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Ketchup homogenization Equipment

Homogenization is the process of reducing particle size in mixtures to improve the consistency, uniformity, and stability of the product. The choice of a homogenizer depends on the nature of the product, desired particle size, the physical state of the ingredients, and pressure requirements during the process. Homogenization is widely used in the biotech industry for cell lysis and in the pharmaceutical industry for the emulsification of creams and ointments; it also finds applications in the cosmetics and food industries for improving the consistency and uniformity of various products.

Homogenization

Ketchup processing 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.

Ketchup

<span style="font-weight: 400;">For any industrial pharmaceutical process that relies on high pressure homogenization it’s vital that the equipment used is robust enough to cope with the demands of continuous operation. More than this, modern production demands high levels of process control and automation, as well as seamless integration with plant controls and providing results that satisfy the highest regulatory demands.</span>
<h2>Homogenizer offering the highest level of automation, compliance and capacity</h2>
<span style="font-weight: 400;">The DeBEE 4000 series from BEE International is the company’s top-of-line homogenizing solution for high performance situations. Designed from the ground up to achieve the best results as efficiently as possible, the DeBEE 4000 uses DeBEE’s proprietary homogenization technology for unequalled results, coupled with a hydraulically driven vertical intensifier pumps with a slow stroke rate to provide higher pressure and higher process intensity, all with lower maintenance costs.</span>

<span style="font-weight: 400;">Featuring a PLC with bespoke HMI software and full-colour touch screen, the DeBEE 4000 offers easy access to several features including security modes and authorisations, integrations with plant controls using network data gathering, and dynamic visual schematics for at-a-glance system status and component parameters.</span>

<span style="font-weight: 400;">The DeBEE 4000 features a fully sanitary design making it ideal for pharmaceutical and biotech production, as well as use in the chemical industries.</span>

High pressure industrial homogenizer

<span style="font-weight: 400;">For maximum value, a high-pressure homogenizer that’s suitable for both laboratory and pilot/small scale pharmaceutical production is the ideal choice. Full control over all process elements and 100% scalability coupled with cost-effective electric operation offers substantial cost-savings over alternative options.</span>
<h2>Cost-effective unit suited for both laboratory and pilot use</h2>
<span style="font-weight: 400;">The Mini DeBEE from BEE International is hydraulically driven homogenizer that is suitable for both laboratory use and in pilot plants or in small-scale production. Offering the highest process intensity available in its class, it will disrupt the toughest cells with the highest yield, or obtain the smallest particle size.  </span>

<span style="font-weight: 400;">With proprietary modular homogenising cell, the Mini DeBEE offers completely independent control of pressure, flow, cavitation, impact, shear and process duration. The minimal sample size of only 10ml makes it an excellent choice for R&amp;D and lab work. Because it guarantees 100% scalability, it can easily be transferred to pilot operations, or the machine itself can also be used for small-scale and batch production, offering continuous flow of up to 15 litres per hour.</span>

<span style="font-weight: 400;">PLC control with digital interface means simple operation and monitoring, with user-adjustable operating pressure from 2,000 to 45,000 PSI. Coupled with a wide range of options, this makes the Mini DeBEE suitable for application in the pharmaceutical, biotech, chemicals, cosmetics and food industries.</span>

Pilot high pressure homogenizer

When producing liquid and viscous products such as mayonnaise, sauces, dressings and ketchup it’s vital to achieve thorough emulsification and homogenization to ensure product quality. Traditional homogenizing solutions can be slow and difficult to clean, increasing downtime between batches. A modern vacuum-based system offers the flexibility to produce a wide range of products quickly, with exceptional quality and short cycle time.


<h2>Vacuum processing plant for emulsions, suspensions and gels</h2>
The MultiVacH from Enoop is a state-of-the-art processing plant for the production of high-quality sauces, mayonnaise, <a href="https://making.com/ketchup/">ketchup</a> and other liquid and viscous products.

Designed to be completely flexible, MultiVacH can be used whenever liquids or powders need to be thoroughly mixed and offers both cooling and heating to suit all production methods.

Ingredients are circulated via vacuum pump to a high-shear mixing element, then recirculated. This allows for extremely fast processing, as the circulation of product provides additional macro-mixing.

Downtime associated with batch or product changes is reduced to an absolute minimum thanks to fully pumped emptying via the recirculation line. In addition, rotating clean-in-place nozzles speeds up cleaning, allowing the MultiVacH to be used in multi-recipe environments.

Heating and cooling are via a double-jacket system, with direct steam injection available for high-temperature recipes.

Control is via a Siemens PLC with 12” touchscreen display, allowing observation and control of all parameters. Production can be manual, semi-automatic or fully automatic to your requirements.

Vacuum based homogenizer

Emulsions enhance foods with a creamy mouthfeel and richer flavors. But the immiscible nature of oil-and-water mixtures makes it challenging to maintain consistency in textures and taste across batches.


<h2>Versatile, powerful, and reliable</h2>
The ProxxD® high-shear emulsifier from ProXES guarantees reproducibility batch after batch. The built-in proprietary automation system hands full control over the shear energy input and other critical parameters.

Droplet distribution impacts emulsion stability and the sensory profile of the final product. FrymaKoruma specializes in droplet size control and is the world market leader in emulsion-based food processing systems.  Its technology solution disperses fine droplets with precision to create superior-quality foods and extend their shelf-life.

The ProxxD® is a highly versatile system that is easily adaptable to match your exact processing needs. Besides emulsification, the ProxxD® performs a range of food processing functions, including dosing &amp; weighing, mixing, and vacuum deaerating.

The integrated unit has been redesigned with a small footprint but large capacities, reaching up to 5,000 kg/hour depending on the product recipe.

Batch processing system for emulsions and suspensions

Texture and consistency are critical to foods with delicate compositions like dressings and fruit juices. But the base ingredients do not always mix into a homogenous recipe, especially in the case of emulsions such as mayonnaise.


<h3>Disperse the components uniformly into the mix</h3>
The Standard Production Plant (SPP) from IKA is a high-shear mixer for fine foods and beverages, including ketchup, plant-based cheese, and hummus. The system incorporates a two-stage unit that blends the ingredients and, secondly, disperses them homogeneously across the medium.

A rotor-stator solution achieves dispersion with a narrow particle size distribution, ensuring stable emulsions and suspensions with the longest possible shelf-life. Meanwhile, the dispersing chamber produces a vacuum to maintain a constant flow rate regardless of viscosity level.

The SPP is available in batch volumes from 25 to 4,000 liters and is equipped with spray nozzles for quick and easy clean-in-place without additional pumps.

Homogenization and emulsifying system for fine foods

Texture and consistency are critical to foods with delicate compositions like dressings and spread. But the base ingredients do not always mix into a homogenous recipe, especially in the case of emulsions such as mayonnaise.


<h3>Disperse your sauce ingredients uniformly into the mix</h3>
The Standard Production Plant (SPP) from IKA is a high-shear mixer for condiments and dressings such as mayonnaise, tomato sauce, and cheese spreads. The system incorporates a two-stage unit that blends the ingredients and, secondly, disperses them homogeneously across the medium.

A rotor-stator solution achieves dispersion with a narrow particle size distribution, ensuring stable emulsions and suspensions with the longest possible shelf-life. Meanwhile, the dispersing chamber produces a vacuum to maintain a constant flow rate regardless of viscosity level.

The SPP is available in batch volumes from 25 to 4,000 liters and is equipped with spray nozzles for quick and easy clean-in-place without additional pumps.

Industrial Sauce Homogenization and Emulsifying System

If you want to pack into unique bag styles like Quad-seal and Doypack, but you don’t require acceleration &amp; deceleration, you can save costs by choosing a bagger with a mechanical drive.


<h2>Steady speed vertical form fill sealing</h2>
The VikingMašek Intermittent Bagmaker series (M250, M400, M500 ) are high-performance vertical form fill and seal machines. Its rugged construction and enclosed jaw drive enables hassle-free packaging in dusty or wet environments.

It can accommodate multiple bag designs and dimensions with high speed and accuracy. It can produce maximum up to 70-100 bags per minute and handles bag sizes from 50 x 60 mm (M250) up to 500 x 600 mm (M500).

This vertical bagger is perfect for packaging quad seal, flat bottom, doy style, brick fold down/tape down, and pillow bags, snacks, candy, coffee, fresh and frozen fruit and more.

Bagger with mechanical driven jaw actuation

If you are looking for a compact packing machine that packs multiple smaller packs in one master bag; this automated product is exactly what you need.


<h2>Compact bag-in-bag machine for packing applications</h2>
The VikingMašek Intermittent Bag maker (M250 BiB) is a machine for all types of bag-in-bag applications, from airline/hotel single serves coffee packs to multiple smaller packs in one master bag. This Bag-in-Bag machine has enclosed, direct jaw drive, that provides you with years of smooth maintenance and free operation.

This vertical Bag-in-Bag machine is perfect for packaging from small to large bags of snacks, coffee, pet food, hardware products and more.

Bag-in-Bag machine

If you are looking for a compact packing machine that fits into tight space and tight budgets, proven basic bagging technologies may be your solution.


<h2>Compact and economic vertical form fill sealing</h2>
The VikingMašek Intermittent Bag maker series (E250, E400) is the most compact and economical bag maker for the packaging of small to large bags. It can produce maximum up to 50-60 bags per minute depending on the series of machine. Bag size can vary from 50 x 60 mm (E250) up to 400 x 600 mm (E400).

The robust, stainless steel, open-design frame is easy to access for maintenance. This vertical bagger is perfect for packaging small to large bags of snacks, coffee, pet food, hardware products and more.

Bagger with rotary jaw drive actuation

If you want to pack into gusseted and pillow style bags and packing speed is important for your packaging process, a continuous bagger with twin sealing jaws could be a good investment.


<h2>The world’s fastest vertical form fill sealing machine</h2>
The VikingMašek Continuous motion bag maker velocity is capable of high speed production up to 300 bpm. The unique center mounted filling tube and natural counterbalanced sealing profiles are designed to provide vibration free, extremely smooth operation at all speeds.

The Velocity is also extremely versatile, handling package sizes up to 300 mm wide and multiple package styles. Patented, independently phased, twin sealing jaws separate the velocity from all other high speed machines and virtually eliminate lost cycle time. This is the world´s fastest bagging machine on the market that has no competition.

Continuous bagger with twin sealing jaws

If you want to pack into eye-catching 4-side sealed sachets between 40x50 mm and 250x200 mm in size, investing in a reliable sachet machine will be a good investment.


<h2>Fast and flexible solution for your sachet needs</h2>
The Sachet Machine series SA 300 &amp; SA 600 by VikingMašek are continuous motion multi-lane sachet machines. They make eye-catching 4-side seal packets using just one roll of packaging film that can seal your product with high speed and efficiency.

The versatile multi-lane sachet machines can accommodate from 1 to 6 lanes (SA600) or from 1 to 10 lanes (SA600) to form sachet pouches, running as fast as 80 cycles per minute.

Designed to pack powders, dense, fine, loose and particulate materials as well as liquids and semi-liquids into 4-side sealed sachets and to accommodate different bag shapes including tear notches and easy-open system. They can be fitted with servo auger fillers &amp; volumetric fillers for powder applications, and two different liquid fillers for sauces or creams.

Sachet 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 benefit from the experience from the largest manufacturer of stick pack machines in Europe.


<h2>Benefit from the experience from Europe’s leading producer</h2>
This multilane Stickpack Machine series (ST200, ST400, ST560, ST800, ST1200 ) by VikingMašek can accommodate a large variety of different shapes of stickpack pouches with high efficiency and flexibility.

The versatile multi-lane stick pack machines can accommodate from 1 to 20 lanes, running as fast as 80 cycles per minute.

They are designed to pack powders, dense, fine, loose and particulate materials as well as liquids into StickPack bags and to accommodate different bag shapes including pour spouts, tear notches and easy-open system.

Semi- or fully automated cartoning solutions are also available for individual or bulk cartoning.

Stickpack Machine

VikingMašek is a global leading manufacturer of vertical baggers &amp; multilane packaging solutions.

Due to the fact that meal-kit subscription delivery companies deliver the box of ingredients that they assemble in the kitchen, their business models seem more sensible compared to the food delivery business which depends largely on the affiliated partners. Some restaurants, which only offer dine-in options before, have started to take similar measures to deliver half-processed meals to the end consumers. From kitchen to the consumers' table at home, there are a lot of considerations and challenges regarding the packaging of the food.


<h2>The driving forces of meal kit subscription services and restaurants joining food delivery</h2>
Since cooking at home can generate the sense of being in control during this out-of-control time, <a href="https://www.adweek.com/brand-marketing/meal-kits-had-their-chance-covid-19-has-given-them-another-one/">meal kit subscription businesses have taken initiatives to capture this quarantine-driven momentum.</a>  Meanwhile, the COVID-19 pandemic has also shown us that restaurants which do little takeaway or delivery business have adjusted to expand these capacities to maintain same level business due to the stay-at-home order.

Consumer behaviour is currently changing short term. However, when the consumers become more comfortable with order-in and meal kit preparation, chances are that their behaviours could be impacted long-term.
<h2>Packaging challenges and solutions for food delivery service</h2>
Either to deliver fresh food meal kit or to send fresh-cooked food, the process involves complex logistic and packaging challenges to bring the products across the city to the end consumer. The manufactures need to consider how to keep the ingredients fresh, how to prevent the liquid such as soup or sauce from leaking, and how to save employees' time if the food is packed manually.

While packing all the ingredients in the meal could not be perfectly automated in the standardized serving size, here are some most-requested food delivery packaging automation solutions:

<strong>- Meat, fresh-cut fruits and vegetables</strong>: Putting the ingredients in the sealed bag protects the food go wrong quickly. <a href="https://vikingmasek.com/packaging-machines/vertical-form-fill-seal">Vertical form fill seal (VFFS) machines</a> ensure high packaging speed and accuracy.

<strong>- Spices and sauces</strong>:  <a href="https://making.com/equipment/sachet-machine">Sachet</a> and <a href="https://making.com/equipment/stickpack-machine">stickpack machines</a> automatically form, fill, and seal small packets of ingredients like spices and sauces.

<strong>- Cold packs</strong>: Another emerging application is the packaging of cold packs for shipment of the ingredients to consumers' homes.

https://www.youtube.com/watch?v=JoIHv73s2zY

Packaging solutions for meal kit and food delivery

Food

Our food chain starts in the soil, growing crops and livestock. But between the fields and the stores, there is a line of industrial food processing equipment. Processes may be as minimalistic as cleaning fruit and as complex as homogenizing milk alternatives made from pressed legumes. In each case, processing technology is an important link in the food production chain.

Frigojollinox is an Italian company specialized in the manufacturing of equipment for the canning, dairy, fishing, confectionary, and cosmetic industries.

There was a period when ketchup bottles looked more like poster colors than condiments. The fad filled retail shelves with edgy ketchup palettes of purple, blue, green, pink. But the introduction coincided with a growing appetite for unprocessed food ingredients, and producers quickly reverted to red ketchup.

Most consumers will not be aware of lycopene, the compound that gives tomatoes their pigment. However, they know that the natural color of ripe berries is a rich red. The era of multicolor ketchup was, alas, short-lived.

But ketchup is more than tomato sauce. The classic recipe combines vinegar, sugar, and seasoning into the base sauce. Cooking combines the aromas and reduces the sauce into a denser liquid. But while it enriches the taste and texture, the rise in temperatures turns the glowing red of the tomatoes into a fading brown.


<h3>Natural pigments on red alert</h3>
“Conventional industrial cookers subject the ketchup mixture to temperatures up to 100°C,” explains Maurizo Pettini from Frigojolinox. The elevated heat diffuses the natural pigmentation and makes the orange and yellow undertones of lycopene more pronounced.

The discoloration can be corrected with food-grade additives, often Allura Red AC (E129 / FD&amp;C Red 40). However, preserving the original red pigment of the tomato sauce minimizes the degree of color adjustment required.

The trick is to balance temperatures with atmospheric pressure. Cooking the ketchup mixture under a vacuum reduces the thermal stresses considerably, circumventing the 'burn’ effect caused by traditional high-heat cookers.

“Vacuum cooking is conducted at around 50°C and removes a significant measure of the thermal burden from tomatoes,” Maurizio tells us. The decreased pressure lowers the boiling point of the moisture content in the sauce and the water in the vacuum cooker.
<h3>Take the pressure off color, texture, and taste</h3>
Lycopene perishes under intense heat, but the vacuum technique treats them gently. While the ingredients combine and thicken into ketchup, the tomatoes retain vivid redness.

But that is not the whole story, Maurizio points out. Besides the color, vacuum cooking develops other organoleptic qualities. It controls the extraction of water which regulates the viscosity levels. Meanwhile, the low temperatures prevent the caramelization of sugars that often produce off-tastes.

The vacuum technique protects the natural color of tomatoes and produces more authentic ketchup hues. However, that is no guarantee that the polychromatic craze will not make a comeback.

Ketchup shows its true colors with vacuum cooking

Sauces bring personality to a dish. From a spicy, dense Zhoug to a tangy, runny Suero, sauces add an extra dimension of flavor, texture, and mouthfeel. But developing recipes into industrial products with long shelf lives and consistent tastes is a complex process. Specialized sauce making equipment prepares and combines the ingredients into delicious, high-quality foods. The result is a sauce ready to elevate meals.

Sauce

Large-volume producers of single-serve packs, such as sugar sticks, instant coffee, and instant soup, continuously pack different product sizes into cartons. Intelligent and flexible infeed systems are needed to ensure your products integrate smoothly into the carton line at higher speeds.


<h2>Pack stick packs or flow packs into cartons continuously</h2>
The VENTO Cartoner from Mpac is a carton packaging system with a smart infeed system suitable for single-serve products such as condiments or coffee and milk powders. The unit is made of hygienic stainless steel materials. It has an open design for easy visibility of product flow and quick access to the components in case of maintenance and cleaning.

The entire system is servo-driven and coupled directly to its components for minimum maintenance and long operating life. It is designed to operate 24/7, allowing maximum production yield, and is equipped with an advanced intelligent machine interface that provides information on machine status, maintenance, and changeover controls based on product application. The processes include carton erecting, loading, transportation, and closing. Changeover for different carton sizes and types can be done quickly and automatically.

High-speed Cartoner For Single-Serve Products

Basically, to make milk powder, you need to remove the water content from the liquid milk and turn it into powder. How to do it? After pasteurizing and homogenizing the milk, milk’s water content is removed through filtration, evaporation, and drying. You have then to cool and sieve it before filling the containers. Here's how you get milk powder.

Milk powder

Sugar is the fuel that drives photosynthesis in plants. The leafy organisms constantly convert water and carbon dioxide into glucose. But it takes manufacturers specialized sugar processing technology to extract the sweet crystals from them. Today, most sugar products are derived either from sugarcane or sugar beet.

Sugar

Mayonnaise is created by blending oil with eggs, and then flavoring with vinegar, mustard, herbs, and spices. The eggs are a natural emulsifier that creates a uniform mixture. Ingredients are pumped into mayonnaise manufacturing equipment. First, a dynamic mixer maintains the desired level of emulsification of the mixture, which then moves on to packaging and bottling once reaching a satisfactory consistency.

Mayonnaise 

White, black and brown seeds from the mustard plant are the key constituents of this colorful and classic condiment. The various mustard production technology includes a mixer that mixes the mustard seeds with a handful of other ingredients and a mill that finely grinds the seeds to impart their characteristic flavor.

Mustard

Mpac Group is an industry leader in packaging automation, cartoning, and case-packing technologies.

Its complexity begins with the term itself, which has no clear and precise definition in the industry. As Jan Verweijen and Frank Jeurissen from the Mpac Group explain, the big question is always: is it a sachet or a stick pack?

“What is what” is defined by the way it is sealed, not by its width or length. A stick pack is a product with three seals, one of which is in the middle, lengthwise. Instead, a sachet is a four-sided sealed product with no seal in the middle.

First introduced in Japan in the 70s to pack sugar, these single-use sticks are now used to pack everything you can think of. But what impact does your product have on the cartoning process?


<h2>The first step is to find the right balance.</h2>
Stick packs are first filled vertically; this means that all the product is on the bottom.

Before entering the stick packs into the cartons, you need to evenly divide the product over the left and the right side of the stick packs. This step is called equalization and it is done by horizontally shaking the product to redistribute the contents inside the sticks.

“<em>If the weight is not evenly distributed, all the stick packs will slide off toward one corner of the box leading to an unstable formation that can damage the sticks</em>.” Frank points out.

For mere mortals, powder is powder, but for the experts, coffee powder, for instance, has a different structure than cocoa powder.

“<em>Liquids do not need equalization as the fluids divide automatically.” </em>Jan explains.

In addition, the sticks must have a minimum size, usually around 80 or 90 millimeters, to be cartoned horizontally and the shorter the sticks, the more difficult to keep them stable.
<h2>On edge vs. random orientation - Which side do you stand on?</h2>
Premium single-use products, such as coffee or pharmaceuticals, are often packed with the brand name and description always facing the consumer.

“<em>When this is the case, we use a paddle conveyor that brings each stick pack on a single edge so that when pulled out of the box, the branded face is the first thing the consumer sees,</em>” says Jan.

Frank adds: “<em>In 90 percent of cases, manufacturers choose speed over where the stick pack is facing. With random orientation, you can easily speed up to 900 sticks per minute</em>”.

“<em>Our bomb bay system counts each stick individually and puts them together in the quantity the producer requires; then it drops the sticks into the bucket conveyor</em>.” continues Jan.

To prevent damage, the bomb bay system consists of multiple drop levels, and the sticks need to be always dropped at a limited height - no higher than 250 mm.

As every stick has two ends, cartoning single-serve packs may seem easy, but as Jan and Frank explained, the journey from equalization to orientation and bomb bay dropping is not exactly a piece of cake.

Unpacking the world of stick pack cartoning

Cosmetic

Pharmaceutical

With over one-third of the population consuming it daily in different forms, coffee is one of the most popular processed beverages worldwide. Not only serving as drinks, but coffee is also often regarded as a culture. Coffee manufacturing is a knowledge-intensive industry. Coffee beans from different regions will reveal different tastes, while the level of caffeine could also be different. When it comes to coffee bean processing, the range of roasts varies from light golden brown all the way to dark. The method of tasting coffee differs between countries, habits, and tools.

Coffee

According to a legend, Cleopatra soaked her sails in her perfume so that Mark Antony could smell her ships before they arrived. This is to say that, from soaps and shampoos to perfumes, conditioners and pomades, cosmetics have always been highly valued and used for their properties of aesthetic enhancement. Cosmetics are a broad class of topical agents applied for various purposes such as cleansing, protecting, beautifying, or otherwise altering your appearance. As a result, a wide array of processing equipment is used in the cosmetics industry.

Cosmetics

Eating is more than just nutrition, but we have found ways to increase the nourishing power of our foods. Nutraceuticals manufacturing, from vitamin C powder and probiotics to omega 3 oil, is a concentration of natural ingredients and health supplements that complement our diets. While dietary supplements are not quite haute cuisine, the process of extraction and purification is no less a blend of science and art.

Nutraceuticals

The building blocks of matter have driven the imagination of philosophers, scientists, and artists for millennia. But, for manufacturers, these elements have a more concrete existence as powders. Powder processing technology conditions these primary materials to create a vast range of products, from chemicals and foods to pharmaceuticals and ceramics.

Powder

<span style="font-weight: 400">Spice manufacturing is one of the world's oldest trading products. The word spice refers to any dried part of a plant other than the leaves and is used for seasoning and food coloring. Spices are made from dried barks, roots, berries, and twigs, while green leafy parts of plants are considered herbs. Well-known examples include cinnamon, chilies, star anise, ginger, garlic salt, turmeric, cumin, or pepper, as well as pre-mixed blends such as Masala, Five-Spice Powder, or Old Bay.</span>

Spices

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