy to maintain. Accur...

Corundum disk mill

Wet milling and grinding of viscous liquids or pastes containing solid particles such as peanut butter,mus...

Dispersing machine for emulsions and suspensions

Equipment operating under the rotor/stator principal is often employed wh...

Dispersing machine for very fine emulsions and suspensions

For continuous high performance mixing of solid and liquid ra...

Cone mill

When your raw materials include agglomorated suspensions of grainy or crystalline solids and your process needs a st...

Inline batch mixer for solids and liquids

Several issues often arise when your process requires batch-wise mixing of powde...

Continuous homogenizing system

Certain mixing tasks present unique challenges and manufacturers need equipment that is speci...

High accuracy homogenizing system

When extremely high accuracy is required in your recipe or formulation traditional mixing...

Horizontal kneader

For high viscosity products, better results and reduced process times can be achieved with kneading type r...

Vertical kneader

Production of highly viscous products with high solid content often benefits from kneading processes rather t...

Continuous kneader

Effective mixing of highly viscous products with extremely high solids content can be difficult and the re...

Batch dispersing machine

Equipment operating under the rotor/stator principal is often employed when more traditional methods...

Batch dispersing machine for abrasive products

For mixing and dispersing tasks that cannot be completed by conventional st...

Batch dispersing machine for bottom entry into vessels

When your process requires high performance mixing or dispersion b...

Cost-effective homogenizing and emulsifying system

Manufacturers need production mixing equipment that is capable, flexib...

Dust-free continuous homogenizing system

Producers in a wide variety of industries benefit from equipment that can continuo...

Dilution system for two or more liquids in one pass

Onsite dilution of liquid process ingredients has historically been a...

Small-scale laboratory dispersing machine

Developing and validating new processes requires reliable and highly versatile e...

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Tell us about your production challenge

When selecting production equipment for a production plant, it is important to talk to someone with experience in your field. Our industry experts have experience with various industrial applications. We’d love to help you!
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Converting fresh tomatoes into a tomato paste

The first thing you need is tomato paste. It’s usually bought as an ingredient due to the seasonal nature of tomatoes. But, if you are processing the paste too, fresh tomatoes first need to be washed in rotating drums, sorted and cut them into smaller pieces. To remove the seeds and the skin from the pulp, the tomatoes must go through a pulping machine and then the resulting pulp has to be filtered through screens. Tomatoes then go to a hot break treatment unit which involves heating them at a processing temperature of 90˚C or higher. The hot break step is a core process for enzymatic inactivation to preserve the pectin.

Ketchup – The Asian’s origin you don’t expect

Kê-tsiap, that’s the original name of our beloved table condiment, comes from southern China, and, here ye, at first it was tomato-free. It was a sauce made with fermented fish. After a long journey through England and America, the recipe of the tomato-based ketchup we know came to us. But how is it made?

From paste to ketchup – what equipment is required?

Tomato paste arrives vacuum-packed in large storage bins, ready for further processing. After quality control, you can move it to a cooking kettle for a second heating treatment where you can add vinegar, sugar, and spices. An industrial cooker mixes all the ingredients and heats them to the desired temperature. The ketchup mixture is filtered to remove fibers and particles and a homogenizer is then used to achieve the right consistency. A de-aerator can help you to get rid of the air stuck into the tomato ketchup which reduces the risk of bacterial growth and discoloration. Before moving to a filling line a final check is done on the viscosity for a perfect sauce texture.

A viscometer to analyse your ketchup's consistency

Have you ever noticed that if you turn a bottle of ketchup upside down nothing happens unless you shake it? Ketchup is made of tomato pieces suspended in a liquid that, by touching each other, create a network that can resist motion as long as you apply the right amount of force to it to make it flow. With a viscometer you can analyze how fast the ketchup travels and what is the viscosity. Studies have shown that the correct flow speed is 0.045 km/h or 0.028 miles/hour.

Using a hot fill solution for your ketchup bottles

Before filling, ketchup should be heated to no less than 88°C to avoid contamination. During the hot filling, both the product and the container are sterilized by heat. Hot ketchup is injected into a container that is then kept at high temperatures for a period of time to ensure that there are no bacteria in the food or in the packaging. After hot filling, ketchup should be cooled immediately to preserve the taste and flavor. Although hot filling of ketchup is considered safe for the shelf life, some manufacturers choose to perform a pasteurization process (another heating treatment) at 85-88°C.

Cap and close your ketchup bottles after filling

You can choose to pack your ketchup in pouches, sachets, tubes, or bottles and it’s important to close your package quickly after filling to avoid contamination or spilling. Capping or other closing systems such as seals are often installed in the same filling system. When filling glass or plastic bottles containers in line, crew caps, lug caps or snap-on are placed after filling up to the desired weight or height.

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