TOMATO KETCHUP, TOMATO PUREE AND TOMATO JUICE
[CODE NO.3409]
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.
COST ESTIMATION
Plant Capacity : TOMATO KETCHUP, TOMATO PUREE JUICE
land & Building (2000 Sq.Mtr) : Rs. 2.89 Cr
Plant & Machinery : Rs. 1.40 Cr
Working Capital for 2 Months : Rs. 97.82 Lacs
Total Capital Investment : Rs. 5.44 Cr
Rate of Return : 20%
Break Even Point : 61%
INTRODUCTION
USES AND APPLICATIONS
TOMATO PUREE CAN BE USED VARIOUS WAYS SUCH AS:-
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
MARKET SURVEY OF PROCESSED TOMATOES
PROCESSED PRODUCTS AND PROCESS
THE INDIAN PROCESSED TOMATO MARKET AND TOMATO SUPPLY CHAIN
LEADING INDIAN TOMATO PASTE MAKERS AND PRODUCT MANUFACTURERS
CURRENT TRENDS
GLOBAL OVERVIEW OF TOMATO AND ITS AVAILABILITY
MOROCCO: TOMATO EXPORTS INCREASED THANKS TO GOVERNMENT
SUPPORT
TURKEY IS CONSIDERING OPENING ITS BORDERS
EU: DECREASING ACREAGE, HIGHER YIELD
THE NETHERLANDS: UNSTABLE MARKET
BELGIUM: LOW PRICES
FRANCE 36
GERMANY WELCOMES TRANSITION TO SPANISH SEASON
UK: LARGEST TOMATO GROWER EXPANDS
MARKET POSITION AND AVAILABILITY OF TOMATOES
TOP 10 KETCHUP BRANDS IN INDIA 2017
BELOW MENTION IS THE LIST OF TOP 10 KETCHUP BRANDS IN INDIA 2017
FIGURE: TRENDS IN INDIA'S TOMATO PRODUCTION
FIGURE: AVERAGE YIELDS OF TOP 10 PRODUCERS
FIGURE: INDIAN TOMATOES - GROWTH IN COVERAGE, PRODUCTION
AND YIELD
TABLE: KEY TOMATO PRODUCING STATES IN INDIA - 2014
TABLE: TOP 10 TOMATO GROWING DISTRICTS IN INDIA ‐ 2013
FIGURE: INDIAN TOMATOES EXPORT TRENDS
FIGURE: TOMATO FARM YIELD LEVELS IN INDIA
FIGURE: AVERAGE ANNUAL PRICES OF TOP TOMATO PRODUCING COUNTRIES
TOMATO PRODUCTION IN KARNATAKA
TABLE: DISTRICT‐WISE TOMATO PRODUCTION IN KARNATAKA ‐ 2013
TOMATO PRODUCTION IN MAHARASHTRA
TABLE: DISTRICT‐WISE TOMATO PRODUCTION IN MAHARASHTRA ‐ 2013
TOMATO PRODUCTION IN ANDHRA PRADESH
TABLE: DISTRICT‐WISE TOMATO PRODUCTION IN ANDHRA PRADESH‐2013
GLOBAL TOMATO PROCESSING MARKET
DETAILED EXPORT DATA OF TOMATO PROCESSING
MANUFACTURERS/EXPORTERS OF TOMATO PROCESSING
COMPOSITION OF TOMATO
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
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
PLANT LAYOUT
SUPPLIERS OF PLANT AND MACHINERY (IMPROTED)
SUPPLIERS OF PLANT AND MACHINERY
ROTARY WASHER
EVAPORATORS
AUTOMATIC POUCH FILLING MACHINES
WEIGHING MACHINE
LABORATORY TESTING EQUIPMENTS
MATERIAL HANDLING EQUIPMENTS
BOILERS
COMPLETE PLANT & MACHINERY SUPPLIERS FOR TOMATO PROCESSING UNIT
SUPPLIERS OF RAW MATERIALS
TOMATOES
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