PRODUCTION FLOW FOR PASTA SAUCE

RAW CLEANED PASTA

FIRST STEAM JACKET KETTLE

SECOND STEAM JACKET KETTLE WITH AGITATOR

INGREDIENTS TAKEN FROM STORAGE

PULPER

CONCENTRATION TANK (INGREDIENTS ARE WEIGHED AND CONCENTRATED WITH THE PULP)

BOTTLES PUT IN POSITION

FILLING LINE

LABELLING

CAPPING

STORAGE

DISTRIBUTION

TESTING DONETesting is done at 3 stages. Raw materials Finished products Before storage

RAW MATERIALS TESTING Sensory tests are conducted for raw materials before storing in godowns. 1. Tomato - ripe and firm tomatoes free from any damages are chosen. Damaged tomatoes are removed as they may degrade the quality of the product. 2. Pasta i. Must have uniformly smooth appearance and texture ii. No spots or dark shades iii. Must have clear amber yellow color iv. Must be odourless v. Must taste slightly sweet vi. When broken it must make a dry sound and the fracture must appear smooth and glassy with no air bubbles. 3. Spices Must have good fragrance and should be free from impurities. 4. Other ingredients should be free from impurities. FINISHED PRODUCTS 1. 2. 3. 4. Brix (Refractometer reading-by gentle stirring) Color by means of colorimeter Texture of pasta-by means of texture analyzer Consistency-by means of consistometer i. Place a tbs of pasta sauce on a flat dry tray. It is kept for 2 min. Amount of sauce that overflows the pasta and amount of serum separation are noted 5. Examine the presence of seeds 6. Examine taste, flavor and chewiness. 7. Determine the pH. 8. Proximate analysis (moisture, ash, protein, fat). 9. Mold count 10. Microbiological analysis-TPC FPO SPECIFICATION OF TOMATO SAUCE TSS not less than 25% w/w

Acidity not less than 1% Added color not permitted Preservative benzoic acid-not more than 750 ppm Mold count not more than 40% of fields examined Bacteria not more than 100 million per cc Appearance free from skin and seeds. pH not more than 4.5 TESTS DONE BEFORE STORAGE 1. 2. 3. 4. Check the manufacturing date Check the expiry date Labeling of used ingredients Quantity

PRODUCTION COST ESTIMATION RAW MATERIAL (PER MONTH) S.NO DESCRIPTION 1 2 3 4 5 6 Tomato Pasta Sugar Vinegar, salt, spices Pet bottles of 500 ml Cartons Total UNIT Kg Kg Kg Kg QUANTITY 100000 10000 600 1200 25000 100 RATE (PER KG) 25 100 15 60 4 20 AMOUNT(RS) 2500000 1000000 9000 72000 100000 2000 3683000

UTILITIES (PER MONTH) DESCRIPTION Power, fuel for boiler, water OTHER EXPENSES Rs. 10000 TOTAL WORKING CAPITAL (PER MONTH) S.NO DESCRIPTION AMOUNT(RS) AMOUNT(RS) 30000

1 2 3

Raw material Utilities Other expenses Total

3683000 30000 10000 3723000

COST OF PRODUCTION (PER ANNUM) S.NO DESCRIPTION 1 Total working capital TURN OVER (PER YEAR) S.NO DESCRIPTION 1 Bottles UNIT 500 ml QUANTITY 500000 RATE(PER BOTTLE) 120 AMOUNT(RS) 60000000 AMOUNT(RS) 44676000

NET PROFIT - Rs.15324000

EQUIPMENTS REQUIRED Equipments Weighing balance Steam jacketed kettle Transfer pumps Filling machine Crown corking machine Pallet jack Pulper Concentration tank Refractometer Texture analyser Colorimeter Total Quantity 1 2 1 1 1 5 1 1 1 1 1 Estimated cost(Rs) 5000 120000 10000 10000 7000 10000 40000 20000 1000 100000 50000 373000