Food Industry

Tomato sauces and ketchups

With the huge demand for ketchup around the world for pizzas, frozen foods, etc., the need for quality tomatoes is increasing. This is definitely placing high demands on your production and particularly on mixing technology. The standardized raw tomato paste and tomato ketchup with appropriate product viscosity need to be obtained from the appropriate ratio of ingredients. A wide range of tomato products can be prepared using tomato paste – purees, passata, paste, pizza sauces, salsa, soups, and ketchup by maintaining high quality.

The Process

Typical ketchup reception and processing sections are as follows:

Reception Section:

  • Fresh tomatoes would be fed into the infeed conveyor to feed the raw tomato to the reception section
  • The tomatoes are conveyed to fruit washing station to remove outer dirt and foreign matter from the fruit skin and grading section
  • Washed tomatoes would be fed to the inspection cum sorting table where unwanted and damaged tomatoes would be separated manually

Processing Section:

  • Washed and graded tomatoes would be passed on to the fruit mill having rotors and stator with inner and outer serration respectively to form an initial thick puree
  • The material passed through the mill is pumped into a pulper to pulp the puree formed through the mill and de-seed the pulp to process further into a fine paste
  • The so formed de-seeded pulp is fed into an inline pasteurizer for pasteurizing and further transferred to the processing/mixing vessel
  • The mixing vessel is mounted with a homogenizer and vacuum pump to process under vacuum and a feeding system to feed the desired volume of ingredients directly into the cooking kettle
  • The produced ketchup is then pumped into a buffer storage vessel which is then transferred into the packaging station

Packing Section:

We have customized packing solutions based on a variety of needs

  • Glass Bottle Packing for Tomato Puree/Ketchup:

(Rotary Bottle Washing Machines, Inspection Conveyor (Semi-Automatic), Twin/Four Head Liquid Filling Machine for Ketch-up, Bottle Crowning and Sealing Machines (Automatic), Labelling Machine (Automatic)

  • Can Packing for Paste/Concentrate:

(Hot Filling Screw Pump, Can body reformer, Can Flanger, Can bottom seamer, Semi-Automatic Filling Machine, Can top seamer (Stationary Type), Lid embossing machine, Vacuum Tester, Canning Retorts, Steam Lines, Can Conveyor, Sticker Labelling Machine, Labelling Table)

Utility Section:

Steam Boiler with water softener, Cooling Tower, pump piping, Air compressor, Effluent Treatment Plant, Boiler Chimney, All service pipelines.

The Problem

Several problems arise while using conventional agitators:

  • Additives prepared to thicken the product could tend to agglomerates, which agitators cannot easily breakdown
  • Ingredients that are partially hydrated could accumulate on the vessel wall and on the mixer
  • Complete dispersion required prolonged mixing times
  • To dilute tomato paste prolonged mixing times are required and may vary in viscosity
  • Series of pre-mixing is required by the homogenizer to get the desired product
  • Too much homogenization pressure can destroy, adversely affecting flavor, color, damaging water retention properties.
  • Improper handling and homogenization can lead to unattractive finishing of the product
  • Tomato pips in the product when whole tomatoes are used can be crushed while milling, resulting in bitter taste

The Solution

Wahal Engineers optimal solution helps you to prepare ketchups and other wide range of products using innovative food production technology. Based on expertise, our solutions are designed to allow you to get the right viscosity. In regards to recipe, the high shear mixing action under regulated heat treatment achieves the right product quality and characteristics. Our production line enables gentle mixing of particles, de-seeding, and processed under vacuum to maintain uniform distribution of flavour, color and consistency. Packing the end product – tomato paste and ketchups into glass bottles, can packing are performed using automatic machines to ensure vacuum sealed.


  • Reduction in processing times
  • Uniform mixing of ingredients to get smooth texture, improved product color and desired consistency
  • A mixer is used to polish the product after homogenization to enhance texture, consistency and sheen of ketchup

The Mayonnaise Packaging Industry

How to make mayonnaise procedure

Mayonnaise might be a thick, creamy sauce that is made up of oil, egg yolks, lemon juice or vinegar, and seasonings.

Mayonnaise is an emulsion, that may be a mixture of 2 liquids that commonly cannot be combined. Combining oil and water is a classic example. Emulsifying is completed by slowly adding one ingredient to another while simultaneously combining quickly.

It’s not the identical as a sauce, which does not contain egg yolks and is usually sweeter than mayonnaise. Mayonnaise is made by combining lemon juice or vinegar with egg yolks. Emulsions are usually thick in texture and satiny in appearance. In mayonnaise, the emulsifier is egg yolk, that contains lecithin, a fat surface-active agent.  Eggs which contains the surface-active agent lecithin bind the ingredients together and stop separation. Then, oil is added drop by drop because the mixture is speedily whisked. Adding oil too quickly can keep the 2 liquids from combining emulsification. This disperses and suspends little droplets of 1 liquid through another. However, the 2 liquids would quickly separate again if an emulsifier were not added.  Mayonnaise may be a cold sauce with a thick surface and a rich flavor, an oil-in-water emulsion containing edible oil, egg yolks, and spiced water. The sauce is used as spreads on sandwiches and burgers, the creamy base in cold salads, dip for fries and far more. Based on consumer preferences for taste, texture, and looks which may change from country to country. This is the main reason for the mayonnaise variance in production are many. In simple words, the emulsification process is highly important to the manufacturing activity of mayonnaise.

Tetra Pak is often delineated in precisely three words Innovation, Quality, and Trust. Safety is the most significant parameter in every project. Tetra Pak has established track records more than five decades of delivering everything from innovative individual processing units to customize, machine-controlled production solutions with secured performance. Tetra Pak provides a complete system for processing, packaging and distributing not just liquid food products such as milk or juice, but in other fast-moving consumer products. Tetra Pak is a Swedish company that opens up in sterile packaging, one of the food science innovations of the 20th century.  Tetra Pak’s goal is to remain trustworthy for valuable customers.  All customers are aware, that Tetra Pak offers the equipment, packaging, and service to ensure they get their products to customers safely and expeditiously, with the superior standards of food safety and quality.

Global mayonnaise market growth pattern.

The global mayonnaise market was worth around US Dollars 10.15 Billion in 2017. The market is further projected to cross more than 12 Billion US Dollars by 2023, at a CAGR of 4% during the year 2018-2023.  The global mayonnaise market is watching steady growth.
Factors such as growing urbanization, increasing disposable incomes, and thriving fast-food chains have resulted in the changing lifestyles and altering eating patterns of the consumers. Currently, many good options are available which require minimal cooking. At the same time, many types of mayonnaise are available in many flavors for the consumer. These include multiple flavors like cheese, mint, tangy pickle, chipotle, tandoori, etc., and also low-fat and no fat mayonnaise which can cater to the taste and preferences of a large number of consumers. Earlier, the consumption of mayonnaise was largely restricted to the western countries. However, with the influence of the increasing trend of westernization of food patterns, which increases the consumption of mayonnaise in developing countries. The growth of the organized retail sector is witnessing a positive impact on the global mayonnaise market. Nevertheless, with a rise within the variety of organized retail stores, numerous players are investing in these markets. This can be expected to eventually end in the multiplied consumption of mayonnaise in the next few years.

Getting the right taste with proper texture.

Tetra Pak has developed a unique piece of tool to optimize mayonnaise production methods. That offers a piece of highly specialized equipment which can be tuned to different modes of production. Tetra Pak is able to convert your blended sauce processes from trial-and-error activities to the final product, which need plenty of resources into a systematic, efficient and measurable processes.
Sauce production is a rapidly growing with innovative technology worldwide, with a wide and growing range of value-added sauce products. Certainly, there will be good demand related to production and product innovation. Tetra Pak creates your best sauce production solution, with competitive and guaranteed performance. That will meet your needs and enable you to meet growing demand from retailers, food services, renowned restaurant customers and some hotel consumers. Based on specialized food production and technology expertise, all solutions of Tetra Pak enable you to produce a wide range of sauces from mayonnaise, ketchup,  pasta sauces, and soy sauces. At the same time, flexibility in packaging and distribution, from dehydrated to bottled, small sachets of sauces and chilled sauces will meet the demand.

Technical Know-how

Tetra Pak developed a novel high shear mix method that may reduce the price of mayonnaise production. This innovative technique of high shears mixers that are generally using for cold emulsion products, that reduces the cost per kilogram of the final product.
This process starts with ingredients being pumped-up or drawn into the blending vessel by vacuum. When a vacuum is used, this also de-aerates the product quickly and completely. The ingredients enter an optimally agitated vessel, instead of being fed directly into the high shear mixer head. This speeds up oil or powder incorporation to regarding 5 times the normal rate, which saved on mixing time and energy consumption, in both production and cleanup. Furthermore, the Two-step mixing process simplifies the unique emulsification process. This process is supported by Dynamic HS Mixing Head and agitator system. The first step involves high flow and low shear to make a rough emulsion, whereas the second involves high shear combining to form a fine emulsion. All details are well controlled by speed, force, and time. All these activities are tuned to achieve the texture and droplet size. This entire process is only for breaking down the emulsion or the emulsification process. This mixture solution will handle all types of emulsified sauces and with or without particles. It may be set up to provide a wide range of capacities, in batch and continuous mode. It will handle all form of ingredients, like powders, liquids, even particles, and other blocks. The entire system is flexible, guaranteed and known for its consistent quality.  With a high shear mixer from Tetra Pak, the product can always be properly mixed. This is because of the Dynamic HS mixing which works in a harmonical way with the double-shaft agitator, whose counter-rotating blades enable sensible tank flow which gives a homogeneous product. Further to add, any manufacturer can take advantage of prediction tool software, that will allow producers to make the most of their high shear mixer’s performance. This facility is available at a very low price. At the same time,  lot many saving packages are available which may reduce the cost of the said project.

Important role of homogenizers in the food industry

The important role of homogenizers in the food industry

Food producers are now working to offer new product categories to meet customer needs, for example, eliminating trans-fat and reducing the content of sugar, fat, and sodium. These new requirements are to be fulfilled while balancing consumer satisfaction and nutrient content. In order to face those challenges, homogenization processes are the way in which food production is completed. There is an optimal mixing procedure for each emulsion, dispersion, and lipid that achieve objectives with the most economical methods. The developer optimizes the mixing process to better suit the product characteristics and requirements, resulting in unprecedented results. The options that adjust the mechanical forces applied to the product during mixing are simple to use. Wahal group of industries and its equipment is used by food biologists to produce high yield cell disorders and stable emulsions. New food and drink products can be created and improved and harmful bacteria eliminated.

Wahal engineers have a modular approach which supports a wide range of process configurations including support options for functions like pasteurization at high pressures. Our equipment is designed for sanitary applications in order to understand the need for an absolutely clean production process. Wahal Group offers unique benefits in terms of innovative technology for producing nano-emulsions or micro-emulsions, dispersions, lipids, improving quality, a longer shelf – life, stability, bioavailability, color, flavor, texture, and nutritional value for many of its products. Production benefits include 24/7 reliable operation and reduced costs at fewer passes and less wear. Jump is ensured to increment production on a daily basis. Options such as automated control, inline process design, data collection, and validation documentation have complied with strict FDA requirements. The different advantages over other methods of homogenization are increasingly being used as a method of food production. The decision of a consumer to purchase one food brand from another is based in large part on its consistency, taste, and appearance. The processing technique, which dictates these factors, should be considered carefully with the most common homogenization.

The benefits of homogenization in the production of food include Enhancing the results of food processing, a Very efficient way to food preservation method and Extending the product’s durability.

(A) Enhancing the results of food processing

The easiness of improving the results of food treatment can really raise a product to higher sales than competitors. A few years back, Tomato juice has been demonstrated to have increased consistency and viscosity due to a high-shear homogenization of the particles, which suspended during processing. The simple ability to improve the results of food processing can actually increase sales of a product over competitors.

(B) A Very efficient way for food preservation method

Like food results, high shear homogenizers are also extremely effective in preserving food. In fact, the method continues to increase popularity for its high level of function over traditional heat treatment. This is because while high hear and heat are able to kill harmful microorganisms, heat exposure kills some nutrients from the food – while the pressure homogenization leaves them undeterred and ready to be used.

(C) Extending the product’s durability.

helf life or the ability of a food to stay fresh before consumption is linked to food preservation in relation to chemical stability. The intense pressure from a high – shear homogenizer leads to more stable chemical structures in most foods, which allows a longer period of freshness than would otherwise be possible compared to foods consisting of larger particles.

A large number of factors can be attributed to a food capacity to have its intended impact, in particular, particle size and particle size consistency. One such example is the high-pressure homogenizer by Wahal group of industries. ​The Wahal group of companies (Delhi / Pune) ​product is trustworthy for the major benefits of nano or micro-emulsions, dispersion and suspension production from researchers and laboratory managers worldwide. This equipment can achieve a consistent particle size of 100 nm or less, an important advantage for a foodstuff product.

Please contact The Wahal group of companies (Delhi / Pune) today to test your food industry product on the top of the line.