List of equipment for the cutlet business. The project of the technological line for the centralized production of semi-finished products "cutlets stuffed with frozen poultry"

With the high pace of life in the modern world, people often do not have enough time to cook food, studies show a constant increase in demand for convenience foods. This state of affairs indicates that the workshop for the production of semi-finished meat products as a business is a promising area that allows the owner to receive significant profits. The opening of such an enterprise is of great social importance, as it allows you to create new jobs and give additional money to the regional budget.

What are semi-finished products?

Semi-finished products are products that are converted into ready-made food through simple manipulations. Their preparation is characterized by high speed, which is why this type of product has recently become increasingly popular. Production can be carried out from meat or other raw materials, that is, a natural or processed product is obtained. A distinctive characteristic of the product is its division into portions in the factory.

Finished goods are classified according to the following criteria:
- according to the applied production process (natural, chopped);
- for animal meat (rabbit, pork, beef, lamb);
- according to the characteristics of the temperature state (chilled, frozen).

Semi-finished products can be sold at retail and wholesale, when concluding contracts with shops, cafes, etc. The production of dumplings is currently a fairly busy niche, but the production of pancakes with meat or other fillings, cabbage rolls, sausages for frying and other meat semi-finished products of various degrees of readiness is growing demand and such products are in great demand among the consumer. A separate area in the business of semi-finished products can be considered the production of ready-made meals, using shock freezing of raw materials and the sale of sets of products and spices with instructions for preparing dishes of various cuisines.

Today's business for the production of semi-finished products, using modern equipment, allows you to produce high quality products with the preservation of all nutrients, quickly reconfigure your production for the production of a particular product.

Consider the business of semi-finished products based on the production of cutlets. Someone will say that cutlets are nonsense. You can supply your products to schools, institutes, canteens, cafes and various eateries. So the market for this product exists and requires cheap and high-quality raw materials for its development.

Description of the enterprise

When choosing an organizational form of doing business, it is better to open an individual entrepreneur or a limited liability company. It is cheaper and faster to open an individual entrepreneur, therefore we choose this organizational form for our enterprise. To pay taxes, it was decided to choose a simplified system of taxation "income-expenses". Such a system will avoid a number of problems that novice entrepreneurs usually face. Before starting production, we recommend that you familiarize yourself with GOST R 52674-2006 and GOST R 51187-98, you can search for other standards on the Internet.

OKDP codes:

1511400 - semi-finished frozen meat products;

1511410 - quick-frozen ready-made products;

1511420 - portioned natural semi-finished products.

Future products are subject to conformity certification, the production facility must receive an epidemiological conclusion.

Workshop space.

In order for the possibility of food production to be present, the premises must comply with the standards of Rospotrebnadzor, the sanitary and epidemiological service and fire safety. The best choice would be a place where work has already been carried out in this area (cooking, a confectionery shop), otherwise a fairly high-quality repair is required. You should not consider the option of selecting premises for production in the basement, located in a residential building, with low ceilings, where it is impossible to bring the necessary communications, including supply and exhaust ventilation.

The logistics component is important, the building must have convenient access ways so that raw materials can be unloaded and finished products can be loaded without any problems. The cost of real estate in the center reaches high values, this is not the best choice for starting a business, so you can consider the available options on the outskirts, in close proximity to the resource base.

The premises for the production of semi-finished products should be divided into the following zones:
- acceptance and cutting of raw materials;
- direct production of semi-finished products, in the form of minced meat;
- packaging and labeling operations;
- warehouse.

Separately, a room for the employees of the workshop should be equipped; a convenient location for the shower and toilet will be a big plus. The administration requires a separate room for comfortable work.

For our calculation, we assume that we have rented a room of 100 sq. meters, the cost of the rent is 300 rubles / m2. This area will house the production itself, warehouses for storing products and amenity premises for employees.

The cost of the initial investment in equipment and repairs to organize a semi-finished business.

We remind you that at our enterprise we are going to produce homemade cutlets from minced meat. The functioning of the enterprise cannot be imagined without the purchase of specialized equipment, this will become the main line of expenses for starting a business. In total, the purchase of equipment in the amount of 828,500 rubles is required, such costs consist of the purchase of the following things:

SPLIT-System - 70,000 rubles. (the temperature when cooking minced meat should be no more than 14C);
- meat grinder - 40,000 rubles;
- apparatus for molding cutlets - 150,000 rubles;
- a freezer for storing raw materials and finished products (2 pieces) - 200,000 rubles;
- meat mixer - 160,000 rubles;
- packaging machine - 88,500 rubles;
- other production equipment and improvised means (cutting tables (2 pieces), hooks for carcasses, knives, bowls, buckets, etc.) - 50,000 rubles;
- organization of household premises for the manager and employees - 50,000 rubles;
- computer and printer - 20,000 rubles.

The costs are not limited to the purchase of equipment, the following costs should be taken into account:
- carrying out repair work in the premises - 200,000 rubles;
- connection of communication networks - 300,000 rubles;
- purchase of additional equipment and special clothing - 50,000 rubles;
- other associated costs, including product certification - 60,000 rubles.

The total initial investment in the business for the production of cutlets is 1,438,500 rubles. Also, at the initial stage, working capital will be needed to start production. In our case, it took 1430 thousand rubles.

Purchase of equipment
working capital
Repair work
Organizational expenses
Total expenses

The technological production process is divided into separate stages:
- reception of raw materials;
- primary processing;
- cutting;
- sorting operations;
- cooking individual products (grinding the main ingredients, kneading minced meat, molding cutlets and freezing);
- packing work.

To gain credibility, it is required to use the highest quality raw materials that meet the highest standards. For certain types of products, their own GOST standards apply. It is preferable to work with farmers or established large producers. All purchased meat must pass the maximum control by the veterinary service.

Marketing plan.

The high demand for high-quality semi-finished products shows that opening a workshop at the moment is a profitable investment. There is some competition in this area, but the lack of relevant products in retail shows that there is a necessary place for development in the niche. Promotion of products is carried out by advertising in local newspapers, bulletin boards and specialized Internet resources, debugging personal relationships.
To achieve maximum efficiency, the sale of manufactured products will be carried out in three directions:
- retail outlets;
- wholesale sales to large suppliers;
- Wholesales directly in the network of stores.

Staff for business organization.

The full operation of production involves the work of a staff of 4 employees, which includes:

Preparation of raw materials - 1 employee;
- accountant - outsourcing services;
- preparation of products - 2 employees;
- cleaner - 1 employee.

As production develops, wage indicators can be increased. In some cases, the use of the work of an accountant is not efficient, the services of outsourcing companies are more economically viable.

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Production
Cleaning woman
TOTAL FOT
TOTAL TAXES

Enumeration of the let out production.

The profitability of the enterprise largely depends on a successful start, it is important from the very first stages of the functioning of the business to start making tangible profits. To solve this problem, it is necessary to decide on the goods offered, as the initial product of our workshop will be the production of homemade cutlets, the cost of 200 rubles per kg. or 15 rubles apiece.
For wholesales, such prices are quite natural. As income increases, the list of products offered can be replenished with new positions.

For our calculations, every day we will produce and send 500 kilograms of products to stores, with an increase in productivity up to 1000 kilograms per day in six months. If the manufacturer can prove himself from the best side due to high quality, a worthy demand for his products is guaranteed.

Immediately after the start of activities, reaching such a volume is a problematic task; initially, as many semi-finished products will be produced as it is possible to provide buyers. Building connections, finding sales outlets will gradually increase production capacity, characterized by the amount of goods produced.

Our business costs consist of the following:

fixed costs
Wage
Payroll taxes
Rent
Depreciation
Accountant services
Variable costs
Food cost
Communal expenses
Transport
Insurance IP
Packaging cost
Other variable expenses
Total cost

The cost of raw materials for the production of cutlets.

	The cost of production of cutlets.
		price, kg/r.	consumption/kg	article, rub/kg
meat beef
Raw beef fat
wheat bread
Breadcrumbs
Onion
Ground black pepper
Salt
drinking water
Total consumption per 1 kg of minced meat
Meat yield rate after deboning,%

Payback of business and its financial results.

More clearly, the profitability of a business is demonstrated by performance indicators, which, according to the calculations, acquire the following values:
- profit for two years - 13,842 thousand rubles;
- profitability of the enterprise - 17%;
- payback period - 10 months.

Determination of the net profit of the enterprise.

We will determine the profitability and payback of the business.

According to the results of the planning horizon, the profit will be slightly less than 14 million rubles, and the profitability indicator will be 17%. If these values ​​are accurately reflected in practice, then all investments will pay off in 10 months, which is an excellent result.

To start the operation of the enterprise, an amount of about three million rubles will be required. If possible, you can take advantage of various small business support programs that will cover part of the costs for starting a business.

Output. The market for the production of semi-finished products is interesting, there are many niches for development that are currently not occupied. Since this business employs quite technological equipment, it is worth paying special attention to debugging production so that goods of exceptionally high quality are produced. Such products can easily win the competition in the market and bring you to a leading position. Good luck in business!

In this article:

Frozen semi-finished products are an integral part of the diet of our compatriots. Experts attribute this trend to the growth of citizens' incomes and rising living standards.

The main advantages of the business include the ability to quickly respond to market needs, which makes it possible to produce various types of cutlets in one shift. At the same time, there is no need to reconfigure the equipment, as well as to implement other global changes in the operation of the mini-workshop.

Organizational moments for the creation of a mini-factory

Registration actions

When choosing an organizational form of business, it is recommended to make a choice in favor of individual entrepreneurship or a limited liability company.

Registering an individual entrepreneur will cost much less, however, the vast majority of large suppliers and retail chains prefer to cooperate exclusively with legal entities. In addition, the magnitude of the risks of an LLC is an order of magnitude lower than that of an individual.

When drawing up organizational and legal documentation, the following classifications of the OKVED code should be indicated:

• 1511400 — Frozen semi-finished meat products.
• 1511410 — Quick-frozen ready-made products.
• 1511420 — Semi-finished products portioned natural.

Before starting the production of the first batch of finished products, it is necessary to study the regulatory documentation:

• GOST R 52674-2006: Meat and meat-containing semi-finished products.
• GOST R 51187-98: Labeling of consumer containers for meat, chopped semi-finished products, dumplings, minced meat.

2. Certification of finished products

Frozen semi-finished products are subject to mandatory certification.

It is also necessary to obtain a declaration of conformity, as well as a sanitary and epidemiological conclusion for the production workshop.

Technologies for the production of semi-finished products

Cutlet production technology

In order for the cutlets to be tasty, the meat must be not only of high quality, but also fresh. Therefore, multi-stage control is a mandatory daily event. For each batch of meat, the supplier must present veterinary documents.

The technological process for the production of frozen semi-finished products consists of the following steps:

• preparation of raw materials;
• compiling minced meat (Fig. 4);
• formation of semi-finished products (Fig. 5);
• storage and sale.

The first step in the production process is deboning when the meat is cut into pieces, i.e. brought to marketable condition.

The specialist separates the veins and bones from the meat. Deboning is manual labor, so a man will handle the functions performed.

It is also necessary to carefully monitor that small bones and cartilage do not get into the meat. This, in turn, complicates the subsequent trimming.

Next, proceed to creating ground beef, the optimal ratio of components in which is 50/50. Cooking takes place in batch mixers, where all components are added, according to the recipe of the semi-finished product.

It is often customary to use minced meat, wheat bread, water, onions, spices and table salt.. When mixing, all components begin to be evenly distributed throughout the volume of the mass.

It is noteworthy that the temperature of the finished minced meat should not exceed 14ºС. Otherwise, there is a violation of its bacterial characteristics and taste. It is strongly not recommended to use twice-frozen meat or darkened bacon. Some manufacturers are actively use of proteins vegetable as well as animal origin soy, milk proteins, etc.), egg powder and other ingredients.

Cooked minced meat is immediately sent for the manufacture of a semi-finished product. The resulting mass is subject to dosage, molding and breading in breadcrumbs in automatic mode or manually.

Most specialized equipment is versatile and allows you to produce a large number of different forms of finished products with a simple change of nozzles. It is noteworthy that fish and rather exotic horse meat cutlets can be made in this way.

As for the additional ingredients ( bacon, onion, etc.), it all depends on the recipe.

After shaping the finished product, cutlets are subjected to shock freezing. Then they are packaged and sent to a storage chamber.

Pancake production technology

On an industrial scale, the traditional scheme for the production of pancakes is used, which by itself automated. The purchase of specialized equipment will allow you to knead dough, bake blanks, add a variety of toppings, pack, freeze and store finished products.

According to the recipe, for the production of pancakes, batter is used, which is obtained by successively adding flour, milk, sugar and eggs.

The production process consists of the following steps:

1. The initial ingredients are placed in a mixer (mixer).

3. The blanks are fed to the working table, where they are filled with stuffing, and also packaged in polyethylene packaging.

4. Then the formed pancakes are placed in the refrigerator for "shock" freezing. Such an event will preserve the nutritional and organoleptic characteristics of products.

5. The product is packed, and for the purpose of long-term storage, the pancakes are moved to a refrigeration unit.

Business plan for the production of frozen semi-finished products

We purchase equipment for the production of semi-finished products

The following equipment is required to organize the production process:

• flour sifter - 45,000 rubles (Fig. 22);
• meat mixer 65,000 rubles;
• industrial meat grinder - 30,000 rubles (Fig. 23);
• line for the production of cutlets - 568,000 rubles (Fig. 24);
• pancake line, such as model IPKS-0209(beater, pancake machine, shock freezer, hot and work tables) - 600,000 rubles (Fig. 25);
• cold store (for storing raw materials and finished products) - 150,000 rubles (Fig. 26).

The total amount of capital costs is 1,458,000 rubles.

Thanks to sifting, the flour is saturated with oxygen, and debris and all kinds of impurities are removed from it. Ultimately, this will lead to an improvement in the properties of the resulting dough.

It is shock freezing that gives the presentation of pancakes. Otherwise, the dough will be saturated with the juice of the filling and begin to darken.

Many domestic enterprises specialize in the production of equipment for the manufacture of semi-finished products. Therefore, the novice entrepreneur has a wide choice regarding the acquisition of a production line from various factories according to the most preferable price. It is noteworthy that the equipment used is characterized by ease of operation, as well as the production technology of the product itself.

Therefore, the production process can be established in a fairly short period of time, which is about 2 months. It is noteworthy that in the case of the acquisition of new equipment, most often the supplier or manufacturer undertakes to provide services for its installation and debugging. Proper adjustment will reduce energy consumption in the future.

In the conditions of the functioning of a mini-factory, it would be inappropriate to create a workshop for the slaughter of cattle. Therefore, it is necessary to organize the supply of raw materials, and special attention should be paid to its quality, because the taste properties of the finished product and the reputation of the newly minted enterprise will depend on it.

The products of the mini-factory will be in the middle price segment. Its range will be presented in the form of:

• pancakes with various fillings meat, cottage cheese and fish);
• minced meat semi-finished products ( cutlets).

Selection of production areas

It is recommended to rent, purchase or start building a production building close to farms - the main suppliers of raw materials. This is how you can save money on the delivery of the original components.

The area of ​​the premises in which the production facilities will be located, must not be less than 200 square meters. It is also necessary to take care of the arrangement of warehouses for storing raw materials and finished products, and household rooms for employees.

After choosing a room, it is necessary to redevelop it in order to complied with the requirements of fire supervision and SES(installation of sinks for washing hands, certain ceiling heights, etc.).

The production workshop must be located at least 50 meters from residential buildings. Connection of engineering and technical communications ( electricity, water, gas, sewerage) is a prerequisite.

Before starting production activities, it is necessary to notify the territorial department of Rospotrebnadzor about this.

Forming a staff

For the operation of a small mini-factory, 10 people will be enough to service the production process: 2 workers monitor the technological pancake line, 2 - the cutlet line, 1 - prepare the raw materials, 1 - make the stuffing.

For loading and unloading of ready-made semi-finished products into freezers and their packaging, 1 specialist can be involved.

The technologist will monitor compliance with the recipe, and the laboratory assistant will monitor the quality and compliance with the regulations and State Standards established at the enterprise.

The monthly payroll will consist of the following costs:

• Director - 15,000 rubles;
• Technologist - 11,000 rubles;
• Laboratory assistant - 10,000 rubles;
• 7 employees - 9,000 rubles each;
• Total payroll - 42,300 rubles.

Costs and other financial indicators

Raw material costs:

• pork in half carcasses - 180 rubles / kg.
• beef in half carcasses - 175 rubles / kg.
• additives (bread, onions, spices, breadcrumbs) - 43 rubles / kg.

Let's determine the costs of manufacturing the first batch (based on 100 kg of the finished product).

We also calculate the cost of production of 1 kg. cutlet:

• Cutlet pork and beef meat - 54% of the total share (178 rubles / kg.) - 9,612 rubles;
• Raw fat - 5% (20 rubles / kg) - 100 rubles;
• Wheat bread - 13% (20 rubles / kg) - 260 rubles;
• Breadcrumbs - 2% (30 rubles / kg) - 60 rubles;
• Onion - 3% (22 rubles / kg) - 44 rubles;
• Pepper - 0.1% (90 rubles / kg) - 60 rubles;
• Salt - 1% (4 rubles / kg) - 4 rubles;
• Water - 22% - 0 rubles.

Total: 10 140 rubles.

The cost of 1 kilogram of cutlets will be equal to 101 rubles. In the case of using a different recipe, the cost of finished products may differ by approximately 10%. It is noteworthy that the presented recipe is prescribed in GOST.

Thus, even at the legislative level, the share of the meat part is set at 55% and the content of a sufficiently large amount of water (22%).

Estimated output of finished cutlets is 50 kg. in one work shift, respectively, the monthly output (22 working days) will be equal to 1,100,000 kg.

Monthly fixed costs will consist of the following sections:

• FOT - 42,300 rubles.
• utilities - 15,000 rubles;
• rent - 15,000 rubles;
• transportation costs - 10,000 rubles;
• packaging and packing bags - 8,000 rubles;
• other expenses (advertising, etc.) - 10,000 rubles.

Total: 100 300 rubles.

Full cost\u003d Production per shift x Cost of 1 kg. products x Number of working days = 50 rubles. x 101 rubles. x 22 days = 111,100 rubles.

Gross revenue= Production per shift x Retail cost of 1 kg. x Number of working days = 50 rubles. x 400 rub. x 22 days = 440,000 rubles.

The business plan for the production of semi-finished meat products (using cutlets as an example) will look like this:

• revenue - 440,000 rubles;
• cost price - 111,100 rubles;
• gross profit (revenue-cost) - 328,900 rubles;
• monthly fixed costs - 100,300 rubles;
• profit before tax - 228,600 rubles;
• USN tax - 34,290 rubles;
• net profit - 194,310 rubles;
• return on sales (net profit/revenue) — 44.16%.

The profitability indicator of 44% is quite promising for this production area. It is important to note that we have considered only this type of production of semi-finished products. If the company is still engaged making frozen pancakes, then due to the growth in the volume of sales, the increase will be subject to profitability level.

At this rate, it is possible to recoup the invested capital costs in 1.5-2 years.

Sales of finished products

One of the most important directions in the activity of the enterprise is the organization of sales of products. In the presence of a wide range of products ( varieties of cutlets and spring rolls), it would be reasonable enough opening branded outlets or pavilions in the market. Grocery stores can also supply refrigeration equipment with a company logo.

With a small assortment manufactured products will preferably work directly through intermediary wholesalers.

The most promising line of activity of the mini-plant is the long-term cooperation with public catering enterprises. In this case, the strategic partner will need to provide the most optimal price / quality ratio of the products supplied, as well as guarantee regular deliveries.

As for cafes and restaurants, they prefer semi-finished meat products rather than pancakes. It is necessary to take note of this trend and continue working in this direction, gradually expanding our range.

These can be pieces of chicken fillet with various fillers ( ketchup, cheese, ham, greens, etc..)

It will also be beneficial production of single-component and homogeneous products, which require practically no investment (meatballs, meatballs, zrazy, pasties, schnitzels, etc.).

It is noteworthy that it will be more economically feasible to expand the assortment if the mini-factory reaches the level of self-sufficiency, when it begins to consistently make a profit.

If necessary, you can start selling frozen minced meat. However, it should be understood that competition in the face of meat plants will be tough. You can also establish cooperation with distribution companies that specialize in self-delivery of products.

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); a cutting tool consisting of a scoring grid (4), knife grids (5, b), clamping nut (7); loading bowl, electric motor, bed.

Figure 1 - Schematic diagram of the 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. With good grinding quality, the minced meat comes out of all the holes in 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. Knives are capped and crescent shaped to provide high cutting speed while 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 the design features of the 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 the highest values. These indicators include stickiness, water-binding ability of minced meat, consistency and yield of finished products. With excessive cuttering, the minced meat overheats. In order to prevent overheating of minced meat in the cutter, cold water or ice is added at the beginning of cuttering in such a way as to keep the minced meat temperature at the 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 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 of 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 chopped 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 must be removed, and when trimming pork, excess fat is also removed, leaving no more than 3 (> -50%. Trimmed beef, pork, lamb are crushed on a top with a diameter of holes in the output grid 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, onions, spices, rice or semolina, and 2-3 minutes before the end of mixing, pork or bacon is added. 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. The taste of the finished product is 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. They are stored at a temperature not exceeding -10 ° C for no more than 1 month.

Currently, the semi-finished food market is one of the most dynamically developing and profitable business segments that can be opened without investing significant funds.

And those funds that have already been invested often pay off within two to three months, starting to bring a steadily growing and quite significant income - and with good prospects for developing their own business.

But which product is most in demand? And what kind of semi-finished products do not require any large investments in equipment and the availability of highly qualified workers. The answer is simple: this is the production of cutlets.

The fact is that, as you might guess, single-component and homogeneous products - the same cutlets, or just minced meat, or, for example, meatballs and croquettes, are technologically easier to produce and, accordingly, much more profitable than cutlets "a la Kiev" schnitzels, pancakes etc. For products with filling, additional equipment is required that will process this filling, for single-component cutlets or meatballs, nothing but forming machines is required.

Many people do not want to open such a simple business of their own, fearing high competition in this segment. Indeed, there are a lot of cutlets and similar products on the Russian market. It is a fact. However, the number of their producers is not decreasing either - on the contrary, it is growing, and at a significant speed. More and more manufacturers appear, including those whose products do not leave their own region - there are enough buyers anyway.

In general, the food market is perhaps the only area where competition seems to be high, but once you are directly on it, becoming a participant, it is easy to understand that in reality there is practically none. More precisely, it is not felt - the demands of end consumers regarding the assortment are too high.

Therefore, with proper business management, many manufacturers, clinging to their own, often small and specific niche (for example, one produces only pancakes with cottage cheese, and the other only with meat) can not only maintain positions and even steadily increase their presence in the market, but and get very good profits from such a seemingly small segment.

Thus, the production of semi-finished cutlets can and will certainly become, if you take the matter with all responsibility, not just a means of saving money or just additional income, but a source of the main, and quite considerable, income.

Equipment for the production of cutlets

Probably all of us have ever made meatballs at home. And we all know that this process is not at all difficult and not burdensome even for a lazy cook. So, on an industrial scale, cutlets are made exactly the same as at home, adjusted for the full automation of the process, and, of course, the scale.

For the manufacture of minced meat, an industrial-style meat grinder is used. Of course, there are a lot of brands of such meat grinders - both domestic and imported (including from the former republics of the USSR) sample. Accordingly, prices vary greatly.

But if we take the sector of high-quality European industrial meat grinders of the middle category, that is, designed specifically for kitchen factories, then the pricing policy in this case depends entirely on the performance of the equipment: a compact meat grinder with a capacity of 750 kg per hour will cost from about 195 to 230 thousand rubles; a more powerful sample, already producing 1,500 kg of minced meat per hour, will cost from 1,500 to 1,545 thousand rubles.

Of course, cutlets are not made from pure minced meat. And the point here is not at all the greed of manufacturers who try to use up as little meat as possible, but in the recipe itself - firstly, vegetables (usually potatoes) or cheese according to the recipe are added to some types of cutlets. And secondly, after all, cutlets without any additives will really cost quite a lot - this does not mean, of course, that they should not be made at all, and this category enjoys a certain (in fairness, it should be said, not too much) demand.

Of course, salt, onion and (or) garlic, pepper, etc. products are added to minced meat in any case. And this means that for the production of minced meat you will need a special minced meat mixer.

High-quality meat mixers vary in price from about 120 thousand rubles. up to 355 thousand rubles, depending on the capacity of the bunker - in this case, 30-180 kg. Accordingly, such an amount of minced meat can be in the meat mixer at the same time. Usually, a meat mixer in terms of power (volume of products) corresponds to a cutlet machine.

And finally, the last processing unit is the cutlet machine. It is filled with minced meat and automatically produces cutlets of the desired weight.

The cost of a cutlet machine, like that of other industrial food appliances, depends on productivity, but not in pieces of cutlets, of course (the weight of one portion, that is, cutlets, is set in advance) but in liters of a receiving hopper. For medium-sized kitchen plants, models from about 220 thousand rubles are usually used. up to 560 thousand rubles.

The power of the cutlet machines shown in the example (hopper capacity) is 18 and 30 liters, respectively, and the number of cutlets produced per hour is 1000 and 2100 pieces. Accordingly, this number can be considered the total power of the line.

Some cutlet machines are produced with a regular cooler for finished products. Of course, it is not enough for long-term storage - such a cooler only helps the cutlets to freeze faster and keep from drying out. The presence of refrigeration equipment, with a capacity corresponding to the volume of products produced, of course, is mandatory.

Additional equipment includes, for example, vacuum and other packers, cheese graters (if, according to the recipe, cheese is used in cutlets), transport devices - conveyors, belts, etc. Its installation is not mandatory, but it can significantly speed up production.

Required personnel and profitability of the meatball business

The line for the production of semi-finished cutlets does not require high qualifications and any special education from its employees. Although the presence of one food technologist among all employees is still desirable.

The meat grinder and the meat mixer are operated by one operator each, and with small and medium production volumes, machine operators also have time to unload finished products. But, be that as it may, it is better to have one or two auxiliary workers to perform these duties. Since the production is food, each employee is required to have a medical book that meets current standards and requirements of local and federal regulatory authorities.

Regarding profitability, we can say that it can only be calculated approximately: in all regions of Russia there are different prices for both raw materials for production and ready-made semi-finished products.

At the price of pork about 128 rubles. per 1 kg, and beef - 155-173 rubles. per 1 kg and provided that the minced meat for cutlets is mixed in a ratio of approximately 3: 1, the cost of a kilogram of minced meat will be no more than 140 rubles.

If we consider that the cutlet contains only about 70-75% of pure minced meat (the rest is various additives: fat, spices, breading, etc.), then the cost of a kilogram of finished cutlets will be approximately 100 rubles. The selling price for high-quality frozen cutlets (that is, without soy and chicken meat) is 200-250 rubles. for 1 kg.

Of course, a profit of 100-150 rubles. from 1 kg of products - not clean. About a third of it is the cost of personnel, utilities, packaging and logistics. Thus, the net profitability is equal to 85-90%.