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What Are The Costs Involved in Establishing a Tomato Processing Plant?

Tomatoes are a widely accepted vegetable which is a common ingredient in almost all Indian dishes. Apart from cooking, soups, sauces and tomato purees are a few forms of tomato pastes which are being widely used worldwide. To meet the growing demand for tomato pastes, food processing companies have resorted to using tomato processing plants.

These plants have the capability of squeezing the tomato puree out of the vegetable, grinding the same and converting it into a usable paste. However, the manufacturing and establishment cost of a tomato processing plant involves a lot of factors.

What are the Expenses Involved in the Establishment of a Tomato Processing Plant?

  • Cost of Equipment and Machinery

For processing of the tomato advanced and specialised machinery and equipment are necessary. The cost of equipment includes the cost of the washers, peelers, crushers, sorters and the evaporators as well. Companies that use high-quality automated machines for more production, have to bear high equipment costs.

  • Cost of Labour and Training Expenses

Labour cost is an ongoing expense for all tomato processing plants. Tomato processing plants are complex, hence the companies generally need extensive labour sources to operate these machineries. Hence this adds to the labour and training expenses of the company. Again adequate training programs are also required to ensure that the workers can operate the plants safely.

  • Cost of Raw Material

Tomatoes are the primary raw material which is used in the processing plant. However, the availability of tomatoes is subject to seasonal variations. Especially during summers getting tomatoes can be expensive. For raw material procurement, companies are required to negotiate with tomato growers and invest in the raw material procurement process.

  • Cost of Quality Control Process

Processing is not the end step. The companies need to invest in the quality control process as well. Expenses associated with quality control include labour charges, certifications, regular tests, checking shelf life and safety process and regulation expenses.

  • Cost of Packaging and Distribution

Expenses involved in packaging materials and the distribution process of the processes tomato play a significant role in determining the total cost of the tomato processing. Moreover, the packaging expenses also include the costs of the cans, glass jars, pouches and plastic containers where the processed tomato is being stored. Along with packaging distribution costs are also included in the same.

Get in touch with GEM Foodtech a leading manufacturer and exporter of tomato processing plants for the best quality tomato processing units.

Benefits of Using Tomato Processing Plant Equipment over Traditional Method

Do you want to increase the production of your tomato processing? Then, it is better to shift to machinery than traditional manual processes. Gone are the days when industries relied upon manual labour for food processing. Nowadays, every tomato processing plant uses proper equipment and tools to increase productivity, save time, and reduce hassle.

Today, we will know the advantages of using tomato processing plant equipment over traditional manual techniques.

The Reasons To Opt For Tomato Processing Plant Equipment

  •  Increase Productivity

The use of tomato processing equipment helps automate several tasks. These machines streamline processes like peeling, coring, chopping, and packaging. They reduce labour costs and increase the overall productivity in the processing plant.

The tomato processing equipment can constantly and quickly process many tomatoes. Its consistent output ensures uniformity in size, shape, and quality.

Buy the best quality tomato processing machine from a trustworthy dealer who provides compact machines that carry out different services. These machineries have several key sections useful for tomato reception, processing, juice extraction, evaporation, and packaging.

  • Increased Level of Quality and Safety

Modern tomato processing units are designed to maintain the utmost hygienic conditions. The machines reduce the risk of contamination and ensure food safety. They perform tasks with higher precision than manual methods.

  • Affordability

Though the initial investment in tomato processing equipment is high, it will lead to significant long-term savings. Automated tomato processing equipment can reduce labour costs in areas with higher costs. Moreover, the processing machines are highly productive, leading to lower production costs.

  • Higher Scalability

The tomato processing equipment can be scaled to meet the ever-increasing production demand. When the demand grows, businesses can also expand their operations by adding more equipment to the plant to increase production.

  • Leads to Less Waste Generation

The equipment can process the tomatoes precisely, reducing the waste generated in the plants. Some machines are also designed to make byproducts, like tomato peels and seeds, which can be used for other purposes.

The Modern Tomato Processing Machines Have Different Sections-

  • The reception system includes a tomato feed conveyor, washer and sorting table for tomatoes.
  • The juice extraction set-up includes a receiving tank, transfer pump, balance bank, tomato finisher and pulp preheater.
  • The plant evaporator includes a flow control setting, vapour separator, vacuum pump, steam supply, seal water tank, feed pump, concentrate and condensate pumps, control panels, and vapour ducts. 
  • The packaging section includes a glass packaging system and a can packaging system.

GEM Foodtech offers a wide range of tomato processing equipment. Our team produces and exports high-quality tomato processing plants to meet the demands of the global industry. Our machines can produce tomato derivatives like concentrate, paste, and ketchup. Contact us for specialised processing units.

Why Do Food Processing Industries Require Dehydration Equipment?

Are you seeking the best quality dehydration equipment for your food processing plant? You have come to the right place.

Every food processing plant invests in dehydration equipment for several reasons. These dehydration units quickly and precisely remove moisture from vegetables and fruits, reducing the chances of product contamination. The high-temperature gas streams pass through the advanced dehydration machines, eliminating moisture and preventing the deterioration of food items.

The Features of Good Dehydration Equipment

  • Equal drying of fruits and vegetables in different batches
  • Efficient dehydration for a wide range of natural food products
  • Having a long service life and a hassle-free performance
  • Easy to operate in different dehydration modes
  • Optimal energy consumption with prolonged usage

Plantain Chips & flour Processing Machinery

The Various Reasons to Use Dehydration Equipment

  1. Dehydration is an effective method for preserving food. By removing moisture, dehydration restricts the growth of bacteria, mould, and yeast, thus extending the shelf life of the food items. Using these units reduces food wastage and storage costs.
  2. Dehydration also transforms fresh produce into convenient, lightweight products. Dried fruits, vegetables, and herbs can be stored easily and used to make different products. Dehydration opens up new marketing opportunities for food processors, allowing them to cater to diverse customer choices.
  3. Dehydration enhances food’s flavour and nutritional value. The process concentrates the sugar and nutrients inside the fruits and vegetables, resulting in a more intense taste experience for consumers. Dried food items become lighter in weight and compact, ideal for transportation and distribution.
  4. Dehydration is an energy-efficient process compared to the other preservation techniques available. Dehydration equipment requires less energy to operate, reducing carbon footprints and operational costs.

How To Find A Dehydration Machine Manufacturer?

Finding a suitable dehydration machine manufacturer requires a systematic approach. First, conduct thorough online research using industry-specific directories and marketplaces. Then, visit trade shows to connect with potential dealers.

When evaluating the choices, focus on manufacturing companies with a proven track record, positive customer feedback, and certifications. Also consider factors like machine capacity, energy efficiency, price, and after-sales services. Ask the manufacturer for detailed product specifications, delivery timelines, and pricing. Establishing a strong relationship with a provider is crucial for long-term success. If you are looking for quality dehydration equipment, get in touch with GEM Foodtech. We can provide you with all the essential components and machinery of a dehydration equipment.

The Most Important Components of a Tomato Processing Plant

A tomato processing plant is made of many industrial machinery. Each component of the plant plays a crucial role in transforming fresh tomatoes into various consumer products like ketchup, paste, and canned tomatoes. Here, we have presented a comprehensive breakdown of the different tomato processing plant equipment. Let’s take a closer look at some of these most important components.

The Essential Components of a Tomato Processing Plant 

Let’s delve into the most important equipment found in a tomato processing plant:

  • Tomato washer

The first step in the process is ensuring clean tomatoes. The tomato washer utilises high-pressure sprays to remove dirt, debris, and any unwanted elements clinging to the tomatoes. Throughput can vary depending on the size and design of the washer, but typically ranges from 10-20 tons of tomatoes per hour.

  • Sorting Conveyor

After the washing stage, a sorting conveyor equipped with human inspectors ensures only the best quality tomatoes proceed further. Inspectors remove any blemishes or unripe tomatoes. This can help maintain the overall quality of the tomatoes.

  • Tomato Crusher

The crusher is where the tomatoes are broken down into a coarse pulp. There are two main types of crushers, distinguished by their operating temperature: hot break and cold break. Hot break crushers utilise heat to achieve a richer colour and higher lycopene content, while cold break crushers prioritise fresh flavour by processing at room temperature.

  • Tomato Pulper

Once crushed, the tomatoes enter the pulper, which separates the juice from the skin, seeds, and coarse fibres. The tomato juice, containing the essence of the fruit, is what forms the base for most tomato products. Pulpers typically have a throughput of 3-8 tons per hour.

  • Evaporator

The evaporator plays a crucial role in concentrating the tomato essence. This machine uses heat and vacuum technology to remove excess water from the tomato juice, resulting in a thicker and more concentrated product. Evaporators have a throughput of 1-3 tons per hour and are typically the most expensive component in a processing plant.

  • Filling and Packaging Line

The final stage involves filling and packaging the finished product into cans, bottles, or pouches. This is where the magic of automation comes into play. Filling and packaging lines can be highly customised based on the desired output speed and level of automation. Throughput is dependent on the line speed, which can range from 2,000 to 5,000 units per hour.

These essential components work together seamlessly to transform a truckload of fresh tomatoes into shelf-stable tomato products. From the initial washing to the final packaging, each piece of tomato processing plant equipment plays a vital role in the efficient and hygienic production of tomato-based goods. If you are looking for quality tomato processing plant equipment, get in touch with GEM Foodtech. We can provide you with all the essential components and machinery of a tomato processing plant.

How to Ensure Quality and Safety in Tomato Processing Plant?

India is one of the leading producers of tomatoes. Processing plants are crucial in bringing tomato products like ketchup, puree, and paste to kitchens. As an owner of a processing plant, you must consistently focus on good quality and safe products. Hence, you must prioritise food safety and maintain tomato processing plant Equipment standards.

Ways You Can Ensure Safety and Quality in Tomato Processing Plant

Tomato Processing Machinery

  1. Choosing The Right Food Processing Manufacturer

The foremost factor for ensuring quality and safety in a tomato processing plant is to have the right machinery. Contact a trusted, reputable, experienced food processing plant manufacturer that supplies best-in-class machinery for tomato processing plants. The machines you pick should be suitable for producing derivative products like tomato concentrate, tomato paste and ketchup. The machinery should have optimal functionality and need very low maintenance.

  2. Prioritise the Food Safety

The first step in ensuring food safety and quality is to implement a HACCP plan. It is a globally recognised system for identifying and controlling potential hazards throughout the tomato processing chain. It includes sourcing the best quality tomatoes from trusted growers, monitoring temperature during processing, and ensuring proper sanitation practices.

  3. Follow Good Manufacturing Practices

The method of tomato processing plant should follow the established good manufacturing process mentioned by the Food Safety and Standards of India (FSSAI). These practices cover different aspects, such as sanitation methods and hygiene, pest control, and proper product storage.

  4. Regular Testing and Traceability

Regular testing of the raw tomatoes and in-process materials is a must. The finished products should also be tested to ensure no potential contaminants, such as pesticides and mycotoxins, are present. Different accredited testing labs should be utilised to ensure the best results. Maintain a robust traceability system for tracking the tomatoes from the farm to the finished product in the plant. This will further allow swift identification and removal of contaminated batches.

  5. Take Preventive Maintenance of Equipment

Implement a detailed preventive maintenance program for all the processing equipment used in the tomato processing plant equipment. This program should include regular cleaning, lubrication, and scheduled inspections to identify and address issues before they cause major problems.

  6. Upgrade the old Tomato Processing Plant Equipment

Maintaining the existing equipment is crucial. But you often need to upgrade it to new and efficient models. The new equipment comes with advanced safety features that are easy to clean and reduce the chance of contamination. 

  7. Compliance with the processing regulations

Ensure that the tomato processing plant adheres to all the regulations FSSAI and other regulatory bodies set. This includes using food-approved food-grade materials for equipment and maintaining specific processing parameters.

Having a safe and efficient processing plant has various advantages. It reduces the risk of product recalls, improves product quality, and increases operational efficiency. GEM Foodtech offers the best quality processing machinery and equipment for tomato processing. Our tomato processing plant has a reception system that includes a tomato feed conveyor, washer system, and sorting table for raw materials. Buying tomato processing machinery from GEM Foodtech is a good choice to ensure safe production in your processing plant. Call us now to learn more.

Challenges in Mango Pulp Processing and How to Overcome Them

Mango pulp processing is the process of extracting juicy flesh from mangoes. This flesh is refined and packaged for consumption or further use. This method involves several steps but comes with certain challenges. The experts working in the plants of mango processing must be familiar with these challenges.

Let’s explore the obstacles in mango processing and tips for overcoming them:

Mango Processing machinery

  • Contamination: Mango pulp contamination can happen at several phases of processing like harvesting, transportation, and processing itself. Mango pulp’s high sugar concentration makes it prone to microbial growth, which can lead to spoilage. Contaminants might be pathogens, foreign items, or certain chemicals.

Effective cleaning practices, correct handling, and compliance with food safety standards are critical for preventing contamination.

  • Wrong Harvesting Time: The choice of ripe and mature mangoes is a determining factor for producing high-quality pulp. If mangoes are harvested too soon or too late, the pulp may lack the ideal flavour, colour, and texture.

During processing, the mangoes’ ripeness and maturity must be carefully monitored. It is necessary for mango processors to have strong relationships with dependable suppliers and apply strict quality control processes.

  • Enzymatic Browning: Enzymatic browning is a common problem with mango pulps. It happens when fruit enzymes react with oxygen. Browning has an adverse effect on the pulp’s colour and appearance.

Enzymatic browning can be managed by applying antioxidants and implementing certain processing techniques like blanching or adding citric acid.

  • Over-processing or Under-processing: Mango pulp can be over or under-processed as a result of improper processing parameters, such as temperature and duration. 

Under-processing may not entirely eliminate enzymes or microbial pathogens, while over-processing will result in unwanted changes to flavour, colour, and texture of the pulp.

Precise processing parameters are necessary to guarantee pulp safety and quality. To achieve the desired texture, processors must implement contemporary equipment and monitor variables like temperature and blending.

  • Microbial Spoilage: Mango pulp’s high water activity and nutrient content make it vulnerable to microbial spoilage. If the pulp isn’t properly handled, stored, or preserved, microorganisms, including bacteria, moulds, and yeasts, will grow quickly.

Hence, processors must use technologies like aseptic processing along with appropriate packaging to reduce air exposure and preserve the mango pulp’s inherent flavour and aroma.

Are you looking for a high-quality mango pulp processing line to address your industrial needs? If so, GEM Foodtech will be your ultimate destination. We have years of experience in this realm and deliver products that match your expectations. Contact us today.