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 Pakistans 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
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. 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.
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 Kharif Rabi
FE B MA R
Date for release of crop Ist February Ist August

MA Y
Provinces / Months
JAN
APR
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 & Livestocks)
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
years 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 Balochistans 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 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 Punjab Sind NWFP Balochistan 405.08 437.17 295.08 516.33 634.50 466.90
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
(Source: Ministry of Food Agriculture & Livestocks)
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 Balochistan NWFP Balochistan Balochistan Sindh Balochistan NWFP NWFP NWFP NWFP Hectares 6,488 5,752 1,569 1,605 3,520 1,340 1,070 835 772 1,220 Tonnes 85,473 65,374 27,918 22,187 20,876 15,990 12,553 10,430 10,073 8,545 Tonnes/ Hectare 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

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 Pishin K. Abdullah Chagai Loralai Musa khail Barkhan Zhob Killa Saifullah Sibi Ziarat
251 758 44 40 284 40 1,605 25 6,488 150
2,693 6,090 354 308 2,656 435 22,187 205 85,473 2,373
10.73 8.03 8.05 7.70 9.35 10.88 13.82 8.20 13.17 15.82
1.39 3.15 0.18 0.16 .37 0.22 11.46 0.11 44.14 1.23
Kohlu Dera Bughti Nasirabad Jaffarabad Bolan Jhal Magsi Kalat Mastung Khuzdar Awaran Kharan Lasbela Turbat Panjgoor Gwadar Total
22
342
15.55
0.18
1,569 1,340 400 27 117 125 825 213 218 620 173 37 4 15,375
27,918 15,990 5,240 354 1,014 1,065 6,945 1,534 1,671 6,456 2,027 275 28 193,633
17.79 11.93 13.10 13.11 8.67 8.52 8.42 7.20 7.67 10.41 11.72 7.43 7.00 12.59
14.42 8.26 2.71 0.18 0.52 0.55 3.59 0.79 0.86 3.33 1.05 0.14 0.01 100
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 Killa Saifullah Nasirabad Barkhan 44 14 12 Pakistan 18 6 5
Jafarabad
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
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 Market/Year QUETTA 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 526 394 399 319 610 395 196 221 298 292 455 387 208 327 246 194 490 265 501 403 288 595 757 230 707 558 238 1122 715 440 733 483 342 1005 685 580 253 293 336 572 657 609 235 547 286 368 722 563 514 597 263 514 721 729 330 594 219 490 588 367 277 395 285 270 650 476 381 434 341 455 695 648 405.08 437.17 295.08 516.33 634.50 90 Aug Sep Oct Nov Dec Jan Feb Mar Apr Ma y Jun Avg.
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:
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.
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. Pures 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
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 65-75C for Cold Break processing or to 85-98C 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 pulps 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 evaporators 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.
The entire concentration process (evaporation) takes place under vacuum conditions and at low temperatures, significantly below 100C. 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 5Brix 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 concentrators 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 products PH value. Generally speaking, a product with a pH value equal to or less than 4.2 could have a sterilization temperature of 115C 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 35-38C 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 products aseptic quality.
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
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:
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.
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, Chinas 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.
The target market of tomato paste/puree and pulp is as follows: Food processors like Mitchells 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 Pakistans 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
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 Hotels & Restaurants House Hold = = = 3,000-3,200 MT 800-1,000 MT 200 300 MT
The demand for tomato paste in near future is expected to increase at around 15% per annum.
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.
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 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 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
8. PROJECT COST
Rs. (000)
Cost Heads
Land & Development Building & Civil Works Plant & Machinery Erection and Installation Furniture & Fixture Vehicles Pre-Production Expenses Contingencies Total Fixed Cost Net Initial Working Capital Total Project Cost
Local
3,900
Imported
-
Total
3,900 15,125
15,125 80,000 1,500 2,790 650 2,200 2,000 9,663 80,000 37,828 5,247 80,000 43,075
81,500 2,790 650 2,200 2,000 9,663 117,828 5,247 123,075
Rs. (000)
PROJECTED INCOME STATEMENT

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 Taxation NET PROFIT AFTER TAX DIVIDEND Cum - Retained Earning
2008 85% 88,243 47,819 4,570 2,721 2,360 400 10,582 68,452 3,423 65,029 23,214 4,251 4,251 18,962 3,510 773 4,283 14,679 5,138 9,542 0 9,542 9,542
2009 90% 102,925 53,163 4,798 2,978 2,478 400 9,521 73,339 3,423 3,667 73,095 29,830 4,464 4,464 25,366 3,991 1,069 5,060 20,307 7,107 13,199 0 13,199 22,741
2010 95% 113,833 58,789 5,038 3,249 2,602 400 8,573 78,651 3,667 3,933 78,385 35,447 4,687 4,687 30,760 4,486 1,314 5,800 24,960 8,736 16,224 0 16,224 38,965
2011 95% 119,317 61,461 5,290 3,377 2,732 400 7,725 80,986 3,933 4,049 80,869 38,449 4,921 4,921 33,527 4,827 1,435 6,262 27,266 9,543 17,723 0 17,723 56,688
2012 95% 124,505 64,133 5,554 3,505 2,869 400 6,966 83,428 4,049 4,171 83,306 41,199 5,167 5,167 36,032 5,167 1,543 6,710 29,322 10,263 19,059 0 19,059 75,747
2013 95% 129,693 66,805 5,832 3,634 3,012 0 6,285 85,569 4,171 4,278 85,462 44,231 5,426 5,426 38,805 5,507 1,665 7,172 31,633 11,072 20,561 0 20,561 96,308
PAKIST AN HORT ICULT URE DEVELOPMENT EXPORT BOARD
23
PROJECTED BALANCE SHEET

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
Rs. (000)
2008 2009 2010 2011 2012 2013
25364 4,835 3,930 1,782 100 200 36,211 1,600
49,738 5,640 4,370 2,003 100 200 62,050 1,200
76,079 6,237 4,832 2,148 100 200 89,596 800
102,529 6,538 5,052 2,216 100 200 116,634 400
129,476 6,822 5,271 2,282 100 200 144,152 0
156,958 7,106 5,491 2,341 100 200 172,197 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
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 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 0 2,948 1,582 5,138 773 0 10,440 0 0 3,277 1,705 7,107 1,069 0 13,158 0 0 3,624 1,833 8,736 1,314 0 15,507 0 0 3,789 1,931 9,543 1,435 0 16,697 0 0 3,953 2,031 10,263 1,543 0 17,790 0 0 4,118 2,134 11,072 1,665 0 18,989 0
24
Rs. (000)
PROJECTED CASH FLOW

OPERATING ACTIVITIES
Operating Profit Add: Depreciation Preliminary Expenses Working capital changes: (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 Cash Generated From Operations Financial Charges Paid Dividend Paid W.P.P.F Income tax NET CASHFLOW FROM OPERATING
2008
2009
2010
2011
2012
2013
18,962 10,582 400 29,944 (100) (5,712) (4,835) (200) 1,290 (9,558) 20,387 (3,218) 17,169
25,366 9,521 400 35,288 0 (660) (804) 0 83 (1,382) 33,906 (3,951) (773) (5,138) 24,044
30,760 8,573 400 39,734 0 (607) (598) 0 87 (1,118) 38,616 (4,445) (1,069) (7,107) 25,994
33,527 7,725 400 41,653 0 (288) (301) 0 69 (519) 41,134 (4,798) (1,314) (8,736) 26,286
36,032 6,966 400 43,398 0 (286) (284) 0 72 (499) 42,899 (5,139) (1,435) (9,543) 26,783
38,805 6,285 0 45,090 0 (279) (284) 0 75 (488) 44,602 (5,479) (1,543) (10,263) 27,317
INVESTING ACTIVITIES:
Fixed Assets Acquired Long Term Investments Preliminary Expenses NET CASHFLOW FROM INVESTING (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
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 0 2,948 123,065 0 126,013 25,364 0 25,364 0 329 0 0 329 24,374 25,364 49,738 0 347 0 0 347 26,341 49,738 76,079 0 165 0 0 165 26,450 76,079 102,529 0 165 0 0 165 26,947 102,529 129,476 0 165 0 0 165 27,482 129,476 156,958
25
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
2008 Capacity % Potatos Production Add: Opening Inventory Less:Closing Inventory(5% of storage) Sale Volume 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 85% 2009 90% 2010 95% 2011 95% 2012 95% 2013 95%
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 2,565 2,309 2,565 2,309 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 50.00 500.00
26
REVENUE
Tomatos Tomatos Wastage
2008 87,210 1,033 88,243
2009 96,930 1,094 102,925
2010 102,330 1,154 113,833
2011 102,600 1,154 119,317
2012 102,600 1,154 124,505
2013 102,600 1,154 129,693
COST OF SALES
RAW MATERIAL
TOMATOS Requirement of Tomatos at 100% operation worked out as follows:
TOMATOS M. Tons 10,800 10,800
Years Capacity % Tomatos
2008 85% 9,180
2009 90% 9,720
2010 95% 10,260
2011 95% 10,260
2012 95% 10,260
2013 95% 10,260 200.00
The prices of tomatos fluctuates during the peak tomatos procurement season,therefore,average tomatos cost/40kgs is Rs. CHEMICALS AND OTHERS PERSERVATIVES Sodium Benzoate(.1%) Potassium Metabysulphate(.1%) Glacier Acetic Acid(5ml/kg) PACKING MATERIAL Polythine Bags(50grams/bag) Tomatoes Cost Chemicals and perservatives Packing Material Material Cost(subject to 5% annual increase) 45,900 1,818 101 47,819 51,030 2,021 112 53,163 56,430 2,235 124 58,789 58,995 2,336 130 61,461 61,560 2,438 135 64,133
70/kg. 120/kg. 160/liter.
110/kg. 64,125 2,539 141 66,805
27
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) Add: Fringe benefit 40% No. 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 3,000 160,000 Salary Per Annum 480 240 360 84 300 300 300 900 300 3,264 1,306 4,570 2012 5,554 2013 5,832
Years Labour Cost subject to 5% annual increase
2008 4,570
2009 4,798
2010 5,038
2011 5,290
POWER AND FUEL

Connecting Load kW Load Required KW Fixed charges Rs.352 per kW per month. Energy Charges Energy Cost(1.15+1.97)/2 Fuel adjustment & Duty Additional Surcharge(1.89+2.08)/2 Surcharge10.4% Per Unit 1.56 0.18 1.99 0.30 4.02 422 2,704 2008 422 2,299 2,721 2009 422 2,556 2,978 2010 422 2,826 3,249 2011 422 2,955 3,377 2012 422 3,083 3,505 2013 422 3,212 3,634 100 80
Fixed Charges Variable Energy Charges at 100% capacity Power Cost Subject to 5% annual increase Fixed Variable
WATER
No water charges are assumed for the proposed project as it will be taken from tube well sunk domestically.
28
OTHER MANUFACTURING OVERHEAD

Repair and Maintenance
Rs. (000)
These have been taken @ 1 % of the plant and machinery& building in first year subject to 5% increase in subsequent years 2008 Repair and Maintenance 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 Insurance Charges These have been taken @ 0.50 of the assets subject to 5%annul increase Insurance Charges 589 2,360 619 2,478 649 2,602 682 2,732 716 2,869 752 3,012 810 851 893 938 985 1,034 961 2009 1,009 2010 1,060 2011 1,113 2012 1,168 2013 1,227
TOTAL
DEPRECIATION SCHEDULE
Description Land Factory building Plant and Machinery Furniture, Fixture and Utilities Vehicles Cost 3,900 15,125 83,780 1,200 2,200 106,205 Other Cost 1,470 8,143 9,613 Total Cost 3,900 16,595 91,923 1,200 2,200 115,818 Rate % 0 5 10 10 20
Other Cost Contingencies 9,613 9,613
29
YEAR WISE DEPRECIATION Years 1 2 3 4 5 6 7 8 9 10 Factory Building 830 788 749 711 676 642 610 579 550 523 6,659 Plant & Machinery 9,192 8,273 7,446 6,701 6,031 5,428 4,885 4,397 3,957 3,561 59,871
(Rs. 000) Furniture 120 108 97 87 79 71 64 57 52 46 782 Vehicle 440 352 282 225 180 144 115 92 74 59 1964 Total 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 Chief Executive Accounts Manager Admin. Manager Marketing Manager Accounts Executives Clerks Marketing Executives Security Staff Time Office Staff Peon & Others Add: Fringe Benefit @ 40% No. 1 1 1 1 2 2 2 8 1 3 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 (Rs.000) Salary Per Annum 600 240 144 180 240 120 144 480 84 126 2,358 943 3,301 2012 4,013 2013 4,213
2008 Employees Salary Subject to 5% annual increase 3,301
2009 3,466
2010 3,640
2011 3,822
General Expenses
Travelling (Including Marketing) Printing and Stationery Telecommunication Others 400 150 300 100 950 950 4,251 998 4,464 1047 4,687 1100 4,921 1155 5,167 1212 5,426
General Expenses Subject to 5% annual increase
Total Admin. & General Expenses
30
FINANCIAL EXPENSES
Financial Charges: 2008 Cash Finance Other 2,510 1,000 3,510 2009 2,791 1,200 3,991 2010 3,086 1,400 4,486 2011 3,227 1,600 4,827
Rs. (000)
2012 3,367 1,800 5,167
2013 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
31
9. FINANCIAL INDICATORS
Present Value (at 15%) Pay Back Period IFRR IERR Employment Break Even Capacity
= = = = = =
Rs 130.138 million 5.15 years 16.32 % 28.03 % 60 Nos 77 %
APPENDIX - I
LIST OF PLANT & MACHINERY
Lift/Elevator
Washer
33
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

CRUSHER
This machine is applicable for various fruits and vegetables.
35
Preheating Machine
Multi-tube preheating machine is use to pasteurize the crushed products and to protect the original colourand to soften the products meanwhile. Max capacity:3000KG/H tubular board cover structure heat exchange area: 3.5~4.0 m2 input at mormal tempretureoutput tempreture around 80~85 adjustable steam consumption: 300~500KG/H dimension 1700*500*1400 longth * width * highth
36
Pulping Machine
The machine is applicable for pulping, peeling and deseeding of tomato, apricot etc.
37
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. The machine is applicable for juicing from tomato,orange,gringer,apple,pineapple etc.
38
Decanter
DECANTER TYPE V SERIES
DECANTER TYPE P SERIES
1Liquid Collector 2Liquid Level 3External 4Spiral 5Feed Pipe 6Screw Feeder 7Drum 8Antierosion Busbings 9Solid Discharge10Reduction
39
outlet of concentrated tomato process extract
Disk Centrifuge Skimming Separator
40
Vaccum Concentrator
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
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.
43
DETAILED PLANT LAY OUT

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PRE-FEASIBILITY STUDY

TOMATO PASTE PLANT

Feasibility study for Tomato Past Plant

Feasibility study for Tomato Past Plant

2 PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD

Feasibility study for Tomato Past Plant

3 PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD

Feasibility study for Tomato Past Plant

Date for release of crop Ist February Ist August

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

(Source: Ministry of Food Agriculture & Livestocks)

Feasibility study for Tomato Past Plant

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

(Source: Ministry of Food Agriculture & Livestocks)

*Rank with respect to yield

Feasibility study for Tomato Past Plant

251 758 44 40 284 40 1,605 25 6,488 150

6 PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD

Feasibility study for Tomato Past Plant

Feasibility study for Tomato Past Plant

Feasibility study for Tomato Past Plant

Feasibility study for Tomato Past Plant

10 PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD

Feasibility study for Tomato Past Plant

3. TOMATO PASTE PRODUCT

The production process will involve the following steps:

Feasibility study for Tomato Past Plant

Feasibility study for Tomato Past Plant

13 PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD

Feasibility study for Tomato Past Plant

PROCESS FLOW CHART:

14 PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD

Feasibility study for Tomato Past Plant

Feasibility study for Tomato Past Plant

16 PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD

Feasibility study for Tomato Past Plant

Top Ten Exporters of Tomato Paste in the World (Figures in tons)

Feasibility study for Tomato Past Plant

Feasibility study for Tomato Past Plant

Feasibility study for Tomato Past Plant

6. PLANT & MACHINERY

Feasibility study for Tomato Past Plant

7. HUMAN RESOURCE REQUIREMENTS:

21 PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD

Feasibility study for Tomato Past Plant

81,500 2,790 650 2,200 2,000 9,663 117,828 5,247 123,075

22 PAKISTAN HORTICULTURE DEVELOPMENT & EXPORT BOARD

Feasibility study for Tomato Past Plant

PROJECTED INCOME STATEMENT

PAKIST AN HORT ICULT URE DEVELOPMENT EXPORT BOARD

Feasibility study for Tomato Past Plant

PROJECTED BALANCE SHEET

25364 4,835 3,930 1,782 100 200 36,211 1,600

49,738 5,640 4,370 2,003 100 200 62,050 1,200

76,079 6,237 4,832 2,148 100 200 89,596 800

102,529 6,538 5,052 2,216 100 200 116,634 400

129,476 6,822 5,271 2,282 100 200 144,152 0

156,958 7,106 5,491 2,341 100 200 172,197 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

M. Tons at 100 % Production of Tomato Paste(324150*20%) 2,160 2,160