W. D. Bigelow

“ The laboratory of the National Canners’ Association is frequently asked to examine samples of tomato products to determine whether or not they comply with the Government requirements. In examining these samples we use the Government method (the Howard method) , but do not participate in the discussions regarding its merits and shortcomings.
It is our experience that skilled analysts can check themselves and each other with reasonable accuracy, and it is our duty to tell the manufacturer whether his product is legal. ”

“ Ketchup is defined in the Federal food standards as the clean, sound product made from properly prepared pulp of clean, sound, fresh, ripe tomatoes, with spices, and with or without sugar and vinegar.
The solid matter, or total solids, in ketchup varies from less than 12 per cent to over 37 per cent. This means that the product varies from a substance having barely sufficient tomato added to give color and taste, to a rich, heavy tomato ketchup. The variation of total solids in any one brand is, of course, less, but large differences are not unusual. ”

“ Manufacturers of tomato pulp have considerable difficulty in securing a product of uniform concentration and in determining at what point to stop evaporation. Some manufacturers turn off the steam when it is believed that the concentration has gone far enough and make a hasty determination of specific gravity. If it is found the concentration is not as great as is desired, heating is resumed for a time and the specific gravity again determined. ”

“ The acidity is one of the most important factors in preventing the growth of bacteria and yeasts in the ketchup after being opened. In order to secure the best results the ketchup should have an acidity of over 1 per cent (expressed as acetic acid) and an acidity of 1.25 per cent or higher adds to the keeping quality of the ketchup after the bottle is opened. An increase in acidity will necessarily require an increase in the amount of sugar in order to secure the proper flavor; or, vice versa, an increase in the sugar will necessitate an increase in acidity. ”

“ On the other hand, the specific gravity should not be materially above the specifications. The buyer, who is usually a manufacturer of ketchup, desires the pulp of the specific gravity stipulated, and a higher degree of concentration is therefore not a [51] mark of superiority in pulp intended for that purpose. Moreover, material increase in concentration above the specifications of the purchaser causes considerable loss by reason of reduced volume. For instance, 100 gallons of pulp with a specific gravity of 1.036 are equivalent to 103 gallons of a pulp with a specific gravity of 1.035. ”

“ Some manufacturers of tomato products use the Howard method as a check on their factory control. For this purpose it is not satisfactory to have samples examined in a laboratory located at a distance from the factory. Even if several samples are examined from a day’s run, they probably do not represent all the pulp manufactured on that day. It sometimes happens that one wagonload of tomatoes is almost entirely free of rotting material, whereas the succeeding load contains a considerable amount. ”

“ Some maintain that a better color is obtained by cycloning hot. Others, apparently equally skilled and able to manufacture an equally good product, maintain the reverse. Much depends on the control of the cyclone—the setting of the paddles and the speed at which they are operated.
The evaporation should be as rapid as possible. The operation of the kettles in such a way that the pulp burns on the kettles or on the coils damages the flavor of the product and impairs its color. ”

“ If only trimming stock is made into pulp, however, nearly half the tomatoes are used for canning and the remainder (50 or 55 pounds of trimming stock) will only make something like 35 or 40 pounds of cyclone juice. Yet, since the rot is almost entirely on the outside of the tomatoes, this 35 or 40 pounds made from the trimming stock contains the same amount of molds as the 85 pounds manufactured from the whole tomatoes. The mold count of the trimming stock pulp, therefore, is much higher than that of whole tomato pulp made from the same raw product. ”

“ In the determination of the specific gravity of hot pulp during the process of its evaporation speed is essential, and the conditions of a manufacturing plant do not always permit a high degree of accuracy. ”

“ Moreover, when it is attempted to strain the insoluble solids from hot pulp or cyclone juice, considerable evaporation occurs, causing concentration of the product and producing an error in the results. When hot pulp is handled, therefore, it must be strained as quickly as possible, and more accurate results may be obtained if the pulp is cooled quickly before straining. This may be done by placing in a large can and stirring vigorously while the can stands in ice water, or shaking under water in a large flask. ”

“ Chili sauce is of the same general character as ketchup but is made from peeled and cored tomatoes without removing the seeds, contains more sugar and onions and sometimes is made hotter than ketchup by the use of more cayenne pepper. There is a great variation among different manufacturers with respect to the methods of treating the tomatoes. Usually large to medium sized tomatoes are employed, separated from the small tomatoes which are used for making pulp and ketchup. ”

“ For instance, if the specific gravity or index of refraction of a filtrate prepared from a pulp of unknown origin, and the per cent of solids in the pulp by drying, do not agree approximately with the relation between these determinations as shown in Table 5, it may be assumed that the sample was not prepared from whole tomatoes, or that some other substance, such as salt, [12] has been added. Moreover, trimming stock pulp rarely conforms to the relations found in whole tomato pulp. For instance, the insoluble solids are usually higher and the acid lower in trimming stock pulp. ”

“ Fortunately the solids in cyclone juice have a fairly uniform composition. The ratio of total solids to insoluble solids is fairly constant, likewise the ratio of sugar to acid. The sugar in cyclone juice varies from about 42 per cent to 54 per cent of the total solids, averaging about 50 per cent.
As the consistency or body of ketchup is due chiefly to the tomato solids, the amount of evaporation necessary to secure ketchup of the desired consistency from a known volume of pulp measured at the boiling temperature and of known Brix or specific gravity can be determined from Table 9, page 56. ”

“ So many cases have come to our attention, however, in which canners have not succeeded in maintaining the degree of sorting necessary with a product of this kind that we have grown to feel that the presence of an analyst working continuously in a plant is an additional safeguard.
The conditions attending the canning of tomatoes are widely different from those attending the manufacture of tomato pulp. ”

“ Final concentration of the ketchup is controlled in the same manner as for pulp, either by a gauged tank or by specific gravity determination. If we start, therefore, with a given volume of partially concentrated cyclone juice and determine the solids present, we can in every case quickly ascertain from the appropriate table the number of gallons of finished product we should obtain, and the gauge stick or attached gauge glass will indicate when to stop evaporation in the tank. ”

“ If the bottled product can be sealed at 180° F. or better a process is not necessary and is an unnecessary expense and waste of time, besides it may injure the color of the product. With the modern type of equipment it is possible to fill the bottles at a temperature which obviates sterilization. Care must be taken that the temperature of the ketchup in the receiving tank feeding the filler does not fall too low. Care must also be avoided in order not to fill the ketchup at too high a temperature as it results in excessive shrinkage of the contents. ”

“ There is included in the bulletin beginning on page 13 a detailed description of the Howard method for the microscopic examination of tomato products, and following that a detailed statement of the chemical and physical methods employed in this laboratory for their examination. Such methods are only of value to those trained in laboratory work. They are included here because the laboratory receives many requests for these methods from chemists employed by manufacturers of pulp. Men who are employed only for the tomato season find special need for such information. ”

“ Pulp packed in five-gallon cans is rarely processed. It should, however, be filled into the cans at a temperature of at least 180° F. It is best to give pulp in No. 10 and smaller size cans a short process in boiling water. With pulp filled at 180° F., ten or fifteen minutes is a sufficient cook. Pulp filled at lower temperatures or which is allowed to partially cool before processing requires a longer process.
In order to protect the color it is best to water cool No. 10 cans of pulp after processing. Pulp in cans of any size should not be stacked solid while it is still hot. ”

“ An examination of the pulp, therefore, by an analyst who is not thoroughly conversant with this method as it is employed by the Bureau of Chemistry not only is useless but may actually afford a manufacturer a false sense of security which will be greatly to his disadvantage. ”

“ The process necessary will depend upon the temperature at which the ketchup is filled and on the time that may elapse between filling and processing. Sanitary conditions of the factory and equipment are exceedingly important not only in relation to ease of sterilization but also in securing a product of good quality. ”

“ Close the graduate, or pour the contents into an Erlenmeyer flask, and shake the mixture vigorously for 15 to 20 seconds. To facilitate thorough mixing the mixture should not fill more than three-fourths of the container in which the shaking is performed. For tomato sauce or pastes, or products running very high in the number of organisms, or of heavy consistency, 80 cc. of water should be used with 10 cc. or 10 grams of the sample. In the case of exceptionally thick or dry pastes, it may be necessary to make an even greater dilution. ”

“ It has been repeatedly demonstrated, however, that a carefully selected man or woman with common school education can learn the method and use it with sufficient accuracy for factory control. The person selected for this work should have good powers of observation and a positive character.
This laboratory has heretofore advised that manufacturers of tomato pulp should not give too much attention to the microscopic count of their product. ”

“ Repeat the centrifuging and the filtration of the supernatant liquor once more, and then finally transfer the insoluble solids to the filter paper and thoroughly wash with hot water. Dry the paper and insoluble solids, and weigh. The insoluble solids are quite hydroscopic and the weight must be taken quickly.
Determination of Sugar
The sugar of tomatoes is probably always present as invert sugar. If cane sugar is ever present in the raw product it is doubtless inverted during the concentration of pulp. ”

“ The metal of the can has a bleaching action on the pulp and this is greatly increased if the pulp is stacked hot or stored in a hot warehouse. If stacked while excessively hot, stack-burning may occur with consequent darkening of the pulp. ”

“ Conveyors, receptacles and machines must be constructed and installed with a view to convenience in cleaning. Care must be taken to expedite the manufacture of the product in every way possible in order to give no opportunity for bacterial growth during the process of manufacture. ”

“ In making the counts, the analyst should avoid counting an organism twice when it rests on a boundary line between two adjacent squares.
Bacteria.—Tentative
Estimate the number of rod-shaped bacteria from the mounted sample used in 29 [10] (yeasts and spores) , but before examination allow the sample to stand not less than 15 minutes after mounting. Employ a magnification of about 500, which may be obtained by the use of an 8 mm. Zeiss apochromatic objective with X18 Zeiss compensating ocular with draw-tube not extended, or an 8 mm. ”

“ He is therefore entitled to a substantial share of the credit for the material in this bulletin.
SANITARY CONTROL OF TOMATO PULP FACTORIES
The manufacture of tomato pulp requires careful supervision from beginning to end. The raw product must be carefully selected, and all possible steps should be taken to induce growers to discard rotting [7] tomatoes in the field and to expedite the movement of the raw product from field to factory. Tomatoes must be carefully washed and sorted. ”

“ It should be stated that the results given under the heading “Pouring cold and whirling by hand” were obtained by much more careful work than is practicable in the factory. The flasks in which the determination was made were equipped with a bail, as shown in Fig. ”