Any individual can start tomato processing as small and large scale basis. Tomato is a most popular vegetable globally. And people consume tomato in the both raw and processed form. Basically, the tomato is a perishable item. Therefore, the processing enhances the shelf life of the product.
The business is easy to start. Additionally, you can deal with single or multiple value-added items productions.
The scientific name of tomato is Lycopersicum Esculentum. And it belongs to the family Solanaceae. Additionally, tomato ranks second after potato in the world. The major tomato growing countries are China, USA, Italy, Turkey, India, and Egypt.
Americans consume three-fourths of their tomatoes in processed form. U.S. consumption of processed tomatoes began a steady climb that accelerated in the late 1980s with the rising popularity of pizza, pasta, and salsa. Additionally, exports are becoming an important component of the U.S. tomato-processing industry. By itself, California leads the world in the production of processing tomatoes.
Tomato Processing Market Opportunities
Basically, tomato processing includes different types of value-added product manufacturing. These are tomato juice, puree, sauce, ketchup and tomato pulp. Basically, tomato juice and pulp have industrial use along with domestic consumption.
Due to increasing standards of living in the cities and the rapid urbanization in the rural areas, the demand for ready-to-eat items is also growing. Additionally, the changing food habits including the growing fast food industry has created a boost in the demand for processed tomato items.
Another aspect is modern packaging technology. Basically, the Multi-layer- Flexible plastic packaging, Tetrapack, and Brick packing have a tremendous impact on the growth of the processed tomato market. This type packaging allows distributing tomato products to wide, distant and remote areas. In addition, it allows storing the products at room temperature for a period of more than 4 months.
Tomato Processing Business Plan Sample Checklist
In starting the business, you must have a business plan in your hand. Basically, crafting a business plan starts from the market research. According to your location, it is important to have some clear ideas about the demand for the specific items. Additionally, try to identify the established companies in this segment and their products. If you are starting with small start-up capital, it is advisable to start with a single product manufacturing operation.
Registration & Licensing
You must register your business as per the Federal law. Choose the right form of your business according to the ownership and investment pattern. It is advisable to consult with a small business expert to understand the permission and licensing issues. In addition, identify the upcoming tax and compliance liabilities for your business.
Tomato Processing Plant & Machinery
For the manufacturing operation, you must secure a location. However, the requirement of the area depends on several aspects. These are production line, production capacity and the number of finished products. Talk to the machinery suppliers. And have a machinery floor plan from them. In addition, check the available utilities like electricity, water and skilled manpower for the factory operation.
Basically, the machinery requirement depends on the specific product you want to produce. However, here we have compiled a basic list of machinery for your ready reference.
- Steam boiler
- Washing machine (Rotary rod, Washer equipped with spray arrangement, collection tank, etc.)
- S.S. tilting type steam jacketed kettle of cap
- S.S. tilting type steam jacketed Vacuum kettle of cap
- Pulper cap.
- Exhaust and processing tank
- Pasteuriser tank
- Bottle washing machine
- Vacuum filling machine
- Water storage tank cap (HDPE)
- Misc. equipment such as buckets, cutting, and peeling knives, etc.
- Weighing balance
- Crown cork machine
- Weighing Scales platform
- Working Tables
- Laboratory Equipment
- Pollution Control Equipment
Availability of Raw Materials for Tomato Processing
It is needless to say the major required raw material is a full grown tomato. And you must make an arrangement of the regular availability of the raw tomato at your factory. You can have the contract with the tomato growers also. Additionally, you will need to arrange sugar, preservative, salts, and spices for different types of products.
Also Read: Tomato Cultivation Guide for Beginners
Tomato Processing for Juice
First of all, you have to procure fully ripe well-developed color tomatoes for making juice. Then, wash the tomatoes. After trimming and steaming, crush them in a crusher or cut into pieces with knives. Then heat the crushed pieces in the steam jacketed kettle till they become quite soften.
Finally, pass the heated tomatoes through the pulping machine using a fine mesh sieve to separate juice from seeds and the skin. Keep heating to 85-90ºC and add the sugar and salt @ 1%. Finally, fill the hot juice in bottles, seal immediately and sterilize in boiling water for about 30 minutes and cool.
Tomato Processing For Ketchup
Basically, the percentage of the soluble solids in the ketchup varies from state to state. Therefore, you must check the local norms and regulations.
The juice obtained as above is concentrated with spices, salt, sugar, etc. The spices like cloves, cardamom, pepper, cinnamon and other ingredients etc. are tied loosely in a muslin cloth and placed in boiling juice in steam Jacketed Kettle. The sugar, salt, and vinegar or acetic acid, etc. are added later on.
Tomato Processing For Paste & Pulp
To prepare tomato paste and pulp, the juice is further concentrated under vacuum to around 9% to 12% solids. Also, you can prepare tomato powder using different technologies depending upon the end use of the product. Additionally, you can source the tomato processing technology from any reputed Government research institutes.
Tomato Processing For Puree
First of all, obtain the juice obtained as above. Then, concentrate it under vacuum to about 9% to 12% total solids so as to get tomato puree. Finally, fill the product in bottles. Seal the bottles with crown cork and process in boiling water for 30 min. and cool.
Tomato Processing For Sauce
For preparing sauce, you will need to concentrate the juice under vacuum and controlled temperature. In addition, you have to add salt, sugar, vinegar, spices, onion etc as per requirement. Then, boil this mixture under vacuum till it contains minimum 12% tomato solids and 28% total solids. Then pass the sauce through a sieve to remove fibrous and other materials. Finally, cool the material and add the preservative prior to sending it for packing.
Promotion & Marketing
Promotion and marketing are the musts to get the overall success in this business. Additionally, you must pay attention to the packaging. First of all, try to hit the local consumers. And a well-penetrated distribution channel is the best option to capture the local retail market. Additionally, supermarkets and malls are the great places to promote your product. If you are starting the tomato processing at large scale, you can consider export also.