1. Project Overview
Product: Tomato Paste (Concentrated tomato pulp, 28–30% or 36–38% TSS)
Form: Thick, semi-solid concentrate
Raw Material: Fresh ripe tomatoes
Production Capacity Example: 1,000 kg paste/day (requires ~7–8 tons of tomatoes/day)
End Use:
- Industrial ingredient for ketchup, soups, sauces
- B2B supply to hotels, restaurants, food processors
- Bulk export (200–250 kg aseptic drums)
2. Market Opportunity
- High export demand (Middle East, Africa, Asia, Europe).
- Used in ketchup, pizza/pasta sauces, ready meals, etc.
- Long shelf life (1–2 years in aseptic packs).
- India’s low tomato cost = competitive export advantage.
Key Buyers:
Food industries, ketchup manufacturers, HORECA distributors, exporters, and private label importers.
3. Raw Materials & Ingredients
| Material | Purpose | Source |
|---|---|---|
| Fresh ripe tomatoes | Main raw material | Farmers / own farm |
| Salt / Citric acid | Preservation & acidity control | Food-grade |
| Packaging (aseptic bags, cans, drums) | Storage & export | Packaging vendors |
| Power & steam | Processing | Industrial utility |
| Water | Washing, blanching | Borewell / RO system |
4. Machinery & Equipment
| Equipment | Function | Approx. Cost (INR) |
|---|---|---|
| Tomato washer & sorter | Cleaning | ₹1,00,000 |
| Crusher / pulper | Extract pulp | ₹1,50,000 |
| Pre-heater / Blancher | Inactivate enzymes | ₹80,000 |
| Pulp refiner | Remove seeds & skin | ₹1,00,000 |
| Evaporator (Vacuum / Triple-effect) | Concentration | ₹5,00,000–₹10,00,000 |
| Steam jacketed kettle | Heating | ₹2,00,000 |
| Pasteurizer | Sterilization | ₹1,00,000 |
| Filling & sealing machine | Cans / pouches | ₹2,50,000 |
| Boiler / steam generator | Steam supply | ₹2,00,000 |
| Miscellaneous (tanks, conveyors, pumps) | — | ₹1,50,000 |
Total Machinery Cost: ₹20–30 lakh (small–medium scale semi-automatic)
5. Production Process (Step-by-Step)
- Sorting & Washing: Select ripe tomatoes, remove damaged fruits.
- Blanching / Pre-heating: Inactivate enzymes and loosen skins.
- Pulping: Extract pulp using pulper and refiner.
- Filtering: Remove seeds, skins, and coarse fibers.
- Concentration: Use evaporator to reduce water and reach 28–38% total solids (TSS).
- Deaeration (optional): Remove air bubbles for longer shelf life.
- Pasteurization: Heat at ~90°C for microbial safety.
- Filling & Sealing: Hot-fill into sterilized cans or aseptic bags.
- Cooling & Storage: Rapid cooling, then packing for sale/export.
6. Plant Layout (Flow Chart)
Sorting → Washing → Crushing → Blanching → Pulping → Refining →
Evaporation → Pasteurization → Filling → Cooling → Packaging → Storage
7. Manpower Requirement
| Role | No. of Persons |
|---|---|
| Production Supervisor | 1 |
| Machine Operators | 2 |
| Helpers / Laborers | 3 |
| Quality Control | 1 |
| Packaging Workers | 2 |
| Admin / Sales | 1 |
Total: 9–10 staff members
8. Quality & Standards
- FSSAI License
- BIS IS 3882:1995 (Tomato Paste and Ketchup Standard)
- ISO 22000 / HACCP / GMP (For export certification)
- MSME / Udyam Registration
- APEDA / IEC Registration (For export)
Testing Parameters:
- Total Soluble Solids (TSS): 28–38%
- pH: 4.1–4.3
- Consistency: Smooth & homogeneous
- Preservatives: Within FSSAI limits
9. Financial Overview (Small Scale Example)
| Item | Cost (INR) |
|---|---|
| Building (rented) | ₹3–4 lakh/year |
| Machinery & Equipment | ₹25–30 lakh |
| Raw Material (monthly) | ₹3–4 lakh |
| Labor & Utilities | ₹2 lakh/month |
| Packaging & Marketing | ₹1 lakh/month |
| Working Capital | ₹6–8 lakh |
| Total Initial Investment: | ₹35–45 lakh |
Profit Margin: 25–35%
Break-even: 2 years
10. Packaging Options
| Type | Size | Application |
|---|---|---|
| Aseptic Bag-in-Drum | 200–250 kg | Export / B2B |
| Tin Can | 850 g / 3.1 kg | HoReCa / Retail |
| PET Jar / Pouch | 500 g – 1 kg | B2C retail |
| Industrial Bulk Tank | 1000 kg | Food industries |
11. Marketing Strategy
B2B (Domestic):
- Supply to ketchup & sauce manufacturers.
- Sell to hotel, restaurant, and food service suppliers.
Export:
- Private label or bulk tomato paste in aseptic drums.
- Focus markets: Middle East, Africa, South Asia, and Europe.
- Partner with importers under “Kolar Red Gold” brand or OEM label.
Retail (B2C):
- Tomato paste jars under your brand.
- Sell on e-commerce (Amazon, Flipkart) and supermarket channels.
12. Integration Benefits
If you already operate Purée, Sauce, Ketchup, or Powder units, tomato paste fits naturally:
- Acts as base for ketchup & sauce — saves cost.
- Adds export-ready product with higher margins.
- Ensures zero waste from tomato processing.
Full Integration Chain:
Fresh Tomatoes → Purée → Paste → Ketchup / Sauce / Powder
13. Sustainability & Waste Utilization
- Tomato seeds & skins → animal feed or compost.
- Steam condensate reuse for heating.
- Solar-assisted evaporation (optional).
- Use recyclable drums & pouches for export packaging.
✅ Advantages of Tomato Paste Manufacturing for Kolar Red Gold
- Long shelf life → year-round export supply.
- Bulk product → higher volume, lower transport cost.
- Complements your existing tomato products.
- Strong B2B and export profit margins.