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Ketchup and Chili Sauce Food Mixing Tank – Tomato Ketchup Green Chili, Sauce, Mayonnaise Making Machine

Overview

The Ketchup and Chili Sauce Food Mixing Tank is designed for the efficient mixing and heating of sauces and jams, catering to food processing needs. Constructed from high-quality stainless steel, these tanks ensure durability and compliance with food safety standards.

Cooking and Pulping Unit: The automatic processing machine features a cooking and pulping unit where the chopped tomatoes are cooked to soften and release their juices. This unit may consist of a cooking vessel with heating elements and temperature controls to maintain optimal cooking conditions. After cooking, the tomatoes are pulped to remove seeds and skins, yielding a smooth tomato base for the ketchup.

Tomato Paste Tomato Sauce Tomato Ketchup Making Production Line

Mixing and Seasoning Unit: Once pulped, the tomato base is transferred to a mixing and seasoning unit where other ingredients such as vinegar, sugar, salt, and spices are added. The machine may feature automated dosing systems to ensure precise measurement and uniform distribution of ingredients, allowing for consistency in flavor and texture.

The Tomato Paste, Sauce, and Ketchup Making Production Line is designed to efficiently produce a range of sauces and emulsified products, ensuring high quality and consistency. This production line incorporates several key components, each serving a specific purpose in the manufacturing process.

Tomato Ketchup Green Chilli ,Sauce , Mayonnaise Making Machine

Key Components

1. Oil Tank
   • Function: Stores vegetable oils, emulsifiers, and thickeners.
   • Role: Provides the necessary fat content and stability for emulsified products like ketchup and mayonnaise.
2. Aqueous Tank
   • Function: Contains egg yolks and other water-soluble ingredients.
   • Role: Essential for products requiring emulsification, contributing to flavor and texture.
3. Vacuum Emulsifying Unit
   • Purpose: Facilitates vacuum homogenization and emulsifying processes.
   • Advantages:
     • Ensures a stable emulsification, minimizing the risk of separation in final products.
     • Operates under vacuum to reduce air incorporation, enhancing product quality.
4. Pre-Filling Tank
   • Function: Holds the sauce before the filling process.
   • Role: Ensures that the product is ready for efficient packaging, maintaining quality.

Product Applications

The production line is suitable for making various products, including:

• Ketchup
• Mayonnaise
• Salad dressings
• Custards
• Non-dairy creamers
• Coconut cream

Quality Control Points (CCP)

To ensure product quality, the following parameters are monitored:

• Formula: Adherence to the specified recipe.
• Mixing & Emulsifying Process: Ensuring uniformity in texture.
• Organoleptic Index: Evaluating color, viscosity, and flavor.
• Physicochemical Index: Monitoring fat, protein, pH, salinity, acidity, density, and Brix levels.
• Microbiological Index: Implementing process design, SOPs, online quality control, and microbiological detection.

Quality Defect Analysis

Common issues and their causes include:

• Product Separation: Poor emulsification or unstable emulsifying structure.
• Color Change: Excess oxygen exposure leading to fat oxidation.
• Taste Issues: Inadequate emulsifying, incorrect thickener, or low oil content.
• Unpleasant Smell: Overcooking or contamination with untreated metal ions.
• Microbiological Contamination: Formula or process defects, inadequate microbiological control.
• Poor Bake Performance: Formula defects or incorrect emulsifier/thickener usage.

Solutions

To address these quality concerns, consider the following solutions:

• Vacuum Mixer:
  • Utilizes a bottom high shear mixer and agitator to ensure complete emulsification and homogenization.
  • Eliminates dead corners and air bubbles in the final product for superior quality.
• Automated Processing Control:
  • All processing stages can be monitored and controlled automatically to ensure consistency and adherence to quality standards.
• Scraper Heat Exchange:
  • Used for sterilization and cooling, guaranteeing 100% sterilization.
  • Enhances product taste and extends shelf life by effectively managing heat treatment.

Applicable range: Used as blending tank, mixing tank, preparation tank fermentation tank, disinfection tank and ageing tank etc.

Key Features

• Material:
  • Available in 304 or 316 Stainless Steel for enhanced corrosion resistance and durability.
• Tank Volume:
  • Options range from 100L to 5000L, with custom solutions available for volumes up to 10,000L.
• Design Options:
  • Tank Type: Available in Horizontal or Vertical configurations.
  • Insulation: Choose between Single Layer or Insulated designs to maintain temperature.
  • Top Head Type: Options include Dish Top, Open Lid Top, or Flat Top.
  • Bottom Type: Select from Dish Bottom, Conical Bottom, or Flat Bottom.
• Heating Options:
  • Jacket Types: Choose from coil, dimple jacket, or full jacket for efficient heating.
• Pressure Rating:
  • Designed to operate under a pressure range of 0-20 bar.
• Agitator Types:
  • Various mixing options are available to suit specific processing needs, including:
    • Impeller: For general mixing.
    • Anchor: For thicker products.
    • Turbine: For high-shear mixing.
    • High Shear Magnetic Mixer: For emulsifying and dispersing.
    • Anchor Mixer with Scraper: Ideal for viscous products to prevent sticking.

Applications

• Suitable for a wide range of products, including:
  • Tomato ketchup
  • Chili sauce
  • Jams and preserves
  • Other sauces and semi-liquid foods

Customization

• Design Flexibility: The tank can be customized based on specific requirements, ensuring optimal functionality for your production needs.

The Automatic Tomato Ketchup Processing Machine is designed to enhance efficiency and flexibility in the production of tomato ketchup, catering to both small and large-scale food processing operation.

Cooking and Pulping Unit

• Purpose: Cooks the chopped tomatoes to soften them and release their juices.
• Design:
  • Cooking Vessel: Equipped with heating elements and precise temperature controls.
  • Pulping Process: Removes seeds and skins to create a smooth tomato base for the ketchup.
• Mixing and Seasoning Unit
  • Function: Combines the pulped tomato base with other ingredients such as vinegar, sugar, salt, and spices.
  • Features:
    • Automated Dosing Systems: Ensures precise measurement and uniform distribution of ingredients, promoting consistency in flavor and texture.

• Mixing and Cooking: Mix tomatoes with other ingredients such as salt, sugar, and spices in a large mixing bowl. Heat and stir the mixture constantly to ensure even cooking and prevent sticking.
• Packaging: Ripe tomatoes are placed in containers (such as bottles or cans) and sealed. Containers are labeled, packaged, and shipped.
• Pasteurization: To ensure product safety, tomato paste is pasteurized by heating for a short time to kill any bacteria or harmful organisms.

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Common Tomato Sauces:

Tomato ketchup is just one type of tomato-based sauce. Here are some other common tomato sauces:

• Classic Tomato Sauce: Made from tomatoes, onion, garlic, olive oil, salt, and pepper. Often used as a base for stews and other sauces.
• Marinara Sauce: Contains tomatoes, garlic, onion, and herbs like basil and thyme. Used as a topping for pasta, pizza, and other Italian dishes.
• Arrabbiata Sauce: Made from tomatoes, garlic, pepper flakes, and olive oil. Frequently used in pasta dishes and bread sauces.
• BBQ Sauce: Sweet and tangy, often used as a glaze or marinade for barbecued meats.
• Ketchup: A sweet and thick sauce, commonly used as a condiment for hamburgers, hot dogs, and fries.

• Mixing Tank: Where various ingredients like spices, vinegar, and sugar are mixed with the tomato pulp.
• Cooking Kettle: Used for cooking the mixture to enhance flavor and ensure food safety.
• Homogenizer: Helps in achieving uniform texture and consistency in the sauce or ketchup.
• Packaging Machine: Used for filling the sauce or ketchup into bottles or sachets and sealing them.
• Labeling Machine: Applies labels to the packaging containers with product information.
• Capping Machine: Applies caps or lids to the bottles or containers.
• Coding Machine: Prints batch numbers, manufacturing dates, and other details on the packaging.
• Shrink Wrapping Machine: Used for bundling and shrink-wrapping multiple bottles together for retail packaging.
• Cartoning Machine: Packs individual units of sauce or ketchup bottles into cartons for bulk transportation.
• Palletizing Machine: Arranges cartons or crates of packaged products onto pallets for storage or shipping.

These machines, when integrated into a complete production line, enable efficient and standardized manufacturing of tomato ketchup and sauce products.

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Conclusion

This Ketchup and Chili Sauce Food Mixing Tank offers a robust and versatile solution for food manufacturers looking to enhance their production processes. With a focus on quality materials, efficient heating, and customizable features, this tank is designed to meet the demands of modern food processing.