Overview of Tomato Ketchup Manufacturing
Tomato ketchup is one of the most popular tomato-based products globally. It serves as an efficient method of conserving tomato solids and is widely consumed in households and foodservice sectors. According to food safety standards, tomato ketchup must be produced by blending tomato juice, puree, or paste with sweeteners, spices, vinegar, and other ingredients, followed by heat processing to achieve the required consistency and shelf stability.
✅ Key specs:
- Total Soluble Solids (TSS): Not less than 25%
- Acidity: Not less than 1% as acetic acid
This ketchup differs from tomato sauces in its thicker consistency and higher concentration of spices and sweeteners.
Tomato Ketchup vs. Tomato Puree vs. Tomato Paste
The difference between these tomato-based products lies in thickness, preservation techniques, and TSS values:
Food processing consultants often use these definitions to guide product line development.
Sodium and Sugar Content in Tomato Ketchup
Tomato ketchup contains:
- Sodium: 1.84% to 2.58% – acts as a preservative and flavor enhancer
- Sugar: 17.64% to 29.62% – provides texture, flavor, and viscosity
These additives help improve shelf life and consumer appeal.
Viscosity of Tomato Ketchup
Ketchup viscosity ranges between 50,000 to 70,000 centipoise, which plays a vital role in defining its flow behavior, mouthfeel, and packaging suitability.
Step-by-Step Tomato Ketchup Processing
A) Selection and Washing of Tomatoes
Fresh, ripe tomatoes are manually inspected for quality. Selected tomatoes are washed using freshwater and food-safe sanitizers to remove surface contaminants.
B) Chopping, Pre-Cooking, and Pulping
Cleaned tomatoes are chopped and pre-cooked, then fed into pulping machines (cyclones) that separate seeds, skins, and stems. The extracted pulp is screened and sent for further processing.
C) Ingredient Addition and Cooking
The pulp is transferred into agitated cooking tanks, where sweeteners, salt, vinegar, and spices are added. Cooking is done at temperatures above 80°C for 30–45 minutes, ensuring flavor development and microbial safety.
D) Finishing
The cooked ketchup is passed through finishing machines with fine screens to remove fiber and ensure a uniform, smooth texture.
F) Filling
Hot filling (at ~88°C) is done into pre-sterilized containers. Proper sealing ensures freshness and prevents contamination. Filling is tailored to specific SKUs (bottles, pouches, etc.).
G) Cooling
Filled containers are cooled using cold air or water to avoid "stack burning," which can impact flavor and color.
H) Labelling and Packing
Ketchup containers are labelled and packaged according to branding requirements. Labels include product details, ingredients, manufacturing and expiry dates, and regulatory compliance information. Final inspection ensures product quality before dispatch.
Conclusion
Tomato ketchup has become a staple across the globe due to its versatility, taste, and long shelf life. Its rising consumption is closely tied to the growth of QSRs (Quick Service Restaurants) and adoption of Western food habits. This presents vast opportunities for food manufacturing consultants, food technology consultants, and food industry entrepreneurs to innovate and expand within the tomato processing industry.
7. Reference
· https://foodscienceuniverse.com/tomato-ketchup-production-process/
· http://www.madehow.com/Volume-2/Ketchup.html
· http://ecoursesonline.iasri.res.in/mod/resource/view.php?id=147617
Back 
PMG stands for Projects Management Group. We provide state-of-the-art Engineering Services to build world-class food processing factories. 
Engineering is the difference between Chaos and Excellence. If you are going to do it, do it right. 
Explore the diverse range of Products in the Food Processing Industry. 
Explore the technologies at the heart of the the Food Processing Industry. 
