We can setup tomato processing plant on turnkey basis where fresh tomatoes will be processed to manufacture tomato puree/ketchup, tomato concentrate and tomato paste. Plant comprises following sections: Reception section: Fresh tomatoes would be received at reception section and passed on to the fruit washing and grading section. Tomatoes from reception will be washed in washing section to remove outer dirt and foreign matter from the fruit skin. Washed tomato would be fed to the inspection cum sorting conveyor where unwanted, damaged tomatoes would be separated out manually. Major Equipments: Infeed conveyor, tomato washer, sorting table Processing and Juice Extraction section: Washed & graded tomatoes would be passed on to the fruit juice extraction and processing unit. From fresh tomatoes the juice will be extracted out in juice extraction system. The outer skin, seed and fiber of fruits would be separated out from extraction machine and then disposed manually. Extracted juice is passed to the heat treatment to avoid the quality degradation. Again it is fine pulped in pulper cum finisher to get finished juice. This juice will go for further processing to juice concentrate to concentrate it to 12 Brix for tomato puree, 14 Brix for tomato ketchup or 28-30 Brix for tomato paste. Major Equipments: Tomato juice extractor, receiving tank, transfer pump, Pulp preheater(Shell & tube heat exchanger), Pulper cum Finisher, Receiving tank, Transfer pump, Juice storage cum balance Tank Evaporation section: In concentration section, tomato juice with 5 brix would be concentrated to 12, 14, or 30 brix in multiple effect vacuum evaporators. This will be two effect rising film type evaporation plant. Feed is received in a level controlled balance tank and fed to the 1st effect calandria for evaporation. Calandrias are shell and tube type vertically arranged heat exchangers. Preheated fruit juice is pumped by recirculation pump through the bottom of the calandria tubes with high velocity from down to upward. Dry saturated steam/vapour is supplied as heating medium in the jacket which causes high heating of juice through the tubes. The high heated juice enters the Vapour liquid separator located at the side top of calandria. Vapour separator unit is maintained under vacuum conditions so as to evaporate water by flash evaporation in vapor separator. Vapors generated are separated in 1st vapour separator and passed in the jacket of 2nd calandria as heating medium. Part of vapors would be used as heating medium for the attached pre-heater. Concentrated product from 1st effect is fed to inlet of calandria of 2nd effect. It then passes through all the effect to meet its final required concentration. Product with desired solid content from last effect is taken out. Vapours from last effect are condensed in surface condenser. All the evaporation effects operate under vacuum maintained by vacuum pump/system. This juice is concentrated in the evaporator upto 30 brix for paste. At this concentration, juice is converted into paste. Then the concentrated paste is blended and pasteurized. Pasteurized paste is transferred to a paste storage tank. Major equipments: 2 Effect Forced Circulation Vacuum Evaporator (Balance Tank, Graduated Flow Control Valve, Feed pump, Calandria, Vapour Separator, Condenser, Concentrate Recirculation Pump, Concentrate discharge Pump, Condensate Pump, Vacuum Pump, Vapour Duct, SS Pipes and Fittings, Seal Water Tank, Steam Supply System, Service Water Line, Control panel), 1 Effect scrapped surface evaporator for tomato paste (BALANCE TANK FOR FEED, FEED PUMP, GRADUATED FLOW CONTROL VALVE, SCRAPPED SURFACE HEAT EXCHANGER, CONDENSER, VACUUM PUMP, VAPOUR DUCT, SS PIPES AND FITTINGS, CONDENSATE PUMP, PRODUCT DISCHARGE PUMP, Control Panel) For packing paste requires special packing due to their low shelf life. Ketchup has higher shelf life as it has sugars and spices. Ketchup Preparation Section: For ketch up, the juice is concentrated to 12-14% TS and then it is mixed with sugar solution and all spices. Then the ketch up is pasteurized and then allowed for packing. Major equipments: Sugar dissolving vat, Sugar solution transfer pump, Inline filter, Blending tank, Screw pump, Paste Pasteurizer, Balance tank, Transfer pump (Lobe Type), Buffer tank (insulated) Utility Section: Steam Boiler with Water softener, Cooling Tower, pump & piping, Air compressor, Effluent Treatment Plant, Boiler Chimney, All service pipelines Packing Section: GLASS BOTTLE PACKING FOR TOMATO PUREE/KETCH-UP (Rotary Bottle Washing Machines, Inspection Conveyor (Semi-Automatic), Twin/Four Head Liquid Filling Machine for Ketch-up, Bottle Crowning and Sealing Machines (Automatic), Labeling Machine (Automatic) CAN PACKING FOR PASTE/CONCENTRATE (HOT FILLING Screw Pump, Can body reformer, Can Flanger, Can bottom seamer, Semi Automatic Filling Machine, Can top seamer (Stationary Type), Lid embossing machine, Vacuum Tester, Canning Retorts, Steam Lines, Can Conveyor, Sticker Labeling Machine, Labeling Table) Total Cost of Plant & Machineries: Complete plant designed to process fresh tomatoes (500 kg per hour) and to manufacture and pack tomato puree (187.5 kg per hour), tomato ketchup (161 kg per hour) and tomato paste (80 kg per hour) could cost around INR 25.00 million including utility and packing machines. How we could serve you? Detailed Process Flow along with quotations of related machines, quotations of other equipments, Detailed Project Report, Layout & Construction Cost Estimate and related documents for sanction of project can be prepared as ‘original piece of work’. Such documents cannot be standardized for every client. We prepare above documents according to the unique needs of client. Admissible subsidy from MOFPI is 25% subject to maximum amount of INR 5 million.