Production of semi-finished meat products. We are opening a workshop for semi-finished meat products. How to open a workshop for the production of semi-finished products

IN Russian cities The main segment of consumption of chilled meat products falls on the production of semi-finished products of varying degrees of readiness. This means that with proper organization of activities the workshop semi-finished meat products will bring a stable income.

Where to start

Working in the real sector of the economy always requires large one-time investments in premises, equipment, and permits. And if the trade knows examples of successful spontaneous startups, then all the nuances of production need to be thought out in advance to the smallest detail. Necessary:

• explore local markets and identify niches of unmet demand;
• study the presented assortment of goods, price range, sales volumes of competitors;
• calculate production parameters, including: productivity, assortment matrix, equipment for the production of semi-finished meat products.

The quality of products is largely determined by technology and the original recipe. It is necessary to develop and approve technical specifications (TU) for each type of product at Rospotrebnadzor or decide to work in accordance with GOST. Each specification will cost the entrepreneur about 15 thousand rubles. It is usually more difficult to achieve compliance of the final product with GOST, but this contributes to promotion in the market: the consumer is inclined to trust products marked “GOST”.

A key factor in the success of a manufacturing business is access to high-quality and cheap raw materials.

If cooperation is established with reliable suppliers, the cost of the final product will be consistently low. One of the most advantageous options is to open a workshop for the production of semi-finished meat products in tandem with a workshop for slaughtering livestock. This will allow you to get fresh meat in the right quantity.

It is important to achieve a minimum level of waste. Slaughterhouses, as a rule, supply raw materials in half carcasses. Muscle and connective tissue are used to prepare semi-finished products. Bones, cartilage, hooves and trimmings will remain unclaimed. All this should be processed if possible (for example, to make animal feed) and disposed of.

Sales organization

It is necessary to work out the issue of sales. Opening your own retail outlets is beneficial because it makes it possible to sell final products at a high price. But for a novice entrepreneur, simultaneously organizing the production of semi-finished meat products and their trade is difficult and expensive. It is necessary to seek partnership with:

• markets;
• supermarkets;
• catering establishments;
• wholesale bases.

You should be prepared for the fact that the products will have to be delivered by your own special transport (wholesalers are an exception; they can pick them up themselves). At first, a product of a brand unknown to the consumer will have to be sold on deferred payment terms, that is, given for sale. This may create a shortage of working capital.

Assortment

On initial stage It is worth focusing on traditional dishes for your area, be it cutlets and meatballs or shish kebab and lula kebab. Experimentation is in order. For example, the “children’s” assortment – ​​semi-finished products of interesting shapes (bears, stars) – is in good demand. To be able to produce something like this, you need high-quality equipment.

Given limited funds, you will most likely have to abandon the idea of ​​starting the production of dumplings. For dough products, specific equipment is required - a dumpling machine, a hard dough mixer and an expensive “shock” ultra-fast freezing refrigerator. Without it, it is almost impossible to provide the dumplings with a marketable appearance: the filling softens, saturates the dough and the entire dumpling looks soggy.

Semi-finished meat products are:

• large pieces - these are individual muscles, layers of meat or pulp with aligned edges, stripped of tendons and connective films;
• portioned (natural or breaded), intended for preparing one serving of food;
• small pieces;
• chopped - minced meat, chopped products.

It is necessary to strive to provide two key parameters final products:

• high added value (semi-finished products with a high degree of readiness are sold at the highest premium);
• long shelf life with minimal use of preservatives (the modern consumer is scrupulous about the shelf life and will definitely find out how it is ensured).

Technological equipment

For a person who came into the semi-finished meat product business from outside, it is very difficult to competently plan production capacity. It is better to entrust the construction of a technological chain and the selection of workshop equipment to a professional.

You can save significantly on equipment by selecting used or domestic equipment. Purchasing new Russian equipment also has a number of organizational advantages:

• guarantee;
• effective assistance in selection;
• often free delivery and commissioning;
• no complaints about the equipment from the SES, fire inspection and Rospotrebnadzor at the production launch stage.

Equipment for the production of semi-finished meat products:

• washing bath;
• cutting press;
• scales;
• sets of knives and cutting boards;
• industrial meat grinder;
• minced meat;
• meat grinder;
• band saw;
• slicer for cutting;
• molding apparatus;
• equipment for preparing cutlets;
• freezers;
• packaging machines;
• storage chambers (according to the requirements of the SES, finished products and raw materials must be kept in different chambers);
• bactericidal lamps.

Organizational issues

Before opening a workshop for the production of semi-finished meat products, you must register your business activity. It is better to open an LLC rather than an individual entrepreneur. Firstly, the owner of an LLC is not liable for business debts with personal property. Secondly, legal entities prefer to cooperate with LLCs. An individual entrepreneur will be sufficient if a businessman plans to organize sales independently and sell products directly to the public.

Key OKVED – 10.13.4 “Production of meat (meat-containing) semi-finished products.” When registering, it is enough to indicate the grouping in 4 digits 10.13. This includes, among other things, the production sausages, canned food, smoked meat.

When registering, you need to take care of including information in the Unified State Register of Entrepreneurs/Unified State Register of Legal Entities and potential types activities: trade, production of animal feed, etc.

Otherwise, changes will have to be made to the registration documentation later.

When choosing a room, you should focus on SanPiN 2.3.2.1078-01. It will be easier to obtain a conclusion from the SES and firefighters if such production has already taken place on the premises. This placement option also guarantees the absence of problems with electrical power, water supply and drainage, and ventilation.

Rospotrebnadzor must be notified of the start of activities. The first batch of goods is used to obtain a product certificate. If the meat is supplied in the form of unprocessed carcasses, it is necessary to involve a veterinarian or negotiate with the veterinary service. You will also have to conclude contracts for disinfection and waste removal.

Production of semi-finished meat products: Video

The demand for fresh meat products is constantly growing. The main competition is between the chilled and frozen segments. There is a place in this niche for now for everyone, because different types semi-finished products are clearly differentiated by purpose and distribution channels.

The volume of meat consumption in Russia has been constantly increasing over the past 10 years. Even based on the results of the depressed year 2015, there is an increase (3%) compared to the previous period. At the same time, the production of semi-finished products is growing most actively, as well as their consumption. This is explained by the employment of the population and the accelerated dynamics of modern life. To understand whether this area is promising for small businesses, let us briefly describe:

• features of the Russian meat products market;
• types of products, preferences, sales network;
• technologies and equipment for meat processing;
• regulatory regulation of this type of business.

Supply and demand for semi-finished products

About 50% of the total volume of meat (Russian and imported) is sold raw. Approximately 30% goes to sausage products, 5% to canned food, about 15% to the production of semi-finished meat products and supplemented with other ingredients. In recent years, their consumption has increased by 10-15% annually, while sausages have increased by only 5% (Fig. 1).

Almost tenfold growth is a response to constantly growing demand. But production is distributed unevenly across regions (Fig. 2). Traditionally, over 60% falls on the Central and Northwestern district, where large meat processing plants are concentrated. According to experts, consumption of these products will grow in the next 3 years, with the highest rates expected in the periphery.

Increased demand has changed the strategy of large meat holdings (Fig. 3). If earlier they focused on the production of sausages, frankfurters, and other delicacies, then in the last two years they have been actively repurposing them into raw semi-finished products. This will certainly lead to increased competition. The developed capacities of giant enterprises, their own raw material base, and the possibility of purchasing imported equipment and new technologies place small businesses in obviously unfavorable conditions.

Most large meat processing plants produce frozen products. The transition from sausage production to products for culinary processing, the purchase of new technologies increases its cost. Standard packaging is also inconvenient: small ones are expensive for the manufacturer, large ones are not suitable for the buyer. Bulk goods are now in high demand.

Small businesses find a place in this niche for several reasons. Proximity to sales points saves transportation costs. And price in times of crisis is the main regulator of consumer demand. In addition, consumers are increasingly choosing chilled meat rather than frozen meat; even if its cost is 10 - 15% higher. Since the shelf life of such products is up to 7 days, retailers buy them from local producers. However, they often complain about the poor assortment and low quality of the goods.

Types of products, sales directions

Semi-finished meat products are produced from all types of meat: beef, pork, poultry, including offal. Currently, their range includes about 40 units. Products are usually divided into two large categories: chilled and frozen. According to manufacturing technology, they are:

1. Natural. Large, small-piece products, mainly from chilled meat: oven-baked beef and pork, steaks, natural cutlets, shish kebab, stew, soup sets.
2. Breaded. Ready-to-cook dishes from fresh and defrosted meat in liquid (with egg) breadcrumbs: offal, chops, rump steaks.
3. Chopped. Products made from low-grade raw materials, often with the addition of bread and spices: cutlets, steaks, meatballs. This group also includes packaged and loose minced meat.

On Russian market Mixed semi-finished products with the addition of dough and, to a lesser extent, vegetables are widespread (Fig. 4). Unconditional leader- dumplings, they even came up with a special vending machine for them.

Product sales channels:

1. Networks retail — their share is about 50%. Dumplings and cutlets sell well in retail outlets all kinds. Sliced ​​meats (kebabs, goulash), minced meat, pancakes, pasties, manti - prevail in markets and supermarkets. Both frozen and chilled products are sold.
2. Specialty cookeries- occupy approximately 10%. These are ordinary stores that sell goods from the counter. Our own culinary workshops allow us to prepare a diverse range of ready-made dishes, quickly responding to seasonal changes, changing tastes and needs. They sell finely chopped meat in marinades, kebabs, goulash, khinkali, cabbage rolls.
3. HoReCa segment— about 14% of semi-finished meat products are sold through it. It is developing the fastest thanks to the spread of fast food. Buyers - restaurants, bars, canteens, cafes fast food. Frozen products are often supplied to catering establishments; large high-tech production benefits here.

Main trends for 2016 - 2019:

1. Increased demand for chilled products; increasing the share of poultry meat: chicken and turkey.
2. Expanding the range of dishes in sauces, marinades of original recipes; with the addition of vegetable ingredients.
3. Displacement of traditional products by new, original dishes of the national cuisine of the peoples of the world.
4. Increased consumption of semi-finished products in the expensive segment, ready-to-eat meals.

How to open a workshop for the production of semi-finished products

If an entrepreneur decides to open a meat business, first you need:

• determine which market segment to work in, select an assortment;
• find, master, develop recipes taking into account modern technologies;
• purchase professional equipment, transport for delivery.

The technological process, for example, for natural semi-finished products includes:

• defrosting of carcasses, half-carcasses (defrosting) in the amount of daily processing - if necessary, if the workshop is located separately from the slaughter place;
• washing, drying, cutting into large cuts, trimming, trimming;
• preparation of portioned, small-piece, chopped products using special machines;
• packing goods into functional containers, sealed bags, labeling;
• cooling (freezing), storage, transportation to a warehouse.

As for the recipe, buyers prefer semi-finished meat products with a minimal degree of processing. For example, if these are chickens, then they are simply cut into half carcasses, breasts, wings, etc. However, there is a growing demand for “convenient” products, balanced in composition, with different ingredients, allowing you to prepare a dish using quick culinary methods. For this purpose, modern packaging such as “protective atmosphere” or “gas environment” is used. Experts believe that owning them will soon become a ticket to the natural chilled food segment.

Inexpensive equipment for all types of processing is produced by Russian factories. It can be selected individually, or you can purchase a ready-made modular workshop for the production of semi-finished products. The selection depends on the future assortment. As a rule, the equipment of the workshop is formed by: band saws, cutting presses, meat grinders of various capacities, machines for applying breading mixture, cutlet or dumpling machines. If you have no work experience, it is advisable to find a supplier who provides comprehensive services, including training and information support. Often such equipment is purchased on lease. Main selection criteria: integrated approach(multifunctional lines) and rationality - the ability to ensure the sale of the entire volume of manufactured products.

Organizational and legal issues

Production of meat and other food products containing it (semi-finished products, canned food, sausages); rules of storage, transportation, packaging, labeling are regulated by the Technical Regulations of the Customs Union “On the safety of meat and meat products” (TR CU 034/2013). This document contains all the requirements, manufacturing conditions and classification of products with different meat contents, for example:

• meat - (> 60%) with the addition of other ingredients;
• meat-containing - (5 - 60%), including flour, eggs, cereals, water;
• meat and vegetable - (30 - 60%) using plant components.

Only the main groups are listed, in fact there are many more. After the development of the relevant GOSTs, their names will be indicated during labeling. In accordance with the Regulations, manufacturers are required to issue one of three documents:

• veterinary certificate— fresh unprocessed meat (veterinary organization of the Ministry of Agriculture);
• state registration certificate— meat products for baby food (Rospotrebnadzor);
• declaration of conformity(DoS) - processed meat, including semi-finished products (certification body).

Declaration is carried out according to three schemes: for the period of storage, 3 and 5 years (Fig. 5). An accredited laboratory of the Customs Union has the right to conduct tests, draw up and register DoS.

Each manufacturer must have a package of documents including technical documentation, laboratory test reports and DoS. As for the sale of meat products, it does not have any special differences and is regulated by general rules for retail trade.

To sum it up. Manufacturing is not profitable for small businesses finished products, since it is difficult for them to compete in terms of quality with sausages and sausages from large meat processing plants. It is more practical to produce fresh products that do not require deep processing of meat and do not duplicate common well-known brands. It is cheaper, does not require mastering complex processes or attracting qualified specialists.

With a high pace of life in modern world People often don’t have enough time to prepare food; studies indicate a constant increase in demand for semi-finished products. 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 make a significant profit. The opening of such an enterprise has important social significance, as it allows you to create new jobs and provide additional money to the region’s budget.

What are semi-finished products?

Semi-finished products are products that are transformed into ready-made food through simple manipulations. Their preparation is different 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. Distinctive characteristic production is its division into portions in the factory.

Finished goods are classified according to the following criteria:
- according to the production process used (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 stores, cafes, etc. The production of dumplings is currently a fairly busy niche, but the production of pancakes with meat or other fillings, cabbage rolls, frying sausages and other semi-finished meat products of varying degrees of readiness is growing demand and such products are in excellent demand among consumers. A separate direction in the business of semi-finished products can be considered the production of ready-made meals using blast 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 us to produce products high quality while preserving all nutrients, quickly reconfigure your production to produce one or another product.

Let's consider the business of semi-finished products based on the production of cutlets. Some will say that cutlets are nonsense. Your products can be supplied to schools, institutes, canteens, cafes and various eateries. So the sales market for this product exists and requires a market for 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. Opening an individual entrepreneur is cheaper and faster, so for our enterprise we choose this organizational form. To pay taxes, it was decided to choose simplified system 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 – ready-made quick-frozen products;

1511420 – natural portioned semi-finished products.

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

Workshop space.

In order for food production to be possible, the premises must comply with the standards of Rospotrebnadzor, the sanitary-epidemiological service and fire safety. The optimal choice would be a place where work in this area has already been carried out (cooking, confectionery shop), otherwise a fairly high-quality renovation will be 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 provide the necessary communications, including supply and exhaust ventilation.

The logistics component is important; the building must have convenient access routes so that raw materials can be unloaded and finished products loaded without unnecessary 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 raw material 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

A separate room for workshop employees should be equipped; a convenient location of 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 rented a premises of 100 sq. m. meters, rental cost 300 rubles/m2. This area will house the production itself, product storage warehouses and living quarters for employees.

The cost of initial investments in equipment and repairs for setting up a semi-finished products business.

We remind you that at our enterprise we are going to produce homemade cutlets from minced meat. It is impossible to imagine the functioning of an enterprise without the purchase of specialized equipment; this will be the main cost line for starting your own 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 rub. (the temperature when cooking minced meat should be no more than 14C);
- meat grinder – 40,000 rubles;
- apparatus for forming cutlets – 150,000 rubles;
- freezer for storing raw materials and finished products (2 pieces) – 200,000 rubles;
- minced 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 living quarters for the manager and employees - 50,000 rubles;
- computer and printer – 20,000 rubles.

Costs are not limited to the purchase of equipment; the following costs should be taken into account:
- carrying out repair work on 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 cutlet production business is 1,438,500 rubles. Also, at the initial stage, working capital will be needed to start production. In our case, it took 1,430 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 main ingredients, kneading minced meat, forming cutlets and freezing);
- packaging work.

To gain authority, it is necessary to use the highest quality raw materials that meet the highest standards. Certain types of products have their own GOST standards. It is preferable to work with farmers or reputable large producers. All purchased meat must undergo maximum control by the veterinary service.

Marketing plan.

The high demand for high-quality semi-finished products shows that opening a workshop is currently a profitable investment cash. There is some competition in this area, but the lack of relevant products in retail shows that there is required space for development. Product promotion is carried out through advertising in local newspapers, bulletin boards and specialized Internet resources, and by establishing personal connections.
To achieve maximum efficiency, sales of manufactured products will be carried out in three directions:
- retail outlets sales;
- wholesale sales to large suppliers;
- wholesale sales directly to chain stores.

Staff for organizing a business.

Fully ensuring the functioning of production requires the work of a staff of 4 employees, which includes:

Preparation of raw materials – 1 employee;
- accountant – outsourcing services;
- product preparation – 2 employees;
- cleaning lady – 1 employee.

As production develops, wage rates can be increased. In some cases, the use of an accountant’s labor is not effective; the services of outsourcing companies are more economically feasible.

Blank
Production
Cleaning woman
TOTAL PAYROLL
TOTAL TAXES

List of manufactured products.

The profitability of an enterprise largely depends on a successful start; it is important to start making tangible profits from the very first stages of the business’s operation. To solve this problem, we need to decide on the products offered; the initial product of our workshop will be the production of homemade cutlets, the cost is 200 rubles per kg. or 15 rubles per piece.
For wholesale sales Such prices are quite natural. As income increases, the list of products offered may be replenished with new items.

For our calculations, we will produce and send 500 kilograms of products to stores every day, with an increase in productivity to 1000 kilograms per day in six months. If the manufacturer can establish itself with the best side Thanks to high quality, a decent demand for its products is ensured.

Immediately after the start of activity, reaching such a volume is a problematic task; initially, as many semi-finished products will be produced as can be supplied by buyers. Increasing connections and finding sales points will make it possible to gradually increase production capacity, characterized by the quantity of goods produced.

Our business costs consist of the following indicators:

Fixed expenses
Wages
Payroll taxes
Rent
Depreciation
Accountant services
Variable expenses
Cost of products
Utility costs
Transport
Insurance individual entrepreneurs
Packaging cost
Other variable expenses
Total costs

Cost of raw materials for the production of cutlets.

	Cost of production of cutlets.
		price, kg/r.	consumption/kg	st., rub/kg
Beef meat
Raw beef fat
Wheat bread
Breadcrumbs
Onion
Ground black pepper
Table salt
Drinking water
Total consumption per 1 kg of minced meat
Meat yield rate after deboning,%

Business payback and financial results.

The profitability of a business is more clearly demonstrated by efficiency indicators, which, according to 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.

Based on the results of the planning horizon, the profit will be slightly less than 14 million rubles, and the profitability indicator will be equal to 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 this is possible, you can take advantage of various small business support programs that will help cover part of the costs of starting a business.

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

Semi-finished meat products are a product that is used in great demand from buyers. They take very little time to prepare, so they are a good alternative to “full” meals. Semi-finished products have a number of specific advantages in production: they can simplify and facilitate the work of procurement shops, reduce the time required for preparing meat snacks and increase the throughput of the enterprise. We will tell you in this article what nuances should be taken into account when opening your own meat production.

General information

Statistics report that the production and consumption of meat and meat products in our country is increasing from year to year. According to forecasts, this market will only grow in the next few years. Experts note the highest growth rates in the segment of chilled semi-finished meat products.

What is a semi-finished product? This is a portioned product made from chopped minced meat or other raw materials with various additives. Products are classified into several types:

• According to processing methods, chopped, natural semi-finished products, dumplings are distinguished;
• by type of meat used: beef, lamb, pork products, as well as rabbit and poultry products;
• according to thermal state - frozen and chilled.

In addition, the production of semi-finished products is divided into two separate segments - processed products and natural products.

Natural products

This segment, in turn, consists of several subgroups. These are meat and bone, chopped, large-piece, small-piece, portioned, marinated and meat sets. To prepare chopped semi-finished products, the scapular, cervical, and thigh muscles, which contain tougher and coarser connective tissue, are used. The meat is ground into special equipment, after which fat, eggs and spices are added.

Processed Products

This segment mainly includes cutlet products. These include cutlets, meatballs, meatballs, and other processed minced meat and meat products.

Technology

Let us consider in more detail how the technology for the production of semi-finished meat products is carried out. Frozen meat raw materials are supplied to the enterprise in the form of blocks. It is crushed using a crusher. Mechanically separated meat prepared in a meat and bone separator is often used for minced meat.

After the meat has been minced, the minced meat is passed through a grinder. Then add ground bacon, chilled water, salt, spices and other additives. The mass is thoroughly kneaded on a mince mixer or using a cutter. This device is designed for grinding soft meat raw materials and turning it into a homogeneous mass.

The prepared minced meat is immersed in a machine to form semi-finished products. At this stage, the product takes on a specific shape with a specific weight for each portion. Depending on the volume of production of semi-finished products, a rotary or screw system for forming the product is used.

The forming machine gives the cutlets the desired shape, then the products are laid out on a conveyor belt. After this, depending on the recipe, the products are sent to a icing machine, and then to breading equipment. The next step is transportation of the semi-finished product to a blast freezing chamber or to a spiral freezer.

Freezing varies in duration. For example, a cutlet weighing 85 grams should spend about 2 hours in a blast freezing chamber, but in spiral freezing equipment this time is reduced to 40 minutes. The production of semi-finished products is completed at the packaging stage. For this they use plastic bags, cardboard boxes or other containers. Finished products should be stored in low-temperature refrigerators.

Business plan for a workshop for the production of semi-finished products

Own production of semi-finished meat products must begin with the development detailed business plan. Calculations and forecasts should be based on marketing research data. It is necessary to carefully study the sales market, raw materials, and offers from equipment suppliers.

Production capacity

Purchase necessary equipment for the production of semi-finished meat products is one of the important points when developing a business plan. You will need:

• meat grinder;
• cutting press;
• slicer for cutting semi-finished products;
• band saw for cutting meat;
• molding machine;
• equipment for preparing dumplings and cutlets;
• freezers;
• packaging machines;
• storage chambers (separately for finished products and raw materials);
• scales;
• equipment for leasing;
• mince mixers;
• meat grinder;
• washing bath;
• sets of knives and cutting boards;
• bactericidal lamps.

If you intend to start cooking dumplings, then you should buy additional equipment for the production of semi-finished products:

Room and location

To open a workshop for the production of semi-finished products with a productivity of one ton of finished products per shift, you need a room with an area of ​​approximately 16 square meters. m. In addition to the production area where the equipment will be located, it is necessary to have a room for staff, a room for storing raw materials, as well as toilet and shower facilities.

It is recommended to locate the production of semi-finished meat products close to farms and peasant farms involved in animal breeding. They will be able to become suppliers of environmentally friendly raw materials and reduce transportation costs. Rental costs can be about 50 thousand rubles per month.

The meat processing plant cannot be located in basements, where there is no natural light, in residential buildings and near them, in rooms with limited installation capacity. Also not suitable for the production of semi-finished products are premises where there is no gas supply and limited ceiling height (recommended - more than 3 meters).

Buildings with complex architectural and planning solutions, places where it is not possible to create flow-exhaust ventilation, where there is no relationship between any production premises with waste disposal should also not be considered as a workshop.

Staff

To service the equipment, 2-3 workers per shift are enough. In addition to this you will need:

• director;
• deputy directors for financial and production issues;
• farm manager;
• accountant;
• chef;
• logistics;
• chief technologist;
• HR specialist;
• quality inspector;
• IT specialist;
• cleaner;
• sales and purchasing managers.

Of course, at the initial stage of the business, many of these employees will not be needed or their work can be combined by one person. But when successful development To work effectively, you will need additional personnel.

Profitability

The production of semi-finished meat products has a profitability of about 30%. Some entrepreneurs increase this figure to 80%. This is achieved due to a good original recipe developed at the enterprise, as well as high-performance equipment and cheap raw materials. Semi-finished meat products, whose producers strive to maximize profits and save on the amount of minced meat in the finished product, may be of low quality and can undermine the reputation of the enterprise.

Documentation

Collecting documents is one of the problems that a new entrepreneur may encounter. It is not easy to comply with all legal requirements in this area of ​​business. If you do not have experience, it makes sense to contact equipment suppliers. They are ready to provide a full set of documents and provide the enterprise with the necessary production capacity.

You should start a business with registration legal entity. You can register as an individual entrepreneur ( individual entrepreneur) or LLC. Considering the main points, it should be remembered that the production of semi-finished products requires mandatory imprisonment SES. In addition, it is necessary to develop a production control program in accordance with which production will be carried out.

Do not forget also that it is necessary to obtain certificates of conformity for all types of products. The list of standards for starting a business is not small. It makes sense to involve specialists who will help you collect and prepare all the necessary documentation.

In conclusion

When planning this type of business, the main task is to find distribution channels. If you do not think through this issue properly, you can end up with a warehouse filled to capacity with finished products without the possibility of selling them. This can lead not only to damage to the goods, but also to the closure of the entire production.

When opening your own business, be prepared for the fact that there is a lot of competition in the production of semi-finished products. One of the main ones are retail chains that have their own processing plants. If you want to sell products through them, then long-term cooperation is out of the question. After all, they themselves are producers.

But besides the “giants”, there are also smaller trading enterprises that will be ready to work with you. You should pay attention to small cities and towns where network companies have not yet opened their branches. There are also specialized butcher shops, where people purposefully purchase meat products.

The production of semi-finished products is one of the priority areas in the state program for the development of small and medium-sized businesses. To open a workshop, you can receive government support and provide financing for the project.

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Introduction

Meat products are one of the most important elements of the human diet. They contain complete, easily digestible proteins and animal fats, biologically active substances, microelements and vitamins. The meat industry has enormous potential and, as the most promising and attractive, will take a dominant place in the structure of the Russian food industry in the coming years.

The meat business has come a long way in its development: from primitive slaughterhouses and meat processing workshops to modern enterprises corresponding to the European level.

Russia's progress along the path market economy stimulates the process of integration into the European and world communities, requires manufacturers to produce high-quality and competitive products. The market dictates strict conditions for the quality of goods, and only by mastering modern technologies can an enterprise achieve the required level of production. Product quality becomes priority direction development of the meat industry.

An important role is given to providing the industry with highly qualified meat specialists. A modern meat specialist needs to have a complex of knowledge in the field of physical, chemical and biological sciences, engineering, technology, and economics. The basis for the theoretical training of such specialists is knowledge of the leading discipline “Technology of Meat and Meat Products”.

Recently, significant changes have occurred in the industry that have influenced the development of technological science and practices in the production of meat and meat products. Time-tested production processes are increasingly being revised in order to improve these processes, shorten the production cycle and at the same time improve the quality of meat products.

For catering establishments, these semi-finished products are of particular value, since without them it would be impossible, even in the most limited quantities, to satisfy the demand of visitors for such widely popular and favorite dishes as steak, beef Stroganoff, etc. After all, from the whole carcass of cattle, which contains only two tenderloins (with a total weight of no more than 3 kg), it would be possible to prepare, at best, 20-25 servings of steak, langet or beef stroganoff, i.e. a quantity that in no way satisfies the needs of a large dining room and restaurant.

The advantage of minced semi-finished meat products is that, by facilitating and reducing the work of procurement shops, reducing the time required to prepare a hot meat dish or snack, they allow you to increase the throughput of the enterprise. Meat processing plants produce semi-finished products under conditions that fully guarantee the freshness, good quality, cleanliness and hygiene of the products. The technological process and recipe are designed in such a way that for this type of semi-finished product only that part of the meat is used that strictly corresponds to the product in terms of tissue structure, fatness, quality and culinary properties.

Every year, minced semi-finished meat products will be supplied to public catering establishments in a wider and more varied assortment; every year, these products will increase the range of dishes and snacks, reduce and simplify production processes cooking while maximally preserving all the taste and nutritional properties of the best delicacies and gourmet dishes.

In recent years, the demand for semi-finished products that do not require significant time spent on food preparation at home and in catering establishments has increased significantly. Semi-finished meat products, as a rule, are produced in packaged form, which also determines their high consumer qualities.

The range of chopped semi-finished meat products is constantly expanding as a result of the use of various combinations raw meat with vegetables, cereals, flour and other protein components. Thanks to the use of flow-mechanized lines in the production of semi-finished meat products, their external design is improved and packaging is improved.

Minced meats of various recipes are becoming increasingly widespread, from which you can prepare large number variety of dishes.

1. Characteristics and theoretical basis for the production of minced meat semi-finished products

Meat is one of the most important food products with excellent culinary qualities. It can be easily combined with various products - vegetables, cereals, pasta prepared as side dishes. Along with complete proteins, it contains fat and so-called extractive substances, which contribute to better absorption of food.

To prepare semi-finished products, meat processing plants use meat from cattle, sheep and pigs.

Depending on the structure of meat tissue, mechanical processing and culinary purpose, all semi-finished meat products are divided into natural, breaded, minced and cooked meat. In addition, the industry produces semi-finished products such as frozen dumplings.

Minced semi-finished meat products are a portioned product made from chopped raw meat with additives (minced meat). Minced semi-finished meat products after production can be raw chilled or raw frozen. As an example, we can cite the following chopped raw semi-finished products: cutlets, meatballs, hamburgers, schnitzels, steaks, rump steaks, kebab, meatballs, meatballs, quenelles and croquettes.

Chopped semi-finished products. The cervical, femoral, and scapular muscles, which contain coarser and tougher connective tissue, are the main raw materials for the preparation of chopped semi-finished products.

Careful grinding of meat on special technically advanced machines and the addition of fat, eggs, and spices to the minced meat ensures good quality for these semi-finished products.

Moscow cutlets contain beef meat (of any fatness category) - 25 g, raw lard - 4.47 g, wheat bread - 7 g, as well as onions, pepper, salt and water. The prepared minced meat is given an oval-flattened shape. Cutlet weight 50 g.

Amateur cutlets are prepared from beef carcasses of fatty, above-average and medium fatness. After stripping, the pulp is crushed, mixed with spices, white bread and other ingredients, shaped into a large cutlet with a pointed end and breaded in ground breadcrumbs. The weight of the semi-finished product is 75 g.

Pozharsky pork cutlets are prepared from lean pork (45 g) with the addition of egg melange (2 g), wheat bread (Yug), pepper, salt and water. At the request of the customer, meat processing plants add onions to Pozharsky pork cutlets, as well as to amateur ones. Cutlet weight 75 g.

Kyiv cutlets are made from pork containing up to 30% fat. The semi-finished product recipe contains approximately 30 g of pork, 7 g of wheat bread, onion, pepper, salt, water. The weight of one cutlet is 50 g.

Beef schnitzel is made from minced beef meat. best quality, having the shape of a flat oval cake. Schnitzel weight 100 g.

Pork schnitzel differs from Pozharsky pork cutlet in weight and shape. The pork schnitzel is given a flat oval shape. This semi-finished product weighs 100 g.

The meatballs are shaped like a ball. They are prepared according to the same recipe and from the same raw materials as Moscow cutlets.

Zrazy is made from ground beef stuffed with hard-boiled chopped eggs mixed with fried onions and ground breadcrumbs.

Beefsteak is a dish of fried beef, originally one of the types of steak, steak from the head of the sirloin. Often there is such a subtype of steak as chopped (often minced) steak, which is the prototype of the cutlet. Steaks are also classified as rare or rare.

Rump steak is a lightly pounded 115g piece of meat cut from the thick end or sirloin and soaked in a beaten mixture of fresh eggs, water and salt.

Bitochki are small round cutlets made of minced meat (originally chops).

Meatballs - a dish consisting of balls of minced meat or fish, prepared with the addition of finely chopped onions, herbs and spices. Sometimes, to improve the consistency of meatballs, soaked loaf or bread is added to the minced meat. Meatballs are usually the size of a walnut.

Kufta is a type of meatball dish made primarily from lamb. A traditional dish from the Middle East and South Asia.

Quenelles are balls of meat, fish and chicken, with cream and egg.

2. State of the art and prospects for the development of the production of semi-finished meat products

Taking into account the current economic situation, I think everyone is interested in what is happening today in the market of frozen semi-finished products, and how the current crisis will affect the development of this segment.

Market of semi-finished products in Russia.

According to analysts, the segment of semi-finished meat products shows an impressive percentage increase in the frozen food market share - 45.29%. I believe that the data is slightly exaggerated due to the fact that since 2013, researchers began to include regional manufacturers in the list of analyzed companies, which were not previously included in the analysis of market structure.

In general, the market capacity of frozen semi-finished products (SFF) in 2013 amounted to approximately $3 billion in monetary terms and 1,698 thousand tons in in kind. According to preliminary data, its capacity in 2014 is $3.5-3.8 billion. But I think this figure is somewhat lower, because the study was conducted before the dollar exchange rate changed, and most likely the market capacity in monetary terms will be $3 billion 200 million. As for the market growth rates, in monetary terms they are significantly higher (in 2013 - 23.6%) than the market growth rates in physical terms (in 2013 - 4.10%).

The market development forecast for 2015 is very interesting. The increase in sales volumes will directly depend on the income level of the population. During a crisis, when there is a risk of losing a job, the opportunity to have dinner becomes increasingly important for the consumer, and the convenience of cooking is far from the first place in the scale of his interests. However, analysts expect market growth of 10-12% in monetary terms and 2.5-3% in physical terms.

Why do people buy convenience foods?

The main reasons for consuming semi-finished products are the convenience of their preparation (47%) and taste (28%). In reality, man today cannot compete with modern industrial production methods. Considering the development of technologies that are used in the Russian and world markets, the consumer cannot make a similar product at home. Plus, due to the high degree of product readiness, a lot of time is saved. And instead of gutting a chicken, a woman, when she comes home after work, can play with the children or watch a TV series. Therefore in real life, having once tried semi-finished products and appreciated the time and taste saved, the consumer remains our client forever.

Among others, the most common reasons consumption of semi-finished products, respondents also noted a wide range of products (13%) and low price (11%).

In general, in recent years, consumer attitudes towards semi-finished products have changed towards increasing their consumption. As noted by 17-19% of respondents, this is due, first of all, to an increase in the quality of products. Over the past 3 years alone, the share of active buyers has increased by more than 15%. Indeed, in recent years, along with the growth of household incomes, manufacturers of semi-finished products began to use more expensive and high-quality ingredients in production. For example, breast in the production of semi-finished chicken products.

Further growth in the consumption of frozen products is associated with an increase in the share of active consumers and the frequency of their purchases.

Distribution

Over the past 15 years, the distribution system for frozen semi-finished products has undergone very interesting changes. In the early 2000s there were no supermarkets and sales were carried out through markets. Today we have come to the conclusion that retail is the main distribution channel for frozen semi-finished products - more than 78% of products are sold at retail. Of these, 51% are in supermarkets, 21% in counter stores, 17% in markets, 11% in mini-markets. However, retail is not the only distribution channel.

The prospects for the development of retail trade in Russia are quite optimistic. The most active development is expected in the segment of discounters and hypermarkets. In addition, the process of consolidation of retail chains will accelerate both at the federal and regional levels.

Forecasts for the development of the closed pension fund market in crisis conditions.

As for the private pension fund market, despite the crisis, it is expected that it will maintain positive dynamics, although the growth rate will be reduced. We expected the market to grow by 7-8%, but according to current estimates it will most likely be 2-3%. But I also consider this growth good, especially in times of crisis.

A reduction in demand in the high and premium price segments is expected due to a decrease in household incomes and an increase in demand for semi-finished products in the “medium” and “medium-” categories.

Speaking about forecasts for market development, analysts note the possibility of restoring growth in the level of income and living standards of the population, and as a consequence of the gradual restoration of demand for products in the high price segment. It is also possible that the pace of development of network retail trade will accelerate and the rate of growth in consumer prices will slow down.

Threats and opportunities in times of crisis.

Threats. Taking into account the current economic situation, there may be a natural decrease in purchasing power or a shift in demand from the high to the middle price segment.

Among the threats, I would like to note possible savings on the quality of ingredients on the part of some manufacturers and, as a result, deterioration in product quality. It is also possible that there will be a slowdown in the development of modern retail formats, a decrease in the level of purchases of products from manufacturers and, as a result, a reduction in the breadth of assortment and innovativeness of products.

A decrease in the level of distribution is possible due to the fact that now investments in its development in the regions may not receive the required return, and distributors, understanding the risks, are suspending their expansion into the regions.

Possibilities.

Manufacturers who produce traditional products on average have good opportunities today price segment, as demand for them is predicted to increase.

It is also possible to reduce the costs of manufacturers to launch and promote new brands and reduce the level of competition in the middle and high price segments.

To summarize what has been said, I would like to note that even in a crisis, the frozen food market will retain its attractiveness and will grow, but not at such a high rate. At the same time, analysts predict fairly high rates of development for the segment of semi-finished meat products. According to the Meat Union's forecast, poultry consumption will reach 50% of the total volume of meat consumed. In this situation, producers of semi-finished poultry meat products have real development prospects.

3. Technology for the production of semi-finished meat products

Semi-finished products include products made from natural and minced meat without heat treatment. These are products that are maximally prepared for culinary processing.

Semi-finished meat products are divided into: natural (large pieces, small pieces, portioned, portioned breaded); chopped; semi-finished products in dough; minced meat

Natural semi-finished products. These are pieces of meat pulp of various weights, cleared of tendons and coarse surface films. Natural small-piece semi-finished products also include meat and bone pieces of meat with a certain bone content. Semi-finished products are produced chilled or frozen. The raw material is meat in chilled or frozen states. The meat of bulls, boars, sheep, meat frozen more than once, and lean meat is not used.

Lump semi-finished products. Depending on the type of meat, large-piece semi-finished products are divided into four groups:

First group: from beef - longissimus dorsi (dorsal part, lumbar part), tenderloin (iliopsoas muscle, located under the bodies of the last thoracic and all lumbar vertebrae), hip part (upper, inner, side and outer pieces); from pork - loin, tenderloin; from lamb - hip part;

Second group: from beef - the shoulder part (shoulder and shoulder parts), subscapular part, chest part, as well as the edge (supracostal muscles, removed from the 4th to 13th rib, remaining after separating the subscapular part, brisket and longissimus dorsi muscle ) from beef of the 1st category of fatness: from pork - hip, scapular, cervical-subscapular parts; from lamb - shoulder, loin;

Third group: from beef - cutlet meat and beef trim of the 2nd category; from pork - brisket; from lamb - brisket, cutlet meat;

Fourth group: pork - cutlet meat. Cutlet meat (using the example of beef) - pieces of meat pulp from the neck, flank, intercostal meat, pulp from the tibia, radius and ulna bones, trimmings obtained by stripping large-sized semi-finished products and bones.

Portioned semi-finished products. They are made from large-piece semi-finished products, cut manually or using special machines across the muscle fibers obliquely or perpendicularly. An assortment of portioned semi-finished products: from beef - natural steak (from the tenderloin), languette (from the tenderloin, two thinner pieces than the steak), entrecote (from the longissimus dorsi muscle), rump steak (from the longissimus dorsi muscle or the most tender pieces of the hip part - the upper and internal), natural zrazy (from the same pieces of the hip part), braised beef (from the side and outer pieces of the hip part).

The range of portioned semi-finished pork products includes: natural cutlet (from the loin), escalope (from the longissimus dorsi muscle), brass pork (from the cervical-scapular part), tenderloin, schnitzel - from the hip part.

Portion-breaded semi-finished products: rump steak (beef), natural cutlet and schnitzel (pork and lamb). For portioned breaded semi-finished products, pieces of meat are lightly beaten to loosen the tissues and rolled in finely crushed white bread crumbs to preserve meat juice.

Small-piece semi-finished products. From beef we get: beef stroganoff (from tenderloin, longissimus dorsi and the upper and inner piece of the hip part), azu (from the side and outer pieces of the hip part), goulash (from the scapular and subscapular parts, as well as the edge), soup set (meat and bone pieces weighing 100-200 g with the presence of pulp at least 50% of the portion weight), beef for stewing (pieces of ribs with the presence of pulp at least 75% of the portion weight), brisket for kharcho (with a pulp content of at least 85% of the portion weight) .

Small-piece semi-finished pork products are represented by the following names: roast (from the hip part and loin with a fat content of no more than 10%), goulash (the same as beef goulash), barbecue meat (from the hip part), stew (pulp content not less than 50% by weight of the serving), homemade stew (bone content no more than 10% and fat tissue content not more than 15% by weight of the serving).

Large-piece semi-finished products are sold mainly by weight, portioned - packaged, product weight 125 g (tenderloin 250 and 500 g), small-piece - portion weight 250, 500 and 1000 g (meat and bone).

Salting and massaging can be used in the production of natural semi-finished products. The brine contains salt, phosphates, granulated sugar; For some items, a dusting of spices and decorative spices is used.

Semi-finished products in dough. IN technical conditions, developed by VNIIMP, presents a traditional and new assortment of dumplings, as well as other semi-finished dough products: meat sticks, manti, khinkali. According to other specifications, several dozen types of dumplings are produced, designed for buyers with both high and low income levels. The minced dumplings contain beef and pork, trimmed onions, ground black or white pepper. To prepare the dough, use premium flour (sometimes 1st grade) with a standardized quantity and quality of gluten, and egg products.

Meat sticks have a cylindrical or rectangular shape and are up to 10 cm long. Manti is a dish of Uzbek cuisine. They are larger in size than dumplings. They are not boiled in water, but steamed in a special vessel - manti-kaskan. Khinkali is a dish of Transcaucasian cuisine such as dumplings in the shape of a diamond or square. The meat for manti and khinkali is chopped coarser than for dumplings and sticks; the minced meat for these products contains an increased amount of onion.

The minced ravioli also contains mushrooms and rennet cheese; they have the shape of a semicircle, rectangle, or square.

Chopped semi-finished products. They are prepared from minced meat with the addition of other ingredients according to the recipe. The traditional range of chopped semi-finished products includes: Moscow cutlets, homemade cutlets, Kyiv cutlets, rump steak, beefsteak. The main raw materials in their production are beef and pork cutlet meat, 2nd grade trimmed beef, and fatty trimmed pork. During the years of the economic crisis, the range of chopped semi-finished products expanded due to the use of cheaper raw materials - mechanically separated poultry meat, soy protein preparations, mainly textured soy flour, vegetables, and cereals.

The cutlet recipe consists of cutlet meat: Moscow - beef, Kyiv - pork, homemade - beef cutlet and half-and-half fatty pork. The composition of all items includes (%): wheat flour bread - 13-14, onions - 1-3, water - 20, breadcrumbs - 4, salt, pepper, in Kyiv - egg melange. Rump steak uses hydrated soy protein instead of bread; in a steak - beef cutlet meat - 80%, sausage lard -12%, water - 7.4%, pepper, salt, no breading. It is allowed to replace 10% of raw meat in cutlets with soy concentrate or texturate and in all items 20% of raw meat with mechanically separated poultry meat. Chopped semi-finished products are produced chilled (0-6 °C) and frozen (not higher than -10 °C).

Minced meat. Minced meat is obtained from meat by grinding it on a grinder with a grid hole diameter of 2-3 mm. Traditional assortment of minced meat: beef, pork, homemade, lamb, special meat and vegetable. For the production of minced meat, meat that has been frozen more than once, boars, bulls, lean meat, and pork with signs of yellowing is not allowed. The main raw materials for minced meat: beef cutlet meat or trimmed beef of the 2nd grade (minced beef), lean pork or pork cutlet meat (minced pork). The composition of homemade minced meat includes (%): beef (50) and pork (50) meat; special minced meat - beef (20), pork (50), soy concentrate (30).

Minced semi-finished meat products after production can be raw chilled or raw frozen. As an example, we can cite the following chopped raw semi-finished products: cutlets, meatballs, hamburgers, schnitzels, steaks, rump steaks, kebab, meatballs, meatballs, quenelles and croquettes.

To prepare minced meat for chopped semi-finished products, frozen raw meat (blocks) is crushed in a crusher. Mechanically separated meat obtained from a meat and bone separator can also be used to prepare minced meat.

The minced meat is then passed through a grinder. Pork lard is added to the minced meat, which is pre-ground on a grinder or on a lard cutting machine. Add salt, pre-chilled water with ice, additives, spices to the minced meat and mix everything well in a minced meat mixer. A cutter can also be used for mixing.

The minced meat, ready for molding semi-finished products, is loaded into the hopper of a machine for molding semi-finished products, where the product of the required shape and weight is formed, for which, depending on the production volume, a rotary or screw molding system is used. The forming machine shapes and dispenses the patties onto a belt, after which the product can be sent to a sheeter and/or breading machine for liquid and dry breading, respectively.

Then the cutlets are sent on trolleys to the blast freezing chamber or automatically along a conveyor to a spiral freezer in case of high line productivity. The duration of freezing cutlets w75x20 mm weighing 85 g in a blast freezing chamber is 2 hours, and in a spiral freezer - 40-45 minutes. After freezing, the cutlets are packaged and moved to a low-temperature refrigerated chamber for storage.

Main raw materials.

The main raw materials used are beef, pork, lamb, horse meat, as well as meat from other types of slaughtered animals.

Do not use twice-frozen meat or pork with darkened lard.

Along with meat raw materials, various protein preparations of plant and animal origin (soybean products, blood, milk proteins, etc.), as well as melange, egg powder, vegetables and other components, are widely used, depending on the direction of use of the meat product.

Supporting materials.

Auxiliary materials for all products are salt (1.2% of the minced meat mass), black pepper (0.04-0.08%) and water (6.7-20.8%), added to the minced cutlet to increase its juiciness. The introduction of isolated soy protein and high-protein milk concentrate into minced minced semi-finished products in an amount of 10-20% allows you to replace up to 10% of meat, improve their organoleptic qualities, increase nutritional and biological value, increase water-binding capacity, and reduce losses during frying. When preparing auxiliary raw materials, onions and vegetables are washed and chopped. The bread is soaked and also chopped. The melange is defrosted in advance in baths with water, the temperature of which is not higher than 45C.

Basics technological equipment.

Frozen block crusher - a machine for chopping deep-frozen meat (with temperatures up to - 30°C) for further processing on a cutter or grinder. In this case, preliminary defrosting of the product is not required, which allows you to preserve the taste of the product and prevent loss of nutrients.

The crushing of the block, depending on the subsequent purpose of the raw materials obtained after the crusher (pieces the size of a fist or into slices), can be done on a machine with a rotating shaft with knives or rollers or on a guillotine-type machine.

The meat grinder is designed for industrial grinding of meat, meat products, fats for the purpose of producing sausages and other food products.

The meat grinder is the main machine in technological lines for the production of sausages and semi-finished products. The quality of the resulting product directly depends on how finely and accurately the grinder cuts the pieces of meat.

The principle of grinding pieces of meat used in meat grinders has remained unchanged for many years: the meat in the receiving hopper is captured by an auger or augers and, through a body with internal ribs, is fed to a cutting tool, which is a set of fixed grids, usually consisting of three pieces, and movable knives, consisting of two pieces.

Different meat grinders, despite the same grinding method and apparent simplicity of design, have completely different grinding quality. It is affected by even minor design features inherent in each design, as well as the degree of wear of both the cutting tool and the housing with the auger.

Mince mixer. The purpose of minced meat mixers is to mix crushed products with spices and other ingredients. Usually minced meat, cereals and other products are mixed in minced meat mixers.

The main components of the minced meat mixer are the bowl, the lid and the mixing mechanism.

The bowl is a mixing bowl connected to a kneading unit. Usually the mixing bowl is made from stainless steel with a smooth surface, which greatly facilitates its cleaning and operation in general. The minced meat mixer is designed in such a way that it promotes uniform mixing of all minced meat ingredients. Mixing occurs through kneading screws.

The design features of the bowl (bowl) and mince mixer blades provide uniform distribution ingredients for minced meat.

There are vacuum and open (non-vacuum) mince mixers. Kneading minced meat in a vacuum minced meat mixer ensures a dense, pore-free structure of the minced meat and increases the color fastness of the product.

All mince mixers have protective mechanisms. In particular, this is a mechanism for blocking one or more kneading augers when the bowl lid is opened. The process of loading and unloading raw materials is usually fully automated.

Meat and bone separators, or minced meat machines, are used to separate meat from bones in the production of edible minced meat, chicken or fish.

The resulting minced meat can be used to produce high-quality products, since it preserves the structure of muscle tissue.

The operating principle of the machine is that incoming raw materials are loaded into the separator hopper without preliminary grinding (with some exceptions). It is recommended to pre-grind pork or beef bones into fist-sized pieces, without the need to use an additional grinder, which allows optimizing the use of production space.

All designs of mechanical separators are based on the use of the separation principle, taking into account the physical characteristics of the processed raw materials.

Using various pressures, meat or other product is forced through the slotted or round holes of the separating head, and bones, cartilage and (or) sinews are removed through the front of the machine. The product output is manually controlled using cones in the front of the separating screw and restrictor.

The minimum temperature increase in the case of an incoming raw material temperature of 0-2 °C (this temperature is optimal) is usually 1-2 °C for chicken, 4-7 °C for turkey, and approximately 10 °C for beef.

Cutter - turns meat into soft fluffy minced meat for preparing boiled sausages, frankfurters, sausages. The cutter grinds the product in a vacuum. Rapidly rotating knives (up to 4500 rpm) instantly transform meat into minced meat, which, in the absence of oxygen, retains its natural color, vitamins, and nutrients. Thanks to processing without air access, the quality of the final product and its shelf life are significantly increased.

Cuttering is the process of finely grinding raw meat. The duration of cutting significantly affects the quality of minced meat. Chopping lasts on average 5-12 minutes depending on the minced meat being prepared, design features cutter, shape of knives, speed of their rotation. Cuttering not only ensures the proper degree of grinding of meat, but also binds the added ice. And it is the cutting process that largely determines the quality of the final product.

Ice maker. The meat processing industry requires large amounts of water ice to produce various products. Flake ice produced by flake ice machines is optimal for use. It has a flat shape, thanks to which it has a large heat transfer surface, so it cools minced meat better than other types of ice.

The temperature of the produced flake ice at the outlet of the ice generator is up to minus 12°C, the thickness is from 0.8 to 2.8 mm. Machine productivity from 380 kg to 23 t/day.

Lard cutter - allows you to cut into cubes, strips or circles fresh, boiled and frozen (up to - 5°C) meat, lard, as well as ready-made sausages, ham, and vegetables. Products containing bones should not be cut.

Machine for molding semi-finished products. After grinding the raw meat, adding other ingredients, mixing and cooling, the minced meat is ready for shaping. Forming equipment can be used to shape products into a variety of shapes.

Breading machine. The next stage after shaping minced meat products is the stage of breading (coating) the product. The breading process consists of three operations - pre-sprinkling, liquid breading and coating with breadcrumbs. The manufacturing process may use various combinations of these operations or all three coatings. However, there are standards for the amount of sprinkles used, the amount of which should not exceed 30% of the weight of the finished product.

In fact, breading improves the product in many ways: it makes the product juicier while retaining moisture and flavor. Breading makes food more attractive. In addition, breading adds weight to the food, increasing the cost.

Pre-coating is often used in the manufacture of breaded products to improve the adhesion of the liquid breading. This operation is very important for products with a wet or greasy surface. For this operation, flour or a dry protein mixture for breading is usually used.

There are many different types of dry breading used in the manufacture of meat products. They can come in different sizes, shapes, textures, colors and flavors. Finely ground breadings are very popular and traditional. They give the product an airy appearance and resemble a homemade product.

Lizoning machine. Liquid breading plays a very important role in the technology of coating semi-finished meat products. When preparing foods, two types of breading can be used: yeast and fresh. The choice of one type or another depends on the product formulation. Liquid breadings are a mixture of various ingredients, which may include flour, starches, eggs, milk, spices, raising agents and stabilizers.

When applying liquid breading, in order to increase adhesion, it is used in combination with dry breading. In this case, fresh breadings with different viscosities are more often used.

Equipment for chopping chopped semi-finished meat products from chopped raw meat (minced meat) beef, veal, pork, lamb without filling (cutlets, hamburgers, meatballs and other similar products).

Shock freezing chamber. Nowadays, food is frozen thanks to a special technology for removing heat from the product. At the same time, the temperature drops and at a certain point the water in the product begins to turn into ice crystals.

A product is considered frozen if its temperature is -6 degrees. In meat, 75 percent of the water freezes at minus 5°C; 80 percent - at minus 10°C; and 90 percent - at minus 20 degrees.

Freezing food is used primarily for long-term storage.

Technologically, the freezing process can take a different amount of time. Fast (shock) freezing best preserves product quality. As a result of this process, very small ice crystals are formed inside the product, which has a positive effect on the quality of the product, since minimal damage to the tissue of the product occurs.

It was for these purposes that special devices were created - blast freezing chambers. They allow you to quickly freeze a product or dish, preserving its beneficial properties.

Packing machine. Filling and packaging machines, multi-heads (electronic high-precision weighing dispensers), packaging systems for food or non-food small-piece, bulk, dust-free products. The equipment uses the principle of weight dosing and is used for packaging.

Refrigerated warehouses and storage chambers include: a thermal insulation circuit (chambers) with doors and a refrigeration system.

Chambers made of polyurethane foam sandwich panels with refrigeration doors produced in our own plant are used as a thermal insulation circuit. The refrigeration system includes: refrigeration compressor unit, condenser, oil cooler, circulation receiver and pumping station(if a pump-circulation refrigerant supply circuit is used), electrical control panel, refrigerant piping and electrical cable lines.

4. Range of products.

“Spicy” bits.

Beefsteak "Mosaic".

Cabbage rolls "Rural".

Lazy cabbage rolls “Homemade”.

Hedgehogs “Delicious”.

Zrazy "New".

Zrazy "Family".

Cutlet "City".

Cutlet "Village".

“Homemade” cutlet.

Cutlet "Kyiv".

Cutlet "Moskovskaya".

Lula-Kebab “Southern”.

Meatballs "Amateur".

Schnitzel "Original".

Dumplings:

"Grandmother's."

"Homemade"

"In Russian."

"In Siberian style."

"Strugovskys".

"Ural".

Khinkali "Lazarevskie".

Chebureks “At Homemade”.

in “Lingonberry” marinade.

in “Italian” marinade.

in “Mexican” marinade.

in a “Spicy” marinade.

in “Garlic” marinade.

in “Garlic with herbs” marinade.

"Branded"

From poultry meat in marinade for chicken.

"Peasant".

"Dining room."

"At home."

5. Packaging, labeling, storage and transportation

Each type of chopped semi-finished products must meet the appropriate organoleptic and physicochemical parameters. Cutlets, rump steaks and meatballs are characterized by a rounded-flattened shape, for schnitzels - oblong, for minced meat and steaks - rectangular (in the form of briquettes), for meatballs - spherical or elongated spherical.

When cut, chopped semi-finished products should look like well-mixed minced meat. The taste and smell of chopped semi-finished products in their raw form should be characteristic of benign raw materials, and when fried - characteristic of a fried product. The surface of breaded semi-finished products should be evenly sprinkled with breadcrumbs.

The classification of semi-finished minced meat products, dumplings, minced meat for baby food is presented in GOST R 51187-98 "Semi-finished minced meat products, dumplings, minced meat for baby food. General technical conditions."

Minced semi-finished meat products, dumplings, minced meat for rational, preventive and therapeutic nutrition of children must comply with the requirements of GOST R 51187-98 "Semi-finished minced meat products, dumplings, minced meat for baby food. General technical conditions."

Marking. In accordance with GOST R 51187-98, the labeling of consumer packaging of meat, minced semi-finished products, dumplings, minced meat is determined in accordance with GOST R 51074-2003 with additional information indicated (GOST R 51074-2003):

Thermal state (chilled, frozen);

Date of manufacture and date of packaging;

The label of minced semi-finished meat products, dumplings, minced meat intended for preventive and therapeutic nutrition of children additionally indicates the purpose.

Packages or bags of dumplings must indicate the method of preparation in a typographical manner.

Transport marking - in accordance with GOST 14192-96, with an additional stamp “Baby food” and using handling signs (GOST 14192-96) “Perishable cargo”, “Temperature limitation”.

It is allowed not to apply transport markings to reusable containers containing products intended for local sale.

Package. In accordance with GOST R 51187-98, chopped semi-finished meat products are packaged in corrugated cardboard boxes in accordance with GOST 13513-86, multi-return polymer boxes in accordance with GOST R 51289-99, aluminum, as well as specialized containers or packaging equipment.

Reusable containers must have a lid. If there is no lid, it is permissible for local sales to cover the container with parchment, sub-parchment or wrapping paper.

Acceptance rules. According to GOST R 51187-98, the acceptance rules and sample volume are determined in accordance with Chapter 6 of GOST R 52675-2006.

Semi-finished minced meat products are taken in batches.

A batch is considered to be semi-finished minced meat products of the same weight and name, produced during one shift and issued with one quality document.

Transportation. According to GOST R 51187-98, chopped semi-finished meat products, dumplings, minced meat are transported in refrigerated trucks in accordance with the rules for the transportation of perishable goods in force in road transport (Rules for the transportation of perishable goods by road in intercity traffic (section 13 of the Rules for the transportation of goods by road)).

Storage (GOST R 51187-98). Chopped semi-finished meat products and minced meat should be stored refrigerated at a temperature of 0 to 4°C for no more than 12 hours. Frozen at a temperature not exceeding minus 18°C ​​- no more than 30 days, in sealed packaging - no more than 3 months.

The shelf life of chopped semi-finished meat products, dumplings, minced meat, guaranteeing the safety, quality and safety of products, must be standardized normative document on specific type product, taking into account the “Conditions and shelf life of perishable products” SanPiN 2.3.2.1324-03 “Hygienic requirements for shelf life and storage conditions of food products”

6. Quality control of chopped semi-finished products

Assessment of the quality of semi-finished products begins with an external inspection of the container (boxes, containers, trays, functional containers). The container must be intact, closed with lids. Then the number of packaging units is calculated and weighed to determine the gross mass of semi-finished products. To assess the quality of semi-finished products, a recess is made by opening a certain number of units of transport packaging. From the opened packaging units, to compile an average sample, a certain number of semi-finished products is selected, specified in the current regulatory and technical documentation (GOST, RST, etc.).

Selected semi-finished products are evaluated according to organoleptic and physico-chemical indicators, and their weight is determined.

Requirements for finished products.

The quality of semi-finished products is assessed by appearance, consistency, taste, and smell. Measuring methods determine the moisture content of bread and salt.

The freshness of semi-finished products is determined in the same way as the freshness of meat. The surface of semi-finished products must be without damage, the shape must not be deformed and correspond to the name of the product. The presence of coarse connective tissue, tendons, films and cartilage is unacceptable. In chops, the length of the bone should not exceed 8 cm. In stew, the bone content is no more than 20%, fat - no more than 15%; in homemade stew, bones - no more than 10%, fat - no more than 15%. Meat for barbecue and pilaf should contain no more than 15% fat; in a soup set up to 50% bones are allowed. Pork fat thicker than 1 cm is not allowed on escalopes. Breaded products must be flat, with properly trimmed edges and covered with an even, thin layer of crushed breadcrumbs. Unkneaded bread and fat, as well as finely crushed bones, are not allowed in semi-finished products. Frozen dumplings should have the correct shape in the form of a semicircle, tightly sealed edges without protrusions of minced meat. Sticky lumps of dough, broken parts and dough content exceeding 50% of the mass of dumplings are not allowed. The smell of natural semi-finished products should be characteristic of benign meat of the corresponding type. The taste and smell of chopped semi-finished products after cooking are pleasant, moderately salty, with a taste of onion and pepper, the consistency is not crumbly and juicy; Flavors of bread and spoiled fat are not allowed. The consistency of semi-finished products should be elastic, and the finished products should be soft, juicy, and not crumbly; Breaded products should have a crispy crust. The consistency of frozen products is hard; The dumplings should make a characteristic sound when shaken. After cooking, the consistency of the minced meat should be elastic, dense, and the surface of the dumplings should not be sticky. The moisture content in chopped semi-finished products is allowed 65-68%, bread - 18-20 (depending on the name) and salt - 1.2-1.5%. The deviation in the mass of individual portions of natural and breaded semi-finished products should not exceed ±3%, chopped - +5%; weight deviation is not allowed 10 pcs. The deviation in the mass of individual boxes of dumplings is allowed ±7 g; the deviation in the net weight of 10 boxes is not allowed.

Sampling rules.

The study of quality control of semi-finished meat products is carried out using organoleptic and physico-chemical methods.

Quality assessment in laboratory conditions begins with the selection of an average sample. Next, organoleptic indicators are assessed - appearance, color, consistency of semi-finished products. The degree of grinding and the uniformity of mixing of the minced meat are determined by cutting 2 pcs. semi-finished product along.

In preparation for physicochemical research, 4 or 6 semi-finished products are cut lengthwise, after which 4 (or 6) halves are thoroughly ground in a mortar to a homogeneous consistency and placed in dry flasks with tight-fitting lids. From the prepared sample, weighed portions are taken to determine the mass fraction of moisture, salt, and total acidity.

Types and rules for quality control of semi-finished meat products.

Determination of the mass fraction of moisture and dry substances.

Drying in a drying cabinet. The method is based on the release of hygroscopic moisture from the object under study at a certain temperature. Drying is carried out to constant weight or by accelerated methods at elevated temperature within a specified time.

Drying of samples is carried out with calcined sand, which gives the sample porosity, increases the evaporation surface, and prevents the formation of a crust, which makes it difficult to remove moisture.

Very wet samples are dried in a water or sand bath. For drying, porcelain cups, glass or aluminum bottles, previously dried and weighed, are used.

7 Calculation of economic efficiency of production of chopped semi-finished products

Table 1. Recipe and raw material costs

	Cost of 1 kg of Raw Materials, rub.	Schnitzel "Original"	Cutlet "Village"
		Amount of raw materials per 10 kg.	Costs of raw materials, rub.	Amount of raw materials per 10 kg.	Costs of raw materials, rub
Cheek meat (pork)
Single grade beef
Side lard
Melange dry (egg powder)
Textured soy flour ALMROTE
Soy protein isolate
Peeled onion
Soprotex-N textured
Phosphate Abastol 305
Effect 2797 V/D
Black pepper (mol.)
Crushed garlic
Dumplings Khinkali 34674 V/D
Breadcrumbs (bread)

Based on these data, the cost of all raw materials consumed is calculated. Economic efficiency meat product production is calculated per 10 kg of main raw materials according to the indicators given in table 2.

Table 2 - Economic efficiency of production of 10 kg. Schnitzel "Original"

Indicator	Recipe
	Control option	Experimental option
Cost of products consumed per 10 kg of basic raw materials, rub.
Yield of finished products, %
Costs of finished products, rub.
Production costs, rub.
Total cost, rub.
Sales price, rub.
Proceeds from the sale of 10 kg.
Profit, rub.
Profitability, %

The cost of finished products is calculated taking into account the output of finished products. Cost 10 kg raw products amounted to 1757.2 rubles, and the yield of finished products was 106.5%, therefore:

rub. cost of 10 kg of finished products.

Production costs amount to 20-30% of the cost of raw materials (main meat products). The total cost is calculated as the sum of the cost of finished products and production costs. The selling price is indicated based on the prices for this product in stores. Profit is calculated as the difference between the selling price and the total cost per 10 kg of finished products. Profitability is the ratio of profit to full cost, expressed in %. Profitability level:

R=P:SbH 100% 2424.93: 2108.64 H 100 = 15

P - level of profitability, P - profit from sales, Sb - cost.

Conclusion

semi-finished meat minced meat mixer cutting

Minced semi-finished meat products are a portioned product made from chopped raw meat with additives (minced meat). Each type of chopped semi-finished products must meet the appropriate organoleptic and physicochemical parameters. When cut, chopped semi-finished products should look like well-mixed minced meat. The taste and smell of chopped semi-finished products in their raw form should be characteristic of benign raw materials, and when fried - characteristic of a fried product.

The range of minced semi-finished meat products is constantly expanding as a result of the use of various combinations of raw meat with vegetables, cereals, flour and other protein components. Thanks to the use of flow-mechanized lines in the production of semi-finished meat products, their external design is improved and packaging is improved. Minced meats of various recipes are becoming increasingly common, from which a large number of different dishes can be prepared.

And it is precisely because of this that minced semi-finished meat products enjoy well-deserved recognition from consumers and every year they occupy an increasingly stronger place in the diet of the population.

Literature

1. Antipova L.V. Methods for researching meat and meat products: textbook / L.V. Antipova, I.A. Glotova, I.A. Rogov. - M.: Kolos, 2001. - 376 p.

2. Bautin V.N. Mechanization and electrification of agricultural production / V.N. Bautin, V.E. Berdyshev, D.S. Booklagin. - M.: Kolos, 2000. - 536 p.

3. Bredikhin S.A. Technological equipment of meat processing plants / S.A. Bredikhin, Yu.V. Kosmodemyansky, L.L. Nikiforov. - 2nd ed., rev. - M.: Kolos, 2000. - 392 p.

4. Gizatullin R.S. Laboratory workshop on milk and meat processing / R.S. Gizatullin, S.G. Kanareikina, L.A. Zubairova; BashGAU. - Ufa, 2011. - 210 p.

5. Zayas Yu.F. Quality of meat and meat products: textbook. allowance / Yu.F. Zayas. - M.: Kolos, 1996. - 480 p.

6. Ivashov V.I. Technological equipment of meat industry enterprises: textbook / V.I. Ivashov. - part 1. Equipment for slaughter and primary processing. - M.: Kolos, 2001. - 552 p.

7. Ivashov, V.I. Technological equipment of meat industry enterprises: textbook / V.I. Ivashov. - part 2. Equipment for meat processing. - SPb.: GIORD, 2007 - 464 p.

8. Poznyakovsky, V.M. Examination of meat and meat products - textbook. allowance / V.M. Poznyakovsky. - Novosibirsk: Sib. Univ. publishing house, 2002. - 526 p.

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