KETCHUP PRODUCTION 2023

ROCESSING ENGINEERING PLANT DESIGN

PROJECT TITLE: PRODUCTION OF KETCUP

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Acknowledgement
We would like to thank Miss. AynadisMollaforher advice and give us good lecture about project.
Generally we would like to thank all those persons that we did not mention their name, but who
helped us to complete this proje

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 KETCHUP PRODUCTION 2023

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 KETCHUP PRODUCTION 2023

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 KETCHUP PRODUCTION 2023

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 KETCHUP PRODUCTION 2023

Abstract
Tomato ketchup is produced by selecting matured and ripe tomatoes are thoroughly washed and
then boiled in a steam jacketed kettle for smooth pulping. Pulping enables extraction of juice and
separation of juice and seeds, fibers and other solid materials. Many ingredients like ginger,
garlic, clove , pepper, salt, sugar, vinegar and preservatives are added to the juice and this
mixture is once again cooked to make it thicker and then packed.
Tomato ketchup consumed by households, restaurants, hotels and institutions like hospitals,
schools, etc.
This profile envisages the establishment of a plant for the production of tomato ketchup with a
capacity of 293.8 tons per year. The plant will create employment opportunities for 37 persons.

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List of table
Table 6.1……………………………………………………………………………………………………………………………………………30

Table 6.2…………………………………………………………………………………………………………………………………………….31

Table 6.3…………………………………………………………………………………………………………………………………………….31

Table 7.1…………………………………………………………………………………………………………………………………………….33

Table 7.2…………………………………………………………………………………………………………………………………………….33

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Table of Contents

Chapter 1.....................................................................................................................................................1
1. Introduction.........................................................................................................................................1
1.1 Background........................................................................................................................................1
1.2. Problem of Statement......................................................................................................................2
1.3 Objective............................................................................................................................................3
1.3.1 General objective........................................................................................................................3
1.3.2 Specific objective........................................................................................................................3
Chapter 2.....................................................................................................................................................4
2 Literature review..................................................................................................................................4
2.1 raw materials.................................................................................................................................4
2.2 Composition of tomato ketchup.....................................................................................................4
2.3 Quality Control of tomato ketchup................................................................................................5
2.4 Chemical and physical property of tomato ketchup.......................................................................6
2.5 Packaging of Ketchup....................................................................................................................7
2.6 Ketchup as Health Food.................................................................................................................8
Chapter 3.....................................................................................................................................................9
3.1 Process type and selection................................................................................................................9
3.1.1 Process type................................................................................................................................9
3.1.2 Process selection.........................................................................................................................9
3.2 Process Description.........................................................................................................................10
3.3 Flow diagram...................................................................................................................................12
3.4 pictorial flow diagrams....................................................................................................................14
Chapter 4...................................................................................................................................................15
4.1Material and energy balance............................................................................................................15
4.1.1Material balance........................................................................................................................15
4.1.2 Energy balance.........................................................................................................................19
Chapter 5...................................................................................................................................................24
5.1Design and sizing of equipment........................................................................................................24
5.1.1Mixing tank size........................................................................................................................24
5.1.2Pasteurizer.................................................................................................................................24

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 5.1.3Homogenizer.............................................................................................................................26
5.1.4 Evaporation...............................................................................................................................26
5.1.4 Washer......................................................................................................................................28
5.1.5 Filter..........................................................................................................................................28
Chapter 6...................................................................................................................................................30
6.1 Site selection and plant layout.........................................................................................................30
6.1.1 Site selection.............................................................................................................................30
6.1.2Plant layout................................................................................................................................32
Chapter 7...................................................................................................................................................33
7.1 Economic evaluation and cost estimation.......................................................................................33
Chapter 8...................................................................................................................................................40
8.1 Conclusion and discussion...............................................................................................................40
8.1.1 Conclusions..............................................................................................................................40
8.1.2 Recommendation......................................................................................................................40
Reference..................................................................................................................................................41

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 KETCHUP PRODUCTION 2023

Chapter 1

1. Introduction
Tomato ketchup, tomato juice and tomato puree, the secondary processed products of fresh
tomato, have come to be consumed in vast amount today in our homes as well as in restaurants
and other places as indispensable food in our daily living.

Ketchup is the number one condiment worldwide. Heinz is leading ketchup producer worldwide.
There are a lot of ways ketchup gets made. Some people even make their own. Depending on
where you are in the world the recipe used to make ketchup may be different. Thousands of
recipes for making ketchup have been published around the world. In addition, many recipes
include ketchup as ingredient.

Despite the many difference in ketchup worldwide, is used to perform similar culinary function:
to add zest, to add color, and flavor to other food, and to camouflage the taste of unsatisfactory
food, unfamiliar or monotonous food. Ketchup also serves as components in other sauces, soups,
stews, ragouts, hashes, and many other “main” dishes. Historically, ketchup recipes have
included the following ingredients: tomatoes, vinegar, spices (such as cloves, peppers, garlic,
onions), and corn syrup (sugar).

1.1 Background
In the 1600s Dutch and British seamen brought back a salty pickled fish sauce called 'ketsiap'
from China. In this version, it was more related to soy or oyster sauce than the sweet, vinegary
substance we call ketchup today. Variations in both the name and the ingredients quickly
developed. British alternatives included mushrooms (the favorite), anchovies, oysters, and
walnuts. In 1690 the word 'ketchup' appeared in print in reference to this sauce, and in 1711
'ketchup'.

+The first ketchup recipe was printed in 1727 in Elizabeth Smith's The Complete Housewife, and
called for anchovies, shallots, vinegar, white wine, sweet spices (cloves, ginger, mace, nutmeg),
pepper, and lemon peel. Eighty-five years later the first tomato ketchup recipe was published in
Nova Scotia by American ex-pat James Mease, which he often refers to as 'love apple' ketchup-
he attempts to give it more cachet by stating that this variation is influenced by French cooking,
although there is no proof of it.

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Recipes continued to appear periodically, featuring mushrooms in Britain and tomatoes in the
United States. A New England Farmer offered it for sale in 1830 in bottles, and priced from 33 to
50 cents. In 1837, Americans selling ketchup in Britain were encouraged to rename it 'tomato
chutney' in order to draw attention to the differences between their product and the mushroom
ketchup popular in Britain. In addition to the difference in ingredients, the British version also
differed in texture, being nearly transparent and very thin in consistency.

Ketchup was sold nationwide in the US by 1837 thanks to the hard work of Jonas Yerkes, who
sold the product in quart and pint bottles. He used the refuse of tomato canning-skins, cores,
green tomatoes, and lots of sugar and vinegar. Lots of other small companies followed suit-by
1900 there were 100 manufacturers of ketchup. The big success came in 1872 when HJ Heinz
added ketchup to his line of pickled products and introduced it at the Philadelphia fair. The
Heinz formula has not changed since, and has become the standard by which other ketchups are
rated.

In 1848 some ketchup manufacturers came under fire for their unsanitary practices-coal tar was
frequently used to heighten the red color. Others made the condiment from concentrated tomato
pulp in the off-season, which they stored in questionable circumstances. This debate continued
until the 1900s, when the Pure Food Act put strict limits on food manufacturers. (Today's FDA
has very strict guidelines on what even constitutes ketchup, specifying the spices that must be
used, as well as the thickness of the end result.)

So, what's in a name? Variations such as catsup, catch-up, catsup and others abounded alongside
'ketchup'. However, when the Reagan administration briefly decided to count ketchup as a
vegetable in 1981, Del Monte Catsup found itself out of the loop due to their spelling-they
permanently changed to 'ketchup', but by then public outcry had forced a reversal of
administration policy. Eversince, though, you'll be hard-pressed to find a bottle from any
manufacturer labeled anything other than 'ketchup'.

Although it frequently graces such foods as fries and greasy burgers, ketchup itself has a
moderate health benefit, as it contains lycopene, an antioxidant associated with decreased cancer
risk. (Unlikely that it's enough to cancel out the negative effects of the fries, though.)

1.2. Problem of Statement

Today tomato is not used for tomato ketchup production in domestic industries in Ethiopia.
Although many farmers cultivate these plants, they are not beneficial from the products, because
the local industries do not use tomato for ketchup production. This condition may restrict the
production of tomato plant in the country in huge amount unless a certain solution is formulated.
The demand of tomato ketchup increased from day to day and this demand fulfill by import
suppliers, because there is no local industries that produce tomato ketchup. Ketchup is a good

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product and delicious to the mouth and also economically beneficial for the country but it is not
popular as it is in Ethiopia because of supplier limitation and shortage of the ketchup product. To
solve this problem the local industries should produce tomato ketchup from tomato.

1.3 Objective
1.3.1 General objective
 Production of ketchup from tomato.

1.3.2 Specific objective

 To design modern ketchup manufacturing plant in Ethiopia.
 To create work opportunity for unemployed.
 To minimize the money that spends on the imported tomato ketchup.
 To satisfy the consumer needs on the tomato ketch up

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Chapter 2

2 Literature review
2.1 raw materials

The main ingredients of ketchup are tomatoes, sweeteners, vinegar, salt, spices, flavorings,
onion, and/or garlic. The types of sweetener used are usually granulated cane sugar or beet sugar.
Other sweeteners include dextrose or liquid sugar in the form of corn or glucose syrup. The
white vinegar, commonly 100-grain distilled, helps to preserve the ketchup. The spices
commonly used to enhance the flavor of the tomatoes are allspice, cassia, cinnamon, cayenne,
cloves, pepper, ginger, mustard, and paprika. Some manufacturers believe that whole spices
produce a superior, milder flavor than ground spices or spice oils. More modern processes use
premixed or encapsulated spices, which are easier to use but more expensive. Whatever the form,
spices must be of a high quality.

The various brands of ketchup have slightly different formulas, which vary primarily in the
amounts of spices or flavorings. Thicker consistencies require a greater ratio of sugar and spices
relative to the tomato juice. Occasionally formulas must be slightly adjusted according to
variations in the acid and sugar content of tomatoes, which occurs with changes in growing
conditions and types of tomatoes.

Reference(http://www.madehow.com/Volume-2/Ketchup.html#ixzz2NpcAJH6O)

2.2 Composition of tomato ketchup

2.2.1 Calories

Only 15 calories are found in a serving of ketchup. All of these calories come from
carbohydrates. Because of this, calorie-counters can eat ketchup guilt-free it is unlikely that you
would consume enough ketchup in a day to ever make a difference in regards to your weight.

2.2.2 Sodium
Like many condiments, salt figures heavily into ketchup both as a flavoring and as a nutrient. A
single tablespoon of ketchup contains about 190 mg of sodium, equivalent to 8 percent for daily
dietary needs. This isn't a particularly high number, but sodium consumption can add up quickly
like to douse the foods in ketchup. Thoughthe sodium is critical to ketchup's strong flavor.

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2.2.3 Carbohydrates
Four g of carbohydrates are found in a single serving of ketchup, and all of these carbohydrates
are sugars. The 4 g constitute only 1 percent of daily carbohydrate requirements.

2.2.4Vitamins and Minerals

The only vitamin or mineral listed as being present in ketchup in significant quantities is vitamin
A according to The Daily Plate, Heinz ketchup provides about 2 percent of daily vitamin A
needs in a single serving. While other vitamins and minerals may be present in trace amounts,
they are not significant enough for ketchup to be considered a source of these nutrients.

2.2.5 Other Nutrients

No other nutrients are found in ketchup; for better or worse - it contains no fats or cholesterols
and features zero grams of proteins. This isn't necessarily bad, since it is used as a taste
supplement for other foods and is not eaten on its own.

Reference (The Daily Plate: Heinz Tomato Ketchup and Heinz Tomato Ketchup: Products)

2.3 Quality Control of tomato ketchup

Some of the commonly used preservatives during the 19th century included benzoate of soda,
borax salicylic acid, benzoic, and formaldehyde, all of which could pose health risks when
consumed in large quantities. A series of Pure Food Laws beginning in 1906 banned the use of
the harmful preservatives.

In 1940, the U.S. government established a "Standard of Identity" for ketchup as tomato-based.
Thus consumers could tell from the label that the product was made of tomatoes, since ketchup
could also be made from other foods, including bananas, beets, or mangoes.

The quality of ketchup is insured by taking samples of the product during various stages of
production. Tomato growers must comply with regulations set by the Environmental Protection
Agency and the Food and Drug Administration regarding the use of fertilizers and pesticides.
Increasing concern in the closing decades of the 20th century led to increased use of natural
fertilizers and pesticides. Inspection is necessary of the tomatoes, ingredients, and of all
processing equipment which comes into contact with the product.

Oxidation of ketchup can darken the color of ketchup, but de-aeration of the sauce during
manufacture can prevent this problem. However, once the containers are opened, oxidation may
still occur. Although the acidity of ketchup preserves the sauce, manufacturers recommend that

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once containers are opened they should be refrigerated to prevent deterioration of the ketchup
color, flavor, and quality.

To maintain consistency in color and flavor, manufacturers determine the concentration of

tomato solids in the mixture, since about one-third of the ketchup's acidity and sugar content
depends on the amount of solids. The ketchup Grades A through C must conform to specific
concentrations. The quality of the ketchup can be measured by its physical consistency, or body,
which refers to the ability of the ketchup to retain its liquid in suspension. The slower the rate,
the higher the grade of the ketchupFor instance, theBootlickConsist meter, recommended by the
USDA, set Grades A and B at flow rates at less than 4 inches (10 cm) in 30 seconds at 68°F
(20°C).

Reference (Gould, Wilbur A. Tomato Production, Processing, and Quality Evaluation, 2nd ed)

2.4 Chemical and physical property of tomato ketchup

Technological characteristics, such as chemical composition, rheological properties, physical

properties and sensory properties play an important role in the formation of the processing steps,
which are necessary for the production of tomato ketchup. Ketchup is a descriptive term for a
number of different products, which consist of the pulp, strained and seasoned, of various fruits;
the variety made from tomatoes being the most popular condiment. Good ketchup is judged by
flavor, consistency, uniformity and attractiveness of color. Tomato ketchup is a clean, sound
product made from properly prepared strained tomatoes with spices, salt, sugar and vinegar with
or without starch, onion and garlic and contains not less than 12 per cent of tomato solids. It is
the most important product of tomato and is consumed extensively. A major part of the tomato
processed is used for making ketchup compared to other tomato products. Commercial ketchup
can have an extremely variable composition; nearly every manufacturer has a formula of their
own which differs in some respects from those of other manufacturers. These differences are
mainly in the quantity, number and amount of spices or other flavoring agents used. The yield
point values of ketchup were correlated with pectin content. Ketchups are time-independent,
non-Newtonian fluids that show a small Thixotropy and Bottiglier. The different brands
examined differed essentially only in viscosity and yield point values.

The quality of ketchup is strongly dependent on its preservation. The most typical use of ketchup
is in ‘fast-food’ restaurants where it is normally stored at room temperature after the opening of
the container, the classic black ring which forms in the bottle neck is a definite sign of the result
of a Millard-type degradation which implies other important quality changes.

All the test models discussed so far involve subjecting the foodstuff to a step change in share rate
(γ&) or share stress (τ) and measuring the stress as s function of time. A useful procedure in the
study of food rheology is to subject. The viscosity of tomato ketchup is a major quality

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component for consumer acceptance. Tomato ketchup has an additive, usually xanthan gum,
which gives the condiment a pseudoplastic or "shear thinning" property. This increases the
viscosity of the ketchup considerably with a relatively small amount added - usually 0.5%. -
Which can make it difficult to pour from a container. However, the shear thinning property of the
gum ensures that when a force is applied to the ketchup it will lower the viscosity enabling the
sauce to flow. A common method to getting ketchup out of the bottle involves inverting the
bottle and shaking it or hitting the bottom with the heel of the hand, which causes the ketchup to
flow rapidly.. Several parameters contribute to the flow behavior of tomato ketchup, including
the quality of the raw material and the processing conditions.

Tomato ketchup is a heterogeneous suspension product, controlling of the phase separation in

tomato ketchup is of a major commercial importance due to a high or low degree of serum
separation during storage. The consistency of tomato ketchup can be improved by adding
polysaccharides such as gums. Reported that hydrocolloids increased the viscosity and reduced
the serum loss of tomato ketchups. Also, hydrocolloids can be used to improve
consistency/viscosity of tomato ketchups. Hydrocolloids are water-soluble, high molecular
weight polysaccharides that find wide application in food industry because of their ability to
improve the rheological and textural characteristics of food systems and often used as food
additives for enhancing viscosity, creating gel-structures and lengthening the physical
stability.Reference (http://bu.edu.eg/portal/uploads/agriculture/Food%20Science)

2.5 Packaging of Ketchup

Ketchup is usually packaged in either glass or plastic bottles. Most bottles are made from plastic
to reduce cost of packaging. However the right polymer must be selected in the packaging so that
it will not reduce the shelf life of the ketchup or affect the taste of the product. Most ketchup
bottles are made from a plastic material, poly (ethylene terephthalate), also known as PET or
PETE. Heinz® bottles also have what is known as a “trap cap”. The design of the “trap cap” is to
eliminate the watery discharge that often first emerges from squeezable plastic bottles of
ketchup. This problem is known as syneresis which is the natural separation of ingredients that
cause water to puddle at the top. The “trap cap” is a new taller domed deck on the cap that serves
as a reservoir to trap the water that’s left on top of the denser product when the bottle is stored
upright. When the bottle is inverted and squeezed, the short tube descending from the orifice
discharges the product and not the water. The new cap also improves the “suck back” function of
the cap after the squeeze has been released. This reduces the product from being cut off and
remaining on the cap. The latest trend in the packaging of ketchup is the new upside down
bottles. Hunt’s® and Heinz® have both developed an upside down bottle that stands on their
closings, allowing easy squeezing and dispensing of the condiment. The new design eliminates
the residue left on the cap and minimizes the syneresis effect. The Heinz® bottle is made from

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PET whiles the Hunt’s® bottle is made from polypropylene with a barrier of ethylene vinyl
alcohol. This is a softer and pliable material compared to PET and makes it easier to squeeze the
bottle.
Reference(http://www.eng.buffalo.edu/Courses/spring04/ce457_527/Barbara )

2.6 Ketchup as Health Food

Oxidative stress, induced by reactive oxygen species (ROS), is associated with the incidence of
chronic diseases such as cancer, coronary heart disease (CHD) and osteoporosis. ROS are highly
reactive oxidant molecules that are generated endogenously through normal metabolic processes,
life style activity and the diet. Antioxidants provide an effective means to combat the deleterious
effects of ROS and are increasingly being considered as strategic chemo preventive agents in the
management of human diseases. Lycopene a carotenoid phyto-nutrient is the most potent
antioxidant naturally present in tomato. Lycopene in the presence of vitamin C, can repair both
itself and other antioxidants to restore their antioxidant qualities. However, tomatoes and
processed tomato products constitute the major source of dietary lycopene accounting for up to
85% of the daily intake.

Reference(www.parrynutraceuticals.com)

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Chapter 3

3.1 Process type and selection

3.1.1 Process type
The breaking stage is very important in the processing of tomatoes, so much so that it’s
considered essential to choose the type of tomato to be produced. In this stage the tomatoes are
heated very quickly. The tomato ketchup can be processed either as:

 Hot break
 Cold break

3.1.2 Process selection

Hot/cold break treatment units process of tomato ketchup guaranteeing the total or partial
deactivation of pectolitic enzyme, thus allowing the preservation of pectin which will give the
product bigger consistency.

Basically, the breaking process is like cooking the tomatoes, but done through a process which is
completely monitored and controlled by temperature sensory.

The difference between hot break and cold break due to the enzymes polymethlesterase,
polygalacturonase and lipoxyenase, which decompose a chemical substance known as
pectin.pectins are naturally occurring compounds which cause the joining of tomato cell.

In the hot break process the pecitc enzymes are deactivated, inhibiting the decomposition of
pectin thus creates a more viscous product.

In the cold break process, the polymethylestrase and the polygalacturonase enzyme are not
deactivated, and this is a disadvantage for the viscosity but an advantage for the flavor. The
obtained product is, therefore, less viscous than that obtained with the hot break technology.

Hot break is selected, due to its advantages and suitability to processing tomato ketchup .the
advantages are:

 Recommended for high viscosity products, such as sauces, ketchup, puree and the like.

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  Completely deactivates enzymatic activity of pectins and increases the consistency and
viscosity of the mixture.
 Deactivation temperature ranges between 90 oc. and 98.8 oc.
 This temperature is reached in a short period of time, resulting in an instant increase of
temperature, from room temperature to breaking enzyme deactivation temperature.

3.2 Process Description

The processes involved in the manufacture of tomato ketchup are indicated in the accompanying
process flow sheet, a description as following:

Fresh tomato shipped to the plant is first of all washed clean with water.

Washed tomato is crushed in to tomato to pulp, which is strained and filtered .this is followed
with preheating and concentrated to about one-third of its original volume by means of a
continuous concentrator, for which boiler heat is used. Since the concentration should necessarily
be achieved in very short time.

Instantaneous concentration is necessary. Otherwise, heating the tomato pulp would cause it to
be oxidized and discolored in to a dark-reddish, disagreeable color, losing the savory, delightful
color, losing the savory, delightful color, of natural tomato.

Concentrated tomato pulps homogenized, then given an addition of salt, sugar, spices and other
ingredients in the seasoning room, to give the tomato pulp the flavor associated with tomato
ketchup. The product is next filled in to bottles, then packed into dozen or gross cartons for
shipment. The description given above generally summarizes the process involved in the
manufacture of tomato ketchup. But while some manufacturers may process their entire stock of
tomato into ketchup at a stroke, some may process a part or all of their tomato in to primary
paste, tomato pulp or tomato puree, and further process these stocks in to tomato ketchup in
accordance with market demands.

I. Collection

Ripened tomato will harvest and collect at the plant during the day.

II. Charging

Collected tomato is charge in to the washing line.

III. Washing

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 Dirt and other foreign matter are removing from tomato by washing and bubbling.

IV. Sorting

Good tomato willselect by removing rotten, crushed or unripen tomato.

V. Crushing

Tomato will be crushed whole.

VI. Concentrating

Tomato pulp will concentrate instantly by one-third its volume to get the prescribed density.

VII. Filtrating
Tomato peel and seed will remove here.

VIII. Homogenizing

Tomato pulp willhomogenize.

IX. Flavoring

Salt, sugar, vinegar, spices, etc. are added. Mixer used to mix items during processing with the
required ratio.

X.Pasteurizing

A process of heat treatment of the product at specific temperature, and a process of heating food,
usually liquid to a specific temperature for definite length of time.

X. Bottling

Ketchup is filled in to bottles.

XI. Cooling

Quick-cooling is done to inhibit quality deterioration due to temperature changes.

XII. Packaging

It requires protection, tempering, resistance, and special physical, chemical, or biological

needs.It also shows product that is labeled to show any nutritional information on food being
consumed.

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 3.3 Flow diagram

Fresh
tomato

Rotten &
crushed Sorting
tomato

Dirt & foreign

Water Washing material

Crushing

Peel & seed

Filtration

Evaporation Water

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 Cooler

Homogenizing

Sugar, salt,
Flavoring vinegar and spice

Bottling

Pasteurization

Cooling

Ketchup

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3.4 pictorial flow diagrams

Fig: pictorial flow diagram of tomato ketchup process

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Chapter 4
4.1Material and energy balance
4.1.1Material balance
Materials quantities, as they pass through processing operation can be described by material
balance such balances are statements on the conservation of mass. If there is no accumulation,
which goes in to a process must come out.

Mass Balance on sorter

Raw tomato (B) 260Kg/h

Rotten, crushed 2% of Buunripen tomato

Sorter
X (sorted tomato)

Input = Output

B = X Kg/h + 0.02(260) Kg/h

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260=X+5.2Kg/h

X=260-5.2

X = 254.8 Kg/h sorted tomato

Total mass balance on washer

254.8Kg/h (sorted tomato)

Water (127.4 kg/h) waste (129.9 Kg/h)

Washer

Z (Washed tomato)

 We use 0.5 liter of water to 1 kg of tomato

Input = Output

(254.8+127.4) kg/h = (Z +129.9) Kg/h

Z = (382.2 – 129.9) Kg/h

Z = 252.3 Kg/hwashed tomato

 Mass balance on crusher

252.3(washed tomato)

Crusher
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 252.3 (crushed tomato)

Mass balance on Filtration

252.3Kg/h (crushed tomato) Y

Filter (W) Waste (3%of Y)

Input=Output
Y= (W+V) Kg/h
252.3Kg/h= (V+0.03(252.3))Kg/h
252.3Kg/h= (v+7.569)Kg/h
V= (252.3-7.569)Kg/h
V=244.731kg/h  filtered tomato

Mass balance on evaporator

244.731(filtered tomato) (V)

(7% total soluble solid)

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Evaporator
Water (W) (0% TSS)

(14% total soluble solid)

Z (concentrated tomato juice)

Total mass balance

Input=Output

V = (w+Z)Kg/h……………………………………………………………. (1)

Component mass balance based total soluble solid

Input=Output

V(0.07) = Z Kg/h (0.14) * w (0)………………………………………… (2)

244.731(0.07) = 0.14Z Kg/h

Z = (17.131/0.14) Kg/h

Z = 122.365 kg/h concentrated tomato

From equation (1)

W = v -122.365Kg/h

W = (244.731 – 122.365) kg/h

W = 122.366 Kg/h evaporated

 Mass balance on flavoring (mixer)

Concentrated tomato 122.365Kg/h (x)

Salt=0.01Kg/h
Sugar=0.03Kg/h =0.0563 Kg/h Mixer
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 Vinegar=0.013 Kg/h
Spice=0.0033 Kg/h

Y (14 % total soluble solid)

Input = Output
0.0563Kg/h +122.36 Kg/h =Y Kg/h
Y = (125+0.0563) Kg/h

Y = 122.42Kg/h Final product (ketchup)

4.1.2 Energy balance

Energy quantity can be described by energy balances, which are statements on the conservation
of energy. If there is no accumulation, which goes in to a process must come out.

Energy balance on evaporator

Vapor

244.731kg/h(7%Tss) 122.365kg /h(14%Tss)

(200c) Evaporator (1050c)

Steam@1200c, M=575kg/h

Given
M = 244.731 kg/h

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T1in= 200c

T2out= 1050c

Ws1in=575kg/h@1200c

Vout=?

CP of tomato = 3.952KJ/kg k

Datum temperature =273k

Qin=Qout

Qfeed+Qsteam=Qvapor+Qproduct

Mcpf(20k)+Wsλs=McpvTV+Mcpp(105k)………(1)

 Cp for specific heat capacity of any fruit and vegetable at different concentration:

Cp=873.36*XNSF+4186.8XMC

Where XNSF=mass fraction of solid

XMC=mass fraction of moisture

 Determine cp of feed

Cp=837.36*0.07+4186.8*0.93

Cp=3952.3392J/kgk

 Determine cp product

Cp=837.36*0.14+4186.8*0.86

Cp=3717.878J/kgk

244.731kg/h*3952.339J/kgk*20k+2270J/kg*575kg/h
=122.365kg/h*4186.8J/kgk*Tv+122.565kg/h*3717.878J/kgk*105k

Tv =39.418k

QT=Qin+Qout=41300671.57kJ/h

20 | P a g e
Energy balance on cooler

Concentrated tomato juice

1050c

Cold water Cooler hot water

(100c)

Cold juice (300)

Given
M Product= 122.365 kg/h

T1 product = 1050c

T2 product = 300c

CP product = 3.98KJ/kgk

CP Water =4.18KJ/Kg k

Q in = Q out

Qfeed+Qcold=Qhot+Qproduct

Mfeed=Mproduct

Mcold=Mhot

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Qin=MfcpfT+MccpcT

Qin =3.98kJ/kgk*105K+4.1921KJ/kgk*10k

Qin =459.821KJ/H

Qout= MpcppT+MhcphT

Qout=4.1784kJ/kgk*Th+3.98kJ/kgk*30k

340.421
Th=
4.1784

Th=81.47k

QTotal= MP * CPP * TP

QTota=122.365kg/h*3.98kJ/kgk*(105-30)k

QTota=36525.95kJ/h

Energy balance on pasteurization

Mixed product 300c

1200c steam cold water

Pasteurizer

Pasteurized tomato 990c

Given
T1 steam(in)= 1200c

T2cold(out)= ?

M product = 244.731 kg/h

T1 product = 300c

22 | P a g e
T2 product =990c

CP product = 3.98KJ/kg k

CP water= 4.18kJ/kg k

Q gained by product = Q loss from steam

MP * CPP * TP =MS * Cps *TS

Q gained = MP * CPP * TP

Q gained =244.731Kg/h * 3.98KJ/Kg k *(99-30) k

Q gained = 67208.03J

Q loss = Mw * Cpw*Tw

= 575*4.18KJ/Kg k (120-T2) k

2403.5T2cold water= (288420-67208.03)J

288420−67208.03
T2cold water=
2403.5

T2cold water =92.04K

QTotal=Qin=Qout

QTotal== MP * CPP * TP

=244.731Kg/h * 3.98KJ/Kg k *(99-30) k

QTotal =672.08 KJ

23 | P a g e
Chapter 5

5.1Design and sizing of equipment

5.1.1Mixing tank size
The volume can be calculated v = m / v

Where v = volume of tank in m3

M = mass of the homogenized tomato juice in kg

The density of homogenized tomato juice is 1400 kg /m3

V=m/ρ

V = 122.42 kg / h 1400 kg / m3

V = 0.087 m3 / h

5.1.2Pasteurizer
Pasteurizer can be determined by its area

 Internal tube diameter=0.05m

 External tube diameter=0.07m
 Thermal conductivity of tomato=0.58
 Hot temperature of steam(water)=T1=1200c, T2=920C
 Cold temperature of product=T1=300c, T2=990c
 Thickness (X)=0.02m

Logarithmic mean temperature difference for counter current

( T 1−t 2 )−(T 2−t 1) T 1−T 2

LMTD= =
ln ⩟ t 1/⩟t 2 ln T 1/T 2

Where T1=T1-t2=(120-99)k
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T1=21k

T2=T2-t1=(92-30)k

T2=62k

21−62
LMTD=
ln 21/62

LMTD=37.87K

Then the overall heat transfer coefficient will be

r2
1/u= +r2Ln(r2/r1)/k+1/ho
r 1 hi

Where r2=external tube radius

r1=internal tube radius

r1=d1/2=23/2=11.5mm=0.115m

r2=d2/2=25/2=12.5mm=0.125m

Where

Film heat transfer coefficient for the tube side tomato juice (hi)

Film heat transfer coefficient for the shell side water (ho)=1500w/m2 k

Overall heat transfer coefficient (u)

Thermal conductivity of tomato ketchup(k) = 0.58w/m2k

hi=k/x=0.58/0.02=29

r1=d1/2=0.05/2=0.025

r2=d2/2=0.07/2=0.035

Then

1/u=r2/r1hi+r2Ln(r2/r1)/k+1/h0

1/u=0.035/0.025*29+0.035Ln0.035/0.025/0.58+1/1500

U=14.44

Q=UALMTD

25 | P a g e
Q from energy balance=672.08kJ

A=Q/ULMTD=672.08/14.4*37.87K

A=122.9M2

5.1.3Homogenizer
The volume can be calculated v = m / v

Where v = volume of tank in m3

M = mass of the homogenized tomato juice in kg

The density of homogenized tomato juice is 1400 kg /m3

V=m/ρ

/
V=122.365kg/h 1400kg/m3

V=0.087m3/h

5.1.4 Evaporation
Mass flow rate of products (Mf) = 244.731Kg/hr

Temperate of feed (Tf) =20K

Temperate of boiled liquid (T1) =100K

Temperate of products (T2) =105K

Mass flow rate of steam (MS)=575Kg/hr

Temperate of steam (TS) =120K

Specific heat capacity of products (Cf) =3.98kg/KgK

 From material balance

W1+ W2= 122.365kg/hr…………………………………………..1
 Heat balance of first effect

Ws ለ s +wfcf(t1 -t2) =w1 ለ 1

Ws2270 + 3.98*244.731(100-20) = w1 ለ 1

Ws2270 +77922.032 = w1 ለ 1

w1 2141- Ws2270 = 77922.032………………………………………………2

26 | P a g e
 Heat balance on second effect

W1 ለ 1 + (wf –w1)*c1 (t2 -t1) = W2 ለ 2

W1 2141 + (244.731 -w1) *4.243 *(105 -100) = W2 2370

W1 2141 – 21.215 W1 + 5191.97 = W2 2370

W2 2370 – 2119.785 W1 =5191.97……………………………………………3

 Simultaneous equation 1&3

W1+ W2= 122.365

W2 2370 – 2119.785 W1 =5191.97

Know eq 1 multiply by 2119.785

2119.785W1 + 2119.785 W2= 2119.785*122.365

– 2119.785 W1 +W2 2370 = 5191.97

W2 =58.93Kg/hr

 W + W = 122.365
1 2

W1 = (122.365 -58.93) Kg/hr

W1 =63.44 kg/hr

 Find W from equation 2

S

SubstituteW1 =63.44 kg/hr

w1 2141- Ws2270 = 77922.032

(63.44 *2141) -77922.032 = Ws2270

WS =25.508kg/hr

 Then calculate area

A=Q/U∆T =WS ለ S /U∆T

When: - overall heat transfer coefficient from energy balance (u) = 14.44

25.508∗2270
A¿
14.44∗(100−20)

A =50.124m2

27 | P a g e
 ¿
 Steam economy =ratio water remove ¿ evaporate steam mass flow rate

W 1+W 2 122.365
= =
WS 25.508

Steam economy = 4.797kg/kg

5.1.4 Washer
The volume can be calculated v = m / v

Where v = volume of tank in m3

M = mass of the washed tomato in kg

The density of washed tomato is1014.4kg /m3

V=m/ρ

/
V=254.8kg/h 1014.4kg/m3

V=0.251m3/h

5.1.5 Filter
The volume can be calculated v = m / v

Where v = volume of tank in m3

M = mass of the washed tomato in kg

H = height of filter tank=2m

The density of washed tomato is1400kg /m3

V=m/ρ

/
V=252.3kg/h 1400kg/m3

28 | P a g e
V = 0.052 kg/m3

V = Ah

A = v/h => 0.052kg/m3/2m

A = 0.026m2

29 | P a g e
Chapter 6

6.1 Site selection and plant layout

6.1.1 Site selection
The location of the plant can have crucial effect on the profitability of the project and the scope
for future expansion. A lot of factors should be considered when selecting the suitable site and
only a brief review of the principal factors will be given in this selection.
The principal factors to be considered and selected sites are;

Factors; Sites;

F1= transportation S1=tankuagebrel

F2= power source S2=quhara abo

F3= labors S3=gumera

F4= site characteristics

Equal weight method

All factors were assigned with equal weight and each location was evaluated along the factor
scale. The manufacture for production of tomato ketchup selected four factors by witch to rate
three sites. Each site was assigned rate of 0-5 points for each factor.

Table 6.1 decision matrix

Factor/potential S1 S2 S3
F1 2 4 3
F2 3 2 1
F3 1 4 2
F4 2 3 3
Site rating 8 13 9
Sample calculating: 8= 2+3+1+2

Site two has highest rating of 13 hence, this site would be chosen.

30 | P a g e
 Variable weight method

All factors were assigned with variable weight and each location was evaluated along the factor
scale. The manufacture for production of tomato ketchup was selected four factors. For each
factors 50, 200, 150 and 100 point was assigned respectively.

Table 6.2 decision matrix

Factor Maximum points Potential sites

S1 S2 S3
F1 50 30 40 35
F2 200 180 170 160
F3 150 100 140 130
F4 100 40 90 70
Site rating 350 440 395
Sample calculating: 440=40+170+140+90

Site two has highest rating of 440 hence, this site would be selected.

Weight-cum rating method

For this method potential location site was assigned variable weights to each factor. The location
factor point assigned for the factor is then obtained by multiplying the location rating for each
factor by the factor weight. For this rating weight of 1-5 could be assigned to the four factors.
For each factor 2, 5, 4 and 3 point assigned respectively. Now for each site could receive 10-50
points as follow and the site rating could be obtained.

Table 6.3 decision matrix

Factor Factor rating point Potential site

S1 S2 S3
F1 2 20 35 15
F2 5 10 45 20
F3 4 30 20 30
F4 3 25 15 25
Site rating 195 420 325
Sample calculating: 195= (2*20)+(5*10)+(4*30)+(3*25)

Site two has highest site rating of 420 hence, this site would be selected.

31 | P a g e
The envisaged plant should be located in areas where fresh tomato can be abundantly supplied
and labor and market is available. Taking this in to consideration, quhara abo, which are found
inworetaworeda can be the possible locations for the project.

6.1.2Plant layout

Key
 1  Row material storage room
 2  washer
 3  sorting
 4  crusher
 5  concentrator
 6 cooler
 7  filter
 8  homogenizer
 9  mixer
 10  pasteurizer
 11  packaging machine
 12  cooler
 13  labeling machine
 14  product storage room

32 | P a g e
Chapter 7

7.1 Economic evaluation and cost estimation

Table 7.1 Man power requirement and employer cost

Description Req. Salary/Month (Birr) Annual Salary

No. Expenditure (Birr)
Plant manager 1 6,000 72,000
Technologist 1 3,500 42,000
Chemist 2 5,000 60,000
Engineer 1 4,000 48,000
Mechanic 4 8,000 96,000
Operators 4 8,000 96,000
Clerks 4 4,000 48,000
Sales person 1 1,403 16,836
Guards 4 3,600 43,200
Laborers 15 15,000 180,000

Total 37 $3079.10)58503($36949.05) 702036

Table 7.2 List of machinery and equipment

Type of equipment Construction material Quantity Price of each $

Mixer Stainless steel 1 59900
Evaporator Stainless steel 1 197900
Filter Stainless steel 1 15600
Homogenizer Stainless steel 1 3500
Washer Stainless steel 1 2900
Cooler Stainless steel 2 3500
Packaging Stainless steel 1 2600
Pasteurizer Stainless steel 1 65200
Crusher Stainless steel 1 40400
Total equipment purchased cost $ 391500

33 | P a g e
Estimation of total capital investment cost

Direct cost

Purchased equipment cost (PEC) ----------------------------------------------------=$391500

Installation (40 %) of PEC ----------------------------------------------------------- =$156600

Instrumentation and controls (15%) of PEC----------------------------------------=$58725

Piping (installed (60%) PEC -----------------------------------------------------------=$234900

Electrical (installed) (10%) PEC ----------------------------------------------------- =$39150

Buildings (including services) (18%) PEC ----------------------------------------- =$70470

Service facility and yard (70%) PEC -------------------------------------------------- =$274050

Land 6% PEC ------------------------------------------------------------------------- =$23490

Total direct cost (DC) ---------------------------------------------------------------- =$1248885

In Direct Cost(IC)
Engineering and supervision (15%) DC =$187332.75

Construction expenses (11%) DC = $137377.35

Contingency 10% (FCI) = $157359.51

Total indirect cost(IC) = Engineering and supervision+ Construction expenses

=$187332.75+137377.35

=$324710.1

34 | P a g e
Fixed capital investment cost(FCI)=DC+IC

=$1248885+$324710.1

=$1573595.1

Estimation of total product cost

Total product cost=manufacturing cost+ general expenses

Cost of operating labor

Total number of labor = 37

Total employer cost ==$36949.05/year

Operating labor (OL) (10% of TPC)

TPC=0L/0.1

TPC =$36949.05/year /year/0.1

TPC =$369490.5/yr

Raw material cost (11% of TPC) ---------------------------------------------------=$40643.95

Operating labor (OL) (10% of TPC) -------------------------------------------------= $36949.05

Direct supervisor and clerical labor (12% of OL) --------------------------------= $4433.88

Utilities (13% of TPC) ----------------------------------------------------------------= $48033.76

Maintenance and repair (3% of FCI) -------------------------------------------------= $4720.77

Operating supplies (0.5% of FCI) --------------------------------------------------= $ 7867.97

35 | P a g e
Laboratory charge (11% of OL) -----------------------------------------------------= $4064.39

Patent and royalties (2% of TPC) ------------------------------------------------= $7389.81

Total direct production cost -----------------------------------------------------=$ 154103.58

Fixed charge cost(FC)

Depreciation (10% of FCI) --------------------------------------------------------= $157359.51

Local taxes (4% of FCI) ------------------------------------------------------------= $62943.80

Insurance (0.8% of FCI) -------------------------------------------------------------= $12588.76

Total fixed charge cost ---------------------------------------------------------------= $232892.07

Plant overhead cost (POC)

POC (60% of OL) -------------------------------------------------------------------= $22169.43

INDIRECT PRODUCTION COST = FIXED CHARGE + PLANT OVERHEAD

IPC=FCC + POC

=$232892.07+$22169.43

=$255061.5

Manufacturing cost = direct product cost + indirect production cost

=$154103.58+$255061.5

=$409165.08

General expense
Administrative cost (AC)

AC (4% of TPC) = $14779.62

Distribution and selling (DS)

36 | P a g e
DS (8% of TPC) = $29559.24

Research and development cost (RDC)

RDC (5% of TPC) = $18474.52

Total general expense = administrative cost (AC) +distribution and selling cost (DSC)
+research and development (RDC)

= $14779.62+$29559.24+$18474.52

=$62813.38

Total cost (TC) = manufacturing cost + general expense

=$409165.08+$62813.38

=$471978.46

Total capital investment (TCI) = FCI + TC

=$1573595.1+$471978.46

=$2045573.56/yr

Using straight line method depreciation value is calculated as follows;

d= (V-Vs)/n where, d = depreciation

V =starting value of service life span

Vs =salvage value at the end of service life

n = service life

V =$1573595.1

n =20yr

Vs = 10% V

Vs = 0.1*$1573595.1

Vs= $157359.51
37 | P a g e
 D= (v-vs)/n

d = ($1573595.1-$157359.51)/20

= $1416235.59/year

Sell cost of ketchup =56 birr/kg

= $2.94/kg

Annual cells income of ketchup =$2.94/kg*300day/yr*979.36kg/day

= $863795.52/yr

Gross profit = total income – total product cost

GP=$863795.52/yr -$369490.5

=$494305.02/yr

Annual tax =35%total annual income

=0.35*$494305.02/yr
= $173006.75

Net profit = Gross profit - Annual tax

=$494305.02-$173006.75

=$321298.27

Rate of return on investment (ROI)

Assume minimum acceptable rate of return (mar) = 15% and assuming a 15 years’ service life,

Net profit average = $321298.27/yr

38 | P a g e
ROI = (net profit average / total capital investment)*100

/
= ($321298.27/yr $2045573.56/yr)*100

= 15.70%

Payback period
Payback period =total capital investment-working capital/ (net profit/yr+ Depression/yr)

/ +
=$2045573.56-$409165.08 ($321298.27 $157353.51yr)

Payback period =3.4year

Since the payback period is less than 5 years the project is feasible and acceptable

39 | P a g e
Chapter 8

8.1 Conclusion and discussion

8.1.1Conclusions
Tomato ketchup industry is an industry which produces ketchup from tomato by using different
machines like washer, sorter, crusher, homogenizer, filter and pasteurizer by using different
ingredient like tomato, sugar, vinegar and spices.

Ketchup is an important product which is produced in home, restaurant, and hotels that improves
the palatability of different foods.

Generally our project creates work opportunity for 37 employees and increases the economy of

our country by reducing the import of ketchup .

8.1.2 Recommendation
It will be recommended from the project is that even though production of ketchup from tomato
is acceptable and profitable but there were several considerations it includes;

 During production of tomato ketchup there were loss by contamination during

processing, storage, and distribution. So that the manufacturer should give a care for
those problem.
 To encourage by giving training for farmers whom found in the territory in order to
produce tomato this fit for production of tomato ketchup.
 Tomato ketchup is not well known in the Ethiopia, so that the manufacturer should be
work on advertising with different media.

40 | P a g e
Reference
1. http:\\ www.miro-soavit.it
2. The Daily Plate: Heinz Tomato Ketchup and Heinz Tomato Ketchup: Products
3. http://www.madehow.com/Volume-2/Ketchup.html#ixzz2NpcAJH6O
4. http://www.eng.buffalo.edu/Courses/spring04/ce457_527/Barbara
5. Gould, Wilbur A. Tomato Production, Processing, and Quality Evaluation, 2nd ed
6. frelgmdries international mahara stera.mumbai-400013,india
7. http:\\ www.match.com

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