What We Did

• Pre-Investment and Strategic Advisory:

  Our comprehensive feasibility study analysed Tunisia's tomato processing ecosystem including relationships with 340 contract farmers across Kairouan and Nabeul governorates producing 85,000 MT processing tomatoes annually. We evaluated the competitive landscape including local tomato paste producers and assessed opportunities for backward integration with paste production versus procurement strategies. Location analysis compared advantages (proximity to Port for European exports, established food processing zone with shared effluent treatment, natural gas availability, and government incentives) against alternative sites in Sousse and Sfax. CapEx planning of TND 45 Million covered aseptic processing lines, cold storage infrastructure, quality laboratories meeting EU standards, and comprehensive traceability systems.

• Engineering & Design Services:

  IMARC designed a state-of-the-art facility featuring segregated production zones for allergen management (mustard, celery used in specialized variants). The process flow incorporated aseptic tomato paste reconstitution, cooking kettles (500L jacketed vessels) with precise temperature control (±2°C), homogenization, vacuum deaeration removing 98% dissolved oxygen, hot filling at 88-92°C ensuring commercial sterility, and rapid cooling tunnels. Plant layout across 8,500 sq.m optimized material flow from dry ingredient receiving, liquid ingredient storage with temperature control, processing halls with epoxy floors and wall cladding, automated filling lines (250 bottles/minute for 500g formats), packaging areas, and cold storage (15,000 pallet positions at 5-15°C). Our design incorporated separate pedestrian and material flows, strategically placed hand washing stations (42 locations), and footbaths at all entry points.

• Procurement & Supply Chain Support

  We conducted supplier evaluation for critical processing equipment, selecting Italian manufacturers for cooking systems and filling lines proven in tomato processing applications. Packaging procurement strategy balanced quality and cost: sourcing European-manufactured PET preforms for retail bottles ensuring clarity and barrier properties, local glass jar suppliers for premium lines, multilayer pouches for food service formats, and printed shrink sleeves from Turkish suppliers. We established vendor qualification protocols including supplier audits, ingredient specifications with identity testing requirements, and certificate of analysis review procedures. Tomato pastes sourcing strategy incorporated contracts with three Tunisian paste producers (70% local sourcing), supplemented by Italian suppliers (30% during domestic shortages), with specifications defining 28-30% Brix, colour values, consistency, and Salmonella absence in 375g.

• Project Execution & Site Management:

  Our turnkey project management covered 16 months coordinating civil construction, food-grade equipment installation, and comprehensive pre-operational validation. We managed construction of processing buildings with smooth, cleanable surfaces, cold storage with 150mm PUF insulation, QC laboratories equipped for microbiological, chemical, and sensory testing, and office facilities. Installation supervision ensured food-grade specifications: 316L stainless steel for product contact surfaces with 0.8µm Ra finish, automated CIP systems with validated cleaning cycles, calibrated flow meters and temperature sensors with ±0.5% accuracy, and SCADA systems logging critical control points for HACCP compliance. We implemented comprehensive pest control infrastructure including air curtains, UV fly traps (67 units), rodent monitoring stations (43 external positions), and sealed building penetrations.

• Compliance, Quality & Sustainability:

  IMARC developed comprehensive food safety management systems including 68 SOPs, HACCP plans identifying 9 critical control points (receiving temperature, cooking temperature and time, hot fill temperature, cooling rates, metal detection, cold storage temperature), allergen management protocols, glass and hard plastic control procedures, and foreign material prevention programs. We conducted three-day mock BRC audits identifying and resolving 47 potential non-conformances across infrastructure, product safety, process control, and personnel practices before certification audit. Our team implemented traceability systems enabling forward and backward tracking within 4 hours from supplier batches through to customer shipments, critical for product recalls.

Final Results

The facility achieved commissioning in 15 months with BRC Grade AA certification secured within 6 months of operation (zero critical non-conformances, 3 minor observations). IFS certification at Higher Level achieved simultaneously, enabling access to premium European retail chains. The plant produces 35,000 MT annually across 8 product variants with 89% capacity utilization.

Final CapEx of TND 43.5 Million delivered 3.3% savings through optimized local procurement and efficient execution. Product quality consistently meets specifications: pH 3.7-4.0, Brix 25-28°, viscosity 50,000-70,000 cP, with microbiological compliance >99.8% (zero pathogen detection in 2,850 finished product samples first year).

Export revenues comprise 72% of sales with products placed in major European retail chains (Carrefour, Lidl, Auchan private label programs), generating €62 Million annual revenue. The facility secured organic certification (EU 2018/848) for organic product line commanding 35% price premium, and halal certification enabling Middle Eastern exports contributing €8.5 Million.

Our energy-efficient design incorporating biogas utilization, heat recovery from cooling water, and LED lighting achieves 22% lower energy consumption versus industry benchmarks, saving TND 780,000 annually. Water recycling from cooling systems and CIP operations recovers 35% of intake, saving 94,000 m³ annually. The project positioned Tunisia as a value-added food processing hub beyond commodity tomato paste, with the client planning expansion into pasta sauces and mayonnaise.