Calculation of the technological line for the production of cutlets. We purchase equipment for the production of semi-finished products

There are well-established technological schemes for organizing production workshops for working with semi-finished meat products, while the scheme of work itself is absolutely the same as for small workshop, and a huge plant. The main difference is in the capacities of the installed equipment and, as a result, in the nominal value of the output. In addition, most areas of work with semi-finished meat products are closely related to each other and, in fact, with fairly insignificant investments and modernization in one workshop, it is possible to produce both cutlets, with all derivative products, and the same dumplings, but more on that in a separate article here. Why is it so?

The answer suggests itself if we compare necessary set equipment for two different workshops - cutlet mini-workshop and. What equipment is needed, and now we will analyze the cutlet business.

At the first stage of making cutlets we are engaged in cutting and processing half-carcasses, as a result, for a mini-workshop it is necessary:

• - cutting tables;
• - hooks, sets of knives, bowls or buckets for transferring meat;

Minimum set for this stage production will cost 10-12 thousand rubles. In addition, it is worth considering the purchase of a variety of plastic containers for the storage of non-meat ingredients, it is in the production of cutlets that a lot of various additives are used, which, in fact, can be in small quantities, but should be all.

The second stage is the grinding of the main ingredients. according to the recipe and for this we need, of course, a meat grinder.

Industrial meat grinders differ from ordinary household ones, not only in rated power, but also have a complete unger. To make it clearer, in a conventional meat grinder it is used:

• Screw;
• Lattice.

But in the list of equipment for the production of cutlets in a small workshop there should be a meat grinder with a full unger, that is:

• Screw;
• Pruning knife;
• Double-sided knife;
• Large lattice;
• Double-sided knife;
• fine grate

I think the difference between conventional meat grinders and those that need to be used in the manufacture of meatballs on an industrial scale is visible to the naked eye.

Regarding the cost of such equipment, it is worth noting that, as in other positions, the cheapest samples are presented by Chinese manufacturers, but they all have a number of “weak” points, which boil down to the use of, to put it mildly, not high-quality metal and rather “hacky” electrical part. Although recently there has been an increase in the quality of Chinese equipment, the price is also growing along with it.

In the middle price group are Belarusian and domestic producers, they are more or less fine with metal, but there are design flaws, in particular, meat grinder knives are produced in one piece, which is not very convenient when servicing such equipment. Although in general they are fully consistent with their cost and will last a long time.

In the higher league, of course, European manufacturers, their equipment for the production of cutlets has one very big drawback, this is its cost.

	GASTRORAG HM-22A	Torgmash MIM-350	Fama FTI 136UTE
Power, W
Voltage, V
Productivity, kg/hour
Type	full UNGER	full UNGER	full UNGER
Reverse
Number of knives, pcs.	2 double knives, 2 grids	scoring knife, cross knife-2pcs. grate 5mm, grate 9mm, bathtub	2 knives, 2 grids, 1 scoring grid
Dimensions, LxWxH mm
Producing country		Belarus
Type of meat grinder	professional	professional	professional
Price

Stage three in the manufacture of cutlets this is the final preparation of minced meat, if in the previous one we chopped all the ingredients, now we need to mix them and add spices and salt.

Of course, the most "cheap" option would be manual mixing, but on an industrial scale this is not possible, and the regulatory authorities will not look very well at such handicraft. Plus, of course, the organoleptic properties of minced meat will be much worse. Once again, I remind you of this because recently one of my acquaintances, when organizing such a workshop, decided to refuse to buy a meat mixing machine because of its cost. I can say that nothing good came of it and I had to buy a meat mixer in the course of work.

A meat mixing machine is a very significant expense item when buying equipment for a cutlet shop, because its cost starts from 30 thousand rubles for Chinese devices and from 50 thousand rubles for domestic counterparts. Comparison table pointed below.

	BWL-50	SIRMAN IP30 3F	IPKS-019
Bowl volume (l.)
Maximum Loading Volume (kg)
Mixing time (min)
Agitator rotation speed (rpm)
Power, kWt)
Dimensions
Weight (kg.)
Manufacturer
Price

The fourth stage is the molding of cutlets, for the manufacture of the products themselves, specialized molding machines are used, as a rule, one apparatus can produce a fairly wide range of products. Varying, both in size, from 20 to 100 mm, and in weight, in most cases from 50 to 100 grams.

It should be noted that the change in configuration and weight occurs through the use of different molds, and if most manufacturers have them fairly unified, then some “manage” to produce a lot of different configurations up to “square” shapes, we are talking about cutlet machines of the IPTS series. True and pleasure is not cheap, for an additional set of forms you will have to pay about 45 thousand rubles.

Approximate prices for molding equipment.

	Cutlet machine AK2M-40U	Cutlet machine IPKS-123	AMB MV patty and hamburger forming machine	AFK-1
Productivity technical ( pcs/hour)
The capacity of the loading cylinder for minced meat ( l)
Shape of cutlets		round/stick/meatball
The mass of formed cutlets ( G)		depending on nozzle
Consumed electricity kWh
Motor power kW
Mains voltage IN
Dimensions ( mm)
Weight ( kg)
The country
Price
Optional equipment	separately	separately
Price

When choosing equipment, first of all, it is necessary to evaluate your financial solvency; the power of any of the listed devices will be enough for a small production.

The fifth stage of freezing, here we “jump over” a little and immediately talk about the two components of the entire technological cycle:

• Shock freezing is essential for correct formation finished products, or rather, so that in the future the cutlets do not spread.
• Storage - refrigerated cabinets for storing finished products.

There are many different offers on the market, but practice shows that refrigeration equipment itself is quite expensive, and therefore it is here that flexibility and resourcefulness are needed. Today, many acquaintances are switching to stationary refrigeration units made using sandwich panels and refrigeration equipment. The second option is to buy used equipment. But at the most optimal conditions all "cold" processes will take at least 200,000 rubles.

Stage six - packaging. Unlike the same dumpling business, cutlets and meatballs require individual packaging, of course they can be shipped in ordinary carton boxes, but this approach does not justify itself, especially for cutlets and meatballs, you can use simple and economical packaging using a "hot" table. Moreover, such a device for packaging will cost 5-8 thousand rubles, which, against the general background, does not look like a global expense.

In addition, for a small cutlet shop you will need:

• trays;
• Carts;
• Buckets, bowls;
• Bathrobes.

The total cost of such "little things" can be about 10-15 thousand rubles.

In total, all the necessary equipment for the cutlet business will not cost:

Stainless steel table
trolleys
Knives (hooks, etc.)
Cutlet machine
Meat grinder
Meat mixer
"Hot" table - packaging
Freezers bu
Chairs
Buckets (other household chalk)
Total

In total, the total cost of organizing a small workshop will cost 423,000 thousand rubles, based on the estimated profit, ours, the payback of the project will be 4 months (120 thousand profits per month), which is not even bad for a small business. Read more about business ideas here.

Interesting on this topic

The production of frozen semi-finished products is promising direction investments Money because there is always a demand for these products. The organization of the business does not require much time, the main task is to equip the workshop where the automatic line will be located - the production of semi-finished products, hire qualified workers, find reliable suppliers of high-quality raw materials and establish a sales system. The easiest way is to establish an enterprise of individual ownership, it is both faster and cheaper. It is necessary to obtain a state permit for this type of activity, a sanitary and epidemiological permit.

Features of production areas

When choosing the premises where the production will be located, one should take into account the proximity to farms that will supply raw materials, this will reduce transport costs. The optimal workshop area is 200 m 2, a warehouse for raw materials and finished products will be required. The building must have all communications, household rooms, an administrative department.

Before starting work, you must obtain permission from the fire supervision and SES authorities. All elements of the line for the production of semi-finished products are powered by the mains, so it is necessary to provide an emergency power generation system, the capacity of which should be enough for at least two hours of work to complete manufacturing process. Since the finished product is produced in a frozen form, the warehouse for its storage should be either a large cold store or equipped with industrial refrigeration units. If the enterprise is located in a rented premises, then the rent will be 15 thousand rubles, another 15 thousand for utility bills per month.

Staff

The production of semi-finished products involves the manufacture different types cutlets and pancakes. Each type of product has its own set of equipment. The cutlet production line is operated by two workers, the pancake line will also require two people per shift. One person will be enough to prepare the raw materials and one to prepare the pancake filling. It will require a loader, a technologist who controls the production process and the quality of finished semi-finished products, and a service engineer to maintain the line. The payroll fund will amount to 100 thousand rubles per month, when the enterprise operates in one shift.

Consumption of raw materials for the production of semi-finished products

The main ingredient for making frozen meatballs is meat. According to the original recipe, there should be 50% pork and 50% beef, the total share of meat in cutlets is 55%, the rest is: water (22%), raw fat (5%), bread (13%), onions (3% ), breadcrumbs (2%), pepper (0.1%), salt (1%).

Table for calculating the cost of manufacturing 100 kg of cutlets:

To make pancakes you will need:

pancakes

• flour;
• eggs or egg powder;
• sugar;
• water;
• vegetable oil;
• salt.

For the filling, you can use fruit jams, curd mass, minced meat or liver. In the production of frozen pancakes, you can use big variety toppings, catering to the tastes of potential buyers.

Pancake production technology

Pancake maker The manufacturing process is carried out using an automated pancake production line. The first step is to prepare the dough. In the bowl of the beater, the necessary ingredients are mixed and mixed for several minutes. The finished mass is fed to the pancake machine, where the dough is rolled out and baked. Semi-finished products are cut according to the specified sizes and served on the table for stuffing. There are lines in which this process is manual, but still most of the devices are fully automated. The baking line is followed by a filling dispenser, then a mechanism that folds the pancake in half and wraps the edges. Finished products must be blast frozen. It is speed that plays an important role, since the dough can be soaked with filling and change the structure and color. After freezing, semi-finished products are ready for packaging and transportation to cold rooms.
Line for double-sided frying of pancakes

To organize the manufacture of this type of semi-finished products, you will need:

• pancake production line;
• cooling chamber;
• low temperature monoblock.

The automated line performs dough kneading, baking blanks, stuffing, wrapping. Characteristics:

The refrigerating chamber is intended for storage of finished goods. Characteristics:

• dimensions - 4040 * 6460 * 2200;
• volume - 58 m 3;
• cost - 177,500 rubles.

The low-temperature monoblock is used for shock freezing of semi-finished products:

• chamber volume - 80 m 3;
• power - 380 V;
• temperature - up to -22 ° C;
• cost - 160 thousand rubles.

Cutlet production technology

Cutlet production line

First initial stage you need to prepare all the ingredients. The meat is cleaned and deboned, veins, cartilage, small bones are removed. To create minced meat, a minced mixing plant is used, which is part of the cutlet production line. All other ingredients required by the recipe are gradually added to the bowl of this installation. At this stage, it is important to temperature regime- do not allow minced meat to be heated above 14 ° C, otherwise its bacterial characteristics may deteriorate. The resulting mass is sent to the molding unit, in which the dosage of semi-finished products takes place according to the specified parameters. Cutlets of different weight, size and shape are obtained through the use of various nozzles. The next step is the blast freezing process. Finished semi-finished products can be packaged and sent to the finished product warehouse.

Profitability of production

For the convenience of calculations, the profitability of the production of cutlets on the line for the production of semi-finished products will be given. The cost of the line itself different manufacturers may differ, for example, let's take the KOPPENS VM model, its cost is 1,450,000 rubles. The cost of finished products consists of the cost of raw materials, wages of employees, rent of premises, transportation costs. Per month fixed costs will be:

• salary - 100 thousand rubles;
• rent - 15 thousand rubles;
• utility bills - 15 thousand rubles;
• packaging - 8 thousand rubles;
• transportation costs - 10 thousand rubles;
• other expenses - 10 thousand rubles;
• total - 158 thousand rubles.

The cost of production is calculated on the assumption that 50 kg of cutlets will be produced in one shift, there will be 22 shifts in a month, and the cost of raw materials per 1 kg of finished products is 101 rubles. We multiply all the indicators - we get 111,100 rubles full cost. The retail price of 1 kg is 400 rubles, the monthly revenue will be 440 thousand rubles. Profit calculation: revenue (440,000) - cost (111,100) - fixed costs (158,000) = 170,900 rubles. With this amount of net profit, the profitability of production will be 40% - this is high rate speaks of a quick payback of capital investments (within 18-24 months).

Video: Process for the production of semi-finished meat products

The ultra-fast pace of life does not leave us a chance to enjoy the comfort of home, and even more so - home-cooked food. This is where a variety of products come to our aid, which have already passed all the stages. technological process, except for the last - cooking. as a business, based on this need, the direction is quite profitable, although it requires certain investments of funds and efforts.

Varieties of semi-finished products

In general, these products can be divided into food and industrial. We, as consumers, of course, are more interested in the former, since they are the ones that get to our stove from store shelves.

From the name, we can conclude that this product has already passed the production process by half and requires only final processing - frying, boiling, stewing.

Semi-finished products can be vegetable, meat, fish, dairy, cereals, combined.

In more detail, the classification looks like this:

• natural meat;
• breaded meat in pieces - chops, rump steak, schnitzel, beef steak, chops;
• pieces of meat, cut into pieces and packaged in bags - langets, entrecote, escalopes, cutlets, schnitzels;
• shashlik;
• meat sets of small pieces - azu, goulash, beef stroganoff, stew;
• meat by-products;
• chopped semi-finished products - minced meat, cutlets from it;
• fish semi-finished products;
• dumplings;
• peeled potatoes;
• frozen vegetables;
• cutlets from vegetables;
• semolina, rice, millet cutlets;
• vegetable mixes;
• syrniki;
• vareniki.

This list, of course, cannot be complete. You can continue it indefinitely, since the conditions modern life make technologists come up with more and more new recipes.

The production of semi-finished products implies another classification, which is based on the principle heat treatment. Here produce frozen and chilled products. Speaking specifically about semi-finished meat products, they are also divided into different types according to the type of meat used - pork, beef, chicken and others.

Registration and documents

At the initial stage, it is necessary to decide in what form your enterprise will be clothed. Two options -. In the first case, you have to go through a simple registration procedure, but the second one will open the doors for you to many supermarkets and large stores, since with legal entities such enterprises work much more willingly.

As equipment you will need:

• rolling pin;
• meat grinder;
• home scales;
• bowls;
• packaging materials;
• freezer.

The only condition is that there should be enough space in your kitchen, especially when production starts to grow and you need extra hands to be able to process all orders. IN home business you will be able to succeed if you strictly observe the issue of the quality of your products. It will cost an order of magnitude higher than store semi-finished products, but the client will also expect more from her. Minced meat should be tasty, most importantly - meat, and in a normal amount.

Business idea: how to open a workshop for the production of cutlets - semi-finished products?
Where we do business: workshop, rented premises
Main costs: purchase of equipment for production (patty molding machine), purchase of raw materials, electricity, wage
Necessary equipment: cutlet molding machine, meat grinders, coolers, cutlet machine, packaging equipment
Expendable materials: packaging, meat, water, breading, onion, garlic, spices and more
Initial capital: from 900,000 rubles. up to 1,600,000 rubles
Payback period: from 12 to 24 months
Possible profit: from 30,000 rubles. up to 120,000 rubles

Making your own meatballs is not difficult. Every hostess knows how, and knows how to do them. Even if you have never cooked before, and decided to try to cook cutlets yourself, you will definitely succeed.

There are a lot of recipes for making cutlets, and of course different ingredients are added everywhere. The main composition of cutlets is: minced meat, salt, pepper, onion or garlic. In some types of cutlets, more cereals are added, for example, buckwheat, such cutlets are called grechaniki. Also add potatoes, cheese, milk, various grated vegetables, carrots, onions.

On the industrial enterprise cutlets are made in the same way as at home, only this process is fully automatic.

Cutlet production technology - briefly.
The enterprise for the production of cutlets, produce cutlets, in large quantities. Cutlets, there are made not entirely from minced meat, but by adding it. Other components are added depending on the recipe. But salt, onion, garlic and pepper are added necessarily. It's all about profitability. If cutlets are produced from pure minced meat, then they will be very expensive, and not every buyer will be able to buy them. And so, cutlets are affordable, and each person will be able to buy them, try and appreciate their taste. I must say that normal production cutlets do not differ much from homemade ones in taste.

Equipment for the production of cutlets.

So what kind of equipment is needed for the production of cutlets? The main thing is:

1) Meat grinder

2) Patty molding machine

3) Refrigeration equipment

4) Packaging equipment

So, for the production of cutlets, you will need a special meat mixer. They are different in price, from 120 thousand rubles to 355 thousand rubles. The price depends on the capacity of the bunker, that is, on how many kilograms of minced meat will fit in it. Usually, from 30 kg of minced meat to 180 kg of minced meat is placed there. The meat mixer is also chosen according to its power. The larger the volume of the product being pledged, the correspondingly the higher the price. Also, for the production of cutlets, you will need to purchase a cutlet machine. It is filled with minced meat, and it automatically releases cutlets, with a certain weight.

Patty molding machine:

The weight of each cutlet, one serving, is pre-set for this machine. The cost of a cutlet machine depends on its performance. A medium power model costs from approximately 220 thousand rubles to 560 thousand rubles. At this price, you can buy cutlet machines with a capacity of 18 - 30 liters of minced meat bunker.
The output of cutlets for 1 hour of work, such a machine is 1000 cutlets and 2100 cutlets. By the number of cutlets produced in 1 hour of work, the total capacity of this line is calculated.

There are cutlet machines that are additionally equipped with a cooler for cutlets. The cooler prevents the cutlets from drying out and freezes them slightly. In mandatory availability, you must have cold storage rooms for this product, capacity, your volume of products that you produce or are going to produce.

And also, you will need to purchase, more and optional equipment. These are cheese graters, vacuum and other types of packaging, transport devices (tapes, etc.).
Transport devices are installed at will, but if you install them, this will give you the opportunity to speed up the release of your products. In this form - cutlets.

Staff.
How many people are needed to service this production. A food technologist must work in production without fail. It is also recommended to have your own sanitary doctor and laboratory assistant who will monitor the quality of the products, as well as the quality of the raw materials from which cutlets will be produced (minced meat, meat, etc.) Then one, better still 2-3 people, for auxiliary works (unloading, loading, etc.) The meat grinder and the meat mixer are usually serviced by one operator, for each device. But if your enterprise will be around the clock, or work in several shifts, you will need more people accordingly. To work at this enterprise, all people working there must have sanitary books. Sanitary books must comply with the requirements of the standard, controlling federal or local authorities.

Even if a person works as a loader or cleaner, he must still have a sanitary medical book. Special education, for the maintenance of the apparatus, is not required. People learn quickly, on the spot.

Business for the production of cutlets and its profitability.
The profitability of production is calculated approximately for each region of Russia. Since everywhere there is a different purchase price for raw materials, for the production of cutlets, as well as for finished products (semi-finished products).

Approximate prices for raw materials: pork - 128 rubles per 1 kg; beef - 155 -173 rubles per 1 kg; Minced meat is mixed with each other, in a ratio of 3: 1 in this case, the cost of minced meat is 140 rubles / kg. The cost of finished cutlets is approximately 100 rubles. The selling price for 1 kg of finished products is 200-250 rubles. for 1 kg. These are frozen meatballs, without soy additives and chicken meat. It turns out profit from 1 kg. Products 100-150 rubles. From here it is necessary to subtract packaging, breading in breadcrumbs, as well as utility costs for maintenance. Good luck!

Chopped semi-finished products include:

• cutlets - homemade, Moscow, Kiev, peasant, Krasnodar, meat and cabbage, meat and potato in Belarusian, meat and vegetable, Yakut, Transbaikal, Buryat, spicy;
• meatballs - low-calorie children's;
• schnitzel - Moscow, special;
• beefsteak - urban, beef, youth;
• rump steak;
• minced meat - beef, pork, homemade, lamb, special, offal, for steaks;
• meatballs - Kiev, Ostankino, meat and vegetable, Leningrad, children's;
• meat croquettes;
• dietary dumplings;
• kyufta in Moscow.

Chopped semi-finished products are produced in chilled and frozen form. Chopped semi-finished products are made from beef, pork, lamb and offal. For the manufacture of all types of chopped semi-finished products, meat is used in a cooled, chilled and thawed state, which, in terms of quality, must meet the requirements of the relevant regulatory and technical documentation. Depending on the type of chopped semi-finished products, cutlet meat (beef, pork, mutton), trimmed beef of I and II grades, semi-fat, fatty, single-grade pork, raw beef and pork fat, sausage unsalted bacon are used. Of the by-products, trimmed meat of beef and pork heads, light pork and beef, trimmed meat trimmings are used. In addition to meat and animal fats, soy and milk protein preparations, blood plasma, wheat bread, chicken eggs and melange, rice and semolina, rusk flour, onions and vegetables (cabbage, potatoes, carrots), as well as milk, butter, drinking water and spices.

The technological process for the production of chopped semi-finished products and minced meat is shown in Figures 1 and 2.

Figure 1 - Flow chart for the production of chopped semi-finished products

Each type of chopped semi-finished products must meet the relevant organoleptic and physico-chemical parameters. For cutlets, rump steak, and meatballs, a rounded flattened shape is characteristic, for schnitzels - oblong, for minced meat and steaks - rectangular (in the form of briquettes), for meatballs - spherical or elongated-spherical.

On the cut, chopped semi-finished products should look like well-mixed minced meat.

Figure 2 - Technological scheme for the production of meatballs, croquettes, dietary quenelles, kufta in Moscow

Quality requirements for chilled chopped semi-finished products

All types of chopped semi-finished products produced chilled, except for natural minced meat, must have a smooth, well-shaped surface without cracks and breaks, with even edges and the same layer of breading flour over the entire surface of the semi-finished product. The consistency should be homogeneous, sufficiently viscous, without coarse inclusions (tendons, small bones, cartilage, poorly soaked and insufficiently crushed pieces of bread). From above and on the break, semi-finished products should have a characteristic smell of fresh meat raw materials. Deviations in the mass of the 1st semi-finished product ± 5% are allowed. The mass of 10 pieces should not have deviations to the smaller side. The temperature inside the semi-finished product when shipped from the enterprise should be no higher than +6 °C.

Equipment for the production of chopped semi-finished products

The device and operation of the top

All tops have a fundamentally the same device of the actuator. In the body of the top there is a working chamber for processing the product, which is a fixed hollow cylinder, inside which there are ribs that prevent the product (meat) from turning relative to the screw. The location of the ribs can be helical or longitudinal (parallel to the axis of the working cylinder). The direction of the helical ribs is opposite to the direction of the screw turns.

To advance the product in the working chamber, feed it to the knives and push it through the knife grates, a rotating auger with a pitch of turns decreasing towards unloading is used.

A feature of the auger is the creation of pressure sufficient to move the meat through the cutting mechanism without squeezing the liquid phase contained in the product.

The cutting tool of the top consists of a fixed scoring grid, rotating cross-shaped knives and fixed knife grids with different hole diameters and
clamping nut. The most widespread gratings with a diameter of 200 and 160 mm.

The degree of meat grinding depends on the size of the outlet grate openings. With a small degree of grinding (16-25 mm), one cutting plane is sufficient, the top is assembled with one knife and one grate; with thinner (2-3 mm) the number of cutting planes should be increased.

The top consists (Figure 1) of the working chamber (1); ribs (3) located on the inner surface of the working chamber; feeding device - auger (2); cutting tool, consisting of a scoring grid (4), knife grids (5, b), clamping nut (7); loading bowl, electric motor, bed.

Picture 1 - circuit diagram spinning top

The top works as follows: from the loading bowl, the raw material is fed using a screw (or a system of screws) to the cutting mechanism (grid and knife), fixed with a clamping nut. The auger rotates from its own motor through a gear train. During the rotation of the auger, the pressure is created in the chamber, which is necessary to push the meat through the cutting mechanism.

The quality of meat grinding can be judged by the nature of its outflow from the neck of the top. At good quality minced meat comes out of all the holes of the grate and flows in even streams. And when it's bad, it flows out in zigzag streams and mainly along the edge of the grate. If the top does not work properly, its neck heats up. In this case, the top must be disassembled and troubleshooted: sharpen the knives, assemble the cutting mechanism correctly, monitor the continuous supply of meat and prevent the top from running idle.

The device and operation of the cutter

Cutters are meat mincers with fast-rotating sickle-shaped knives.

They are used for medium and fine grinding of meat. Cutters are of periodic and continuous action. They differ in the ways of loading and unloading raw materials (manual or mechanical), the location of the knife shaft, the number of speeds of the knife shaft, the presence or absence of programming devices, a hermetic bowl lid and a vacuum system. In the cutter, not only the grinding of raw materials takes place, but also its mixing. The cutter (picture 2) consists of:

• Beds (1);
• Bowl mounted on a vertical shaft (2);
• Knife horizontal shaft (3);
• Cutting tool (4);
• V-belt transmission (5);
• Unloading disk (6);
• Electric motor.

Figure 2 - Schematic diagram of the cutter

The cutting mechanism of the cutter consists of sickle-shaped knives rotating on a shaft, a steel comb that cleans the blade of the knives from meat. The sickle-shaped knives are installed in such a way that there is a minimum gap between the blade of the knives and the bowl of the cutter. The number of sickle-shaped knives depends on the size (capacity) of the bowl, usually 6 sickle-shaped knives are installed, but they can be from 3 to 12. They are mounted in bulk with an open or closed nest.

The raw material is fed into the bowl, which rotates slowly. The inner surface of the bowl has the shape of a semicircle. The bowl rotation shaft is located vertically, and the knife shaft is horizontal. The sickle-shaped knives, during rotation, pass against the surface of the bowl and, after each revolution, cut the incoming raw material. The knives are covered with a lid and are crescent-shaped in order to ensure high speed cutting with sliding along the surface of the bowl. Ready chopped minced meat is unloaded from the bowl using the unloader mechanism, the working body of which is a plate (disk): when the latter rotates, the minced meat is ejected from the bowl.

The main technical indicator of the cutter is the capacity of the bowl in liters. Cutters are available with a capacity of 120, 200 and 300 liters.

Cutting technology

Cupping should ensure not only the proper degree of meat mincing, but also the binding of such an amount of added water or ice that is necessary to obtain a high-quality product at a standard moisture content.

The duration of cuttering significantly affects the quality of minced meat. During the processing of meat on a cutter, mechanical destruction of tissues occurs during the first 2-3 minutes, the surface of meat pieces increases significantly, after which swelling and binding of water added to the cutter begins and a new viscous-plastic structure is formed.

The total duration of cutting is 8-12 minutes. It depends on design features cutters, the shape of the knives, the speed of their rotation. For the optimal duration of cuttering, the duration of the process is taken, in which all indicators of minced meat and finished products reach highest values. These indicators include stickiness, water-binding ability of minced meat, consistency and yield. finished products. With excessive cuttering, the minced meat overheats. In order to prevent overheating of minced meat in the cutter, add cold water or ice at the beginning of cutting in such a way as to keep the temperature of minced meat at a level of 12-15 ° C. With an increase in the content of adipose tissue, the amount of water and ice decreases.

When processing different types of raw materials on a cutter, beef or lean pork is loaded first, and then semi-fat and fatty pork.

Water is added when processing beef and lean pork. An excess amount of moisture, as well as overcutting, leads to the formation of broth-fat edema in the process.
heat treatment.

The device and operation of the meat mixer

Meat mixer periodical action L5-FMB (Figure 3) consists of a frame (1), an electric motor (2) with a drive (3), a bowl (reservoir) (4), in which two kneading spirals (5) rotate towards each other, a lattice cover (6) , and unloading hatches (7). The bed is a welded frame, closed on all sides with quick-release facing sheets. The kneading spirals are driven by V-belts and gears. Tank hatches are designed for unloading minced meat, they are tightly closed with lids. The lattice cover is interlocked with the electric motor, which ensures that the kneading spirals are turned off. The lid in the raised state can be fixed using a special device.

The crushed meat raw materials and other components are loaded into 2/3 of the volume of the container with the lid open. Mixing is carried out until all components are evenly distributed, the finished minced meat is unloaded using kneading spirals with open unloading hatches.

Figure 3 - Meat mixer L5-FMB

Cutlet production

Raw material preparation

Meat, bacon, raw fat, onion, garlic are crushed on a top with a grate opening diameter of 2-3 mm. For peasant cutlets, meat raw materials are preliminarily ground on a top with a lattice hole diameter of 12-16 mm. For chopped Moscow schnitzel, fatty pork is crushed on a top with a lattice diameter of 9-12 mm. The lard is crushed on a lard cutter, cutter or manually, before cutting it is frozen to -2 ° C.

Fresh onions are crushed on a top with a lattice diameter of 2-3 mm. If dried onion is used, it is pre-soaked for 2 hours in water at a temperature of 15-17 °C.

The bread is cut into pieces, soaked in water and crushed on a top with a grate opening diameter of 2-3 mm. You can grind bread without pre-soaking. At the same time, water is supplied to the neck of the top simultaneously with pieces of bread, the amount of which must be taken into account when compiling minced meat.

Melange is pre-thawed in baths with water at a water temperature not higher than 45 ° C. Thawed melange is not subject to storage. Egg powder is mixed with water in a ratio of 274 g egg powder and 726 g of water.

Bread flour is sifted and passed through magnetic traps. Salt is used in dry form with preliminary screening.

In order to improve the quality of the semi-finished product and ensure the output in fried form, it is recommended to use pork cutlet meat with a fat content of up to 30%. For homemade cutlets and minced steaks, beef cutlet meat should be selected with a fat and connective tissue content of not more than 15%.

Minced meat preparation

For its preparation, batch mixers or continuous mince preparation units are used. Raw materials are sequentially loaded into the mixer according to the recipe. Mixing is carried out for 6-8 minutes until a homogeneous mass is formed. To lower the mince temperature during mixing, it is recommended to add flake ice, instead of 20% of the consumed water, the mince temperature should not exceed 8-12 °C.

Forming cutlets

Cooked minced meat is molded on automatic machines AK2M-40, flow-mechanized lines K6-FLK-200, V2-FPA.

The device and principle of operation of the cutlet machine AK2M-40

Cutlet machine AK2M-40 is designed for dosing and molding cutlets.

The cutlet machine (figure 4) consists of a body (1), a loading hopper (2) with a bladed screw (11), a molding table (3) with sockets (4), a disk (5) with a scraper (14), a mass regulator (13 ), electric motor (9).

Figure 4 - Cutlet machine AK2M-40

Cooked minced meat is loaded into the bunker, from where the minced meat is fed by a bladed screw to the hole located at the bottom of the minced bunker. Under the hopper, a working table with nests rotates, and out of five forming nests, only one is fed to the hopper opening. At this point, the piston in the seat drops to the bottom position. With a paddle screw, the minced meat is squeezed into the nest of the table and fills its entire volume due to the pressure created by the rotating blades of the screw in the bunker. With further rotation of the table with sockets, the rod, sliding along the copier, moves the piston upwards, while pushing the molded cutlets from the table surface, from where they are thrown onto a disk under the action of centrifugal force, from which they are manually placed in trays.

The mass of cutlets made on the machine can be adjusted by changing the position of the copier in height - this changes the volume of the cylinder filled with minced meat.

Cooling of semi-finished products

Cutlets intended for sale in a chilled form, after molding and placing on trays-liners, are sent to the cooling chamber.

Cooling is carried out at a temperature of 0 to 4 °C until the temperature inside the semi-finished product reaches no higher than 4 ± 4 °C.

Packaging, labeling and storage of cutlets

Chopped chilled semi-finished products placed in trays are packed in reusable wooden, metal or polymer boxes. Boxes are closed with lids or liners. It is recommended to stack no more than four trays in one box.

The weight of one box should not exceed 20 kg. It is allowed to release chilled chopped semi-finished products wrapped in 5-10 pieces in parchment, sub-parchment, plastic film bags, which are then heat-sealed, clamped with aluminum staples or sealed with adhesive tape.

A semi-finished product of one name and one mass is placed in each box. A label is placed in the box indicating the name of the manufacturer, its subordination, the name of the semi-finished product, the number plate of the packer, the quantity of the product, the mass, price, number of pieces, as well as the date and time of the end of the technological process, shelf life and sale.

The shelf life and sale of chilled chopped semi-finished products at a temperature of 0 ° C to 6 ° C from the end of the technological process is not more than 12 hours, including
at the factory - no more than 6 hours.

Production of semi-finished minced meat natural

Natural minced meat is made from chilled beef, pork and lamb of I and II fatness categories. When trimming for the manufacture of natural minced meat, all cartilage, tendons, connective tissue, and when trimming pork, there is also an excess of fat, leaving no more than 3 (> -50%). Trimmed beef, pork, lamb are minced on a top with a diameter of holes in the output grate of 2-3 mm without adding water.

The minced meat is packaged in parchment, subparchment, cellophane and other transparent films, in portions of 250 and 500 g. Natural minced meat is prepared from one beef, pork or lamb or a mixture of beef and pork in various proportions. Packed manually or on special machines for packaging and packaging of minced meat.

The device and principle of operation of the automatic machine AP1M

Designed for filling and packaging minced meat in parchment or foil in the form of briquettes of 250 g. bunker.

The machine (figure 5) works as follows: the packaging material from the roll (1) enters the guide roller (3), then the adjustable sectors (4) guide the packaging material between the knives (5), which cut the reaming of a certain length. The levers (6) feed the reamer onto the forming die (5) under the punch (7). The presence of a scan on the matrix is ​​controlled by a probe (9) and in case of its absence, the machine automatically stops. The punch pushes the reamer through the die, giving it the shape of a box, which is inserted into the socket of the carousel table (12). The dispenser (10) of the hopper with a screw feeder (11) fills the box with a certain portion of minced meat, and the package valve closing mechanism (13) wraps the package. The pre-pressing mechanism (14) gives the bag its final shape. The bag is automatically removed from the forming table slot and the forming table bag remover (17) feeds the bag to the package tipper (16) which turns the bag closed side down. In this form, the package enters the conveyor (15), from where it is removed manually and placed in a container.

Production of chopped frozen semi-finished products

For the manufacture of chopped frozen semi-finished products, trimmed meat from beef, pork, offal and fatty raw materials of all types of livestock is used in a cooled, chilled and thawed state; milk and dairy products, eggs and egg products; onions, garlic, cereals, salt, spices and other auxiliary materials. It is allowed to use egg powder instead of 1 kg of melange or 24 chicken eggs; dried onion at the rate of 225 g instead of 1 kg of fresh; whole milk powder at the rate of 1 kg instead of 8 liters of pasteurized whole milk.

It is not allowed to use meat and products frozen more than once, pork with signs of yellowing of the fat, meat of bulls and boars, meat with signs of putrefactive decomposition.

Raw materials are selected according to the recipe and prepared in accordance with the requirements of technological instructions.

Minced meat is prepared on the equipment of continuous or periodic action. First, beef is loaded into the mixer, then cold water is added in an amount of 18-20% to the mass of raw meat, milk, salt, onion, spices, rice or semolina and 2-3 minutes before the end of mixing add pork or bacon. The crushed raw materials with all components are mixed for 4-5 minutes until a uniformly mixed mass is formed.

Cooked minced meat is molded on molding machines.

Meatballs are molded in the form of checkers (cylindrical shape) with a diameter of 20 mm and a height of 20 mm, the weight of one meatball is 7-9 g.

Meat croquettes, dietary quenelles, Moscow-style kufta are formed in the form of checkers with a diameter of 36 mm and a height of 30 mm, each weighing 30 g.

Forming meatballs on the FFP machine

The FFP machine is designed for dosing and molding meatballs.

It consists of a frame, an electric motor (1) with a gear (2), a minced meat hopper (7) with an auger (5) located in it, a forming drum with nests (4) and a socket (3) located above it, an eccentric-vane pump (9), designed to force minced meat into the socket, a belt conveyor for feeding trays, a vibrating knife (6) for separating meatballs from the drum (Figure 6).

Minced meat from the hopper is fed by an auger into an eccentric-vane pump, which pumps it into a socket that fits snugly against the cylindrical surface of the drum in its upper part, and fills the nests. When the drum is rotated 180°, the pistons push the meatballs out of their nests onto a tray in which they are transferred to the freezer.

In chambers, meatballs are frozen at an air temperature not higher than -18 ° C, in quick freezers - at a temperature of -30 ° C ... - 35 ° C until the temperature inside the semi-finished product reaches no higher than -10 ° C.

Ready frozen semi-finished products should not be sticky, deformed. Taste finished product characteristic of this type of product with a pronounced aroma of spices and spices. The mince is juicy. Foreign smells and tastes are not allowed. Frozen semi-finished products are packaged in cardboard boxes weighing 350, 500 1000 g. Stored at a temperature not exceeding -10 ° C for no more than 1 month.