Ketchup - Homogenization

The best ketchup comes from the best homogenizer!

Ketchup is generally the term applied to a mashed tomato, whose main ingredients are tomato puree, together with salt, sugar, onion, mustard, vinegar, pepper, mushrooms, and other herbs and spices. Recipes vary according to the regulations in each country.

The minimum solids (dry matter) is normally around 35%. The composition includes: water, mineral salts, proteins, fats, sugars, acids, fibers, vitamins, etc.

The wide range of components and their different properties require a very efficient mixing, which cannot be achieved with traditional agitators, as they do not produce a sufficiently stable mix of the suspended particles so that they still tend to separate.

For this and other reasons, high pressure homogenizers have been used for a number of years in the processing of ketchups and other similar sauces.

The most important part of the machine is without any doubt the homogenizing valve designed and built especially to give the required result in the end product. The effects generally sought are:

Traditional designs of homogenizer valves do not always produce all these effects. Niro Soavi valves are computer profiled, making it possible to satisfy all the different requirements to enable the customer to produce a product with all the desired properties. Flavor enhancement is mainly related to micronization of the particles and to the structure uniformity.

However, the most important aspect in product acceptability on the shelf is the inhibition of syneresis and separation of the phases (serum & pulp) in the container.

The optimum use of motor power enables running at relatively low pressures, giving the advantages of less wear and greater efficiency. Machines for processing of ketchups and sauces also have a number of other important design considerations such as dimensions and morphology of the passages within the compression head, speed of the crankshaft, etc.

Summary

The advantages offered by the Niro Soavi equipment are the result of laboratory research and continued cooperation by our customers:

• improved suspension stability, separation phenomena are inhibited by great enhancing the effect of natural emulsive elements
• capacity to maintain the qualitative standards during production
• an increased level of consistency can easily be maintained

Besides the above mentioned effect, further advantages emerge:

• Increased organoleptic characteristics, due to the dispersion of aromatic elements and the increased surface area in contact with the taste buds
• Creamy texture of the obtained product, product uniformity, and a typical fullness of taste are other valuable qualitative advantages
• Increased digestibility and better assimilation of nutritional principles

High Pressure Homogenization

High Pressure homogenization is an entirely mechanical process; the product is forced by a high pressure piston pump through homogenizing valve. The Niro Soavi homogenizer is suitable for treatment of products having aggressive chemical characteristics (due to the presence of organic acids) and can stand the mechanical action caused by the presence of solid particles in the product.

During homogenization, particles of various nature are crushed:

• single cells
• cellular aggregates
• agglomerate crystals (sugars and salts)
• globules of essential oils
• various other structures (fats, woods, fibers, etc.)

By homogenizing, the dimension of the suspended particles is reduced. At the end of the process, the suspension presents a uniform distribution, according to a "Gaussian" curve, which varies with operating conditions.