TOMATO PRODUCTS - DCMSME

1 TOMATO PRODUCTSPRODUCT CODE: 202402002 QUALITY AND STANDARDS: As per Fruit product Order (FPO),1955 and PFA,Act ISI Specification are: TOMATO JuiceIS 3881 : 1966 TOMATO Ketchup IS 3882 : 1966 TOMATO PureeIS 3883 : 1966 PRODUCTION CAPACITY: Quantity (per annum): TOMATO Juice24,000 Puree24,000 Ketchup 60,000 KgValue : Rs. 48,72,000 MONTH AND YEAR: May, 2003OF PREPARATIONPREPARED BY: Small Industries Service Institute34, Industrial Estate, Nunhai,Agra-282006 Phone No. : 2240545,Fax : (0562) 2240544, 2146122 INTRODUCTIONT omato, though botanically a fruit forthe purpose of trade, is generallyconsidered a vegetable because of theway in which it is consumed. Tomatoesare widely grown in all parts of the , the yield per hectare is thehighest (245 tonnes/hect.) inNetherlands. The world average yield oftomato is 23 tonnes per hectare. Indianaverage yield of TOMATO is tonnesper hectare.

2 TOMATO PRODUCTS such aspuree, juice, ketchup are commonlyused commodities in households, hotelsand restaurants. These items are usedto enhance the taste of different foodproducts. TOMATO puree is used as asubstitute of fresh TOMATO in is a sweeter and diluted versionof puree(Pulp). TOMATO sauce tastessweet and sour. Both sauce and ketchupare consumed with food and is a valuable raw material usedfor processed PRODUCTS such as juice,puree, and paste, ketchup/sauce, andcanned whole. The recent scientificadvances have revolutionised tomatoprocessing project profile has been preparedfor production of TOMATO Juice, TomatoKetchup and TOMATO POTENTIALDue to increasing standards of livingin the cities and the rapid urbanizationtaking place in the rural areas,24138consumption of TOMATO based productsis expected to go up steadily. At present,the market of ketchup/puree, speciallyin the urban areas, is dominated bybrands likes MEGGI and KISSAN.

3 SomeMedium and Small Companies are alsoengaged in its production. Estimatedproduction of Sauce/Ketchup etc. inNorth India was around 4000 MT in1995. The estimated demand for theproducts for the same period was 10000MT which is expected to grow upto12000 MT by 2005 AD. Thus presenceof a demand supply gap of 6000 MT canbe observed which may reach a figureof 8000 MT in 2005 AD. Thus there isample scope for a unit to come up inthis product sector to cater especiallyto the semi urban and rural sectors ofnorth India. TOMATO processing in Indiais still not very significant. Recently, therewas a steady rise in production due tothe entry of multinationals with bettermarket infrastructure and salespromotion high fluctuation in market pricesof fresh tomatoes in the urban market,there are good prospects for tomatojuice, and TOMATO puree in place of freshtomatoes in household sector. Besidesthe boom in the food service sectorincluding fast food chain, has widenedthe demand potential for tomatoketchup and have shown thatadvertisement and publicity haveinfluenced the pattern of consumptionof TOMATO PRODUCTS .

4 Besides, tomatoproducts have good export potentialespecially in the Middle AND PRESUMPTIONS1. The Project Profile has beenprepared on the basis of singleshift of 8-hrs. a day and 25-working days in a month at 75% It is presumed that in the Ist year,the capacity utilization will be 70%followed by 85% in the next yearand 100% in the subsequent Depreciation on machinery andequipments has been taken @ 10%.Depreciation on office furniture hasbeen taken @ 20% per The rates given for salaries andwages for skilled workers andothers are on the basis of theminimum rates in the State of Interest rate for the fixed andworking capital has been taken @14% on an average whetherfinanced by the bankers or The margin money required isminimum 30% of the total The rental value for theaccomodation of office, workshopand other covered area has beentaken @ Rs.

5 20/- per Sq. The rates for machinery, equipmentand raw materials are thoseprevailing at the time of preparationof the project profile and are likelyto vary from place to place andsupplier to supplier. When a tailormade project profile is prepared,necessary changes are to be The pay back period may be 5-years after the initial gestation The gestation period inimplementation of the project maybe to the tune of 6 to 9 monthswhich includes making allarrangements, completion of allformalities, market surveys and tie-ups etc. Once all the aboveTOMATO PRODUCTS139arrangements are made andquality/standards achieved, 100%project capacity may be achievedat the end of three To run the unit throughout the year,other fruit PRODUCTS such assquashes and juices can beprepared with addition of a fewmachinery and SCHEDULEThe implementation of the projectincludes various jobs/exercises such asprocurement of technical know how,transfer of technology, market surveysand tie-ups, preparation of projectreport, selection of site, registration,financing of project, procurement ofmachinery and raw materials etc.

6 ,recruitment of staff, erection/commissioning of machines, trialproduction and commercial productionetc. Project implementation will take aperiod of 8 months from the date ofapproval of the scheme. Break-up ofactivities, with relative time for eachactivity is shown below:Activity Period(In Months)1. Scheme Preparation0-1 monthand approval2. SSI Provisional1-2 monthsRegistration3. Sanction of loan and2-5 monthsFPO licence Clearance from State3-4 monthsPollution Control Board5. Placement of order for4-5 monthsmachinery and delivery6. Installation of machines6-7 months7. Power Connection6-7 months8. Trial run7-8 months9. Commercial Production 9 monthsonwardsTECHNICAL ASPECTSP rocess of ManufactureSpecial varieties of tomatoes likescarlet globe, early red bonny best,pondrosa, seoux, pasaruby, marglobe,etc. are suitable for preparation ofprocessed PRODUCTS of JuiceFully ripe well developed colourtomatoes are washed, trimmed,steamed, crushed in a crusher or cutinto pieces with knives.

7 The crushedpieces are heated in the steam jackettedkettle till they become quite soften. Theheated tomatoes are passed through thepulping machine using a fine mesh sieveto separate juice from seeds and theskin. The sugar and salt @ 1% is addedand heated to 85-90 C. The hot juice isthen filled in bottles, sealed immediatelyand processed sterlised in boiling waterfor about 30 minutes and PureeThe juice obtained as above isconcentrated under vacuum to about9% to 12% total solids so as to gettomato puree. The product is filled inbottles, crown corked and processed inboiling water for 30 min. and KetchupThe juice obtained as above isconcentrated with spices, salt, sugar,etc. The spices like cloves, cardamom,pepper, cinnamon and other ingredientsetc. are tied loosely in a muslin clothand placed in boiling juice in steamJacketted Kettle. The sugar, salt andTOMATO PRODUCTS140vinegar or acetic acid, etc.

8 Are addedlater concentration is done three-fold. It is concentrated to 28 to 30%solids in which 12% are TOMATO final product could be preserved byaddition of sodium benzoate @ 750ppm. The TOMATO ketchup is filled hotinto clean, dry bottles, crown corked andprocessed in boiling water for 30 minutesand cooled at room Control and StandardsThe manufacture of processed fruitsand vegetables is controlled by the FruitProducts Order (FPO), 1955 of the India. The Fruit PRODUCTS Order, 1955is mandatory for TOMATO PRODUCTS . Thetomato PRODUCTS should conform tospecifications laid down in FPO specifications are as follows:i) TOMATO Juice: 5% total ) TOMATO Puree: 9% total Benzoate 250 ppmiii) TOMATO Ketchup: 25% total : Sodium Benzoate:750 ppmThe Bureau of Indian Standards haslaid down the following specifications fortomato PRODUCTS :i) TOMATO Juice: IS:3881 ) TOMATO Ketchup: IS:3882 ) TOMATO Puree: IS:3883 in this era, the entrepreneurs mayadopt HACCP and ISO ControlThere is no major pollution problemassociated with the project.

9 However,material waste (skin, seeds, etc.) are themain effluents for which the provisionof treatment has been made in theprofile. The entrepreneurs may however,contact the concerned State PollutionControl Board for detailed guidance inthe matter. Minimum height of shed willbe maintained and exhaust fans shouldbe installed for removing congestionwith proper ventilation, removal of cokesfumes etc. are to be maintained as perFPO for Final ProductSoupKetchupSauceTomato Juice (Hot)2 5 Kg10 (chopped)20 gm. 100 (chopped)2 Clove1 Cardamom1 Pepper1 gm. 583 gm. 748 Chilli Powder2 Acetic Acid4 gm. Batch Weight1 Kg. Capacity (per annum) TOMATO Juice24,000 Puree24,000 Ketchup60,000 48,72,000 Motive Power15 ConservationThe following steps may be taken forthe conservation of energy: TOMATO PRODUCTS1411. Machinery and equipment parts,which are revolving andreciprocating should be properly,lubricated from time to time withsuitable lubricant Layout of the unit should be insuch a way that no back trackingof material is All electric switches may beturned off, when not The entire transmission belt willbe tightened before starting thework wherever As far as possible solar energy andday light will be used keeping allthe other lights As far as possible inductive loadof motor will be reduced and highpower factor be used with the aidof capacitors of appropriate ASPECTSA.

10 Fixed Capitali) Land and BuildingAmount(In Rs.) Land and Building (rented)3,000 @ Rs 20 Sq. meter Covered Area 150 Sq. metersii) Machinery and EquipmentSl. (In Rs.)(a) Production Unit1. Steam boiler 150 ,20,0002. Washing machine (Rotary rod190,000 Washer equipped with sprayarrangement, collection tank,etc.) with 10 HP motor3. tilting type steam jacketted160,000kettle of cap. 100 gallons4. tilting type steam170,000jacketted Vacuum kettle of gallons5. Pulper cap. 1/2 ton per hr. with140,0003 HP motorSl. (In Rs.)6. Exhaust and processing tank125,0007. Pasteuriser tank (500 lit. cap.)115,0008. Bottle washing machine with two115,000heads complete with 1/4 HP motor9. Vacuum filling machine118,000(cap. 10 to 15 bottles/minute)10. Water storage tank cap. 500 (HDPE)11. Misc. equipment such as buckets, ,000cutting and peeling knives, Weighing balance 500 gm15,000to 5 kg capacity13. Crown cork machine13,00014.