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Cost Breakdown: Setting Up A Tomato Processing Plant With Modern Equipment

There is no doubt that India leads the way in producing tomato products. If the food processing industries are looking to establish a tomato processing plant, they’re making the appropriate decision. Entrepreneurs have a significant opportunity to invest in this sector, as there is a growing demand for products such as sauces, ketchups, and purees. However, before commencing, it is essential to gain a deep insight into the costs involved in setting up a plant with the latest technologies.

What are the Costs Involved in Setting up the Plant?

  • Land and Construction

The primary costs involved are for land acquisition and plant construction. Depending on the desired size, the plant may be smaller or larger in scale. Generally, a medium-sized plant requires 1 to 2 acres of land. From region to region, the cost of land varies in India. The price ranges from ₹10 lakhs to ₹50 lakhs within semi-urban or rural areas. Additionally, there are the costs associated with constructing the building where the plant is located, as well as the costs of storage areas and utility rooms. Depending on the design and materials, the cost can range between ₹30 lakhs and ₹70 lakhs.

  • Plant Equipment

A substantial amount of money is involved when purchasing equipment for a tomato processing plant. This equipment includes washing and sorting units, pulping and crushing machines, evaporators or steam-jacketed kettles, pasteurisation and sterilisation systems and labelling and packaging machines. The cost of equipment ranges from ₹50 lakh to ₹2 crore, especially for small to medium-sized facilities. For long-term performance and reduced maintenance costs, it’s better to invest in energy-efficient and reliable machines from reputed manufacturers.

  • Setup and Utilities

It is essential to establish utilities, including power connections, water supply, steam systems and drainage. For washing and cleaning, tomato processing requires efficient water usage. Depending on the infrastructure and location, the stage will cost anywhere between ₹10 lakh and ₹30 lakh. At this point, installing internal fittings and equipment is another key expense.

  • Licenses and Regulatory Compliance

The food processing plants in India adhere to the guidelines made by the Food Safety and Standards Authority of India. Additional costs, such as licences, quality certifications, registration fees, and initial inspections, add an extra ₹2 lakh to ₹5 lakh. For smoother operations and market acceptance of products, it is necessary to ensure full compliance.

  • Training and Workforce

In a tomato processing plant, it is crucial to deploy trained staff to operate the machinery, manage quality control and handle logistics effectively. In India, labour costs are relatively low. However, the cost of training and initial recruitment varies between ₹5 lakh and ₹10 lakh. Ongoing salaries come under the operational costs.

To get in touch with the leading manufacturer of tomato processing plant equipment, contact GEM Foodtech. With advanced machinery and modern technologies, we are responsible for creating high-standard tomato processing accessories. Our team relies on the functional aspects while manufacturing tomato processing machinery. The machines can process tomato paste, ketchup and concentrate. Our accessories require minimal maintenance and offer maximum functionality. Partner with us today.

Pineapple Processing Plant Maintenance: Practices For Equipment Longevity

To ensure smoother operations, maintain equipment properly to ensure food safety and cost savings. It is essential for a plant that processes pineapple products. A maintenance routine prevents breakdowns for the plant that handles canning, drying, slicing, or juicing. Moreover, the maintenance can extend the shelf life of the machinery and decrease its downtime. To maintain the equipment in your pineapple processing plant, you must follow specific procedures.

Maintenance of the Equipment

Pineapple Processing Plant

Inspection and Routine Cleaning

One of the most essential maintenance practices is to clean the equipment daily. With the acids and natural sugar contained inside the pineapple, it corrodes the surfaces of the equipment. Moreover, it can also entice pests. Therefore, clean them regularly as cleaning gives a shinier look. The performance of the machine is affected as the sticky residues clog the moving parts. Inspect the machines to check for signs of wear and tear, as well as any loose connections. If you overlook minor problems, they can cause significant mechanical issues.

Staff Responsibility and Training

Train your staff on how to handle the equipment safely and securely. The staff must know how to operate the equipment and ensure that they are not making any mistakes. A single mistake can lead to significant issues that are not easily resolved. Whenever the latest machines and procedures are introduced, your staff needs to be aware of them. To ensure accountability for maintenance tasks, assign responsibilities carefully. Operators opt for minor upkeep and daily cleaning, whereas a supervisor supervises weekly checking.

Scheduled Servicing

According to the manufacturer’s guidelines, planned servicing is required. It consists of inspecting sensors, oiling parts, tightening bolts and replacing filters. If you don’t want to miss these tasks, try maintaining a calendar. To implement preventative maintenance, plants adopt a system. Adjust or replace the items based on the usage time if any parts are damaged.

Implement Quality Replacement Parts

Try to use genuine or unique components while replacing the parts of the equipment. Remember that replacing with quality parts is one of the most essential things. To prevent damage to the equipment, you need quality parts. An organised inventory of spare parts needs to be there. The inventory of spare parts avoids any delays in the event of a breakdown.

Environmental Considerations

Ensure that the machinery operates in a safe and secure environment. The condition of the equipment is affected by the changes in humidity, temperature and dust. To prevent machinery from external harm, ensure better ventilation, keep floors clean and dry, and use covers whenever possible.

Record Keeping

To monitor performance and plan future tasks, track detailed records of the activities related to maintenance. Maintain a logbook to record all entries that occur. The entries include replacing parts, maintenance actions taken, and various other activities. It helps to meet regulatory requirements and supports effective maintenance.

Are you looking forward to maintaining the equipment of your plant? Follow these steps. Visit GEM Foodtech, where we’re your partner in providing the finest equipment for your plant. Book an appointment with us now.

How To Make Your Mango Processing Plant More Sustainable?

Sustainability is now a need rather than merely a fad in today’s environmentally conscious society. Like all food processing plants, a mango processing plant is coming under increasing pressure to reduce its environmental impact. There are numerous areas where minor adjustments can have a significant impact, including packaging materials, waste production, energy use and water usage. In addition to helping the environment, making your mango processing plant more sustainable can increase productivity, reduce expenses, and boost your company’s reputation. Here, the experts examine practical and efficient strategies to enhance the environmental impact and future readiness of your mango processing business.

Ways to Make the Plant More Sustainable

These are the ways by which you can make the plant more sustainable:

Optimisation of Water Usage

In any fruit processing unit, water is an essential resource, particularly for cleaning, pulping and washing. To save water:

  • Install flow regulators and nozzles that use less water.
  • When safe and practical, recycle water, especially for non-potable applications like floor cleaning. 
  • Maintain equipment correctly and regularly inspect for leaks or waste.

Effective water management lowers wastewater treatment expenses while also conserving resources.

Renewable Energy

Shifting to renewable energy reduces carbon emissions. Hence, it is smarter to opt for renewable energy instead of traditional power sources. Try to consider:

  • Installing solar panels to supply electricity to certain areas of the building.
  • Utilising biomass energy produced from the leftovers of mangoes.
  • If on-site solutions are not feasible, look into green energy suppliers.

Making the transition to cleaner energy sources helps you future-proof your business and lessen your reliance on fossil fuels.

Reduce Packaging Waste

One of the main causes of pollution in the food industry is packaging. Sustainable substitutes consist of:

  • Utilising recyclable, compostable or biodegradable materials.
  • Maximising container sizes to reduce the need for extra packaging.
  • Collaborating with packaging vendors who use environmentally friendly production methods.

In addition to benefiting the environment, this may draw in eco-aware clients.

Minimise Mango Waste

Large amounts of peel, pit and pulp waste are frequently produced during the processing of mangos. Instead of throwing it away:

  • Transform mango waste into products with added value, such as compost, animal feed or biofuel.
  • Collaborate with nearby companies that can utilise organic waste.
  • Implement a waste segregation system to enhance recycling and disposal practices.

These actions lessen the impact on landfills and open up new sources of income.Energy efficiency

Using less energy is a smarter idea and is responsible for making a huge difference. There are a few tips that need to be considered.

  • Switching to LED lighting and energy efficient equipment.
  • Putting motion sensors in places that aren’t used as much.
  • Identifying energy waste through routine audits.

Long-term savings and reduced operating emissions are the results of improved energy efficiency.

Hence, it is a strategic move to make your mango processing plant more sustainable. For more information, visit GEM Foodtech. We are your partner in providing tailor-made machines for your plant. Our machines surely align with your future expectations. We are looking forward to providing service that exceeds your expectations.

Technological Innovations in Tomato Processing: What’s New in 2025?

The tomato processing sector in India is evolving faster than ever. With rising consumer demand and changing quality standards, traditional methods no longer meet current expectations. Modern businesses need speed, safety, and consistency in every stage of processing.

That is exactly where 2025 brings major breakthroughs. From AI-driven sorting to energy-efficient systems, the landscape of tomato processing plant machinery is undergoing significant shifts. These innovations aim to help businesses scale smarter and stay ahead in a competitive and rapidly growing market.

AI-Driven Quality Sorting and Grading Systems

Manual sorting wastes time and often results in inconsistency. Today, businesses are embracing machine vision powered by AI for grading tomatoes. These systems detect ripeness, colour, shape, and even internal defects instantly.

With real-time image processing, the machinery separates produce with unmatched precision. It ensures only the best-quality tomatoes enter the processing line. This not only boosts productivity but also reduces waste of raw materials. 

The result? 

Higher profits and greater process control with less manual intervention.

Tomato Processing Machinery

Energy-Efficient Evaporation and Concentration Technologies

In 2025, the focus has shifted to sustainable thermal systems. Advanced evaporators now operate on lower energy inputs, utilising vacuum technology and energy recovery systems. These solutions are ideal for producing tomato paste and ketchup on a large scale.

They accelerate the thickening process while reducing fuel and water usage. For businesses processing large volumes, these energy-saving innovations offer long-term operational cost benefits. Many new systems also allow easy integration with existing tomato processing plant machinery setups.

Continuous Processing Lines for Maximum Output

Time is money in food processing. Continuous processing lines now support real-time automation from sorting to filling. New technologies allow plants to fine-tune temperature, speed, and flow rates with centralised control systems.

Customisation is another game-changer. Whether you handle small batches or industrial-scale loads, today’s tomato processing plant machinery is designed to adapt to your specific production targets. Modular design also facilitates smoother upgrades, reducing downtime and maintenance requirements.

Clean-in-Place (CIP) Systems with IoT Efficiency

Hygiene has become a non-negotiable factor. In 2025, CIP systems have become smarter and more efficient. Internet of Things (IoT)-enabled units now monitor flow rates, temperatures, and cleaning cycles in real-time.

These systems clean the entire plant line without requiring the dismantling of equipment. That means less manual effort, shorter cleaning times, and guaranteed compliance with food safety standards. For exporters, this technology ensures alignment with global hygiene and traceability norms.

Building Future-Ready Tomato Processing Plants

Upgrading to the latest tomato processing plant machinery is not just a trend. Rather, it’s a business need in 2025. Whether it’s automation, energy efficiency, or hygiene control, each innovation brings lasting value.

For plant owners ready to scale, modern solutions promise improved speed, savings, and quality control. To explore machinery that fits your business model and growth goals, consult our specialists at GEM Foodtech. We offer tailor-made machinery that aligns with today’s innovations and tomorrow’s expectations.

What Features Must a Tomato Processing Machine Have?

Are you planning to establish a tomato processing plant in India? Undoubtedly, it is a growing field and has a flourishing future. If you want to set a footprint in this industry, you must go for the right equipment. The right tomato processing plant equipment in India ensures the highest efficiency and top-notch product quality. It also helps to comply with food safety standards. To select the perfect one, you must look for specific features in the machine.

Top Features That You Must Look for in a Tomato Processing Plant

Tomato Processing Machinery

  • Capability for High-Scale Production

Select robust tomato processing plant equipment in India. It helps to meet higher market demands. Machines ranging from 500 kg/hr to 5 tons/hr are available in the Indian market. It caters to both small-scale and large-scale operations.

  • Automation Technology for Higher Efficiency 

Almost every field is rapidly adopting automation. Through automation, you can better handle and plan operations. It reduces labour costs and boosts production. Choose machines with automation technologies such as sorting, pulping, and packaging. Minimal human intervention lowers the chances of human error. Naturally, it maintains a standard of delivery.

  • Lower Upkeep Cost and Easy Cleaning

You must regularly clean tomato processing plant equipment in India. This helps maintain health and safety standards and prevent impurity. Hence, always go for machines that are easy to clean. Machines built from stainless steel or equipment with features like CIP (Clean-In-Place) systems are great for this. These machines simplify maintenance. Additionally, they require lower maintenance due to their higher durability.

  • Energy Efficiency Technologies to Reduce Operational Costs

Energy-efficient tomato processing plants or plant equipment consume less energy. It contributes to lower operational costs. They also help the organisation follow sustainability practices. These practices help comply with laws and regulations and ensure a lower footprint.

  • Customisation Facility to Meet the Diverse Market Needs

Investing in a machine or equipment with a customisation facility is a smart decision. It ensures staying competitive. It allows you to easily produce different products. It includes puree, ketchup, sauce, and paste, helping you meet the diverse market demand.

  • Compliance with Food Safety Standards

Following international and national food safety standards is crucial. It ensures transparency, adherence to legalities, and a stable future for your business. Look for CE, ISO 9001:2015, NSF, and FDA-compliant machines. 

  • Efficient Packing Solutions

Packing plays a pivotal role in customer satisfaction. Perfect packaging helps maintain the standard of the food. It ensures zero contamination and boosts shelf life. However, investing separately in packaging can hike up the overall operational costs. To avoid this, always invest in equipment with integrated packaging solutions. The updated machines come with features like filling, sealing, and labelling.

Investing in the right equipment sets the foundation for a successful tomato processing plant in India. Features like capacity, energy efficiency, automation, and hygiene help maintain standards. On the other hand, customisation and packaging help boost consumer satisfaction.

At GEM Foodtech, we offer a range of tomato processing machines. We develop equipment with updated technologies and advanced machinery. It helps our clients meet the highest standards. Our machines are not just equipment for your processing plant. These are bricks of your company’s future success.

Book your call to learn the details.

Maximising Efficiency: Key Benefits of Dehydration Equipment

Dehydration equipment has applications in many industries. It can be used for product conservation, space maximisation, and activity enhancement. Dehydration inhibits spoilage by preventing moisture from entering the product and extending shelf life. Foodstuffs, pharmaceutical preparations, and many chemicals utilise this process. This technique saves waste and improves the quality of the final product. Here, we will discuss dehydration equipment from a cost-cutting and productivity-boosting perspective.

Key Benefits of Dehydration Equipment

Dehydration equipment has several key advantages. It helps preserve products, cuts costs, and maintains quality. It also promotes sustainability by lowering waste and energy use.

  • Longer Shelf Life

Dehydration helps remove moisture and thus prevents spoilage, extending the shelf life of dehydrated goods. In the food industry, fruits, vegetables, and meats remain fresh for a long time without refrigeration. This allows companies to hold their products longer, reducing waste and storage costs.

  • Low Cost

Dehydration is a low-cost option. It uses less energy than refrigeration or freezing. Dehydrated products tend to be lighter and smaller, reducing transport and storage costs. These savings add up for companies over time.

  • Maintaining Quality

Dehydration preserves the product’s natural aromas, colours, and nutrients. It does not include chemicals or preservatives, such as freezing or canning. This results in a product that is entirely natural, healthier, and, therefore, more attractive to consumers.

  • Increased Storage Efficiency

Dehydrated products take up less space, allowing businesses to store larger amounts in smaller spaces. Less packaging also lowers the cost of storage and handling for businesses.  

  • Environment Friendly

Dehydration is an ecological procedure. It requires less energy than other preservative techniques, such as freezing. It helps prevent spoilage, thus reducing food and material wastage, further ensuring its sustainability.  

Investing in Dehydration

equipment in India is a good value addition for an enterprise. It increases the shelf life of products, thereby ensuring their quality, and it even possesses the benefit of being green. Such equipment can save a company money by reducing waste and improving storage and energy consumption.

GEM Foodtech is Kolkata, India’s manufacturer and global exporter of advanced food processing equipment. We specialise in food preparation, processing, and packaging machinery and offer solutions in line with international quality standards. Our innovative designs build footprints in the health-conscious emerging market while ensuring quality food that is processed faster.