V. Technical Aspecta. Manufactur<strong>in</strong>g Process:Process outl<strong>in</strong>e:Special varieties <str<strong>on</strong>g>of</str<strong>on</strong>g> tomatoes like scarlet globe, early red b<strong>on</strong>nybest, p<strong>on</strong>drosa, seoux, pasaruby, marglobe,etc. are suitable for preparati<strong>on</strong> <str<strong>on</strong>g>of</str<strong>on</strong>g> processed products <str<strong>on</strong>g>of</str<strong>on</strong>g> tomato.Tomato Juice:Fully ripe with well developed colour tomatoes are washed,trimmed, steamed, crushed <strong>in</strong> a crusher or cut <strong>in</strong>to pieces with knives. The crushed pieces are heated <strong>in</strong> thesteam jacketted kettle till they become quite s<str<strong>on</strong>g>of</str<strong>on</strong>g>ten. The heated tomatoes are passed through the pulp<strong>in</strong>gmach<strong>in</strong>e us<strong>in</strong>g a f<strong>in</strong>e mesh sieve to separate juice from seeds and the sk<strong>in</strong>. Add sugar and salt @ 1% heat to85-90 C. The hot juice is filled <strong>in</strong> bottles, sealed immediately and processed <strong>in</strong> boil<strong>in</strong>g water for about 30m<strong>in</strong>utes and cooled.Tomato Puree:The juice obta<strong>in</strong>ed as above is c<strong>on</strong>centrated under vaccum toabout 9% to 12% total solids so as to get tomato puree. The product is filled <strong>in</strong> bottles , crown corked andprocessed <strong>in</strong> boil<strong>in</strong>g water for 30 m<strong>in</strong>. and cooled.Tomato Ketchup:The juice obta<strong>in</strong>ed as above is c<strong>on</strong>centrate with spices, salt,sugar, etc. The spices are put loosely <strong>in</strong> a musl<strong>in</strong> bag and placed <strong>in</strong> boil<strong>in</strong>g cloves, cardamom, pepper,c<strong>in</strong>nam<strong>on</strong> and other <strong>in</strong>gredients to be added are sugar, salt and v<strong>in</strong>egar or acetic acid.Generally c<strong>on</strong>centrati<strong>on</strong> is d<strong>on</strong>e three-fold. It is c<strong>on</strong>centrated to 28 to 30% solids <str<strong>on</strong>g>of</str<strong>on</strong>g> which 12% aretomato solids. The f<strong>in</strong>al product could be preserved by additi<strong>on</strong> <str<strong>on</strong>g>of</str<strong>on</strong>g> sodium benzoate @ 750 ppm. The tomatoketchup is filled hot <strong>in</strong>to clean, dry bottles, crown corked and processed <strong>in</strong> boil<strong>in</strong>g water for 30 m<strong>in</strong>utes andcooled as precauti<strong>on</strong>ery measure.b. Quality C<strong>on</strong>trol & Standards:Manufacture <str<strong>on</strong>g>of</str<strong>on</strong>g> processed fruits and vegetables is c<strong>on</strong>trolled bythe Fruit Product Order (FPO) 1955 <str<strong>on</strong>g>of</str<strong>on</strong>g> the Govt. <str<strong>on</strong>g>of</str<strong>on</strong>g> India . The Fruit Product Order 195 is mandatoryfor Tomato products. The tomato products should c<strong>on</strong>form to specificati<strong>on</strong>s laid down <strong>in</strong> FPO.The FPO specificati<strong>on</strong> is as:Tomato juice 5% total solids.Tomato Puree 9% total solids SOD. BENZOATE :250 ppmTomato ketchup 25% total solids. ACIDITY:1.0% SOD. BENZOATE :750 ppmThe Bureau <str<strong>on</strong>g>of</str<strong>on</strong>g> Indian Standards has laid down the follow<strong>in</strong>g specificati<strong>on</strong>s for tomato products:Tomato juice IS 3881-1966.Tomato ketchup IS 3882-1966.Tomato Puree IS 3883-1966.The ISO 9000 series, IS 14000 series <str<strong>on</strong>g>of</str<strong>on</strong>g> European Norm series standards promises a team workwhich may guide the entrepreneurs towards fulfilment <str<strong>on</strong>g>of</str<strong>on</strong>g> a commitment for quality <str<strong>on</strong>g>of</str<strong>on</strong>g> products.c. Polluti<strong>on</strong> C<strong>on</strong>trol:There is no major polluti<strong>on</strong> problem associated with theproject. However, material waste (sk<strong>in</strong>, seeds, etc.) are the ma<strong>in</strong> affluents. The provisi<strong>on</strong> <str<strong>on</strong>g>of</str<strong>on</strong>g> such treatment64
has been made <strong>in</strong> the pr<str<strong>on</strong>g>of</str<strong>on</strong>g>ile. The entrepreneurs may however, c<strong>on</strong>tact the c<strong>on</strong>cerned State Polluti<strong>on</strong> C<strong>on</strong>trolBoard for detailed guidance <strong>in</strong> the matter. M<strong>in</strong>imum height <str<strong>on</strong>g>of</str<strong>on</strong>g> shed will be ma<strong>in</strong>ta<strong>in</strong>ed with exhaust fansshould be <strong>in</strong>stalled for remov<strong>in</strong>g dec<strong>on</strong>gesti<strong>on</strong> proper ventilati<strong>on</strong>, removal <str<strong>on</strong>g>of</str<strong>on</strong>g> cokes fumes etc.d. Process Flow Chart For the preparati<strong>on</strong> <str<strong>on</strong>g>of</str<strong>on</strong>g> TOMATO SOUCE/ KETCHUPTOMATOES (RED& MATURE )WASHINGCRUSHING IN FRUIT MILLCRUSHED PULP HEAT FOR 5 MIN. AT 85oCPASS THROUGH PULPER-----SEPARATE SEEDS &SKINJUICEWEIGH & BOILADD SUGER & SPICE TIED IN A BAGADD SALTCOUNTINUE BOILING TILL 28*BRIXSTOP BOILING AT 28* BRIX AND ADD ACETIC ACID&SODIUM BENZOATEFILL HOT IN PRESTERILISED GLASS BOTTLESTHEN SEAL &STORE AT ROOM TEMP.RECIPE: FOR FINAL PRODUCTKETCHUPSAUCETOMATO JUICE (HOT) :2.5 Kg. :10 Kg :10 Kg.ONION (CHOPPED ) :20 Gm. :118 Gm. :100 Gm.GARLIC( CHOPPED ) :2 Gm. :10 Gm. :10 Gm.CLOVE(DEVOID OF HEAT) :1 Gm. :5 Gm. :4 Gm.SMALL CARDAMOM :1 Gm. :2 Gm. :1 Gm.BLACK PEPPER :1Gm. :2 Gm. :1 Gm.CUMIN :1 Gm. :2 Gm. :1 Gm.MACE :1 Gm. :1 Gm. :1 Gm.CINNAMOM :1 Gm. :5 Gm. :4 Gm.SUGAR :200 Gm. :583 Gm. :748 Gm.SALT :20 Gm. :92 Gm :110 Gm..RED CHILLI POWER :2 Gm. :2 Gm. :5 Gm.GLACIAL ACETIC ACID :4 ml. :23 ml :20 ml.SODIUM BENZOATE : 0.85 Gm. :3.7 Gm. :4.29 Gm.FINAL BATCH WEIGHT :1 Kg. :4.2 Kg. :4.85 Kg.65
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