TOMATO PROCESSING
(TOMATO PULP AND SUN DRY PROCESSING)
[CODE NO.3917]
Tomatoes are amongst the most widely grown crop in India. The largest production centers are in southern and central India-Principally the states of Andhra Pradesh, Telangana, Karnataka, Madhya Pradesh and Maharashtra. Tomatoes are produced and processed during the two main seasons across much of India-August to October (Kharif) and December to April (rabi). Where conditions suit, tomatoes are also grown during the off-season (May to July) including under protected cultivation though given the low volumes of production, prices are often the highest during this period.
India is the world’s second largest tomato producer but processes less than 1% of its production. This impacts farmers by way of high postharvest losses and low returns during periods of market glut. Indian tomato based product manufacturers import significant quantities of tomato pulp and paste at high prices which also entails an import duty of 30%. Existing Indian paste and pulp makers are unable to operate their units at optimum capacities due to a lack of fresh tomato at the required volumes at the right price. Further, the types of tomatoes currently grown in India are generally less suitable for processing due to their low quality parameters for paste and pulp production. The overall result of these constraints is a loss of value to all stakeholders involved with tomato production and processing and its wider impact on local and regional economic development.
COST ESTIMATION
Plant Capacity 6250 Kgs/day
Land & Building (4000 Sq.Mtr) Rs.2.81 Cr
Plant & Machinery Rs. 2.03 Cr
Working Capital for 1 Month Rs. 78.67 Lac
Total Capital Investment Rs. 5.81 Cr
Rate of Return 46%
Break Even Point 49%
INTRODUCTION
USES AND APPLICATIONS
TOMATO PUREE CAN BE USED VARIOUS WAYS SUCH AS
(I) TO MAKE TOMATO JUICE
(II) TOMATO KETCHUP MAKING
(III) TOMATO SOUP
(IV) TOMATO CHUTNEY
(V) TOMATO COCKTAIL
RAW MATERIALS
HARVESTING SEASONS OF TOMATO IN INDIA
HARVESTING SEASON OF CROP IN LEADING STATES
ARRIVAL PATTERN IN MARKET
(A) CONCENTRATED POCKETS
(B) CATCHMENT AREAS OF MARKET
COMMERCIAL TOMATO VARIETIES POPULAR WITH FARMERS
IN KARNATAKA AND MAHARASHTRA
SEASONAL IMPLICATION IN TOMATO PROCESSING
B.I.S. SPECIFICATION
FOLLOWING ARE THE INDIAN STANDARDS AVAILABLE ON TOMATO PRODUCTS.
FOR MORE INFORMATION CONTACT AT:
GLOBAL OVERVIEW OF TOMATO AND ITS AVAILABILITY
MOROCCO: TOMATO EXPORTS INCREASED THANKS TO
GOVERNMENT SUPPORT 25
TURKEY IS CONSIDERING OPENING ITS BORDERS
EU: DECREASING ACREAGE, HIGHER YIELD
THE NETHERLANDS: UNSTABLE MARKET
BELGIUM: LOW PRICES
FRANCE
GERMANY WELCOMES TRANSITION TO SPANISH SEASON
UK: LARGEST TOMATO GROWER EXPANDS
ADVANTAGE OF SUN DRIED TOMATOES
MARKET OVERVIEW OF TOMATO PUREE
HEALTH BENEFITS OF SUN DRIED TOMATOES
SUN DRIED TOMATOES PROVIDE THESE NUTRITIONAL BENEFITS:
TYPES OF TOMATO PLANT
TOP 10 KETCHUP BRANDS IN INDIA
FIGURE: AVERAGE YIELDS OF TOP 10 PRODUCERS
FIGURE: INDIAN TOMATOES - GROWTH IN COVERAGE,
PRODUCTION AND YIELD
GLOBAL TOMATO PROCESSING MARKET
DETAILED EXPORT DATA OF TOMATO PROCESSING
MANUFACTURERS/EXPORTERS OF TOMATO PROCESSING
COMPOSITION OF TOMATO
VITAMINS
METHOD OF TOMATO JUICE EXTRACTION
MANUFACTURING PROCESS
THE VARIOUS STAGES ARE AS FOLLOWS
EFFECT OF STORAGE ON THE COLOUR AND SENSORY ATTRIBUTES
OF TOMATO PUREE
MATERIALS AND METHODS
PROCUREMENT OF MATERIAL
HOT WATER BLANCHING
STEAM BLANCHING
MICROWAVE BLANCHING
MANUFACTURING PROCESS IN DETAILED
TOMATO PRODUCTS
TOMATO JUICE
WASHING THE TRIMMING
CRUSHING
PULPING
HOT PULPING
EXTRACTION OF JUICE
CONTINUOUS SPIRAL PRESS
COLD PULPING
TOMATO PUREE
PREPARATION
PULP CONCENTRATION
OPEN COOKERS
VACUUM PAN
PULP CONSISTENCY
METHOD- 1
METHOD - II
THE END POINT
PACKING
TOMATO PASTE
QUALITY CONTROL
PROCESS FLOW DIAGRAM FOR TOMATO PUREE
PREPARATION OF TOMATO DRYING METHOD
A. TO DRY OUTDOORS
B. TO DRY IN A DEHYDRATOR OR CONVECTION OVEN
DETAILS OF TOMATO DRYING (SUN DRYING)
PROCESS OF MAKING CHOPPED SUN DRIED TOMATOE
MANUFACTURING PROCESS OF SUN DRIED TOMATOES
PROCESS FLOW DIAGRAM OF SUN DRIED TOMATOES
SUN DRIED PROCESS FLOW CHART
PROCESS FLOW DIAGRAM FOR TOMATO PROCESSING
MANUFACTURING PROCESS OF TOMATO KETCHUP
DEVELOPING QUALITY TOMATOES & PREPARATION
PULPING
ADDING INGREDIENTS AND COOKING
FINISHING
REMOVING AIR
FILLING
COOLING
LABELING AND PACKING
PROCESS FLOW DIAGRAM FOR TOMATO KETCHUP
TECHNICAL ASPECTS FOR TOMATO PROCESSING
TOMATO JUICE
TOMATO PUREE
TOMATO KETCHUP
FPO SPECIFICATION
OPERATION IN TOMATO PROCESSING UNIT
TOMATO PROCESSING FOR JUICE
TOMATO PROCESSING FOR KETCHUP
TOMATO PROCESSING FOR PULP
TOMATO PROCESSING FOR PUREE
TOMATO PROCESSING FOR SAUCE
LICENSE & REGISTRATION REQUIRE FOR TOMATO PROCESSING UNIT
LEADING TOMATO PRODUCING COUNTRIES
TOMATO GROWING STATES IN INDIA
COUNTRIES FROM PUREE IS IMPORTED IN INDIA
TYPE OF TOMATO USED FOR TOMATO PUREE IN INDIA
VARIETY OF TOMATOES
SUPPLIERS OF PLANT AND MACHINERY (IMPROTED)
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF ROTARY WASHER
SUPPLIERS OF EVAPORATORS
SUPPLIERS OF AUTOMATIC POUCH FILLING MACHINES
SUPPLIERS OF WEIGHING MACHINE
SUPPLIERS OF LABORATORY TESTING EQUIPMENTS
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF BOILERS
COMPLETE PLANT & MACHINERY SUPPLIERS FOR TOMATO
PROCESSING UNIT
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF TOMATOES
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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