Tomato ketchup is a high-demand product across food service, retail, and export markets. Here’s how it’s made in a commercial setting:
🔧 Ingredients Needed (per 100 kg ketchup batch)
- Fresh ripe tomatoes – ~140–150 kg (Roma/Hybrid variety preferred)
- Salt – 1.5–2.5 kg
- Sugar – 15–20 kg
- Vinegar (acetic acid 4–5%) – 2.5–3.5 liters
- Spices/condiments – Garlic, cloves, cinnamon, pepper, ginger
- Onion/Garlic paste (optional) – For flavor
- Preservatives – Sodium benzoate (within FSSAI limits)
- Starch or pectin (optional) – For consistency
- Citric acid or lemon juice – For pH balance
🏭 Ketchup Manufacturing Process
1. Washing & Sorting
- Use fresh, firm, ripe tomatoes (preferably Roma or Hybrid varieties).
- Wash thoroughly to remove dirt and pesticides.
2. Crushing & Heating
- Crush tomatoes and pre-heat the pulp at 85–90°C to inactivate enzymes.
- Pass through a pulper machine to remove seeds and skins.
3. Pulp Concentration
- Boil or vacuum-evaporate the tomato pulp to reach the desired Total Soluble Solids (TSS) — generally 28–30° Brix.
4. Adding Ingredients
- Mix in sugar, salt, and spices.
- Add vinegar and citric acid to adjust taste and preserve.
- Stir continuously to avoid burning and ensure even consistency.
5. Cooking & Blending
- Cook mixture until desired thickness is achieved (ketchup is thicker than puree).
- Use industrial blenders or homogenizers for smooth texture.
- Adjust acidity (pH ~3.9–4.2) for preservation.
6. Preservation & Cooling
- Add sodium benzoate or potassium sorbate (as per FSSAI standards).
- Cool the mixture immediately after cooking to maintain color and flavor.
7. Bottling / Packaging
- Sterilize glass or plastic bottles/sachets.
- Fill ketchup hot (80–85°C) into containers.
- Seal and label under hygienic conditions.
🧪 Quality Checks
- pH level
- TSS (°Brix)
- Viscosity
- Microbial tests (bacterial/fungal count)
- FSSAI compliance
💡 Tip for Manufacturers
Use Roma or Hybrid Kolar tomatoes for best results—higher pulp content, longer shelf life, and vibrant color make them perfect for ketchup.