Tomato Paste

PRE-FEASIBILITY STUDY

TOMATO PASTE PLANT

Pakistan Horticulture Development & Export Board Ministry of Commerce, Government of Pakistan 126 Y, Commercial Area, Phase III, DHA, Lahore

Feasibility study for Tomato Past Plant

1. INTRODUCTION

Agriculture Agriculture sector is the backbone of Pakistan’s economy employing about 45 % of the work force. Nature has blessed Pakistan with an ideal climate for growing a large variety of vegetables and fruits. According to rough estimates about 30%-40% of vegetables/fruits are wasted due to negligence and lack of cold chain / processing facilities, which could convert them into non-perishable form, permitting its transportation and storage without wastage. With the spread of education, change in habits of populace, growth in working women force and increase in per capita income & urbanization, the demand for processed vegetable/fruit products is increasing progressively. Tomato Outlook Tomato is a rich source of vitamin A & C and is cultivated over vast area of land in the world. It has its origin from Themistition, city of Mexico where it was named as Tomatile. Then its cultivation started in Central America and subsequently shifted to Europe. In Indo-Pak sub continent, its utility is growing year by year resulting into more demand/cultivation. It is popular due to its color, taste & food value. Tomato has long been processed into Ketchup in Italy, Turkey, Greece, USA and European countries. It is used in large quantity at household and restaurants in the shape of tomato juice, tomato puree and paste. These products are also gaining popularity in Pakistan. Tomato, like other vegetables/fruits is a perishable commodity and has a shorter shelf life in normal temperature. Therefore, problems are faced in the supply chain due to non-existence of a cold chain system in the country which results in losses of product and drastic price variations. Tomato Paste provides a way out with extremely positive outcome both commercially and financially. Indeed, tomato consumption by the food processing industry revolves around the availability of user friendly intermediate products like tomato paste, puree, ketchup and sauces. Products, such as tomato paste/puree have potential demand with local fruit/vegetable processors as well as the retail market. Establishment of tomato processing facilities in the country can contribute in reducing the dependence of local industry on imported tomato paste. The paste is currently being imported mainly from China, Iran and Turkey. About 2,400 tons of tomato paste was imported during the year 2005-2006. In Pakistan, 1 PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD

Feasibility study for Tomato Past Plant

business opportunities in processing of vegetables and fruit products are yet to be fully exploited. Opportunity Rationale Vegetables/Fruits processing industry, in general, is showing signs of healthy growth with expanding product range and increased acceptability in the local market. Favorable natural environment, increasing population, rising demand for processed vegetables and fruits, and relatively lower labour cost are some of the factors that can contribute towards sustained growth rate in this particular sector. Tomato is one of the most popular vegetables in the world. The derivatives of tomato like paste, juice, ketchup, etc. are widely used in kitchens all around the world. With the increasing affluence of the world, its demand has increased very rapidly resulting in wide scale development of tomato industry for production of tomato paste/puree. Rise of the fast food industry in the country is also having a significant impact on the demand for tomato and fruit products. It is expected that this trend will continue in the near future and the consumption of tomato will increase. Tomato ketchup industry is just another example of the success for the Pakistani companies which grew from its very humble beginning to the position of a player in the league. The future also looks very bright with developing local and export markets around. Per capita consumption is still very low as compared to developed countries. For example, US consumption of tomato paste per capita is 30 kg per year, EU countries consume 15 kg per capita, and Turkey consumes 1 Kg Per capita. As compared to these figures, per capita consumption in Pakistan is negligible. It shows that there is still big potential for demand from the local market, which is expected to rise with the passage of time. Economic Size of Plant A tomato paste and pulp processing plant can be designed with a wide range of optimal processing capacity and product mix. However, it is suggested that the smallest viable economic processing unit should have 3 tons of tomato processing capacity per hour. Processing plant used for the purpose of this study will have annual processing capacity of 10,800 tons of tomato yielding 2,160 tons of tomato paste. The proposed plant will however, be capable to process upto 5 tons of tomato per hour.

2 PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD

Feasibility study for Tomato Past Plant

2. RAW MATERIAL

Raw Material Requirements The raw materials required for a tomato processing unit are: · ·

Fresh Tomatoes. Preservative including Glacier Citric Acid, Potassium Met bisulphate or Sodium Benzoate.

Packaging Requirements Packing requirements for the end consumers are: · · · ·

Retail Customers: Tin Packs, Pouch Packs and Glass Bottles Processors: Large Plastic Containers Hotel Industry: Large Tin Packs, Plastic Drums Aseptic pack in drums for foreign processors/bulk consumers

In the initial stage, the unit will start with bulk supply to processors/ hotel industry and would gradually move into retail sales. Export markets would be explored in later stage.

Availability of Raw Material Small-scale farmers and wholesale market commission agents in vegetable & fruit markets are the major suppliers of raw material in the local processing industry. Tomato (the primary raw material), salt, preservatives etc. (secondary raw materials) are available locally. Metal containers, pouches and glass bottles (Packing material) are also available locally. Aseptic packs are normally imported and cost very high. Aseptic packing is used for obtaining long shelf life for products without preservatives and is used for export purposes.

3 PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD

Feasibility study for Tomato Past Plant

Availability Period of Tomato in Pakistan The data regarding availability period of tomatoes in Pakistan, is given in the following table: ·

Tomato Crop Calendar

Season

Date for release of crop

Kharif Rabi

Ist February Ist August

Provinces / Months

JAN

FE B

MA R

APR

MA Y

JUN

JUL

AUG

SEP

OCT

NOV

DEC

Baluchistan (Kharif) Baluchistan (Rabi) Sind Punjab N.W.F.P.(Kharif) N.W.F.P.(Rabi)

Production/Price of Tomatoes Following table shows the province wise and overall yearly production of tomatoes in Pakistan. Year 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06

Punjab 60,752 62,226 65,199 63,956 63,710 64,588

Sind NWFP Baluchistan Production of Tomatoes (Tones) 32,930 139,993 35,080 32,838 146,207 52,841 35,011 148,274 57,806 35,722 157,495 155,613 33,968 146,871 181,660 48,326 161,599 193,633

Pakistan 268,755 294,112 306,290 412,786 426,209 468,146

% Increase 9.43 4.14 34.77 3.25 9.84

(Source: Ministry of Food Agriculture & Livestock’s)

Pakistan produced 468,146 tons tomatoes in 2005-06 which was 75 % more than the production in the year 2000-01. The growth in tomato production was normal till year 2002-2003. But there was un-precedented increased of 35 % during 2003-04 as compared to the last year. The main reason behind this was the extra ordinary production of tomatoes in Baluchistan, as.it produced almost three times more tomatoes than the last 4 PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD

Feasibility study for Tomato Past Plant

year’s production. In 2005-2006, out of total tomato production, 41% was in Balochistan, 35 % in NWFP, 14 % in Punjab and 10 % in Sind. Tomato is cultivated throughout the Pakistan. Previously N.W.F.P. was the main tomato growing province which used to contribute nearly 50% of total national production up till 2003-04. Since 2004-05, Balochistan province is the leading producer of tomato in Pakistan. The share of Balochistan’s production has increased from 13 % in 2000-2001 to 41 % in the year 2005-2006. The main reasons are the growth in the development of agriculture-able area, development of agricultural infrastructure, availability of water and favourable Government policies. Following tables shows the yearly average prices of tomato that prevailed in the country. Yearly Average Tomato Price (Rs.)/40 kg Year

Punjab

Sind

NWFP

Balochistan

2000-01 2001-02 2002-03 2003-04 2004-05 2005-06

412.08 515.33 348.25 574.83 729.80 556.08

313.83 299.42 188.17 371.92 423.70 365.10

435.50 400.75 304.42 481.67 715.10 475.50

405.08 437.17 295.08 516.33 634.50 466.90

(Source: Ministry of Food Agriculture & Livestock’s)

The price of tomato is lowest in the province of Sind followed by the province of Balochistan while it is highest in Punjab. Lower price in Sind is due to the consumer behavior and supply factor as tomato from whole of the Pakistan is sent to Karachi (Sind) being a main consumption hub of agriculture produce due to concentrated population. Top ten tomato producing districts of Pakistan for the year 2005-06 District Killa Saifullah Swat Nasirabad Barkhan Badin Jaffarabad Malakand Tank Dir Lower Mohmand Agency

RANK* 3 8 1 2 10 6 7 5 4 9

Province

Hectares

Tonnes

Tonnes/ Hectare

Balochistan NWFP Balochistan Balochistan Sindh Balochistan NWFP NWFP NWFP NWFP

6,488 5,752 1,569 1,605 3,520 1,340 1,070 835 772 1,220

85,473 65,374 27,918 22,187 20,876 15,990 12,553 10,430 10,073 8,545

13.17 11.37 17.79 13.82 5.93 11.93 11.73 12.49 13.05 7.00

%age of Total Production 18.26 13.96 5.96 4.74 4.46 3.42 2.68 2.23 2.15 1.83

*Rank with respect to yield 5 PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD

Feasibility study for Tomato Past Plant

The above data shows that amongst top ten (10) districts, four (4) districts of Balochistan contribute 32 % towards the national production of tomato. While NWFP has five (5) districts which contribute 23 % towards the national production of tomato. On the other side, Sind has only one (1) district which contributes 4 % towards the national production of tomato. It is evident from the above that Balochistan is producing the highest tomato crop in Pakistan. Secondly, it has the second lowest tomato price in Pakistan. These factors make it feasible and tempting to install tomato paste plant in Balochistan. Tomato in Balochistan Tomato is one of the major cash crops of Balochistan. In the year 2005-06 it produced 5.5 times more tomato than was being produced in 2000-01, thus contributing 41% towards national production as compared to 13 % in 2000-01. The following table shows the district-wise production of tomatoes in Balochistan in the year 2005-06. District-wise Tomato Cultivation, Production & Yield in Balochistan for the Year 2006 Production Yield %age to Total District Area (Hectares) (Tones) (Tons/Hectare) Production

Quetta

251

2,693

10.73

1.39

Pishin

758

6,090

8.03

3.15

K. Abdullah

44

354

8.05

0.18

Chagai

40

308

7.70

0.16

Loralai

284

2,656

9.35

.37

40

435

10.88

0.22

1,605

22,187

13.82

11.46

25

205

8.20

0.11

6,488

85,473

13.17

44.14

150

2,373

15.82

1.23

Musa khail Barkhan Zhob Killa Saifullah Sibi Ziarat

6 PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD

Feasibility study for Tomato Past Plant

Kohlu

22

342

15.55

0.18

Nasirabad

1,569

27,918

17.79

14.42

Jaffarabad

1,340

15,990

11.93

8.26

400

5,240

13.10

2.71

27

354

13.11

0.18

Kalat

117

1,014

8.67

0.52

Mastung

125

1,065

8.52

0.55

Khuzdar

825

6,945

8.42

3.59

Awaran

213

1,534

7.20

0.79

Kharan

218

1,671

7.67

0.86

Lasbela

620

6,456

10.41

3.33

Turbat

173

2,027

11.72

1.05

Panjgoor

37

275

7.43

0.14

Gwadar

4

28

7.00

0.01

15,375

193,633

12.59

100

Dera Bughti

Bolan Jhal Magsi

Total

The above table shows that the following four districts contribute 3/4th of the total production in Balochistan and 1/3rd of the total production in Pakistan. % As To Production Of District Baluchistan

Pakistan

Killa Saifullah

44

18

Nasirabad

14

6

Barkhan

12

5 7

PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD

Feasibility study for Tomato Past Plant

Jafarabad

8

3

This data analysis shows that Killa Saifullah is having the highest production of tomato and the third highest yield in Balochistan. Secondly Killa Saifullah has its boundaries with the province of Punjab and Sind, which gives it an added advantage for active and timely supply of its tomato paste products. Following data / graph shows the historical production data for this district (Killa Saifullah): Year 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06

Production (Tons) 5,351 26,425 26,276 80,010 81,161 85,473

% as to production of Balochistan Pakistan 15 2 50 9 45 9 51 19 45 19 44 18

Proposed Location The availability of tomato in large quantum and its low prices in Killa Saifullah are the factors which indicate a lot of potential for a tomato paste plant to be installed in this district. Pishin district can also provide the infrastructural support to the project. Nasirabad, Burkhan and 8 PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD

Feasibility study for Tomato Past Plant

Jafarabad are the other main supportive areas which are in the vicinity of Killa Saifullah. These three districts ensure the timely availability of tomato in Killa Saifullah as these areas produce one third of the total tomato production in Baluchistan and also have good road access to Killa Saifullah. Tomato Prices In The Area: The table below shows the monthly prices of tomato in Quetta for the last six years.

Monthly Whole-Sale Prices of Tomatoes in Main Market (Rs./40 Kgs.) July

Aug

Market/Year

Apr Sep

Oct

Nov

Dec

Jan

Feb

Mar

Ma y

Jun

Avg.

QUETTA 2000-01

526

196

208

501

707

733

253

235

514

330

277

381

405.08

2001-02

394

221

327

403

558

483

293

547

597

594

395

434

437.17

2002-03

399

298

246

288

238

342

336

286

263

219

285

341

295.08

2003-04

319

292

194

595

1122

1005

572

368

514

490

270

455

516.33

2004-05

610

455

490

757

715

685

657

722

721

588

650

695

634.50

2005-06

395

387

265

230

440

580

609

563

729

367

476

648

90

No specific data about tomato prices in Killa Saifullah is available. So the prices prevailing in Quetta, the only organized market in the province, can be relevant for Killa Saifullah. However, it is important to note that the prices in Killa Saifullah will be quite low as compared to prices in Quetta because it is the top tomato producing district of the province and its local consumption is not very high. If a project is set up a in Killa Saifullah - the hub of the tomato producing area, the material will be procured directly from the grower which will be very low as compared to retail market prices of the tomato. In this regard, we assumed that the tomato price will be some-where Rs 3/ Kg, but to be on realistic and higher side for the purpose of projections, the product price has been taken as Rs 5 / Kg.

Expected Yield from Tomato Yield specifies the percentage of output (Finished Product) as compared to the input (Raw Material). Yield is mainly dependent on the following factors: 9 PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD

Feasibility study for Tomato Past Plant

1. Strict quality control on raw material and production processes. 2. Type of plant 3. Processing methodology Normal yield from Tomato Paste is 20 %. Fresh tomatoes are available almost throughout the year in Pakistan.

10 PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD

Feasibility study for Tomato Past Plant

3. TOMATO PASTE PRODUCT TOMATO PRODUCTS Tomatoes and tomato products have always been a natural part of human diet. Everyone appreciates their red color and juicy taste. Recent research also indicates that processed tomatoes are good for human health due to a high content of lycopene. Last twenty years have witnessed an explosion of new and refined tomato products. Purées and passata have become major products together with the more classical ketchup, tomato paste and chilli sauces. Driven by the interest for ethnic food, there has also been a growing market for speciality sauces with particles, e.g. salsas with pepper and onions and a wide variety of tasty dip sauces. The variety of products in this market is already large, and is expected to increase in the future with more and more cooking recipe products. Major products of processed tomatoes include tomato paste, puree, tomato sauces, ketchup, whole canned tomatoes and juices. TOMATO PASTE is the main product of processed tomatoes which is used as a raw material to make ketchup, sauces and other tomato related products. Processors of tomato paste usually sell to re-packaging companies which add different additives to make specialized retail products such as ketchup, sauces and juices. Tomato paste is also used as tomato substitute in restaurants, hotels and individual households.

4. PRODUCTION PROCESS Detailed Production Process

The production process will involve the following steps: Washing Fresh tomatoes arriving at the plant in trucks are unloaded into a collection channel (also known as flume), a stainless steel or cement duct into which a quantity of water 3 to 5 times higher than the amount of unloaded tomato is continuously pumped. For example, a 10 tons/hour rate requires at least 30m3/hour of water. Sorting This water flow carries the tomatoes onto the roller elevator, which then conveys them to the grading station. The delivery trucks park-up alongside the flume and, while the trailers containing the tomatoes are being tilted towards it, an operator, using a special tube, pipes a vast quantity of water inside the truck, so that the tomatoes can flow out from the special 50 x 50cm 11 PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD

Feasibility study for Tomato Past Plant

opening. In this way the tomatoes and the water will be gradually feed into the flume without getting damaged. The tomatoes then arrive at the grading station, after having been rinsed under a clean water spraying system (preferably drinking water). Here the staff removes the green, damaged and excessively small tomatoes which are placed on a reject conveyor (or an auger) and then collected in a large box or directly inside a truck to be taken away. Chopping/ Crushing The tomatoes suitable for processing are transported to the chopping station (a hammer mill or a special mono-pump provided with pre-feeding screw) where they are chopped (broken and pulped). Pre Heating The pulp is pre-heated to 65-75°C for Cold Break processing or to 85-98°C for Hot Break processing. The main control panel on the evaporator regulates the pre-heating temperature. Pulping & Refining The heated tomato pulp (fiber, juice, skin and seeds) is then conveyed via a special pump to an extraction unit composed of two operating stations: a pulper and a refiner, equipped with two sieves having different sized meshes. The first sieve processes solid pieces up to 1 mm, while the refiner processes solid pieces up to 0.6 mm, depending on the type of sieve fitted on the machine (the manufacturer can supply sieves with different sized holes if necessary). Two products come out of the extraction unit: refined juice for concentration and waste for disposal. The average extractor yield varies according to different factors: the pulp’s temperature (a higher temperature will mean an increased juice yield), the variety of tomatoes treated, the type of sieve fitted, the rotation speed and the shape of the rotor on each dejuicing body unit. On average, however, the yield is about 95%. For example, if the extractor is fed with 100 kg of hot pulp, it will produce 95 kg of juice and 5 kg of waste. In addition, there is also a hypothetical product waste of about 1-3% from the grading stations. Therefore, 100 kg of tomatoes unloaded from the trucks will produce about 93-94 kg of juice to be concentrated. At this point the refined juice is collected in a large tank with an agitator which constantly feeds the evaporator. This tank is equipped with maximum and minimum level indicators-adjusters which control the pump supplying juice to the evaporator. Evaporation/Concentration The juice in this storage tank is fed to the evaporator which automatically regulates juice intake and finished concentrate output; the operator only has to set the Brix value on the evaporator’s control panel; during normal working conditions, the evaporator does not require any further regulations. The juice inside the evaporator passes through different stages where its concentration level will gradually increase until the required density is obtained in the final stage or “finisher”. Here the tomato paste is automatically extracted via a pump controlled by an electronic refractometer. 12 PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD

Feasibility study for Tomato Past Plant

The entire concentration process (evaporation) takes place under vacuum conditions and at low temperatures, significantly below 100°C. Product circulation inside the various concentric tubular exchangers is carried out by special stainless steel pumps which are designed to ensure that the product is conveyed inside the exchanger tubes at a speed of over 1.2 m/sec to avoid “flash evaporation” thus avoiding to get burnt. This means it is possible to process for extensive periods without having to shut down the machine. Evaporator output is measured in liters of evaporated water per hour while concentrating tomato juice with an initial 5°Brix concentration and producing tomato paste double concentrate at 30° Brix. All the tomato juice evaporators are designed according to these parameters. The evaporative capacity of tomato juice concentrators is greatly influenced by the viscosity level. If the tomato paste has a low Bostwick value, then the concentrator’s output level will also be low; on the other hand, a higher Bostwick value means an increased output level. It is therefore fundamental to know if the productivity data supplied by a manufacturer refers to HB or CB finished products. Aseptic Filing & Packaging The concentrate is sent from the evaporator directly inside the aseptic system tank. From here it is pumped at high pressure inside the aseptic sterilizer-cooler and then to the aseptic filler, where it is filled into pre-sterilized aseptic bags housed in metal drums. The sterilization temperature and the holding time vary according to the product’s PH value. Generally speaking, a product with a pH value equal to or less than 4.2 could have a sterilization temperature of 115°C measured at the end of the holding section, and a holding time of at least 60-90 seconds. On the other hand, if the pH value is greater than 4.2, it is advisable to acidify the product in order to bring it to about 4.1, improving taste and final product quality. The sterilized tomato paste is cooled down to about 35-38°C before being piped into pre-sterilized aluminum bags housed in special metal or plastic bins via a special aseptic filler. The packaged concentrate can be kept up to 24 months depending on its pH value and ambient conditions. Storing When storing for over 12 months, it is however advisable to conserve it in refrigerated cells, more to reduce oxidization, which could cause darkening than to protect the product’s aseptic quality.

13 PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD

Feasibility study for Tomato Past Plant

PROCESS FLOW CHART:

Production Flow is summarized below: ·

The tomatoes, discharged from trucks, are hydraulically transferred to the sorting tables, where they are washed and quality checked (1). Water recycling and filtering provide optimal operation of the system.

·

After sorting, the whole tomatoes are collected in one tank, then pumped (2) to the chopping system (3).

·

Then, depending on customers' requirements, they are fed either to the Hot-Break enzyme inactivation unit (4) or to the Cold-Break heater (5).

·

After this treatment, the product is fed to the refining groups (6) for separation of the liquid from the solids, producing the refined juice and waste (peels/seeds/stalks). The refined juice

14 PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD

Feasibility study for Tomato Past Plant

is collected in a tank (8) while the waste is treated to recover the remaining part of the juice still present (7).

·

Both the product collection (8) and the storage tanks (9) feed the evaporator continuously by means of centrifugal pumps.

·

The concentration phase allows, during the evaporating process (10), production of concentrated products with different Brix characteristics.

·

UHT sterilizing treatment (ultra high temperature) and cooling (11).

·

Aseptic filling into flexible bags, with a capacity of up to 1,500 l (12).

HOT BREAK is a method where in tomatoes/selected fruits are heated by passing through a steam heated tubular heater. This method gives better yield of pulp having higher viscosity without being separated into juice & pulp. This process also kills microorganism. COLD BREAK is a method where tomatoes are not heated to get the pulp. The pulp obtained through Cold Break process is of lower quality when compared to pulp obtained by Hot Break. End product could be stored either in tin packing or in aseptic bags of 200 kg. For the purposes of our feasibility study, we recommend aseptic packing in the bags of 200 kg because of involvement of cost factor, storing capacity and other allied factors. As regards the end use, there is no hard and fast rule for hot process or cold process. Generally, hot process is preferred as it gives a better aroma, better yield and is in use for production of processed product by the Industry. Hot-Break is considered a better method because it gives better yield and aroma.

5. MARKET ANALYSIS International trend 1. Tomato Processing Industry: 15 PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD

Feasibility study for Tomato Past Plant

Tomato is one of the most popular vegetable in the world. The derivatives of tomato like paste, juice, ketchup, etc. are widely used in almost all the world kitchens. With the increasing affluence of the world, its demand has increased very rapidly resulting in wide scale development of tomato industry. a)

World Tomato Paste Export

Total export market of tomato paste is around 2 billion US $ (fiscal year 2005) and this shows 43 % increase from year 2003 and 27% from 2004.

16 PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD

Feasibility study for Tomato Past Plant

Top Ten Exporters of Tomato Paste in the World (Figures in tons) Country China Italy Spain Turkey Greece Portugal Brazil Israel Mexico France

2003 436,880 465,000 123,556 184,923 80,000 121,228 19,288 6,150 6,790 3,450

2004 527,800 416,818 160,000 165,000 135,000 115,000 14,217 8,950 6,800 5,000

2005 558,250 415,000 180,000 155,000 135,000 125,000 14,500 7,000 6,800 5,000

China is the leading exporter of tomato paste followed by Italy, Spain and Turkey. Italy is not only the top exporter but it is also the top importer of tomato paste. It imports a big quantity from China, re-packs the paste and sells most to Africa and Middle East. Competition has intensified as world exports of fresh tomatoes from key suppliers have been increasing in recent years. It is noteworthy that some of the major exporters of fresh tomatoes are also major importers. Over the last decade, China’s exports of tomato products have grown immensely. b)

World Tomato Paste Import

While the leading importers of the tomato paste are Germany, Italy, England, Japan and France. These countries have imported approximately US$ 500 million paste in 2003. As per the international figures, there has been growth of 20% -25% in tomato paste consumption. Tomato/Fruits processing industry is one of the largest growing industries in the world due to the consumption habits and life style.

Potential Markets · Local Market: According to estimates, about 95% of the indigenous tomato based processed products (puree, paste, pulps, jams, jelly and juices) are sold in the local market. The proposed project has very wide market for processors, hotel industry and retail sellers of tomato paste. 17 PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD

Feasibility study for Tomato Past Plant

The target market of tomato paste/puree and pulp is as follows: ·

Food processors like Mitchell’s Fruit, Shezan International, Ahmed Foods, Shangrila Foods, Rafhan Best Foods, National Foods, Tops Fruit, and Salman Food

·

Hotels like PC, Avari, Holiday Inn, Shelton, Marriot etc.

·

Fast Food / Chinese Restaurants like McDonald, Pizza Hut, KFC, Salt & Pepper etc.

·

Working women / Households It is gathered that Food processors are major consumers of tomato paste in the country. Some of these companies meet their requirements (fully or partially) through in-house production of tomato paste/pulp while others depend on the following outside sources: 1. Import from paste manufacturing countries 2. Local cottage industry paste manufacturers Tomato Paste Imported in Pakistan “Trade Competitiveness Map” of International trade Center Geneva Switzerland, Pakistan reports tomato paste imports in Pakistan over the last five years as follows:

Years US $ (000)

2005-06 1,450

2004-05 1,040

2003-04 469

2002-03 490

2001-02 354

Note: As per the organization (ITC), the reported data is discrepant up-to the extent of 26%. as per the independent sources of the organization as Pakistan’s reported import of tomato paste is not reported completely and actual is on the higher side. The above data is after removal of discrepancy. Based on the above data, it is concluded that demand of tomato paste in Pakistan is increasing at rapid growth rate.

Tomato Paste Produced by Cottage Industry: There are some individual / cottage industry units working in Pakistan which are making tomato paste/pulp and selling it to re-packaging companies which add different additives like vinegar, sugar, salt and spices to make specialized retail products such as ketchup, sauces and juices. The supply is not sufficient and of desired quality. The yield of cottage industry 18 PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD

Feasibility study for Tomato Past Plant

supplies is low. One kg paste of the proposed plant will be equal to about 2.8 kg of the tomato paste produced by the cottage industry. The tomato paste so purchased is of lower brix and quality which gives low yield in ketchup process. Its price range is Rs. 25- 35/kg. Interestingly, due to un-availability of the tomato/paste (at economical price), some people use pulp of other materials like carrots and pumpkins by mixing it with 15 – 20% tomato paste. Retail Supply of Tomato Paste: As stated earlier, major portion of the produce is sold as intermediary product and only a small portion is processed and sold as tomato paste in the retail market. Only the leading food processors like Mitchell have branded products in the market while imported paste is also sold on leading Departmental Stores. Size of this market segment is estimated at 100-200 MT per annum. Due to restricted size of this market, the study has been based on bulk packing. Local Market Demand Development: Local demand can be created for the sale of tomato paste. In Pakistan tomato is an important ingredient of our food. Especially all the continental food stuff is made of fresh tomato. Most of the time, around 4 -6 months during the year, tomato becomes very expensive. It ranges from Rs. 35 to 120 per Kg. During this period, tomato paste can replace the tomato for the cooking ingredient. One kg of tomato paste is as good as 5 Kgs of fresh tomato. Current & Future Demand in Local Market: Establishment of a tomato paste plant in the country can significantly reduce the dependence of local ketchup industry / hotels on imported paste and thus save valuable foreign exchange. The paste is currently being imported mainly from China, Iran and Turkey. Around 2400 MT of tomato paste was imported during the year 2005-2006. The current estimated consumption of tomato paste/pulp in the country is around 4,000-4,500 tons as detailed below: Food Processing Industry

=

3,000-3,200 MT

Hotels & Restaurants

=

800-1,000 MT

House Hold

=

200 – 300 MT

The demand for tomato paste in near future is expected to increase at around 15% per annum. 19 PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD

Feasibility study for Tomato Past Plant

In the local market, tomato paste is available at whole sales level but in small bottle and tin packs. The whole sales market rate for the tomato past is as follows: 1. 2. 3. 4.

1 Kg Packing 500Gms 450 Gms 300 – 330 Gms

Rs.80 – Rs. 120 Rs. 55- Rs. 70 Rs. 30- Rs. 45 Rs. 25 – Rs. 40

· Export Market: There is great potential of tomato paste in Afghanistan, Middle East, Far East, European Countries, USA etc. As per the latest survey of Afghanistan Investment Support Agency (AISA) in 2006-07, currently there is a huge demand for tomato paste, Jams, Jellies, marmalades products. In the recent years the Afghani culture and eating habits of people are changing. Local demand for fruit juices is booming, but presently juices and tomato paste are being imported. Market research indicates that there is a market of USD 16-22 million for fruit juices and USD 8-16 million in tomato paste. Pakistani Investors in the food and beverage processing sector can capitalize on this large and adjacent consumer market.

6. PLANT & MACHINERY

There are no local manufacturers which have experience of manufacturing tomato paste plants. Secondly, the plant & equipment for food industry is to be made from special steel. Therefore, the project is based on imported machinery. Imported Plants of Italian, Chinese and Indian origin are available. The detail on the machinery is annexed. Government has exempted plant and machinery, operated by power of any description as an imported or purchased locally by a registered person to be used for the manufacture of taxable goods by the registered person on the basis of certain requirements. The exemption policy has been notified in the SRO 987 (1)/1999 dated August 31, 1999. Further exemption is also available in respect of Income Tax & Sales Tax at the time of import with a view to start the taxable activity after the trial run. There is no period bar to start the production.

Plant Utilization: For Tomato Paste/Pure, the installed production capacity is to be kept idle for seven (7) months in a year. In order to run the operations for the whole year, the only way out of this dilemma is diversification, in which, other fruit products can replace tomato during those idle months. 20 PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD

Feasibility study for Tomato Past Plant

7. HUMAN RESOURCE REQUIREMENTS:

ADMINISTRATIVE STAFF Description Chief Executive Accounts Manager Admin. Manager Marketing Manager Accounts Executives Clerks Marketing Executives Security Staff Time Office Staff Peon & Others

No. 1 1 1 1 2 2 2 3 1 2

Salary 50,000 20,000 12,000 15,000 10,000 5,000 6,000 5,000 7,000 3,500

PRODUCTION STAFF Description Production Manager Quality Control Incharge Shift Incharge Laboratory Assistant Boiler Engineer Mechanical Engineer Electrical Engineer Semi Skilled Workers Unskilled Workers

No of Employees. 1 1 3 1 1 1 1 15 20

Salary 40,000 20,000 10,000 7,000 25,000 25,000 25,000 5,000 3,000

21 PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD

Feasibility study for Tomato Past Plant

8. PROJECT COST Rs.

Cost Heads

Local

Imported

(000)

Total -

Land & Development

3,900

3,900 -

Building & Civil Works

15,125

15,125 80,000

Plant & Machinery

1,500

Erection and Installation

2,790

81,500 2,790 -

Furniture & Fixture

650

650 -

Vehicles

2,200

Pre-Production Expenses

2,000

2,200 2,000 -

Contingencies

9,663

9,663 80,000

Total Fixed Cost

37,828

117,828 -

Net Initial Working Capital

5,247

5,247 80,000

Total Project Cost

43,075

123,075

22 PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD

Feasibility study for Tomato Past Plant

Rs. (000)

PROJECTED INCOME STATEMENT

2008

2009

2010

2011

2012

2013

85%

90%

95%

95%

95%

95%

88,243

102,925

113,833

119,317

124,505

129,693

47,819 4,570 2,721 2,360 400 10,582 68,452 3,423 65,029 23,214

53,163 4,798 2,978 2,478 400 9,521 73,339 3,423 3,667 73,095 29,830

58,789 5,038 3,249 2,602 400 8,573 78,651 3,667 3,933 78,385 35,447

61,461 5,290 3,377 2,732 400 7,725 80,986 3,933 4,049 80,869 38,449

64,133 5,554 3,505 2,869 400 6,966 83,428 4,049 4,171 83,306 41,199

66,805 5,832 3,634 3,012 0 6,285 85,569 4,171 4,278 85,462 44,231

4,251 4,251 18,962

4,464 4,464 25,366

4,687 4,687 30,760

4,921 4,921 33,527

5,167 5,167 36,032

5,426 5,426 38,805

3,510 773 4,283 14,679

3,991 1,069 5,060 20,307

4,486 1,314 5,800 24,960

4,827 1,435 6,262 27,266

5,167 1,543 6,710 29,322

5,507 1,665 7,172 31,633

Taxation

5,138

7,107

8,736

9,543

10,263

11,072

NET PROFIT AFTER TAX DIVIDEND

9,542 0 9,542 9,542

13,199 0 13,199 22,741

16,224 0 16,224 38,965

17,723 0 17,723 56,688

19,059 0 19,059 75,747

20,561 0 20,561 96,308

Capacity Operation % Sale Revenue Less: Cost of Goods Sold Raw Material Labour Power & Fuel Manufacturing Overheads Preliminary Expenses Depreciation Add: Opening Inventory Less: Closing Inventory GROSS PROFIT Operating Expenses: Admin. & General OPERATING PROFIT Other Expenses: Financial Workers Profit Participation Fund NET PROFIT BEFORE TAX

Cum - Retained Earning

PAKIST AN HORT ICULT URE DEVELOPMENT EXPORT BOARD

23

Feasibility study for Tomato Past Plant

PROJECTED BALANCE SHEET

Rs. (000) 2008

2009

2010

2011

2012

2013

25364 4,835

49,738 5,640

76,079 6,237

102,529 6,538

129,476 6,822

156,958 7,106

3,930 1,782 100 200 36,211

4,370 2,003 100 200 62,050

4,832 2,148 100 200 89,596

5,052 2,216 100 200 116,634

5,271 2,282 100 200 144,152

5,491 2,341 100 200 172,197

1,600

1,200

800

400

0

0

115,818 10,582 105,235 143,047

105,235 9,521 95,714 158,964

95,714 8,573 87,141 177,537

87,141 7,725 79,416 196,450

79,416 6,966 72,450 216,601

72,450 6,285 66,165 238,361

0 2,948 1,582 5,138 773 0 10,440

0 3,277 1,705 7,107 1,069 0 13,158

0 3,624 1,833 8,736 1,314 0 15,507

0 3,789 1,931 9,543 1,435 0 16,697

0 3,953 2,031 10,263 1,543 0 17,790

0 4,118 2,134 11,072 1,665 0 18,989

0

0

0

0

0

0

123,065 9,542 132,606 143,047

123,065 22,741 145,806 158,964

123,065 38,965 162,030 177,537

123,065 56,688 179,752 196,450

123,065 75,747 198,812 216,602

123,065 96,308 219,373 238,362

ASSETS Current Assets Cash & Bank Balance Account receivable Inventory: Raw Material Finished Goods Store & Spares Advances, Deposits and Prepayments Pre-production Expenses Fixed Assets At Cost Less: Depreciation

LIABILITY AND EQUITY Current Liabilities Current Maturity : local currency loan Cash Finance Creditors, Accr. & Lib. Provision For Taxation Workers Profit Participation Fund Dividend Payable LONG TERM LOAN local currency loan EQUITY Paid up Capital Retained earning

PAKIST AN HORT ICULT URE DEVELOPMENT EXPORT BOARD

24

Feasibility study for Tomato Past Plant

Rs. (000)

PROJECTED CASH FLOW

2008

2009

2010

2011

2012

2013

18,962 10,582 400 29,944

25,366 9,521 400 35,288

30,760 8,573 400 39,734

33,527 7,725 400 41,653

36,032 6,966 400 43,398

38,805 6,285 0 45,090

(Increase)/decrease in Stores & Spares (Increase)/decrease in Stock in Trade (Increase)/decrease in Acc. Rec. (Increase)/decrease in Advances, Deposits and Prepayments Increase/(decrease)Creditors, Accrued and Other Liabilities Net Working Capital Changes

(100) (5,712) (4,835)

0 (660) (804)

0 (607) (598)

0 (288) (301)

0 (286) (284)

0 (279) (284)

(200)

0

0

0

0

0

1,290 (9,558)

83 (1,382)

87 (1,118)

69 (519)

72 (499)

75 (488)

Cash Generated From Operations

20,387

33,906

38,616

41,134

42,899

44,602

Financial Charges Paid Dividend Paid W.P.P.F Income tax NET CASHFLOW FROM OPERATING

(3,218) 17,169

(3,951) (773) (5,138) 24,044

(4,445) (1,069) (7,107) 25,994

(4,798) (1,314) (8,736) 26,286

(5,139) (1,435) (9,543) 26,783

(5,479) (1,543) (10,263) 27,317

(115,818) 0 (2,000) (117,818)

0 0 0 0

0 0 0 0

0 0 0 0

0 0 0 0

0 0 0 0

0 2,948 123,065 0 126,013

0 329 0 0 329

0 347 0 0 347

0 165 0 0 165

0 165 0 0 165

0 165 0 0 165

25,364 0 25,364

24,374 25,364 49,738

26,341 49,738 76,079

26,450 76,079 102,529

26,947 102,529 129,476

27,482 129,476 156,958

OPERATING ACTIVITIES Operating Profit Add: Depreciation Preliminary Expenses Working capital changes:

INVESTING ACTIVITIES: Fixed Assets Acquired Long Term Investments Preliminary Expenses NET CASHFLOW FROM INVESTING

FINANCING ACTIVITIES: Demand Finance Acquired/(Paid) Cash Finance Capital Introduced Directors Loan NET CASHFLOW FROM FINANCING NET INCREASE/(DECREASE) IN CASH OPENING CASH&CASH EQUIVALENTS CLOSING CASH&CASH EQUIVALENTS

PAKIST AN HORT ICULT URE DEVELOPMENT EXPORT BOARD

25

Feasibility study for Tomato Past Plant

ASSUMPTIONS TOMATOS PRODUCTION AND SALE VOLUME

The proposed projections are from the year 2007-2008 to onward with the under mentioned capacity. The consumption of tomato is calculated on the basis of 3 M. Ton per hour, 3 shifts of 8 hours each and 150 days a year. Remaining days the process will be closed for maintenance and cleaning. Paste will be produced at 30 - 32 brix at the yield of 20% from the fresh tomatoes of 5 brix.

M. Tons at 100 % Production of Tomato Paste(3*24*150*20%)

2,160 2,160

SALE VOLUME

Capacity %

2008

2009

2010

2011

2012

2013

85%

90%

95%

95%

95%

95%

1,836 0 (92) 1,744

1,944 92 (97) 1,939

2,052 97 (103) 2,047

2,052 103 (103) 2,052

2,052 103 (103) 2,052

2,052 103 (103) 2,052

2,565 2,309

2,565 2,309

2,565 2,309

Potatos Production Add: Opening Inventory Less:Closing Inventory(5% of storage) Sale Volume

WASTAGE Saleable waste is considered to be 25% of the total input and it is assumed that 90% 0f the waste is sold Volume of waste Sale Volume of waste

2,295 2,066

2,430 2,187

2,565 2,309

SALE REVENUE Sale prices are subject to 5% annual increase

SELLING PRICE Tomatos Tomatos Wastage

Per Kg In RS Per Ton In RS

PAKIST AN HORT ICULT URE DEVELOPMENT EXPORT BOARD

50.00 500.00

26

Feasibility study for Tomato Past Plant

REVENUE Tomatos Tomatos Wastage

2008

2009

2010

2011

2012

2013

87,210 1,033 88,243

96,930 1,094 102,925

102,330 1,154 113,833

102,600 1,154 119,317

102,600 1,154 124,505

102,600 1,154 129,693

COST OF SALES RAW MATERIAL TOMATOS Requirement of Tomatos at 100% operation worked out as follows:

Years Capacity % Tomatos

TOMATOS M. Tons 10,800 10,800

2008

2009

2010

2011

2012

2013

85%

90%

95%

95%

95%

95%

9,180

9,720

10,260

10,260

10,260

10,260

The prices of tomatos fluctuates during the peak tomatos procurement season,therefore,average tomatos cost/40kgs is Rs.

200.00

CHEMICALS AND OTHERS PERSERVATIVES Sodium Benzoate(.1%) Potassium Metabysulphate(.1%) Glacier Acetic Acid(5ml/kg)

70/kg. 120/kg. 160/liter.

PACKING MATERIAL Polythine Bags(50grams/bag) Tomatoes Cost Chemicals and perservatives Packing Material Material Cost(subject to 5% annual increase)

110/kg. 45,900 1,818 101 47,819

51,030 2,021 112 53,163

PAKIST AN HORT ICULT URE DEVELOPMENT EXPORT BOARD

56,430 2,235 124 58,789

58,995 2,336 130 61,461

61,560 2,438 135 64,133

64,125 2,539 141 66,805

27

Feasibility study for Tomato Past Plant

LABOUR Labour requirement of the proposed project is given below Description Production Manager Quality Control Incharge Shift Incharge Laboratory Assistant Boiler Engineer Mechanical Engineer Electrical Engineer Semi Skilled Workers Unskilled Workers(5Months)

No.

Salary

1 1 3 1 1 1 1 15 20

40,000 20,000 10,000 7,000 25,000 25,000 25,000 5,000 3,000 160,000

Add: Fringe benefit 40%

Salary Per Annum 480 240 360 84 300 300 300 900 300 3,264 1,306 4,570

Years

2008

2009

2010

2011

2012

2013

Labour Cost subject to 5% annual increase

4,570

4,798

5,038

5,290

5,554

5,832

POWER AND FUEL Connecting Load kW Load Required KW

100 80

Fixed charges Rs.352 per kW per month. Energy Charges

Per Unit

Energy Cost(1.15+1.97)/2 Fuel adjustment & Duty Additional Surcharge(1.89+2.08)/2 Surcharge10.4%

1.56 0.18 1.99 0.30 4.02

Fixed Charges Variable Energy Charges at 100% capacity

422 2,704

Power Cost Subject to 5% annual increase

2008

2009

2010

2011

2012

2013

Fixed Variable

422 2,299 2,721

422 2,556 2,978

422 2,826 3,249

422 2,955 3,377

422 3,083 3,505

422 3,212 3,634

WATER No water charges are assumed for the proposed project as it will be taken from tube well sunk domestically.

PAKIST AN HORT ICULT URE DEVELOPMENT EXPORT BOARD

28

Feasibility study for Tomato Past Plant

OTHER MANUFACTURING OVERHEAD

Rs. (000)

Repair and Maintenance These have been taken @ 1 % of the plant and machinery& building in first year subject to 5% increase in subsequent years

Repair and Maintenance

2008

2009

2010

2011

2012

2013

961

1,009

1,060

1,113

1,168

1,227

Stores and Spares These have been taken @ 1% of the plant and machinery in first year subject to 5% increase in subsequent years Stores and Spares

810

851

893

938

985

1,034

589

619

649

682

716

752

2,360

2,478

2,602

2,732

2,869

3,012

Cost

Other Cost

Total Cost

Rate %

3,900 15,125 83,780 1,200 2,200 106,205

1,470 8,143 9,613

3,900 16,595 91,923 1,200 2,200 115,818

0 5 10 10 20

Insurance Charges These have been taken @ 0.50 of the assets subject to 5%annul increase Insurance Charges

TOTAL

DEPRECIATION SCHEDULE Description Land Factory building Plant and Machinery Furniture, Fixture and Utilities Vehicles

Other Cost Contingencies

PAKIST AN HORT ICULT URE DEVELOPMENT EXPORT BOARD

9,613 9,613

29

YEAR WISE DEPRECIATION

(Rs. 000)

Years 1 2 3 4 5 6 7 8 9 10

Factory Building

Plant & Machinery

Furniture

Vehicle

Total

830 788 749 711 676 642 610 579 550 523 6,659

9,192 8,273 7,446 6,701 6,031 5,428 4,885 4,397 3,957 3,561 59,871

120 108 97 87 79 71 64 57 52 46 782

440 352 282 225 180 144 115 92 74 59 1964

10,582 9,521 8,573 7,725 6,966 6,285 5,674 5,126 4,633 4,190 69,275

ADMINISTRATIVE AND GENERAL EXPENSES Employees Salary Description

No.

Chief Executive Accounts Manager Admin. Manager Marketing Manager Accounts Executives Clerks Marketing Executives Security Staff Time Office Staff Peon & Others

1 1 1 1 2 2 2 8 1 3

Add: Fringe Benefit @ 40%

Employees Salary Subject to 5% annual increase

(Rs.000) Salary Per Annum 600 240 144 180 240 120 144 480 84 126 2,358 943 3,301

Salary Per Month 50,000 20,000 12,000 15,000 10,000 5,000 6,000 5,000 7,000 3,500 133,500

2008

2009

2010

2011

2012

2013

3,301

3,466

3,640

3,822

4,013

4,213

General Expenses Travelling (Including Marketing) Printing and Stationery Telecommunication Others

General Expenses Subject to 5% annual increase

Total Admin. & General Expenses

400 150 300 100 950 950

998

1047

1100

1155

1212

4,251

4,464

4,687

4,921

5,167

5,426

PAKIST AN HORT ICULT URE DEVELOPMENT EXPORT BOARD

30

Feasibility study for Tomato Past Plant

Rs. (000)

FINANCIAL EXPENSES Financial Charges:

Cash Finance Other

2008

2009

2010

2011

2012

2013

2,510 1,000 3,510

2,791 1,200 3,991

3,086 1,400 4,486

3,227 1,600 4,827

3,367 1,800 5,167

3,507 2,000 5,507

Cash Finance: Cash finance is proposed to be financed by Bank @ 14%

PROFIT PARTICIPATION FUND These fund have been taken at a rate of 5% of the net profit before tax

TAXES Tax at the rate of 35% of profit has been calculated on local sale

PAKIST AN HORT ICULT URE DEVELOPMENT EXPORT BOARD

31

Feasibility study for Tomato Past Plant

9. FINANCIAL INDICATORS

Present Value (at 15%)

=

Rs 130.138 million

Pay Back Period

=

IFRR

=

16.32 %

IERR

=

28.03 %

Employment

=

60 Nos

Break Even Capacity

=

77 %

5.15 years

32 PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD

Feasibility study for Tomato Past Plant

APPENDIX - I

LIST OF PLANT & MACHINERY

Lift/Elevator

Washer 33

Feasibility study for Tomato Past Plant

Drum brush fruit washer is suitable for fruits like tomato and carrots which requires accurate cleaning; surfing washer is for cleaning and selection of common fruits .This machine is also useful for apples, pears, and oranges and so on..

34

Technical Data:

Capacity(t/h)

5

10

15

Water Consumption(kw)

0.6

1.1

1.5

Dimension

4850X1480X2000(10T/H)

Crusher

34 PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD

Feasibility study for Tomato Past Plant CRUSHER

This machine is applicable for various fruits and vegetables.

35

Technical Data: Capacity (t/h)

3

10

Power（ KW）

3.7

5.5

Dimension (mm)

1100X750X1200

1350X1100X1450

35 PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD

Feasibility study for Tomato Past Plant

Preheating Machine

Multi-tube preheating machine is use to pasteurize the crushed products and to protect the original colour，and to soften the products meanwhile. ·

Max capacity:3000KG/H

·

tubular board cover structure

·

heat exchange area: 3.5~4.0 m2

·

input at mormal tempreture，output tempreture around 80~85 ℃ adjustable

·

steam consumption: 300~500KG/H

·

dimension： 1700*500*1400 （longth * width * highth）

36

Feasibility study for Tomato Past Plant

Pulping Machine

The machine is applicable for pulping, peeling and deseeding of tomato, apricot etc.

37

Technical Data: Capacity (T/H)

3

5

8

20

Blade Speed(rpm)

525

960

960

2200

Power (KW)

5.5

11

18.5

18.5

Screening size

0.6,0.8,1.1

2.0,0.6

1.1,0.8,0.6

0.5

Dimension (MM)

1300X1200X1200 2000X1400X1800 2000X1700X2300 1800X700X1900

37 PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD

Feasibility study for Tomato Past Plant

Juice Extractor

The new invented belt juice extrator is widely applicable for fruit/vegetables juicing.This machine is featured with high quality , good automazition and high yeild-out.The capacity range is 3~20T/H. 38

The machine is applicable for juicing from tomato,orange,gringer,apple,pineapple etc. capacity（ T/h）

3

power（ KW）

4

spiral speed（ rpm）

400

dimmension (mm)

1560×450×1340

38 PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD

Feasibility study for Tomato Past Plant

Decanter

DECANTER TYPE V SERIES

DECANTER TYPE P SERIES

1、Liquid Collector 2、Liquid Level 3、External 4、Spiral 5、Feed Pipe 6、Screw Feeder 7、Drum 8、Antierosion Busbings 9、Solid Discharge　10、Reduction

39

Feasibility study for Tomato Past Plant

outlet of concentrated tomato process extract

Disk Centrifuge Skimming Separator

40

TECHNOLOGICAL DATA Milk skimming capacity

2000 l/h

Operating water PH value

6.5-7.5

Clarification and standardization

5000l/h

Motor power

6.5 kw

Solids chamber capacity

2.0 l

Voltage

3 × 380/660

Bowl speed

11000 r.p.m

Auxiliary Voltage

24 Ac

Maximum product

1.1 kg/dm3

Frequency

50 Hz 40

PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD

Feasibility study for Tomato Past Plant

density Maximum sludge density

1.35 kg/dm3

Electric system

Maximum product temperature

+90 ℃

Motor and electric panel protection level

Minimum product temperature

+3 ℃

Noise

Minimum feeding pressure for operating water

2 bar

Operating water consumption (each discharge)

10 l

Operating water total hardness

Net weight

≤ 6 dH

Dimensions(L × W × H)

Three phase with earth IP55 76 ± 2 dBA

470kg

1150 × 800 × 1150

Vaccum Concentrator

41 PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD

Feasibility study for Tomato Past Plant

Tube In Tube Sterilizer

Multi-tube coaxial heat exchangers have been successful used in food preservation for many years. They are particularly suitable for sterilizing and/or cooling products having low and medium viscosity with the use of steam, hot and cold water 42

Feasibility study for Tomato Past Plant

Sterilizing And Bulk Aseptic Filler

Filling process, which include bag opening, filling, weighting, and bag closing, is accomplished at aseptic condition. Thanks to the aseptic technology, the ASEPTIC FILLER is particularly suitable for fruit or vegetable juice, concentrates and purees, beverage original and medicine. Model

DWZ-1-200

DWZ-2-200

DWZ-2-50

Filling heads

1

2

2

5 -500L

5 -500L

5 -50L

(adjustable)

(adjustable)

(adjustable)

6-12

12-20

80-100

Bag capacity Filling speed （ bags/h ）

43

(Bag capacity: 200L ) (Bag capacity: 200L ) (Bag capacity: 25L 44

Feasibility study for Tomato Past Plant

DETAILED PLANT LAY OUT

44 PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD