Ketchup is America’s favorite flavored ketchup. Join Science Vietnam to learn the production process of Ketchup through this article. How do they make Tomato Ketchup? It is one of a short video in a series of short, concise videos that reveal the mysteries behind how everyday things happen.
Introduce: Ketchup is the name of America’s favorite flavored ketchup. Ketchup, also spelled catsup, is used primarily as a condiment for hamburgers, hot dogs, and fries, it is also a common ingredient for sauces, meatloaf, beans, and stews. By the mid-1990s, sales of ketchup exceeded $400 million annually.
Originally, the strong-smelling sauce originated in ancient China from soaking fish in brine or shellfish and was called “Ke-tip”. Since then, neighboring countries have adopted their own “ketchup” consisting of fish brine, herbs, and spices.
In the late 1600s, British sailors visiting Malaysia and Singapore were so impressed with the sauce they sampled at home. British chefs tried to replicate that flavorful sauce but didn’t have access to some of the Asian ingredients, so they tweaked it with cucumbers, mushrooms, nuts, oysters, and more.
Other changes.
100 years later, the British invented ketchup when a Maine sailor returned from Mexico and the Spanish West Indies with the seeds of a fruit called a tomato. From there, ketchup quickly became a popular sauce for cod pie, meat, and other foods.
Making ketchup at home is a tedious, day-long process. The tomato mixture is cooked in a heavy iron pot on a wood-burning stove, which requires constant stirring to prevent burning. Scrubbing the pot meticulously is also no easy task. To help housewives, ketchup came on the market in the second half of the 1800s.
Company H.J. Heinz Co. has developed one of the leading brands of ketchup on the market. The narrow neck design of the Heinz ketchup bottle has set the bar for the industry. The narrow-neck bottle simplifies pouring ketchup and minimizes exposure to air, which darkens the sauce.
Glass is an ideal container because it is chemically inert and does not react with ketchup, transparent glass allows the consumer to see the product. Initially, the bottles were sealed with cork, dipped in wax to keep out air, and covered with foil to protect them from contamination.
Entering the new century, screw caps become more convenient. During the 1980s, plastic spray caps revolutionized ketchup packaging and outsold glass bottles. Plastic is not only more convenient than glass, but also safer. Ten years later, in response to environmental concerns, recyclable plastic bottles were also developed.
Ingredient: The main ingredients of ketchup include tomatoes, sweeteners, vinegar, salt, spices, flavorings, onions, and garlic. The sweeteners used are usually cane sugar or sugar from beets. Other sweeteners include dextrose or sugar syrups such as corn syrup or glucose syrup.
White vinegar is usually distilled 100 drops, which helps preserve the ketchup. Spices commonly used to enhance the flavor of tomatoes include Jamaican pepper, cinnamon, single cinnamon, cayenne pepper, cloves, pepper, ginger, mustard, and paprika.
Some manufacturers believe that whole-grain spices produce a more pleasant, premium flavor than finely ground spices or essential oils in seasonings. More modern processes use pre-mixed or packaged spices, which are easier to use but more expensive. Whatever the form, the seasoning must be of high quality.
Different brands of ketchup have slightly different recipes, mainly differing in the amount of seasoning or flavoring. A higher consistency requires a greater proportion of sugar and seasoning than tomato juice.
Sometimes recipes have to be slightly adjusted to changes in the acid and sugar content of the tomatoes, which often occurs with changes in growing conditions and tomato types.
Production process
Check input quality: Ketchup manufacturers must select the best quality tomatoes for the product. Tomato varieties are developed to excel in color, taste, texture, and yield.
Consistency is an important factor, as small changes in tomato characteristics can alter the flavor and color of the finished product. PrepareTomatoes are mechanically harvested from June to July.
The fruit is usually transported by water from trucks into a trough or an inclined channel. This water-washing method protects the tomatoes from bruising while they are brought to the factory.
The U.S. Department of Agriculture or state inspectors approve and grade tomatoes to meet initial standards. Tomatoes will be sorted, washed, and chopped. Next, the tomatoes will be preliminarily processed and placed in stainless steel tanks to preserve tomatoes and kill bacteria.
Squish
Tomatoes after preliminary processing are pumped into a crusher or cyclone to separate the seeds, skin, and stalks in the fruit pulp. The fruit pulp and juices are filtered through the membrane and processed into ketchup, although some can be stored in paste form for use later in the year.
Mix and cook
The pulp is pumped into the cooking bath and heated to a boil. The foam may appear if fresh tomatoes are used, but can be corrected with antifoam agents or compressed air. The exact amount of sweetener, vinegar, salt, spices, and flavorings are all added to the pot.
Most spices are added early in the cooking process. For volatile seasoning, oil and vinegar must be mixed later to avoid excessive evaporation. Onions and garlic come in a separate bag and can be mixed with spices or chopped and added to the mash. Salt and sugar can be added at any stage of cooking, it is better to add sugar later to avoid burning.
The mixture cooks for 30-45 minutes and is stirred evenly with the stirrers installed in the pot. The temperature must be carefully adjusted to ensure the absorption of the ingredients without overcooking.
Second fine grind
Once cooked, the ketchup mixture passes through a strainer. This device will remove excess fibers and particles through the membrane filter, creating a more uniform and smooth. The ketchup is transferred to a storage tank before further processing.
Ketchup can be milled at higher temperatures and pressures to achieve a smoother consistency. Tomato sauce must be de-aired to prevent oxidation, discoloration, and microbial growth. Excess air can also interfere with the canning process.
To prevent contamination, ketchup is transferred from the receiving tanks to the filling machines at a temperature not lower than 190 °F (88 °C). Containers are filled and sealed immediately to preserve product freshness. Ketchup containers come in a variety of sizes and shapes, including 14 oz bottles, No. 10, silver bags, etc. to be able to diversify supply to retail customers as well as large companies.
Cool
Bottled ketchup must be cooled to avoid loss of flavor through scorching – a phenomenon that occurs when ketchup is at a high temperature after cooking. Ketchup containers can be refrigerated in cold air or cold water.
Labeling and packaging
Finally, the ketchup bottles are labeled and coded with product information including ingredients, production date and location, and shelf life. Ketchup is usually re-tested before shipping. The entire ketchup production process usually takes two to three hours.
Quality control
Some commonly used preservatives in the 19th century included sodium benzoate, borax salicylic acid, benzoic acid, and formaldehyde, all of which can pose health risks when consumed in large quantities. A series of Whole Foods Laws beginning in 1906 banned the use of these harmful preservatives.
In 1940, the US government established a “Standard of Identification” for ketchup with the main ingredient tomato. Therefore, consumers can tell from the label that the product is made from tomatoes, as the sauce can also be made from other foods, including bananas, beets, or mangoes.
The quality of the ketchup is ensured by testing the product samples in each of the different stages of production. Tomato growers must comply with regulations set forth by the Environmental Protection Agency and the Food and Drug Administration regarding the use of fertilizers and pesticides.
This growing concern in the last decades of the 20th century has led to the increasing use of natural fertilizers and pesticides. Testing incoming materials such as tomatoes, ingredients and all processing equipment that comes into contact with the product is essential to ensure the final product is of quality.
Oxidation in ketchup can darken the product, but degassing during production can prevent this problem. However, once the bottles containing the sauce are opened, oxidation can still occur.
Although the acidity in the sauce is a preservative, manufacturers recommend that once bottles are opened, they should be stored in a cool (refrigerator) condition to avoid color loss. taste and quality of ketchup.
To maintain uniformity in color and flavor, manufacturers determine the concentration of tomato soluble solids in the mixture, since about one-third of the acidity and sugar content of ketchup depends on the amount of tomato juice. dissolved solids.
The line from A to C must be suitable for the specific concentration. The quality of ketchup can be measured by its physical consistency, which refers to its ability to hold water in the sauce.
The slower the flow rate of the ketchup, the higher the quality. For example, the Bostwick Consistometer, recommended by the USDA, sets Points A and B at a flow rate of fewer than 4 inches (10 cm) for 30 seconds at 68 °F (20 °C).
Are you a farming lover? In the video belѻw, yѻu cɑn see How Tomato Ketchup Is Made | Tomato Harvesting And Processing to Ketchup | Food Factory.
