United States

Department of

Agriculture

Agricultural

Marketing 

Service

Fruit and Vegetable

Division

Processed Products 

Branch

Grading Manual for

Chili Sauce

Effective October 1954

Reprinted April 1994
Chili Sauce

October 1954

Reprinted April 1994

This manual is designed for Processed Products Branch Personnel of the U.S. Department

of Agriculture. Its purpose is to give background information and guidelines to assist in the

uniform application and interpretation of U.S. grade standards, other similar specifications

and special procedures.

The citation of any data, criteria, techniques, illustrations, copyrighted material, or pictorial

representationaccredited to private authorship is used with the permission of the individuals

or sources cited. Unless a specific reference is cited, the information in this manual has been

compiled or developed from sources available to the public as well as from technical

knowledge of personnel in the Department.

Following the suggested guidelines in this manualdoes not excuse failure to comply with the

Federal Food, Drug, and Cosmetic Act or any other applicable Federal or State laws or

regulations.

Exceptfor officialUSDAinspectionaidsordevicesand color guides (or standards) produced

underlicense of the Department, the mentionof any supplier, patented device,product, brand

name or equipment does not imply endorsement by the Department over any other similar,

or equally effective material.

Address inquires to:

Chief, Processed Products Branch

Fruit and Vegetable Division, AMS

U.S. Department of Agriculture

P.O. Box 96456, Rm. 0709, South Building

Washington, DC 20090-6456
Chili Sauce

October 1954

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Table of Contents

Page No.

I. Description of Product ................................................. 1

II. History and Development of the Product .................................. 1

III. Ingredients ........................................................... 1

A. Tomato Pulp ................................................... 2

B. Sugar ......................................................... 2

C. Spices, Salt and Acids .......................................... 2

D. Other Ingredients ............................................... 2

IV. Manufacture ......................................................... 3

A. Tomato Pulp ................................................... 3

B. Adding Other Ingredients ......................................... 3

C. The Finishing Point ............................................. 3

D. Processing .................................................... 4

V. Inspection During Processin ............................................ 4

A. Regularly Observe the Raw Material ............................... 4

B. Work as Closely as Possible With the Plant Quality Control ............ 4

C. Draw Samples of the Tomato Pulp ................................ 4

VI. Inspection of the Product ............................................... 5

A. Sampling ...................................................... 5

B. Inspection Equipment ........................................... 5

C. Setting up the Score Sheet ....................................... 5

D. Fill of Container ................................................ 6

E. Net Weights ................................................... 6

F. Vacuum Readings .............................................. 6

G. Ascertaining the Grade .......................................... 6

1. Color ................................................... 7

2. Consistency ............................................. 7

3. Character ............................................... 7

4. Absence of Defects ....................................... 8

5. Flavor ................................................... 9

6. Limiting Rules for Scoring Factors ........................... 9

H. Examination for Filth and Extraneous Material ....................... 9

VII. Certification .......................................................... 10

A. Tolerances for Concentration ..................................... 10

B. Examples ofProper Informationto Appear in the Bodyof the Certificate

.............................................................. 10

I. Description of Product.

The product covered by these standards is somewhatsimilar in looks and in popular

usage to tomato catsup. The principal differences being that chili sauce contains at

least a portion of the tomato seeds and it usually contains small bits of the chopped

vegetable for the flavoring ingredients; whereas in tomato catsup the ingredients are

all macerated into relativelysmallparticles. The Food and Drug Administration has not

established standards of identity for this product. Regardless of what the product is
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called,these standards apply only to the productdescribedinthe standards, one which

is primarily made of tomatoes. The standards should not be applied to a product

which contains larger portions of pickle relish or other chopped vegetable.

II. History and Development of the Product.

Chili sauce originated byhome cooks and resembled a light tomato preserve, that is,

the body of the product was produced mostly by the larger chunks of broken

tomatoes. The tomatoes were hand peeled and cooked in kettles with the other

ingredients. They were stirred lightly so thatthe tomatoes were somewhatbrokenup.

Produced commercially by similar methods this product has had a good receptionfor

some time; however, because of the amount of hand work it remained in the luxury

class. With increased costs for labor, efforts have been made to short cut the hand

peeling of the tomatoes by using strained tomato pulp for all or a part of the tomato

ingredient. Tomato pulp which more or less closely approaches the appearance of

hand peeledtomatoeswhichhave beanbrokenup by stirring and cooking is produced

by machines.

Chili sauce now is largely made by machinery; however, regardless of the method of

manufacture,efforts are made to approach the appearance of the old-fashioned chili

sauce with respect to the tomato ingredient. This is done to a remarkable degree in

some of the better chili sauces.

III. Ingredients.

The ingredients used in chili sauce are very similar to those used in tomato catsup.

The methods of preparation and the amount of the ingredients used may vary

considerably.
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A. Tomato Pulp.

The primary ingredient in chili sauce is red tomatoes. The tomatoes may be hand

peeled and broken up by stirring or the tomatoes may be prepared by any one of a

number of machines especially designed for the purpose, or there may be a

combination of whole peeled tomatoes and more or less macerated tomatoes from

whichthe peelings have beenremoved by screening out. These machines are usually

similar to the tomato pulper or finisher except that the holes through which the tomato

material is forced are usually quite large and they are not nearly as efficient as the

usual finishing machine at removing the peeling and defects from the tomatoes. For

economic reasons some manufacturers have resorted to using a large amount of

cyclone pulp and a small amount of hand peeled or mechanically peeled tomatoes or

tomatoes which nave been forced through small openings. In generalthe more of the

larger pieces of tomato material present the better the pulp is for chili sauce.

B. Sugar.

In the absence of any Standard of Identity the use of any of the nutritive sweetening

ingredients is permitted in this product. The usualsweetener is sugar (sucrose). The

solids of chili sauce are usually brought up higher by the use ofsugar and lowered by

concentrating the tomatoes than is usual with catsup. Some manufacturers use as

muchas 1/2 more sugar thantheydo with catsup yetfinishatabout the same point with

respect to soluble solids.

C. Spices, Salt and Acids.

About the same spices are used as in the manufacture of catsup,except that garlic is

seldom used in chili sauce. The proportions of the various spice ingredients are not

standardized between manufacturers. Salt and vinegar are used in about the same

proportions as with catsup.

D. Other Ingredients.

The other ingredients, such as onion, bell peppers, celery, and sweet pickle relish,

contribute to the flavor of the product and also provide body to the finished product;

that is, theyprovide part of the consistency and most of the chewiness of the finished

chili sauce. The ingredients used and the proportions of the ingredients used vary

widely from packer to packer, therefore, quite a variety of flavors can be expected in

chili sauces. The onion ingredient is often dehydrated onion flakes. Red or green

diced dehydrated peppers are often used.
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IV. Manufacture.

Most important in the manufacture of chili sauce is the preparation of the tomato pulp.

A. Tomato Pulp.

Where peeled tomatoes are used for a part or all of the tomato pulp they are usually

takenfrom the regular canning lines after at least a partial preparation by mechanical

or hand peeling, trimming and coring. There is usually some selection of the raw

tomatoes which are to be run through chili sauce preparation machines. Some

packers divert veryripe tomatoes whichneedno trimming to the chili sauce lines while

others box-sort or load-sort the tomatoes and trim them on the conveyer belts. This

trimming removes defective parts and stems which would become defects in the

sauce. The trimmers may or may not remove most of the green portions of the

tomatoes depending on the machinery used and the manufacturer's desires with

respect to the appearance of chili sauce. If green pepper, pickle relish, or green

tomatoes are added green shouldered tomatoes are not usually trimmed.

Manufactureconsistsofcombining the ingredients in a manner so thatthe finishedchili

sauce will have the desired qualities of color, consistency, finish, absence of defects,

and flavor. The tomato pulp, whether from broken peeled tomatoes or from special

chili sauce machines, or cyclone juice to which some tomato material containing

tomato seed isadded,is run to kettles, usually steam jacketed,and reduced byboiling

to about one-half the original volume. Concentration in vacuum pans is particularly

satisfactory for this operation.

B. Adding Other Ingredients.

Onionis oftenadded at the beginning of the boil. The other ingredients may be added

at any time but the sugar is usually added late to prevent caramelization. Spices, if in

the form of oils or cream of spice, are usually added late to prevent evaporationof the

flavor ingredients.

C. The Finishing Point.

Because of the nature of the ingredients there is no accurate means of determining a

correct finishing point whichwill apply to all formulae. The first batches when starting,

or after any major change in formula, are dropped when they appear to be about

correct. As with tomato catsup the consistencyof the hotsauce maybe measured by

any suitable device, suchas the Bostwick consistometer and the refractive index may

be taken. Succeeding batches can then be adjusted by these instruments by

increasing or decreasing the boiling or by adjusting the amounts of pulp and sugar to

the desired result.

D. Processing.

Chili sauce is usually closed at about 180 degrees, at which temperature further

processing is usually not necessary. Foaming may occur at higher temperatures and

an additional process is usually given if the sauce is closed at lower temperatures.

V. Inspection During Processing.
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The basic principles of in-plant inspection outlined in pertinent instructions on this

subject apply in general to inspection during the manufacture of chili sauce. The

following inspection procedures are suggested. It may be necessary to vary these

procedures somewhat depending on the particular operation.

A. Regularly Observe the Raw Materials going into this productto seethatthey

are suitable for the purpose. The criteria suggested in connection with

decomposed material in tomato catsup may be useful in connection with chili

sauce. If unsuitable raw material is going into the product (1) immediately call

the attention of the management to the situation, and (2) do not certify the

productfor any grade or specificationwithout first consulting your supervisorfor

guidance.

B. Work as Closely as Possible With the PlantQuality Controlsetup,if there

is one.

CAUTION: Plant quality control records are useful only if there is full

cooperation with controlpeople and the plantmanagementand ifthere

are sufficient independent checks by the inspection force to verify the

findings made by the plant personnel. Plant quality control checks are

particularly useful where the information developed is always subject

to recheck and correction by the inspection force.

C. Draw Samples of the Tomato Pulp as it Enters the Cooking Kettles and

examine for defects, particularly tomato peel. An examination at this point will

spotfaulty machinery or poor preparationbefore the batchis complete and will

give some time for correction of any fault. It will also serve as an indication of

the final score for the product with respect to defects.
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VI. Inspection of the Product.

A. Sampling.

Followapplicable sampling instructions meticulouslywhendrawing samples of

chili sauce. Chili sauce is made in kettle sized batches and every container

from each batch is usually very similar to every other container from that

batch. It may be very different from the containers in another batch even though

they are offered for inspection as part of the same lot. If it is known that each

batch bears a different code every effort should be made to secure a sample

from eachbatchunless the batches are verysmall. If eachbatchdoes notbear

a separate code mark it maybe that a new code mark represents another day

or half day's run or some other period of time. Some knowledge of the coding

system will be very helpful in securing samples which will be representative of

the lot. Suitable equipment has been developed to code bottle caps. Such

coding is more satisfactory than just case coding.

B. Inspection Equipment.

1. Minimum equipment necessary for the inspection of chili sauce.

a. Scale- 1/4 ounce gradations.

b. Flat, white, grading trays.

c. Ruler.

d. Refractometer.

2. Additionalequipment for microanalyticalexaminationformold and other

filth (listed in more detail in other instructions).

a. Mold counting equipment.

b. Insect fragment counting equipment.

c. Maggot and fly egg counting equipment.

C. Setting up the Score Sheet.

Record all important information concerning the inspectionon the score sheet

as directed in basic instructions onthis subject. This includes suchinformation

as net weights, kind of containers, vacuum readings and all significant

information taken from the labels.

D. Fill of Container.

Compliance with the fill of container recommendationin the standards (atleast

90 percent ofthe volume of the container) assures that the headspace in most

containers will not be excessive. Because the presence of air bubbles in the

chili sauce may give the impression of poor color and because there may be

a real loss of color because of oxidation, most packers fill containers of chili
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October 1954

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sauce as full as is practicable. Slack filled containers should be noted and

reported on certificates as directed in basic instructions on this subject.

E. Net Weights.

Althoughchili sauceis a semi-liquid product it is labeled in termsofavoirdupois

weight rather than fluid ounces; therefore, weigh the product and record the

weights on the score sheets.

F. Vacuum Readings.

The red color of tomato products is easily affected by oxidation and certain

types of closures require a good vacuum in the container to keep the closure

in place. For these reasons the vacuum reading is often very important to the

buyer of chili sauce. Vacuum readings canbe takenthroughthe lids of bottled

chili sauce although it may be difficult to pierce both the lid and the

gasket. Every effort should be made to get as accurate vacuum reading as

possible on this product.

G. Ascertaining the Grade. 

There are a number of condiment sauces on the market which contain

tomatoes. They may or may not be chili sauce within the meaning of these

grades. Even though the manufacturer may call the sauce chili sauce to be

eligible foragradeunderthese standards the products must meetthe definition

in the first paragraph of the United States standards. The principal

differentiating requirements in this paragraph are:

1. Predominately composed of a tomato ingredient;

2. At least a portion of the tomato seed present, and

3. The refractive index of the filtrate is not less than 1.3784.

All of the requirements of each grade are scoring factors.
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1. Color.

Because of the addition of various combinations of ingredients other

that tomatoes, chili sauce color is not evaluated by comparing it to the

color of spinning discs as is done with other tomato products. The

evaluationofcolor,however, should be made only undersuitable lighting

conditions as described in instructions on the evaluation of color in

tomato products. It is believed that the color descriptions in the

standards quite accurately describe the requirements of each scoring

group. Theyshould be reviewed carefully. It should be kept in mind that

the tomato color should predominate but thatit need notbe as red as is

required in Grade A color for catsup, juice, and other tomato

products. On the other hand, if the color of the chili sauce is dark and

even slightly off color the score should be dropped into the Grade C

range or lower. If the color is objectionably dark or off color for any

reason the product should be scored in Substandard for this factor.

2. Consistency.

No entirely objective method of measuring the consistencyofchili sauce

has been developed. It is believed that the standards for factor of

consistency quite adequately describe the requirements for each

scoring group.

3. Character.

Characterand consistencyare quite closely related in thatthe character

has a considerable effect on the consistency of the product. Good

character may be imparted to the sauce by the firmness of the larger

pieces of tomato materialor it maycome almostentirelyfrom the added

ingredients, such as onionor pickle.It is particularly desirable thatmost

of the character come from the tomato ingredient and such a sauce

would receive a higher score than if there was little character to the

tomato pulp.

Proper scores for character will be assigned if the standards are

followed quite literally.
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4. Absence of Defects.

The scoring for this factor is based on the effect of the defects present on the

appearance and eating quality of the product. Therefore the examination

for defects is made by viewing the actual product (not a diluted sample) on a

white tray. Pour eight to twelve ounces about a quarter inch deep on the tray for

this evaluation. Because of the wide variationin size, number, kind, type, and

color of defects suchas dark specks, scale-like particles, discolored seeds, or

pieces of abnormally discolored ingredients which might be present, it has not

proven feasible to assign score points on a strictly objective basis, that is, on

the number of the various defects which are present. The decision as to the

degree the defects present affect the appearance and eating quality of the

productmustnecessarilybebasedonexperience with the product and ongood

judgement. Experience can be gained and judgment be improved by checking

samples with supervisors at everyopportunity. This will result in a high degree

of uniformity in rating the factor of defects throughout the inspection service.

Most common and also the most controversial defects inchili sauce is tomato

peel. If hand-peeled tomatoes are used entirely, there is usually very little peel

in the sauce. If the tomato pulp is produced, at least in part, by chili sauce

machines or slow operating pulpers there may be little or there may be a

considerable amount present.

Small bits of rolled up peel are not particularly objectionable unless there is a

considerable number of them. Such material may be so numerous as to

warrant dropping the score to the Grade C or Substandard range. Larger

pieces may be tough and may be quite objectionable, particularly if they are

numerous. In most cases the larger scrolls of peeling are the only ones of any

consequence. Therefore, the following guide considers only pieces of peel

one-half inch or more in the longest dimension. (Rolled up scrolls are not

unrolled for measuring).

a. Guide for Consideration of Peel Only.

The following allowances are guides for the presence of larger pieces

of peel only. In assigning grade and score points the effect of defects

of all types present on the appearance and eating quality of the

product must be considered.
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Minimum Grade A - 3 pieces one-half inch in length or longer, of which

not more than one piece is 3/4 inch or longer, per 2 ounces of chili

sauce.

Minimum Grade C - 3 pieces one-half inch inlength or longer, of which

not more than one piece is 3/4 inch in length or longer, per 1 ounce of

chili sauce.

5. Flavor.

Chili sauce is a formula product and as such the flavor can be adjusted

over a wide range by the use of different ingredients, different

proportions of ingredients, different spices, and different amounts of

sugar and acid. Therefore, all good chili sauces do nottaste alike and

equally competent persons will prefer very different tasting chili

sauces. In order that personal preferences do not affect the scoring

unduely keep in mind that the chili sauce is primarily a spiced and

flavored sweetened tomato sauce and the scoring is based on the

traditionally characteristic flavor associated with this product. With this

concept of flavor in mind the standards will be a satisfactory guide for

assigning the score points for this factor.

6. Limiting Rules for Scoring Factors.

Note that, except for character, scores in the Grade C group limit the

grade of the product to Grade C. The factor of characteris limited only

at the Substandard level. Thus, chili sauce which has only a fairly good

character maybe graded A, provided it meets the other requirements

of this grade. All scoring factors are limited at the Substandard level.

H. Examination for Filth and Extraneous Material.

Before assigning any U.S. Grade to any processed food product every

reasonable effort should be made to be sure that the food is clean and not in

violation of any regulation ofthe Food and Drug Administration. In the case of

chili sauce at least the following analyses are to be made as directed in Part II

of this instruction or other effective interim instructions:

1. Mold counts.
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2. Fly egg and maggot determinations.

3. Insect fragment and other light filth analyses.

(These to be run only if specifically directed or requested or if there is

any question about sanitary manufacture or suitable raw materials).

VII. Certification.

Certification procedure for chili sauce is, in general, exactly as directed in general

instructions on this subject.

A. Tolerances for Concentration.

A refractive index of 1.3784 is a prerequisite to grading a product underthese

standards. Other merchantable tomato sauces are produced at less than

1.3784. However, these are not considered chili sauce for the purpose of these

standards. Chili sauce is difficult to control; therefore, in order not to unduly

penalize a batch which has been dropped too soon, allow the index of any

sample to go to 1.3767 provided the average of all the samples in the lot is

1.3784.

If a product offered for inspection as chili sauce exceeds this tolerance the

proper grade statement would be similar to:

No applicable United StatesStandardforthis product--refractive

index does not comply with requirement for grade standard of

chili sauce.

B. Examples ofProperInformationto Appearin the Body ofthe Certificate.

1. Net weights: 12.0 to 13.4 ounces.

Vacuum readings: 8 to 13 inches.

Refractive index: 1.3788 to 1.3792.

2. Net weights: 12.4 to 12.9 ounces.

Vacuum readings: 8 to 14 inches.

Refractive index: 1.3770 to 1.3795, average 1.3789.