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Tomato Ketchup Manufacturing
Plant

Tomato is one of the important crops used as fresh vegetables and for preparing a variety of processed products like tomato juice, ketchup, sauce, canned, puree and paste. In advanced countries, nearly 80% of the fresh tomatoes are processed. In India, although tomato production is increasing the growth of tomato processing industry is slow, mainly due to the lack of constant supply of good quality and cheaper raw material to the processing centre.
In India, tomato sauce and ketchup are very popular and are being manufactured on an increasingly large scale, mostly in small units. As tomatoes are available practically throughout the year there is scope for setting up large-scale processing units.

Market Size of Tomato Ketchup

In India, the Mayonnaise Market is of more than 5300 crores in INR, and increasing at a rate of around 7% every year. The global tomato ketchup market size was valued at USD 20.90 billion in 2021 and is expected to expand at a compound annual growth rate (CAGR) of 2.8% from 2022 to 2028. The growing processed food industry and rising demand for fast food across the world are driving the market.

Ingredients used in Tomato Ketchup Manufacturing

  • Tomato Paste/Puree

  • Salt

  • Spices

  • Flavours, Essential Oils, Oleoresins

  • Vinegar

  • Sugar

  • Pectin

  • Preservatives

High Shear & High Viscosity Mixing Technology
for Tomato Ketchup Manufacturing

High-shear mixers or high-shear homogenizers are used to produce standard mixtures of ingredients that do not naturally mix. This industrial machinery disperses, or transports, one phase or ingredient (liquid, solid, gas) into a main continuous phase (liquid), with which it would normally be immiscible. A rotor, together with a stationary component known as a stator, or an array of rotors and stators, is used in a mixing tank containing the solution to be mixed, and in a pipe through which the solution passes, to create shear. A high-shear homogenizer mixer is used to create emulsions, suspensions, lyosols (gas dispersed in liquid), and granular products. It is used in the food, pharmaceutical, adhesives, chemical, cosmetic, and plastics industries for emulsification, homogenization, particle size reduction, and dispersion.

Key design factors in the high shear mixers include the diameter of the rotor and its rotational speed, the distance between the rotor and the stator. 

Tomato Ketchup Manufacturing Plant

United Group's Tomato Ketchup Manufacturing Plant uses the high shear and high viscosity mixing technology for production of tomato ketchup, sauces, chutneys with a smooth, creamy texture and consistency.

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United Group's Tomato Ketchup Manufacturing Plant incorporates various equipments as per different capacities. A typical tomato ketchup plant that manufactures 250kg of material in 30 minutes, following technology is used:

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  1. A Double Jacketed Steamer

  2. Agitator

  3. Bottom Entry Mixer

  4. Inline Homogenizer Mixer

  5. Storage Tanks

  6. Control Panel

  7. Additional pipelines and vessels

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Use of Multi-Mill in Large Scale Tomato Ketchup Production

In large scale production for tomato ketchup of more than 500kg in 30 minutes, the capabilities of a standard ketchup plant need to be advanced with the use of intensely robust and highly efficient High-Shear Multi Mill. The Multi-Mill increases the plant's efficiency to process high viscosity products at a high speed. 
 

Advantages of Multi-Mill for Tomato Ketchup Production:

  • Can Process Capacity 1 Tonne/Hour to 20 Tonnes/Hour

  • The same machinery can be used for multiple applications, simply by changing the workheads

  • 100% Efficiency, ensuring no bypass of product through the homogenization process

  • The material used for making is SS-304

  • 20-40 HP Third-Party Motor

  • Easy to Clean and Maintain

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Advantages of United Group's Ketchup Plant

The production of Tomato ketchup, sauces, chutneys is influenced by multiple factors. Achieving cost-efficient production, satisfying high consumer expectations and delivering a stable & consistent product with adequate shelf life are among the essential requirements of food product manufacturers.
Therefore, with over 2 decades of food industry experience, our team has designed and developed highly efficient, fast, reliable processing plant and production machines for manufacturing of tomato ketchup and related products.

  • Short Batch Times

  • Consistently High Product Quality

  • Excellent Homogenization

  • Rapid Emulsification

  • User-Friendly Operation

  • Used to Manufacture a Wide Range of Product

  • Stirrer and Dispersion Device with Speed Control

  • Prevention of Lump Formation & Clumping

  • Controlled Dosage Rate

  • Suitable for Highest Viscosities

  • Long-time Stability of Emulsions

  • Fine Particle Size Reduction

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