Ketchup Industry-Processing and Production
-
Upload
jannine-trinidad -
Category
Documents
-
view
63 -
download
1
description
Transcript of Ketchup Industry-Processing and Production
I.INTRODUCTION
History of Ketchup
Ketchup, a tangy, seasoned tomato sauce, is one of America's favorite
condiments. Although ketchup, also spelled catsup, 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. During the mid-1990s the sales of ketchup exceeded $400
million annually.
The tangy sauce originated in ancient China as a brine of pickled fish or shellfish
called "ke-tsiap." Neighboring countries adopted their own variations of "kechap"
consisting of fish brine, herbs, and spices. In the late 1600s, English sailors visiting
Malaysia and Singapore were so impressed with the sauce that they took samples home.
English cooks attempted to duplicate the spicy sauce, but without access to some of the
exotic Asian ingredients, they improvised with cucumbers, mushrooms, nuts, oysters, and
other variants.
One hundred years later, New Englanders created the definitive tomato ketchup
when Maine seamen returned from Mexico and the Spanish West Indies with seeds of an
exotic New World fruit called tomato. The tangy tomato ketchup quickly became a
popular sauce for codfish cakes, meat, and other foods.
Making ketchup at home was a tedious, day-long process. The tomato mixture,
cooked in heavy iron kettles at wood-burning stoves, required constant stirring to prevent
it from burning. Scouring the preserving kettles meticulously was also no easy task. To
the relief of many homemakers, ketchup became commercially available in the second
half of the 1800s.
H.J. Heinz Co. developed one of the first leading brands of mass-marketed
ketchup. The classic narrow-neck design of the Heinz ketchup bottle established the
norm for the industry. The narrow-neck bottle simplified pouring the ketchup and
minimized contact with air, which could darken the sauce. Glass was an ideal container
because it was inert and did not react with the ketchup, and the clear glass allowed the
consumer to see the product. Initially, the bottles were sealed with cork, dipped by hand
into wax to prevent aeration, and topped with foil to further protect it from
contamination. By the turn of the century, screw caps provided a more convenient
closure. In the 1980s, plastic squeezable containers revolutionized ketchup packaging and
soon outsold glass containers. Plastic was not only more convenient than glass for
pouring the thick sauce, but also safer. Ten years later, in response to environmental
concerns, recyclable plastic containers were also developed.
By the 1920s, when this photo was taken, ketchup operations were highly mechanized.(From the collections of Henry Ford Museum & Greenfield Village)
The history of ketchup and the history of advertising are inextricably intertwined.
This is especially true in the case of the H.J. Heinz Company, a firm that pioneered many
elements of the prepared food business and the modern advertising industry.
Born in 1844, Henry John Heinz began helping his mother with her gardens along
the Allegheny River, just east of Pittsburgh, when he was nine years old. He learned
business practices while working as a bookkeeper for his father's brickyard and at night
school. By his teens he was employing three women to help process garden products and
bottling his mother's horseradish for distribution. Heinz distinguished his horseradish
from his competitors by using clear glass bottles to emphasize the product's purity.
Twenty years later, Heinz was operating another family food processing firm.
Riding the New York elevator one day in 1892, he saw a sign advertising 21 varieties of
shoes. He took the concept, came up with a figure of 57 because he thought it was a
memorable number, and created the catch phrase "Heinz 57 Varieties."
In 1893, seeking to bolster attendance at the World's Columbian Exposition in
Chicago, Heinz distributed thousands of small tokens throughout the fair grounds. The
tokens were redeemable for a free Heinz souvenir, a watch charm in the shape of a pickle,
at the food pavilion, which was soon overrun with visitors. The "pickle pin" went on to
become one of the best-known corporate souvenirs in history, with over 100 million
distributed.
In 1898, Heinz bought the Iron Pier in Atlantic City, New Jersey, renamed it the
Heinz Ocean Pier, and operated it until 1945 as a free public attraction with antique
displays, lectures, concerts, and motion pictures amid the displays of Heinz products and
souvenirs. (William S. Pretzer)
II. THE PRODUCT
Banana Ketchup
Banana ketchup or banana sauce is a popular Philippine
condiment made from mashed banana, sugar, vinegar
and spices. Its natural colour is brownish, so it is often dyed red
to resemble tomato ketchup. Banana ketchup was made when
there was a shortage of tomato ketchup during World War II,
due to lack of tomatoes and a comparatively high production of
bananas. Filipino food technologist Maria Y. Orosa (1893–
1945) is credited with inventing a banana ketchup recipe.
Physical Properties
Tangy. The flavour of the sauce is usually tangy or there is a mixture of sweet and spicy
taste.
Consistency. This refers to the ability of the ketchup to retain its liquid in suspension.
Colour. Traditionally, the color of the ketchup is red, where the basis for the color of the
ketchup is the fruit used for making it, tomato.
Chemical Properties
pH. Acidity of ketchup preserves the sauce.
Concentration. The amount of solids used in the production of the ketchup. They are
recognized as Grades A through C with its specific concentration.
Uses and Application
Banana ketchup is a type of condiment used to enhance the flavour of the food. In
Filipino households, this ubiquitous condiment is used usually on foods especially dry
dishes like - omelettes (torta), hot dogs, burgers, fries, fish and other meats. But for some
other applications, banana ketchup is also a vital and distinct ingredient in Filipino-style
spaghetti (sweeter than the traditional Italian spaghetti). There is also a "hot" version
made by the same company (Jufran). It still has a hint of sweetness, coupled with spicy-
hot taste.
It is exported to countries where there is a considerable Filipino population
(United States, Canada, United Kingdom, Sausi Arabia, Kuwait, Hong Kong,
France, Switzerland, Australia and New Zealand).
Today, more and more food dishes were invented for the efficiency and
satisfaction of the tastes of the Filipinos. Now, ketchups are one of the seasonings of the
main dishes for its unique blend of sweetness and spice that is perfectly matched with
these foods. For Filipino dishes, examples for them are Menudo, Caldereta, Meat balls
with Sauce, Escabeche, etc.
Availability and Cost
In the Philippines, at the time of World War II, the demand for ketchup was very
high where there were lacks of tomatoes and the availability of the production of bananas
were comparatively high. With the help of the Filipino food technologist, Maria Y.Orosa
(1893- 1945) found a way to overcome this crisis. She invented Banana Ketchup with the
same flavour and taste of the Tomato Ketchup that traditionally used by the people at that
time. Therefore, as time flows, more and more banana ketchup production and industries
were developed.
With great abundance of the availability of the bananas here in the Philippines
having a tropic climate where bananas can grow well at this environment, plus the spices
being used for making banana ketchup can help the manufacturing industry to lessen the
cost of its product.
For homemade banana ketchup, about 200 Php will be spent for 2.5 L of banana
ketchup.
Product Safety
The quality of ketchup is insured by taking samples of the product during various
stages of production. Tomato growers must comply with regulations set by the
Environmental Protection Agency and the Food and Drug Administration regarding the
use of fertilizers and pesticides. Increasing concern in the closing decades of the 20th
century led to increased use of natural fertilizers and pesticides. Inspection is necessary of
the tomatoes, ingredients, and of all processing equipment which comes into contact with
the product.
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.
To maintain consistency in color and flavor, manufacturers determine the
concentration of tomato solids in the mixture, since about one-third of the ketchup's
acidity and sugar content depends on the amount of solids. The ketchup Grades A
through C must conform to specific concentrations. The quality of the ketchup can be
measured by its physical consistency, or body, which refers to the ability of the ketchup
to retain its liquid in suspension. The slower the rate, the higher the grade of the ketchup.
For instance, the Bostwick Consistometer, recommended by the USDA, set Grades A and
B at flow rates at less than 4 inches (10 cm) in 30 seconds at 68°F (20°C).
Product Data Sheet: Banana Ketchup
II. RAW MATERIALS
The main ingredients of ketchup are tomatoes/bananas,
sweeteners, vinegar, salt, spices, flavorings, onion, and/or
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.
The spices commonly used to enhance the flavour of the
tomatoes are allspice, cassia, cinnamon, cayenne, cloves,
pepper, ginger, mustard, and paprika. Some manufacturers
believe that whole spices produce a superior, more mild flavour
than ground spices or spice oils. More modern processes use
premixed or encapsulated spices, which are easier to use but
more expensive. Whatever the form, spices must be of a high
quality.
The 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.
Material Safety
In accordance to the product safety standards, the general preferences of using
banana fruit (saba) is strictly followed. The sterility of the working place is very
important in the manufacturing of the banana ketchup in order to avoid contamination of
the product and its high quality. The quality of banana alters the taste and quality of the
product.
III. MANUFACTURING PROCESS
Industrial Scale
( Tomato Ketchup Production Process )
Developing quality tomatoes
1. 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
2. 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. The U.S. Department of Agriculture
or state inspectors approve and grade tomatoes to meet initial requirements. The
tomatoes are sorted, washed, and chopped. Next, precooking, or scaling, in
stainless steel vats preserves the tomatoes and destroys bacteria.
Pulping
3. 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 and cooking
4. 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. 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
5. 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.
6. The ketchup may be milled at higher temperatures and pressures to achieve a
smoother consistency.
Removing air
7. 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
8. 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
9. 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
10. Finally, the ketchup containers are labeled and coded with product
information, including ingredients, date and location of manufacture, and shelf-
life. The bottled ketchup may be inspected again before shipping. The entire
process of ketchup manufacturing generally takes two to three hours.
Traditional Making of Tomato Ketchup at Industrial Scale
Present way of Making Tomato Ketchup
Ketchup manufacturers continue to improve the quality of ketchup by developing
tomato strains that are superior in color, flavor, and firmness. Tomato hybrids are also
engineered to improve resistance to disease and rot, thus decreasing the reliance on
chemical pesticides.
In the 1990s, in response to consumer demand for more healthful foods, ketchup
manufacturers created low-calorie, low-salt ketchup alternatives. The increasing
popularity of Spanish salsas and marinades also influenced manufacturers to develop
salsa-style ketchups which were lower in sugar content. Packaging technology continues
to improve as consumers demand safer, more convenient, and recyclable containers.
Schematic Diagram for the Production of
Tomato Ketchup in an Industrial Scale
Small Scale
( Banana Ketchup Production Process )
Ingredients:
cavendish (saba) bananas (Boiled)
100 grams (7 tbsp.) vinegar
1 gram (3 pcs.) pepper, labuyo
5 grams (1 pc) onion, powdered (medium)
1 gram (1 clove) garlic, powdered (big)
10 grams (2 tsp.) refined salt
80 grams (6 tbsp.) sugar
2.7 gram (1/2 tsp.) red dye (no. 2)
2.8 gram (1/2 tsp.) yellow dye (no. 5)
5 grams (1 tsp.) cinnamon
200 mL (14 tbsp.) water
Procedure:
1. Cook, peel, and grind rare ripe bananas (80%
yellow and 20% green).
2. Weigh the ground pulp and add an equal
amount of water.
3. Blend in warring blender for one minute.
Preparation of the Materials
and Ingredients
Boiling(banana fruit)
PeelingGrinding of the
Banana and Spices
Agitation of the mixture
via Manual or Blender Cooking
Addidtion of SeasoningsCooling
Storage
4. Adjust the pH of the puree to 4.0-4.3 by adding citric acid (0.5% of puree) and
/or sodium hydroxide.
5. Adjust the pH of the vinegar to 4.0- 4.3.
6. Grind the spices and dissolve them in vinegar. Add them to the puree.
7. Cook the mixture for 10 minutes at 75-85˚C,
stirring continuously to prevent scorching.
8. Add coloring and continue heating to desired
consistency.
9. While catsup is hot, pour it in clean, sterilized bottle.
Schematic Diagram for Homemade Banana Ketchup