Own business: chocolate production. Technology and equipment for the production of chocolate. Technological scheme for the production of a sports bar Technological process for the production of protein bars

Today, food quality criteria are changing significantly in favor of their naturalness. Highly valued are those products that do not contain synthetic additives, or, in extreme cases, have a small amount of them. Particularly popular are those products that were made exclusively from fruits or vegetables. Among them is a novelty - fruit bars, which are gradually replacing the more familiar, but less useful to us refined chocolate bars.

Manufacture of muesli fruit bars

Today, food quality criteria are changing significantly in favor of their naturalness. Highly valued are those products that do not contain synthetic additives, or, in extreme cases, have a small amount of them. Particularly popular are those products that were made exclusively from fruits or vegetables. Among them is a novelty - fruit bars, which are gradually replacing the more familiar, but less useful refined chocolate bars.

There are two main new popular technologies that allow you to make a fruit bar: "wet" and "dry". It is on which of them was used in production that the final taste of the product will largely depend.

Features of the production of "dry" fruit bars

Very promising is the production of tasty and nutritious fruit bars using the "dry" technology, which is the following sequence of steps:

1. Thorough washing of raw materials, represented mainly by prunes and dried apricots.

2. Removal of large inedible inclusions - seeds and all kinds of debris that got into the fruit during assembly, storage, drying, transportation.

3. Additional drying of raw materials.

4. Grinding to a homogeneous mass in an industrial-type meat grinder.

5. Simultaneous cooking and mixing of the crushed mass with sugar, apple pieces, coconut flakes, berries and other additional ingredients. This stage is performed at a temperature of 110-120 degrees, and the final moisture content of the product is 12-14%.

6. Cooling of raw materials up to 40-60 degrees. After lowering the temperature, the mixture is placed in a molding machine of the "Former" type, due to which the "gentle" molding of fruit bars into sheets 500 mm wide takes place.

7. After molding (pressing out), the bars are cooled to room temperature in air, and also dried by fans.

8. Cutting bars of the required size is carried out on a special guillotine.

9. Each product is individually packed on a special machine.

10. Well-packed products are placed in cardboard boxes.

This modern technology if necessary, it can be upgraded in several directions:

Mechanization of the washing stage by installing a washing device;

Replacing small plates by continuously placing the strips on a spiral conveyor and then cooling them;

Automatic cutting of bars on the conveyor.

To date, the described innovative technology has already been successfully applied by some manufacturers, who note quick payback purchase and installation costs of equipment.

How to organize your own production?

In order to organize a line of “dry” production of fruit bars, a certain amount of cash investments will be required, consisting of the following categories (the calculation was made for May 2016, the dollar exchange rate is 66 rubles):

30-50 thousand rubles - an industrial-type meat grinder with a capacity of 200-300 kg / h;

150-270 thousand rubles - a 100-liter digester equipped with an oil jacket, as well as a reinforced agitator;

RUB 1,550,000 – Formovatel machine for molding bars using a “dry” technology;

1400-1700 thousand rubles - horizontal packaging machine;

50-100 thousand rubles - additional equipment (fans, sinks, sheets, carts).

The total cost of such a list of devices will be 3180-3670 thousand rubles.

Fruit bars - the main nuances of "wet" technology

The “wet” production technology is somewhat different. It includes the following steps.

1. Washing the fruit mixture (prunes and dried apricots, as well as a small amount of other ingredients).

2. Removal of large inclusions - bones and various debris.

3. Grinding the finished mixture.

4. Mixing fruits with each other with the additional addition of various ingredients, such as apples, berries, flavors, preservatives, etc.

5. The wet mixture of fruits is sent to the molding machine, where it is laid on mesh sheets in long strips of the desired width and height.

6. Placement of sheets on trolleys, and then in a vacuum oven, where drying takes place at a temperature of 50-70 degrees.

7. Cutting fruit strips into pieces of a certain size.

8. Glazing of fruit bars, if it is provided for by the technological process.

9. Packing in a special machine for finished products.

10. Packing products into cardboard boxes.

With a certain degree of conventionality, production lines can be divided into automated and automatic.

Automatic type has a clear performance framework. Such a line is able to perform its work with minimal operator participation. The equipment independently weighs the raw materials, mixes it in the right proportions, etc. You can buy a similar set of devices from a very limited number of manufacturers. For example, in Germany it will cost at least 3-4 million euros.

are separate devices that are located in right order. In this case, the employee will require much more effort and time. Such systems can be significantly improved, bringing to the desired degree of automation.

Calculation of cash costs for the launch of the line

1. The total price of a complete set of equipment for launching a novelty - "wet" production of fruit bars, depends on a number of factors:

2. Desired productivity of the line and the possibility of its increase in the future. For example, if the plans include a doubling of productivity, then it would be rational to immediately buy a filling machine of the appropriate capacity, since its price will be almost the same.

3. Product range. So, for example, the presence of an enrobing machine will increase the overall cost of the line.

4. Equipment manufacturer country: For China, Russia and Italy, the price of, say, a filling machine will differ several times.

The lowest productivity of the line is 50 kg/h, which is determined by the capabilities of one vacuum furnace. Increasing the number of furnaces will increase the speed of production.

You can also save on washing and sorting raw materials. If manual labor is used for this stage of production, then the cost of the line will be 7-10 million rubles. If you create a line with a capacity of 200-250 kg / h, then the equipment will cost 20-25 million rubles (prices are presented taking into account the dollar exchange rate of 32 rubles).

If you decide to create your own production for the production of fruit bars, then contact us and we will help you in the following steps:

Development terms of reference for the production line;

Preparation of a production plan;

Providing devices for purchase;

Installation and start-up of equipment, its verification;

Development of the production process with a technologist.

Do you want to establish your profitable business with innovative technologies? The production of fruit bars is very promising area with a fairly low level of competition so far, which allows to achieve fast positive results. Such production of environmentally friendly products is especially relevant in the Krasnodar Territory, where it will not be difficult to obtain raw materials, because it is here that the issue of processing is always acute. harvested crop fruits and berries.

How a protein bar manufacturer raised over 220 wholesale clients

The sports nutrition market is growing year by year, and its consumers are most often attracted to protein and protein products. Dreams of own production and the trend adopted led the young Novosibirsk entrepreneur Artem Parfenov to the production of protein bars. In 2015, Artem became the founder of the Vasco company, whose products are presented today in more than 50 cities of Russia. Artem told Thirst about the global plans for the project and his own business philosophy.

From small sales to big production

Entering the first year of the Faculty of Law of the Siberian Institute of Management of the RANEPA, Artem Parfyonov thought about self-financing. He needed money, so he was looking for ideas for making money. One of them came to our hero's mind when his classmate ordered an unusual cover for his student ID card in another city. Its price at that time was about 300 rubles. Having estimated that the cost of goods does not exceed 50 rubles, Artem realized that he could make good money on this. He borrowed 10 thousand rubles from his parents to order a minimum batch of covers in Moscow and found assistants to develop the design.

Artem Parfyonov: “When the covers were brought to Novosibirsk, I started selling them at my university. A little later, he switched to other universities in the city. Then I managed to form a team that allowed me to cover neighboring cities for sales. This business lasted about 2 years and was not the only one. Second major project became an online store of sweatshirts from American brand Hoodiebuddie, which had headphones built into the drawstrings to tie the hood. In addition to the main businesses, I constantly clung to emerging ideas and implemented them.

Once one of the guys at the institute approached Artyom and asked if he was engaged in the production of magnets for refrigerators with the symbols of the Tuvan community - there were no such ones on the market yet. So another project of our hero began to spin. He notes that in each new commercial business he had very good turnover. Being engaged in the chosen business, Artem always traded in something. Noticing that in the villages and small towns the market for women's cosmetics and perfumes is poorly developed, he began to buy goods at wholesale warehouses in Novosibirsk and travel by train around the region with an offer.

Artem Parfyonov: “Once I was sitting in a park and for 5 minutes I watched how many people crowded near the rental of electric cars for children. Approached, asked the price - it was about 200 rubles for 5 minutes of use. I quickly calculated the potential income in my mind. Literally the next day I bought cars for hire and put them on the square.

Providing some services, selling or reselling something, our hero dreamed of his own production in the food industry. He was pleased with the idea that somewhere people would enjoy eating his products. Along the way, he analyzed different markets and identified current trends - one of them was protein bars.

The principle of lean manufacturing

The basic principle of Artem Parfenov and his company Vasco is that everything should start with minimal costs. After studying numerous competitors, the young businessman came to the conclusion that protein bars are mainly produced traditional companies Food Industry. They add a little protein to an ordinary chocolate bar, but at the same time there is a lot of sugar, icing, powdered milk and other ingredients. Only slightly increases the amount of protein. Artem's goal was to create exactly protein bars, where there will be a lot of protein, little fat and a minimum amount of carbohydrates.

At the start, he could have hired a team, but decided to try to do everything alone. Having on hand start-up capital 300 thousand rubles, he bought raw materials, equipment, rented a small room with an area of ​​7 square meters. m with friends working in catering, and began to experiment. The recipe was invented right in the kitchen, but this was not due to the desire to figure out the process on our own, but to the lack of good food technologists in the job market. Not finding a suitable person for this position in Novosibirsk, our hero tried to look for him in Moscow, but the search did not bring results. As a result, the planned couple of weeks to start the business turned into six months of painstaking preparation and recipe development.

Artem Parfyonov: “I have read a lot of textbooks, mostly in English language, various scientific studies. It was very hard. I read every day without days off and experimented a lot. The bar not only had to meet certain requirements, but also be tasty. And I did it."

During the first month, Artem himself produced, packaged and offered products to stores, meeting with their directors. The first sale of Vasco bars took place on December 15, 2015 - this day is considered the date of the company's birth. When sales went uphill, his girlfriend came to the aid of the entrepreneur - she was engaged in production, and the implementation processes remained with him. The next step was hiring employees for the team. It is such a start with minimal costs, as Artem Parfenov notes, that makes it possible to manage the company more efficiently in the future, since the founder is perfectly familiar with all the internal mechanics.

However, not only the start was touched by the principle of lean production. Not so long ago, the company released New Product- Protein muffins. Having funds to purchase equipment and speed up the entire production process of this product, manufacturers began with minimal cost. Even the sealing of packages with muffins is done manually with the simplest apparatus. All this allows you to tightly control costs, especially during the period when the product is just launched on the market and has not yet received a full feedback.

Protein offer

Vasco's main product is protein bars. At first, Artem Parfenov developed only one flavor for sale. The people around did not believe in the success of the undertaking, because they were firmly convinced that there was no interest on the part of the consumer in such a small assortment. But they were wrong - the bars began to sell well. Since the composition included peanut butter and its production was one of the stages in the manufacture of the final product, our hero decided to create a separate product - peanut butter under his own brand. The rise of the market in this niche played into the hands. Now both bars and pasta in stores are presented in assortment.

Most often, the principle of work of producers in the food industry involves only the production of products. Further, it is sold to stores by numerous distributors. Vasco has its own sales team that finds and attracts potential customers in the form of supermarkets, sports stores and healthy eating, fitness centers.

Artem Parfyonov: “Distributors are an extra link in the era of the Internet. This is an outdated business model that only worked when there was no direct connection to distant cities and regions. Now there is the Internet.

The main clients of the company are wholesale buyers. They are attracted, among other things, through contextual or targeting advertising, for which a portrait of a B2B client was compiled, but most of them come after a cold call by the sales department. A potential partner is sent offer, after which managers call him back, who work out objections and offer to purchase a trial batch. If a entity does not become a Vasco client on the first try, they call him back until the deal is concluded and the contract is signed.

As Artem Parfenov explains, his competitors in peanut butter and protein bars can delay shipments or simply leave an unfavorable impression on partners - and this is a chance to take their place. There were such clients whom the sales department persuaded throughout the year, and the contract was nevertheless concluded. The marketing department is working on attracting the end consumer. A separate area of ​​the company's work is an online store where a person whose city does not yet have Vasco products can purchase bars, pasta or muffins with delivery.

A look into the future

Despite the qualitative and quantitative growth, Vasco, like many other manufacturers, is experiencing difficulties with suppliers. This is largely due to the fact that absolutely all of them are imported. Foreign manufacturers fail their distributors, and the delay drags along the chain. Either problems with customs, then weather, then unpunctuality. As a result, the delay in the shipment of products by Artem Parfyonov's company. “We apologize, we send a free product, we run promotions just to make amends, but customers say that this is a completely normal situation. And a week of delay is a very short time. Some suppliers let them down for long periods,” says Artem.

The second issue is staffing. Even in such a large city as Novosibirsk, it is difficult to find young guys who are ready to work hard and hard. However, this does not prevent the company from successfully growing and gaining turnover, which has increased several times over the past few months. Our hero advised novice entrepreneurs not to listen to anyone (even experienced businessmen can be mistaken in something) and take responsibility.

Artem Parfyonov: “There is an opinion that you need to do only what you like. Often people use it as an excuse to quit what they started. But I don't like it when it doesn't work out. My business is interesting to me, because I manage to work well, form a team, conquer new markets and cities, release new products. Now we have covered almost all of Russia - by the end of 2017 we plan to complete this process. We also plan to increase current sales and develop new products. The logical next step is international market which we plan to launch in 2018.

Trading and manufacturing company Vasco in facts and figures

Organizational and legal form

Society with limited liability, one founder.

opening date

Chips

- The company has its own sales department.

- There is no desire to bring something unique to the product - everything is done according to traditional standards and technologies, based on certain data, a scientific approach.

– Use of POS materials in stores for promotion.

Start-up capital

About 300 thousand rubles. The money was spent on raw materials, room rental, equipment for making peanut butter, candy bars, and a candy wrapper.

Payback

It is not possible to determine the exact payback period for initial investments, since all the profits in the early stages were spent on business development.

Promotion tools

Online channels: site vasconutrition.ru, groups during

Technological part

Currently, there are three main options for the production of dry specialized multi-component products. In the first case, the initial components are mixed in liquid form before drying, in the second case, the components are mixed in dry form, the third method is a combination of the above.

The first method is quite widely used in the production of dry dairy products. Its disadvantage is the possible destruction of non-heat-resistant components during drying. The third method is implemented in the development of children's dairy products. The second method is practically not used in the industry of our country. At the same time, due to the comparative simplicity of design, it is very promising.

Due to the fact that the product developed in the framework of this work is produced on a unified basis, the most optimal and cost-effective method is the dry mixing of the components. Thanks to this basis, which is prepared at the enterprise, it is possible to create a wide range of balanced and modular products for various, including sports, purposes.

Preparation of sugar-invert syrup.

It is preferable to use sugar invert syrup due to the fact that it does not crystallize during preparation and storage, unlike regular sugar syrup. It is important to observe certain proportions between the dry mixture and the syrup: if the syrup content is insufficient, the dry components will not bond well with each other, as a result of which the finished product will not keep its shape well; with an excess of syrup, the product will have a too viscous consistency, which is difficult to shape.

Invert syrup is obtained by heating a solution of sugar with acid. In this case, sucrose is hydrolyzed to form glucose and fructose.

Laboratory technology

The sports bar was prepared according to the following scheme:

1. Dry ingredients are added to a plastic container according to the recipe and mixed for 5-7 minutes with a glass rod.

3. In parallel with the preparation of the dry mixture, sugar-invert syrup is cooked, which, after mixing the dry components, is poured into the mixer.

industrial technology

The production of a grain sports product must be carried out in accordance with the process flow diagram in the following sequence:

2. Dry mix preparation

3. Preparation of sugar-invert syrup

4 Mixing components

5. Forming and packaging of the finished product

1. Receiving and storing components

1. Dry components are accepted and stored in accordance with the requirements of regulatory documentation for these components.

2. A dry unified mixture consisting of whey protein concentrate, puffed rice, walnut, guaranna extract, grape seed extract and vitamin mineral mixture is prepared as follows:

2.1. According to the recipe, the KSB and the vitamin premix are added to the mixer so that the mixer is filled with no more than 70% of the volume and mixed for 1-1.5 minutes at a speed of 1500 rpm.

2.2. In a mixer with a capacity of 1000 dm 3, according to the recipe, a mixture of CSB and a vitamin premix, guarana extract, grape seed extract, walnut and puffed rice are sequentially added, mixed for 20-30 minutes at a speed of 9 rpm. The mixer should be filled to 50-60% of the volume.

The resulting dry product is stored before mixing with sugar-invert syrup for no more than 48 hours.

3. Water is poured into the digester and heated to a boil, then granulated sugar is loaded in a ratio of 2: 1. The syrup is heated to 100°C and added with constant stirring. citric acid. The amount of added acid (100% concentration) to the mass of sugar is 0.35%. The temperature of the invert syrup during inversion is 102–107°C, the inversion time is 30–40 min.

The prepared invert syrup is cooled to 80--90°C and neutralized with a 10% solution of bicarbonate of soda. The amount of soda (dry) is 0.15 kg per 100 kg of sugar. The soda solution is introduced in separate small portions with continuous stirring. The content of reducing substances in invert syrup ranges from 50 to 65%; the dry matter content is 70%.

4 Sugar-invert syrup is poured into the mixer. Next, the resulting mass is stirred for 40 minutes at a speed of 20 rpm.

5. Forming and packaging of the finished product is carried out by special devices.

All data on the consumption of raw materials and components and the course of the technological process are recorded in technical journals.

Transportation of the product is carried out by all types of transport in covered vehicles in accordance with the rules for the carriage of goods in force for each mode of transport and in compliance with hygienic requirements.

When transporting the product by rail, water or by car use packaging means according to GOST 26663 or containers according to GOST 15102 or GOST 2043 5.

When forming transport packages, pallets are used according to GOST 9557 or GOST 22831.

The shelf life of the product at a temperature of 0 to 25°C and a relative air humidity of not more than 75% is not more than 6 months from the date of production - when packaged in a metallized container.

The finished product is introduced into the athlete's diet during intense training, before important competitions. It is better to use a sports bar 40 minutes before training and immediately after.

Technological process production of a sports bar is shown in Figure 4.

Figure 4 - Technology system sports bar production

It is difficult to find a person who would be indifferent to chocolate - this is both a wonderful delicacy and a product that promotes the production of endorphins, which can improve mood. The technology of making chocolate at the best confectionery factories is constantly being improved, and using various ingredients, tiles of the required color and taste are obtained.

The process of making real chocolate

How is chocolate made in a factory, and what ingredients are needed to make this amazing delicacy? According to the correct technology for the production of chocolate, the seeds of the evergreen cocoa tree, originating from the subequatorial regions of America, are used. The plant, whose scientific name is Theobroma cacao, belongs to the Sterculaceae family and is widespread in the tropics.

Today, cocoa, which is called the chocolate tree in our country, is also grown on other continents. But in the wild it can be found on the coast of Mexico, in Central and South America. The height of the tree depends on the place of growth and ranges from 10 to 20 meters. In cultural cultivation, the height is adjusted by trimming, and it rarely reaches 7 meters. Cocoa leaves are thin, oblong-elliptical, up to 30 centimeters long, the flowers are small, waxy, pinkish-white, appear on the surface of the trunk and large branches. The fruit, the ripening of which lasts four months, is small in cocoa, and its length ranges from 20–38 centimeters. In appearance, it resembles a large cucumber or small melon, with a leathery, slightly woody shell of red, reddish-brown, green or yellow, changing in the process of ripening. In one cocoa fruit there are from 20 to 50 beans immersed in a viscous, sticky liquid that hardens on outdoors. A single seed (bean) is covered with an oily skin.

According to the place of growth, cocoa beans for real chocolate are divided into American, African and Asian, and the largest exporters of cocoa beans are countries such as Côte d'Ivoire, Venezuela, Indonesia, Ghana, Cameroon, Brazil and Ecuador.

The Criollo group of varieties, characterized by a mild taste, is considered to be the best. It is bred in Venezuela, Costa Rica and Nicaragua. Varieties of the Forastero group are most common among producers and exporters. The group of cocoa beans of the Ca-labacillo variety is the cheapest of all, but at the same time the lowest quality.

The right way to make chocolate

What is chocolate made from in modern factories? For the production of chocolate, cocoa beans of all three varieties are used. They are cut from tree trunks with large, long knives (machetes) and collected in baskets. Then the harvest is piled up, and the fruits are cut into several pieces. The next step in the chocolate making process is to separate the cocoa beans from the pulp - an experienced carver opens up to five hundred fruits of the chocolate tree within one hour.

In the process of making chocolate, cocoa beans are laid out on pallets and left for several days to ferment - under the action of natural yeast and enzymes, they darken and acquire a bright chocolate smell and taste. At the end of this process, according to the correct technology for making chocolate, the fruits are dried in the sun and roasted, removing the husk. They are then sorted and packaged for further processing.

On the next step in the manufacture of chocolate in a factory, cocoa beans are ground to a paste-like mass called cocoa mass. Interestingly, the fats that make up the cocoa beans melt when heated and after grinding the cocoa liquor is obtained in liquid form, but thickens and hardens during cooling. Now the product is suitable for the production of chocolate, as well as use in cosmetic and pharmacological products.

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The most valuable product obtained by pressing cocoa liquor is cocoa butter. It is not only one of the essential ingredients of chocolate, but is used to make ointments in cosmetics. Cocoa butter is what gives chocolate its unique taste. But it also has some unique properties, as it consists of three types of fats. One of them is identical to the fat of olive oil. The second is a type of so-called saturated fat, which is converted in the liver into a fat similar to that of olive oil. The third type of fat helps to strengthen the cell membranes of our body. All this suggests that the fat contained in cocoa butter is not harmful to humans.

The dry residue obtained during cooking is ground, and the cocoa powder known to everyone is obtained, used in confectionery production and for making cocoa drink.

Watch a video of how chocolate is made in modern factories:

Chemical composition and nutritional value of chocolate from cocoa beans

Chocolate tree cocoa beans contain up to 300 different nutrients. The approximate chemical composition of chocolate from cocoa beans is as follows: fats are 54%, proteins - 11.5%, cellulose - 9%, starch and polysaccharides - 7.5%, tannin - 6%, water - 5%, minerals and salts - 2.6%, organic acids - 2%, saccharides - 1% and caffeine - 0.2%. Among the substances contained in cocoa beans, one can note: anandamide, arginine, dopamine, epicatechin, histamine, cocohil, serotonin, tryptophan, tyramine, phenylethylamine, polyphenol, salsolinol, magnesium.

Given the chemical composition of chocolate, the nutritional value of the product is very high. The calorie content of 100 g of finished chocolate bar is about 550 kcal.

Numerous studies have noted that the fats contained in cocoa beans belong to the so-called saturated fats, but at the same time they do not have a harmful effect on the human body - chocolate does not increase blood cholesterol levels. The composition of cocoa beans is such that the elements included in it organically complement each other. For example, chromium is involved in the breakdown of glucose, maintaining normal blood sugar levels, and promotes fat metabolism. All this is necessary for us both in cosmetology and with proper nutrition.

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