RU2457695C1 - Ketchup-type tomato sauce and its production method - Google Patents

Abstract

FIELD: food industry.

SUBSTANCE: invention relates to food industry, in particular, to the composition and technology of a ketchup-type tomato sauce production. The ketchup-type tomato sauce contains tomato paste, salt, sugar, water, vinegar and a mixture of natural vegetables, herbs and spices or natural extracts of vegetables, herbs and spices. The tomato paste is represented by Hot Break 28-30 tomato paste, vinegar is represented by 12% vinegar of food raw material; the initial components ratio being as follows, wt %: Hot Break 28-30 tomato paste - 25-35%, sand sugar - 17-25%, "Extra" edible salt -1.7-2.3 %, vinegar of food raw material - 12% - 5-12%, mixture of natural vegetables, herbs and spices or natural extracts, herbs and spices - 0.05-0.5%, drinking water - up to 100%. The ketchup-type tomato sauce production method involves mixing tomato paste, water and other components, the mixture homogenisation and deaeration. Before homogenisation one performs the mixture components deaeration stage. Homogenisation is performed in two stages under varied pressures. Then the mixture is delivered for pasteurisation and sterilisation and then - into a high speed industrial mixer for treatment.

EFFECT: invention is aimed to enhance the naturalness, quality and taste characteristics of the product, its homogeneity, improve the structural and rheological properties and the consistence thickness.

14 cl, 9 ex

Description

The invention relates to the food industry, and in particular to the composition and production technology of tomato sauces such as ketchup.

Tomato-type ketchup sauce and the method for its production have been developed and tested within the framework of the Bio-Control internal quality control system adopted by Kazan Fat Combine OJSC.

A known composition for vegetable seasoning ketchup, including tomato paste or mashed potatoes, a structuring agent, sugar, salt, spicy aromatic substances and water, as a structuring agent use natural mashed potatoes from boiled, mashed yellow cherry plum in the following ratio,%: tomato paste or mashed potatoes 30 0-60.0; plum puree 5.0-12.0; sugar 7.0-10.0; salt 0.3-4.0; spicy aromatic substances 1,0-5,0; the rest is water (RF Patent No. 2385645, A23L 1/24, 2008).

The disadvantage of this composition is the use of cherry plum puree in the ketchup, which can distort the taste of the product, and the absence of vinegar negatively affects the microbiological characteristics of the ketchup and its shelf life.

Closest to the claimed composition is tomato ketchup sauce, which contains 30% tomato paste, modified starch, salt, sugar, water, vinegar 80%, hot red pepper, stabilizer, potassium sorbate, sodium benzoate, garlic powder, onions and carrots, with the following ratio of components in kg per 1000 kg of the finished product: 30% tomato paste 120-200, modified starch 20-27, stabilizer 2, salt 22-27, sugar 100-120, potassium sorbate 0.4 , sodium benzoate 0.7, vinegar 80% 5.4-6.0, hot red pepper 0.3-0.5, garlic powder 1.5, onion 8.0-12.5, green pepper fresh Bulgarian or sweet 25-45, red Bulgarian or sweet pepper 25-45, carrots 7-15, water - the rest (RF Patent No. 2204913, A23L 1/24, A23L 1/39, 2002).

The disadvantage of such ketchups and sauces is that they are starch-thickened ketchups where additives of starches and other thickeners are used to achieve a viscous consistency of ketchup. The presence of starch and thickeners give ketchup a “mucous” consistency and interfere with the flavoring of spices, have the so-called “closed taste”, and also reduce the degree of naturalness of the product.

A known method in which when preparing the sauce is boiled part of the mixture, including tomato paste, garlic, salt, sugar and water, then acetic acid is introduced. The spices are jointly extracted with non-polar liquefied gas with the separation of miscella, which is then dispersed into the above mixture under conditions ensuring evaporation of the extractant (RF Patent No. 2132624, A23L 1/24, A23L 1/39, 1998).

The disadvantage of this method is the unsatisfactory rheological properties of the resulting product, due to its high fluidity.

A known method of producing ketchup, consisting of tomato paste or tomato puree, vinegar, salt, sugar, structurant, mustard, aromatic substances and water. The prescription components are mixed by machining and subsequent homogenization at a temperature of 60-90 ° C under vacuum in a Corum apparatus (RF Patent No. 2110932, A23L 1/24, 1997).

The disadvantage is the need to use a structurant to obtain a stable, viscous and uniform product structure.

Closest to the claimed method is a method of increasing the viscosity of a suspension, which consists in passing a tomato composition with a dry soluble content of tomato paste 6-31% through a high pressure homogenizer at a pressure of at least 345 bar.

The method includes mixing the necessary components with tomato paste, heating (cooking, cooking) the tomato mixture, high pressure homogenization, mixing the obtained product with vinegar, in the alternative, there may also be a stage of deaeration of the finished product (EP 0736262, A23L 1/212; A23L 1/24, publ. 1996).

The disadvantages of this method are:

- the need to add vinegar to an already homogenized, viscous product;

- the deaeration stage is carried out after homogenization, which makes it difficult to extract air bubbles (which accelerate the oxidative processes in the product) from the homogenized viscous product;

- the absence of an industrial high-speed mixer at the final stage of preparation necessitates the use of high pressure (at least 345 bar) at the stage of product homogenization.

The objective of the invention is to improve the quality of the finished product, increase its nutritional value and taste, as well as create a method within the framework of the internal quality control system "Bio-control", which allows to increase the viscosity, uniformity and stability of consistency and expand the assortment of tomato sauces, without the use of additional thickeners.

To achieve the above objective, OJSC Kazan Fat Factory, within the framework of the Bio-Control system of internal quality control standards, developed the composition of tomato-type ketchup sauce and a method for its production.

The problem is solved in that the tomato-type ketchup sauce contains tomato paste, salt, sugar, water, vinegar and a mixture of natural vegetables, herbs and spices or natural extracts of vegetables, herbs and spices, while it contains tomato paste Hot Break 28-30, as vinegar - 12% vinegar from food raw materials, in the following ratio of starting components, wt.%:

Hot Break Tomato Paste 28-30 25-35% Granulated sugar 17-25% Food salt "Extra" 1.7-2.3% Vinegar from food raw materials 12% 5-12% A mixture of natural vegetables, herbs and spices or natural extracts of vegetables, herbs and spices 0.05-0.5%. Drinking water up to 100%.

Additionally, it may contain tomato paste Super Hot Break 30-32 in an amount of 3-10%.

Additionally, it may contain 3-10% papaya puree.

As a mixture of natural vegetables, herbs and spices or natural extracts of vegetables, herbs and spices may contain one or more components selected from the group: onion, parsley, oregano, basil, celery, dill, caraway seeds, fenugreek, garlic, paprika, cloves, cinnamon, black pepper, allspice, cayenne pepper, red pepper, chili pepper.

Additionally, it may contain natural yeast extract in an amount of 0.1-0.5%.

Additionally, it may contain red paprika puree in an amount of 2-10%.

Additionally, it may contain natural Taco flavoring in an amount of 0.05-0.5%.

Additionally, it may contain natural fried onion flavoring in an amount of 0.1-0.5%.

Additionally, it may contain natural Grill flavoring in an amount of 0.1-0.5%.

Additionally, it may contain natural Barbecue flavor in an amount of 0.1-0.5%.

Additionally, it may contain natural flavoring “Garlic” in an amount of 0.1-0.5%.

Vinegar from food raw materials can be 70-80% acetic acid, taken in an amount of 1.1-1.7% and diluted to a 12% solution.

The task is also solved by the fact that in the method for producing tomato-type ketchup sauce, which involves preparing dry components in accordance with the recipe amount, mixing them, before homogenizing, they carry out the stage of deaeration of the mixture of components, homogenization is carried out in two stages at different pressures, then the mixture is sent to pasteurization and sterilization, and then for processing in a high-speed industrial mixer.

Homogenization in the first stage is carried out at a pressure of 10-60 MPa, and in the second, at a pressure of 3-20 MPa.

The technical result of the invention, created as part of the Bio-control, an internal quality control system, is to increase the naturalness, quality and taste characteristics of the product, its uniformity, improve the structural and rheological properties and achieve a dense consistency through the use of special varieties of tomato pastes - Hot Break 28-30, because in this variety of tomato paste, native pectins are stored in a high molecular weight active state and can serve as the formation of the required viscosity of ketchup.

The term “Hot Break” means the process of obtaining tomato paste by chopping fresh tomatoes and short-term exposure of tomato pulp at a high temperature from 70 to 90 ° C. The product obtained during the Hot Break process is more viscous and thicker. The degree of viscosity of tomato paste increases due to enzymatic inactivation. Pectin enzymes, usually found in tomatoes and fruits, under the influence of oxygen during the grinding process, are activated and begin to destroy pectin (reduce the molecular weight of pectin molecules). Within the framework of the Bio-control system of internal quality control standards, it was found that pectin enzymes are completely deactivated at temperatures above 85 ° C. Therefore, all plants equipped with an enzyme deactivation system, better known as Hot Break plants, increase the temperature of the product to 85 ° C and more degrees Celsius to accelerate deactivation of enzymes, thereby preserving the natural viscosity of the product to the maximum.

Thus, the use of tomato paste Hot Break allows you to achieve a dense and uniform consistency of the product without the use of starch in the composition of ketchup, which increases its nutritional value, "naturalness" and improves the taste of the product.

To achieve the viscosity of ketchup, thickened only with tomato pectins, a mixture of tomato paste, water and other ingredients is passed through a high pressure homogenizer (HPH). During this operation, the associates (lumps) of native pectins are destroyed and pectins, already in the form of separate molecules begin to play the role of a thickener (begin to act like swollen starches), bringing the initially liquid mixture of components into a viscous-fluid state, which as a result improves its structural-rheological characteristics, increases the viscosity of the product due to changes in size, optimal distribution of tomato paste particles with the formation of physical mesh structures and activation of native pectins contained in tomato paste e.

Depending on the quality of the Hot Break tomato paste, the tomato sauce may additionally contain Super Hot Break 30-32 tomato paste and / or papaya puree as a flavoring and consistency regulator, as both components have a high content of native pectins.

Vinegar from food raw materials is used in the form of a 12% solution. The use of vinegar in the form of a 12% solution is economical in production and provides the product with a pH value of 3.0-4.5, which in turn increases the microbiological purity of the product and extends its shelf life. As a 12% solution of vinegar, any vinegar used in the food industry can be used, as vinegar from food raw materials (wine, alcohol, apple, fruit, etc.), and vinegar prepared by diluting to a 12% concentration of vinegar acids of chemical-chemical or synthetic 70-80% concentration and food quality.

The sugar content in ketchup is calculated on the basis that sugar has the ability to bind active water, exhibiting the property of a preservative, and the sweet taste of the product will be organoleptically leveled by the amount of 12% vinegar introduced. These two factors also ensure good microbiological preservation of the product, without the use of additional chemical preservatives.

The use of various natural flavors allows you to expand the taste variety and product range.

A mixture of natural vegetables, herbs and spices or natural extracts of vegetables, herbs and spices provide the product with a variety of pleasant harmonious tastes and enrich the product due to the fact that it contains vitamins, mineral salts, essential oils and other useful substances. Essential oils, glucosides and flavoring substances contained in aromatic plants improve the quality of products, stimulate the activity of olfactory, taste and digestive organs. Herbs and spices enrich the taste and aroma of the product.

As a mixture of natural vegetables or natural extracts of vegetables, herbs and spices, the product may contain one or more components selected from the group: onion, parsley, oregano, basil, celery, dill, caraway, fenugreek, garlic, paprika, cloves, cinnamon, black pepper, allspice, cayenne pepper, red pepper, chili pepper.

However, it is also possible to use ready-made mixtures that already have a balanced content of vegetables or their extracts, various herbs and spices. Such mixtures are produced under special names, for example, a mixture of "European", "Chilean", "Mexican", "Italian" and others. This form of using mixtures of vegetables, herbs and spices is the most convenient and simple.

The claimed ratios of the components of the product, as well as its production method, developed and tested at Kazan Fat Factory in the framework of the Bio-Control system of internal quality control standards, make it possible to obtain a product with a rational composition, high quality, balanced for the main food components and having high flavoring properties.

The method is implemented as follows:

1. All prescription components are subjected to standard preparation, determined by the type of component. Sugar, salt, tomato paste, spices, vinegar in a given recipe ratio are mixed in a mixing tank at room temperature. Thus obtained mixture is preheated to 50-70 ° C, then subjected to deaeration to remove air bubbles.

2. The stage of deaeration is specially located before the stage of homogenization, because the tomato mixture does not yet have a high viscosity, which facilitates the removal of air bubbles from it, and also because if we allow the passage of the mixture with the air bubbles not removed into the homogenizer, the latter disperses the air bubbles so finely that removing them from the resulting mixture into it will become next to impossible. And the presence of a developed surface of non-removed air bubbles in the product affects its quality, increases its tendency to oxidize during storage and reduces its shelf life.

3. Next, the prepared mixture is sent to high-pressure homogenization, carried out in a two-stage homogenizer. In this case, the destruction of pectin associates occurs, as a result of which they are activated and begin to play the role of a thickener and structure-forming agent.

Homogenization parameters:

Pressure at the 1st stage - 10-60 MPa

Pressure at 2 stages - 3-20 MPa

The pressure values of the homogenization stage are set depending on the type of tomato-containing product and its desired consistency (viscosity).

4. Then the homogenized mixture with increased viscosity is sent to the pasteurization-sterilization stage, carried out in tubular static heat exchangers. In heat exchangers, the mixture undergoes the following heat treatment: 50-55 ° C → 95-105 ° → 95-105 ° C (holding for 3 minutes) → 55-35 ° C and sent to an industrial mixer.

5. The industrial high-speed mixer carries out fine grinding and additional homogenization of the tomato mass in order to increase the uniformity of its structure, luster and softness of consistency.

6. After the mixer, the product is sent to a buffer tank. The buffer tank is an aseptic tank equipped with a frame stirrer, in which the product is stored before bottling in a nitrogen atmosphere.

It is possible to add pieces of sterilized vegetables and fruits to the product in the buffer tank.

The invention is illustrated by the following examples of the composition of tomato sauce, tested in the framework of the internal quality control system "Bio-control", which, however, do not cover, and even more do not limit the entire scope of the claims of this invention.

Ketchup sauce is prepared in accordance with the above technology.

The starting components of the product are taken in the following quantitative content of the components, wt.%:

Example 1

Hot Break Tomato Paste 28-30 32.3 Granulated sugar twenty Food salt Extra 2.0 Wine Vinegar 12% 7.3 Mixture "European" 0.1 Water Rest

Example 2

Hot Break Tomato Paste 28-30 32.3 Granulated sugar 20.5 Food salt Extra 2 Apple Cider Vinegar 12% 8.7 Mixture "European" 0.1 Water Rest

Example 3

Hot Break Tomato Paste 28-30 32.3 Granulated sugar 21 Food salt Extra 2.0 Alcoholic Vinegar 12% 10 Paprika puree red 2 Mixture "European" 0.1 Water Rest

Example 4

Hot Break Tomato Paste 28-30 25 Super Hot Break 30-32 Tomato Paste 7 Granulated sugar twenty Food salt Extra 2 Acetic acid 12% 9 Mixture "Chilean" 0.1 Natural yeast extract 0.5 Water Rest

Example 5

Hot Break Tomato Paste 28-30 28 Papaya Puree 5 Granulated sugar twenty Food salt Extra 2.1 Acetic acid 12% 10 Mix "Mexican" 0.1 Fragrance natural "Taco" 0.2 Natural yeast extract 0.5 Water Rest

Example 6

Hot Break Tomato Paste 28-30 25 Super Hot Break 30-32 Tomato Paste 7 Granulated sugar twenty Food salt Extra 2.1 Acetic acid 12% 10 Mixture "European" 0,07 Fragrance natural "Fried onion" 0.1 Water Rest

Example 7

Hot Break Tomato Paste 28-30 25 Super Hot Break 30-32 Tomato Paste 3 Papaya Puree 3 Granulated sugar twenty Food salt Extra 2.1 Acetic acid 12% 10 Mixture "European" 0.08 Fragrance natural "Fried onion" 0.5 Fragrance natural "Grill" 0.1 Fragrance natural "BBQ" 0.1 Water Rest

Example 8

Hot Break Tomato Paste 28-30 25 Tomato paste Super HB 30-32 3 Papaya Puree 3 Granulated sugar 21 Food salt Extra 2.1 Acetic acid 12% 10 Natural yeast extract 0.5 Mixture "Italian" 0.15 Dried garlic, ground 1,0 Fragrance natural "Garlic" 0.1 Water Rest

Example 9

Hot Break Tomato Paste 28-30 32.3 Granulated sugar twenty Food salt Extra 2 Acetic acid 12% 9 Mixture "Italian" 0,07 Mixture "Chilean" 0,07 Water Rest

The claimed invention allows to expand the range of food products, with their high quality both in terms of organoleptic characteristics and in physicochemical properties, and eliminates the need for additional thickeners to create the necessary consistency of tomato ketchup sauce.

The test results and chemical-physical analysis of the claimed product, obtained in accordance with the approved industry methods, as well as the methods adopted by Kazan Fat Factory, confirm the conformity of the approved product composition to the declared technical result.

The test results of the claimed method, obtained according to the approved industry methods, as well as the internal quality control standards “Bio-control” developed and tested at OJSC Kazan Fat Combine, confirm the conformity of this method to the claimed technical result.

Claims (14)

1. Tomato-type ketchup sauce containing tomato paste, salt, sugar, water, vinegar and a mixture of natural vegetables, herbs and spices or natural extracts of vegetables, herbs and spices, while it contains tomato paste Hot Break 28-30 , as vinegar - 12% vinegar from food raw materials, in the following ratio of starting components, wt.%:
tomato paste Hot Break 28-30 25-35 granulated sugar 17-25 food salt "Extra" 1.7-2.3 food vinegar 12% 5-12 a mixture of natural vegetables, herbs and spices or natural extracts of vegetables, herbs and spices 0.05-0.5 drinking water up to 100 2. Tomato sauce according to claim 1, characterized in that it additionally contains tomato paste Super Hot Break 30-32 in an amount of 3-10%. 3. Tomato sauce according to claim 1, characterized in that it further comprises 3-10% papaya puree. 4. Tomato sauce according to claim 1, characterized in that as a mixture of natural vegetables, herbs and spices or natural extracts of vegetables, herbs and spices contains one or more components selected from the group: onion, parsley, oregano, basil, celery, dill, caraway seeds, fenugreek, garlic, paprika, cloves, cinnamon, black pepper, allspice, cayenne pepper, red pepper, chili pepper. 5. Tomato sauce according to claim 1, characterized in that it further comprises a natural yeast extract in an amount of 0.1-0.5%. 6. Tomato sauce according to claim 1, characterized in that it additionally contains mashed red paprika in an amount of 2-10%. 7. Tomato sauce according to claim 1, characterized in that it additionally contains a natural flavoring "Taco" in an amount of 0.05-0.5%. 8. Tomato sauce according to claim 1, characterized in that it additionally contains a natural flavoring "Fried onions" in an amount of 0.1-0.5%. 9. Tomato sauce according to claim 1, characterized in that it further comprises a natural "Grill" flavor in an amount of 0.1-0.5%. 10. Tomato sauce according to claim 1, characterized in that it additionally contains a natural flavoring “Barbecue” in an amount of 0.1-0.5%. 11. Tomato sauce according to claim 1, characterized in that it additionally contains a natural flavoring “Garlic" in an amount of 0.1-0.5%. 12. Tomato sauce according to claim 1, characterized in that the vinegar from food raw materials is 70-80% acetic acid, taken in an amount of 1.1-1.7% and diluted to a 12% solution. 13. A method of obtaining tomato-type ketchup sauce, characterized in claims 1-12, comprising mixing tomato paste, water and other components, homogenizing the mixture and deaerating it, while before homogenizing the deaeration of the mixture of components is carried out, and the homogenization is carried out in two stages at various pressures, then the mixture is sent for pasteurization and sterilization and then for processing in a high-speed industrial mixer. 14. The method according to item 13, wherein the homogenization in the first stage is carried out at a pressure of 10-60 MPa, and in the second at a pressure of 3-20 MPa.