04-06-2013, 11:30 AM
PRODUCTION PROCESS AT SUPREME FOODS PVT LTD
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INTRODUCTION
Tomato Ketchup is a table product used in households, restaurants, canteens etc. It is used with sandwiches, snack food items and while cooking many vegetarian and non-vegetarian dishes. Tomatoes are not available throughout the year and their prices shoot-up during lean season. Further, tomatoes cannot be conveniently utilized on or with certain products whereas tomato sauce, ketchup and puree can. Tomatoes are perishable but ketchup has shelf life of 10-12 months. Hence, this product has become very popular and is used in large quantity.
PRODUCTS APPLICATION:
Products like ketchup, sauce and puree are made from tomato juice. Non-availability of tomatoes round the year and their perishable nature means they are used during specified period. But down stream products from tomato juice provide solution as they have longer shelf life. This note discusses only one of them i.e. tomato ketchup. This product can be produced in states like Gujarat, Maharashtra, AP, Karnataka and many others but this note considers Maharashtra as the prospective location in view of ever increasing demand.
ABOUT THE COMPANY
We have visited Supreme Foods Pvt Ltd in the local band supreme foods a district level cooperative organisation registered in 1983 involved in processing of Tomato products.
The organisation has a unique advantage of its strategic location as it is based in Pune city, a place with historic and culture importance and major district of Maharashtra, with second education and industrial infrastructure, located about 180 kilometre form Mumbai the financial capital of India.
Supreme Foods pvt Ltd certified by ISO 9001-2008 and Supreme Foods Pvt Ltd is produce 2 Tones tomato product per day.
This company is private and it is a sole propriety firm and has 15 workers and 2 manager.
RAW MATERIAL
The most important raw material will be good quality tomatoes. They are grown in many parts of Maharashtra and an appropriate location has to be selected. In any case, the annual requirement even at 100% utilization will be about 600 tones. Other materials like sugar, spices, vinegar, salt, preservatives etc. shall be required in small quantities and can be easily procured from local market.
STEP1: WASHING OF TOMATO
Dirt and foreign matter are removed by washing.
Fresh tomato shipped to the plant is first of all washed clean with water. For this special washing technique has been developed that allows for preservation of the fresh, natural qualities of ripened tomato.
STEP2: CRUSHING
Second step of tomato processing is crushing. In this step tomato is crushed at whole.
Crushing of tomato means mash, pulp, smash, squash tomato. In crushing tomato is Converted to mash, smash tomato.
STEP3: HEATING
Third step is boiling or heating of tomato at 90 centigrade for 30-60 second. They are boiled in the steam jacketed kettles to facilitate pulping. During pulping, juice is extracted and other solid materials are separated and split the skins.
STEP4: ADD PRESERVATIVES
The fourth step is adding preservatives. sauce is made by concentrating juice and during the process; salt, sugar, vinegar, spices, preservatives, onion etc. are added to the extent that the mixture contains not less than 12% tomato solids and 28% total solids. Sauce is passed through sieve to remove fibrous and other materials. In case of ketchup, the process is more or less same, but many spices like ginger, garlic, clove, pepper are added with salt, sugar, vinegar and preservatives
STEP5: COOKING
4 The pulp is pumped into cooking tanks or kettles and heated to boiling. Foaming may occur if fresh tomato pulp is used, but can be corrected with anti-foaming compounds or compressed air. Precise amounts of sweeteners, vinegar, salt, spices, and flavorings are added to the tomato pulp. Most spices are added early in the cooking process. To avoid excessive evaporation, volatile spice oils and vinegar must be mixed in later. Onions and garlic can be mixed in with the spices, placed in a separate bag, or chopped and added to the pulp. Salt and sugar may be added at any stage of cooking though it is better to add sugar later to prevent burning. The mixture cooks for 30-45 minutes and is circulated by rotating blades installed in the cookers. The temperature must be carefully regulated to insure absorption of the ingredients without overcooking, which creates a flat body
STEP6: BOTTLING
In this step ketchup is filled into bottles by filler machine and Supreme Food Pvt Ltd is use the semi automatic filler machine.
CONCLUSION
From the collective data, I have concluded the following Point.
While it will be unfair to judge and compare its market standing with other industries of the same sector, however this study focuses on the production procedure of this particular company also this study bring out many interesting facts and figures which are incredible and enlightening.
The Tomato product has managed well to male a strong stand in the marked. Supreme Food Pvt Ltd is a well known brand and over the years the trust for the quality has been build up.
Finally this project had helped the researcher to conclude that by introducing a production and satisfaction regarding reward program the company can further enhance its association with its existing customers by providing them with a host of value added services and also contributed towards the overall success of the organization