Detailed Project Report on tomato processing unit

TOMATO PROCESSING UNIT
(CODE NO. 3071)


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.

On the other hand, the demand in India for processed tomato products has been growing at an annual rate of about 30% over

the past 3 years. Further, the range of processed tomato foods is also expanding with the introduction and demand for

several ready to eat meals, curries and snack products finding favor with the Indian consumer. As a result, new tomato

processing facilities are being established by both existing and new entrants into the Industry. Recognizing the tomato and

paste supply chain constraints, several are taking steps to either establish local paste production themselves or partner

with paste production intermediaries to enhance and sustain local supplies. The critical challenge for these processors is

the availability of sufficient volumes of fresh tomatoes meeting processing quality standards on a consistent basis and at a

price point which makes processing viable.

The German Government’s “Green Innovation Centre in the Agri-Food Sector” (GIAE) which focuses on improving the India tomato

value chain with a focus on two states, Maharashtra and Karnataka provides a platform to examine, test and scale up value

chain improvements to particularly address supply chain constraints which could benefit both farmers and processors.

Tomato is one of the most important food crops in India. It grows in almost every state of the country. Some of the major

producing states are Bihar, Karnataka, Uttar Pradesh, Orissa, Andhra Pradesh, Maharashtra, Madhya Pradesh and West Bengal.

Tomato is a rich source of vitamins A, C, potassium, minerals, and fibers. Tomatoes are used in the preparation of soup,

salad, pickles, ketchup, puree, sauces and also consumed as a vegetable in many other ways. As the raw material is available

throughout the country, a small scale tomato processing unit is a profitable venture in India.

Large scale tomato processing includes various operations like producing tomato juice, ketchup, puree etc.

Tomato processing unit/Tomato Puree is the name implies to tomato Pulp which is concentrated by the evaporators either open

pan or vacuum evaporators.

It is prepared by concentrating tomato juice or pulp without seeds and skin. It is used for preparation of various products

such as Sauces, Ketchup, Chutney, Soup, Tomato Juice.

Tomatoes are taken, which are well-ripened.  So the fresh ripen tomatoes are very refreshing and appetizing.  they are good

source  of vitamin. The main tomato producing states are A.P., Bihar, M.P. Punjab, Tamil Nadu, West Bengal and Maharashtra.  

Two varieties of tomatoes are available in India then are the large round  ones which are quite sour and the tongish type  

which  are sweetish and less sour.  Most of the tomato products are prepared from tomato pulps, which is unflavored, finely

divided flesh and juice separated from skins and seeds. It is usually concentrated to a greater or less degree before used

in other products.

Results of this work are evidence by a large number of articles, patents and commercial installation for conc. of fruits and

vegetable juices or pulps.  Possible savings in packaging, storage, transportation and convenience in certain  instances,

account  for the continued interest in commercial development  of products.   It  is  evident, however,  that  the  present  

trends towards ready to use desserts and other formulated food  products and  much  to  the commercial possibilities of  

tomato  conc  and pulps


COST ESTIMATION

Plant  Capacity                              :       2.00 TON/day
Land & Building (600 Sq.MT)    :    Rs. 68.00 Lacs
Plant & Machinery                        :    Rs. 60.00 Lacs
Working Capital for 2 Months    :    Rs. 59.17 Lacs
Total Capital Investment             :    Rs. 1.94  Cr
Rate of Return                              :    31%
Break Even Point                         :    56%

INTRODUCTION                                            
USES AND APPLICATIONS                                    
RAW MATERIALS                                            
B I S  SPECIFICATIONS                                        
OVERVIEW OF TOMATO IN INDIA                                
MARKET POSITION                                        
MANUFACTURERS/EXPORTERS OF TOMATO PROCESSING                
COMPOSITION OF TOMATO                                    
MANUFACTURING PROCESS                                    
EFFECT OF STORAGE ON THE COLOUR AND SENSORY ATTRIBUTES OF TOMATO PUREE                                
MATERIALS AND METHODS                                    
MANUFACTURING PROCESS IN DETAILED                        
TOMATO PUREE                                            
QUALITY CONTROL                                        
PROCESS FLOW DIAGRAM FOR TOMATO PUREE                    
PROCESS FLOW DIAGRAM FOR TOMATO PROCESSING                
MANUFACTURING PROCESS OF TOMATO KETCHUP                    
PROCESS FLOW DIAGRAM FOR TOMATO KETCHUP                    
TECHNICAL ASPECTS FOR TOMATO PROCESSING                    
OPERATION IN TOMATO PROCESSING UNIT                        
LICENSE & REGISTRATION REQUIRE FOR TOMATO PROCESSING UNIT        
SUPPLIERS OF PLANT AND MACHINERIES                        
COMPLETE PLANT & MACHINERY SUPPLIERS FOR TOMATO            
PROCESSING UNIT                                        
SUPPLIERS OF RAW MATERIALS                                


APPENDIX – A:

 1.      COST OF PLANT ECONOMICS  
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET