home » Business types » Production of pasta. Pasta Assortment and quality of pasta

Production of pasta. Pasta Assortment and quality of pasta

The pasta production process consists of the following main operations: preparation of raw materials, preparation of pasta dough, dough pressing, cutting of raw products, drying, cooling of dried products, rejection and packaging of finished products.

Raw material preparation. It consists in sifting flour, separating metal-magnetic impurities from it, heating (flour temperature must be at least 10 ° C), mixing different batches of flour in accordance with the instructions of the factory laboratory. The water intended for dough kneading is heated in heat exchangers and then mixed with cold tap water to the temperature specified in the recipe.

Preparation of additives consists in stirring them in water intended for kneading the dough. When using chicken eggs, they are pre-washed, and if melange is used, then it is pre-thawed.

Cooking pasta dough. It consists of dosing the ingredients (flour, water and additives) and kneading the dough.

Dosing is carried out using dispensers that supply flour and water with additives dissolved in it in a continuous stream into the kneading trough in a ratio of approximately 1: 3. In the kneading trough, flour and water are intensively mixed, the flour particles are moistened and swollen - the dough is kneaded. However, unlike bread or biscuit dough, pasta dough by the end of the kneading is not a continuous connected mass, but a lot of moistened scattered lumps and crumbs.

Pressing testA. The goal is to compact the kneaded dough, turning it into a homogeneous, bound, plastic dough mass. and then give it a certain shape, mold it. Forming is carried out by forcing the dough through holes made in the metal matrix. The shape of the holes of the matrix determines the shape of the pressed out raw products (semi-finished product). For example, round holes will produce vermicelli, rectangular holes will produce noodles, etc.

Cutting raw products. It consists in cutting raw products pressed out of the matrix into segments of the required length and preparing them for drying. This preparation, depending on the type of manufactured products and the drying equipment used, consists either in laying out raw products on mesh conveyors, frames or tray cassettes, or in weighing long strands of raw products on special drying poles - bastuns. Pressed out products before cutting or during cutting are intensively blown with air to obtain a dried crust on their surface. This prevents wet products from sticking to the drying surfaces and from sticking together during drying.

Drying products. The goal is to fix their shape and prevent the development of microorganisms in them. This is the longest and most important stage of the technological process, the correctness of which depends primarily on the strength of the products. Very intensive drying leads to the appearance of cracks in dry products, and very slow drying can lead to souring of products. At pasta enterprises, convective drying of pasta is used - blowing the dried product with heated air.

Cooling of dried products. This process is necessary in order to equalize the high temperature of the products with the air temperature of the packaging compartment. If the pasta is packed without cooling, then the evaporation of moisture will continue already in the package, which will lead to a decrease in the weight of the packaged products. Most preferably, the slow cooling of dried products in special bins and chambers, called storage stabilizers. Cooled products are subjected to rejection, during which products that do not meet the requirements for their quality are removed, and then packaged.

Package. It is produced either in small containers (boxes, bags) manually or by filling machines, or in bulk" in large containers (boxes, boxes, paper bags)

The owners of the patent RU 2430516:

The invention relates to the food industry. The composition for the production of pasta contains durum wheat flour, soft wheat flour and chickpea flour in the following ratio of components, wt.%: durum wheat flour 5, soft wheat flour 85, chickpea flour 10. The invention allows to obtain a product with increased biological value, with improved organoleptic and structural-mechanical quality indicators. 2 tab.

The invention relates to the food industry and can be used in the production of pasta of increased biological value.

Known composition of the test for the production of pasta, including durum wheat flour or bread flour soft wheat premium and water. In addition, in the form of additives in the dough for pasta, flour of other crops is used, for example, peas (Medvedev G.M. Technology of pasta production. - M.: Kolos, 1999, p. 7, p. 50-52).

The disadvantage of using only wheat flour in pasta dough is the high starch content, which leads to a caloric content of the finished product and a low protein content. In addition, when flour of legumes, such as peas, is added to wheat flour, there is also an insufficient amount of protein.

Known composition of the test for the production of pasta (prototype - RF patent for invention No. 2289952), including wheat flour, water and protein-containing additives - legume flour, namely, either pea flour in an amount of 10% by weight of wheat flour, or lentil flour in an amount 10% by weight of wheat flour, or a complex additive consisting of bean flour in an amount of 2.5% by weight of wheat flour and rowanberry puree in an amount of 7.5% by weight of wheat flour, while the content of raw gluten in wheat flour should not be below 28%.

The disadvantage of the prototype is that when added to wheat flour protein-containing additives in the form of pea and lentil flour in the dough for pasta is not enough amino acids and minerals.

The technical task is to create a composition for the production of pasta with high biological value, with improved organoleptic and structural-mechanical quality indicators.

The technical problem is achieved by the fact that the composition for the production of pasta contains durum wheat flour, soft wheat flour and chickpea flour in the following ratio, wt.%:

chickpea flour - 10

The difference between the present invention and the prototype is that chickpea flour is used in the composition for the production of pasta, in the following ratio, wt.%:

durum wheat flour - 5

flour baking soft wheat - 85

chickpea flour - 10

The composition for the production of pasta is prepared as follows. Durum wheat flour in an amount of 5% is mixed with baking soft wheat flour in an amount of 85% and with chickpea flour in an amount of 10%. The amount of water per kneading is determined by calculation, taking into account the moisture content of soft baking wheat flour, durum wheat flour and chickpea flour. The prepared mixture of these three types of flour and water is fed into the first trough of the dough mixer, after which the finely lumpy dough, homogeneous in moisture, enters the second trough of the dough mixer connected to the screw chamber. Pasta presses are used to make pasta. Pressed pasta is dried in cabinet dryers.

Table 1 shows comparative data on indicators of protein content, essential amino acids and minerals in pasta prepared according to the prototype and the proposed composition.

Table 1
Indicators	Pasta
Composition according to the prototype (with lentil flour)	The composition of the prototype (with pea flour)	Proposed Composition
Protein content, % The content of essential amino acids, g per 100 g	13,02	12,44	14,26
protein, including	28,83	28,80	29,26
Lysine	2,97	2,85	3,26
Threonine	2,68	2,64	2,86
Valine	4,69	4,65	4,88
Leucine	7,03	6,76	6,99
Isoleiiin	3,66	3,64	3,74
Meteonin	1,65	2,13	2,87
tryptophan	1,52	1,32	0,87
Phenylalanine	4,63	4,81	5,99
Mineral composition, mg
Potassium	382,2	388,1	410,5
Calcium	59,6	60,2	70,7
Magnesium	101,6	102,4	106,7
Phosphorus	406,5	399,7	419,1
Iron	5,2	5,8	5,9

As can be seen from table 1, the content of essential amino acids in products with the addition of chickpea flour increased by 12%. The content of minerals compared with the prototype increased by 9%.

The introduction of chickpea flour into the pasta recipe is explained by the need to enrich it with balanced essential amino acids and minerals, which are contained in chickpea flour more than in pea and bean flour. The use of a protein-containing additive in the form of chickpea flour in an amount of less than 10% leads to a deterioration in organoleptic quality indicators and a decrease in biological value. The use of this additive in an amount of more than 10% worsens the structural and mechanical quality indicators.

The introduction of wheat flour into the recipe of pasta dough in combination of its different types - durum wheat flour and soft varieties, and at the same time soft flour for baking in the largest quantitative ratio (85%) is explained by the fact that this type of flour is the most common and affordable in food industry. In the recipe of the present invention, the flour quality improver is a natural additive in the form of durum wheat flour. When using durum flour less than 5%, the structural and mechanical properties of pasta deteriorate, and the use of more than 5% is inappropriate, because. the addition of this flour in an amount of 5% is sufficient to achieve optimal structural and mechanical properties.

Table 2 shows the quality indicators of the cooking properties of pasta, the composition of which is prepared according to the prototype and the invention.

As can be seen from table 2, pasta prepared according to the invention has good cooking properties: the main indicator of cooking properties - the loss of solids in the cooking environment - is 7.8% lower compared to the composition made according to the prototype.

Example. To obtain a dough for the production of pasta, soft wheat flour in the amount of 8.5 kg, durum wheat flour in the amount of 0.5 kg and chickpea flour in the amount of 1 kg are pre-mixed and the mixture is sieved. Carry out the following steps according to the above method of preparing the dough.

The resulting pasta with a protein-containing additive in the form of chickpea flour has a high content of protein, essential amino acids and minerals. Cooked pasta with a protein-containing chickpea additive has the correct shape, elastic texture and an attractive yellow tint.

Thus, the proposed composition for the production of pasta makes it possible to obtain products of increased biological value with improved organoleptic and structural-mechanical quality indicators.

Composition for the production of pasta, containing durum wheat flour, soft wheat flour and chickpea flour in the following ratio, wt.%.

In recent years, attitudes towards pasta have changed for the better. It turned out that pasta can be the basis of healthy and truly delicious dishes. And, most importantly, the product can bring significant profit to those who dare to build their business on the sale of pasta. We advise you to pay special attention to the production of premium products. High quality pasta will always be in demand.

Pasta business. Organizational moments

Pasta is the basis of a wide variety of dishes, from economical options to exclusive restaurant dishes with valuable and expensive ingredients. As we can see, the demand for the product is undeniable. And thoughtful production of pasta will find its niche. If you are afraid of risks, then you can organize a mini-production of pasta. In this case, you can consider the production of pasta at home (at the same time you will save on renting a room).

If you decide to start a pasta business, it is worth putting together an effective business plan that will cover the key points and lead you to a stable profit. The main thing you need to decide:

Potential customers and channels through which you will sell products.
Methods, production technologies, types of pasta.
Organization of the production process, raw materials.
Choice of equipment.
Calculation of profit, economic justification of the project, accounting for existing investments.

Target consumers and types of sale of pasta

One of the important stages of building a business is to identify potential consumers of products. Of course, consumers will be found anyway, but the most profitable segment is premium pasta. After all, the cost of even very high-quality pasta will not be high, but the price of such a product is much higher than the cost of medium and economy class pasta. In this case, we do not rely on quantity, but on quality. Several sales options:

Retail sales (supermarkets, grocery stores).
Wholesale trade.
Sale of cafes and restaurants.
The point of sale is the municipal sector (in the event that you decide to produce economy and middle class pasta).

If you are thinking about which production to focus on (economy, middle or elite class), it is worth analyzing the consumer market in your area and competitors' enterprises.

Pasta has a large number of varieties, and within any type of segment, different types of products can be produced. Depending on the type of flour, your products may have the first category or the highest. The type of flour affects the composition and nutritional value. In addition, pasta varies in shape and size:

Thread-like pasta (vermicelli, thin or in the form of a cobweb).
In the form of ribbons (grooved noodles, smooth, wavy edges).
Tubular (horns).
Various figures in one package.

There are also pasta with additives, dyes, products with fillings for first and second courses, instant noodles, etc. Accordingly, such a large selection involves the purchase of various types of production equipment. By the way, a new technology called vacuuming allows you to make the taste properties of pasta even more perfect. Such pasta does not stick together and does not boil soft. Such properties will certainly increase consumer demand.

Raw material

Depending on which class of pasta you have chosen, you need to choose raw materials and additional ingredients. If you decide to produce pasta of the middle and elite segments, then the flour must be of the highest grade, and the composition of the products must meet the following characteristics:

The humidity level is within 15 percent.
Gluten - from 30 percent.
Enrichment with vitamins is desirable.

Equipment for the production of pasta

Most of the costs in the production of pasta will go to the purchase of equipment. Mandatory positions:

Production line (automatic or semi-automatic) whose efficiency is from 100 to 500 kg per hour.
Forms (the set of these positions depends on the range of your products).
Packing machine.

Expenses

In order to start a pasta business, you need to have capital in the range of 0.8-1.5 million rubles. This amount includes the following expenses:

A complete set of production equipment, its delivery, installation, commissioning.
Room rent, utility bills.
Raw material costs.
Training, wages for employees.
Registration of IP, opening a current account.
Other expenses of an unforeseen nature.

Profitability

The pasta business pays off in about 1.5 years, but only if the supply of raw materials and marketing of products is well thought out. It is worth noting that in the premium segment, the payback will increase significantly. But the most important thing is to establish relationships with reliable suppliers and competently organize the production process.

Net profit

The proceeds from the sale of products average 600-800 thousand rubles, subject to the following conditions:

Production is carried out on equipment that has an efficiency of 150 kg per hour.
The working day of the staff is 12 hours.
Working days - all 30 days.

Based on these calculations, we get 27 kg of pasta and an approximate profit. But do not forget that more than half of the resulting amount will be spent on monthly expenses: salaries for employees, purchase of raw materials, rent, taxes, transportation costs, etc. Approximately 100-300 thousand rubles remain. This is the net profit. The production of pasta as a business is a very profitable enterprise with a reasonable approach.

Ministry of Education of the Russian Federation

Orenburg State University

Correspondence faculty

Course work

on the course: "System of technologies of industries"

on the topic "Technology for the production of pasta"

Completed by: Shapovalov A.V.

Group: 99 c/o MM2

Checked by: Nasyrov A.G.

Orenburg 2001

Introduction………………………………………………………………..……..3

1. Raw materials used in the production of pasta………………………………………………………………………………..4

2. Assortment, classification of products………………………………….7

3. The main stages of pasta production………………..10

4. The main technological schemes for the production of pasta ............................................................................................

5. The main units of pasta production - a pressing device and a matrix……………………………………………………………….19

6. Environmental indicators of production……………………………...24

Conclusion …………………………………………………………………26

List of used literature………………………………………27

Introduction

It has been historically proven that Italy is the birthplace of pasta. In the Middle Ages, pressing devices (a separate chapter is devoted to the device of these units) were driven by horsepower or water mills, and when the first machines appeared, steam units appeared.

The year of origin of the pasta industry in Russia is considered to be 1797, when the first pasta factory was opened in Odessa.

Pasta is a product molded from wheat dough in the form of tubes, threads of ribbons and figures and dried to a moisture content of 13%. They are characterized by good keeping quality, transportability, quick and easy cooking from them, as well as high nutritional value and good digestibility.

Pasta has a number of advantages over the most common food products. During storage, pasta does not become stale like bread, and is less hygroscopic compared to crackers, well transported and stored (up to a year or more) without deteriorating taste and nutritional properties. Pasta is superior in nutritional value to wheat bread, as it is made from wheat flour with a maximum protein content. They contain 9 - 13% proteins, 75 -79 digestible carbohydrates, 0.9 fats, 0.6% minerals and vitamins B 1, B 2, PP, etc. The calorie content of pasta is 360 kcal / 100 g. Their digestibility the human body is higher than the digestibility of cereals. Pasta proteins are digested by 85%, carbohydrates by 98% and fats by 95%. Of these, you can quickly cook a dish, since the duration of their cooking is 5 - 15 minutes.

1. Raw materials used in the production of pasta

The main raw material used in pasta production is flour. GOST 875-69 provides for the use of wheat flour of the highest or I grades as the main raw material for pasta production. At the same time, products of the best quality, having an amber-yellow or straw-yellow color, are obtained from special pasta flour of the highest grade (semolina), obtained by grinding grains of durum wheat or soft vitreous wheat. From pasta flour I grade (half-grains of durum or "soft vitreous wheat"), products with a brownish tint of greater or lesser intensity are obtained. Baking flour of the highest or grade I, obtained by grinding grain of soft wheat, is used in the absence of pasta flour. of the highest grade, they usually have a light cream color, and from grade I flour, they are dark cream with a gray tint.

In appearance, pasta semolina differs from baking flour in large particles (like semolina) with a yellowish tint. Semi-semolina consists of smaller particles than semolina, and therefore with a lighter shade (although it produces darker pasta). Baking flour of any grade consists of powdered particles, and the lower the grade of flour, the darker it has.

The most important indicators of the quality of flour for pasta are color, fineness, quantity and quality of raw gluten. Flour with a low gluten content produces fragile, crumbling products. The quality of raw gluten should not be lower than the second group. Grain flour is valued higher, as it absorbs water more slowly and forms a plastic dough. Flour used in pasta production should not contain significant amounts of free amino acids, reducing sugars and active polyphenol oxidase (tyrosinase), which causes darkening of the dough and deterioration in the quality of finished products.

Warehouses of flour are tare storage (in bags) or bulk. Both with tare and bulk methods, various options for storing, preparing and supplying flour to the presses are possible.

On fig. 1 shows a possible variant of the scheme for the container storage of flour, in fig. 2 - with bulk. Depending on the adopted scheme, one or another equipment is used in the flour warehouses of pasta enterprises. The equipment of flour warehouses is designed for receiving, storing and transporting it inside the warehouse and to pasta presses, as well as preparing for production (cleaning and weighing).

Figure 1 - Scheme of a warehouse for container storage of flour:

1-car, 2-belt conveyor. 3 - pallet with bags; 4 - electric loader 5 - bag tipper, 6 - vacuum cleaner, 7 - pit; 8 - bucket elevator; 9 - sifter, 10 - large elevator, 11 - screw conveyor distributor, 12 - bunker

Figure 2 - Scheme of bulk storage of flour:

1 - automukovoz. 2 - receiving shield, 3 - flour pipeline, 4 - switch 5-silo. 6 - screw dispenser, 7 - screw conveyor. 8 - electric motor; 9 - blower, 10 centrifugal sieve, 11 air filter, 12 - hopper above the press

Water is an integral part of pasta dough. It determines the biochemical and physico-chemical properties of the dough. Use tap drinking water, which should be moderately hard and meet the requirements of GOST-R for drinking water.

Additional raw materials used in pasta production are divided into: enrichment, which increases the protein value of pasta; for flavoring and aromatic additives; improvers; vitamin preparations.

The main type of enrichment additives are protein enrichers, which include fresh eggs, egg products (melange, egg powder), wheat flour gluten, casein, whole and powdered milk, whey, etc.

Egg products are added at the rate of 260 - 400 eggs or 10 - 15 kg of melange per 100 kg. flour.

The nutritional value of pasta with the addition of 10% milk powder is almost the same as for products enriched with egg products.

When using wheat gluten, the content of protein substances in products can increase by 30 - 40%. Gluten is a waste product in the production of wheat starch and it is economically feasible to use it as a fortifier.

Protein isolates obtained from soybean meal, sunflower and other oilseeds are also used. They can serve as substitutes for egg products.

Natural, concentrated or dry vegetable and fruit juices are used as flavoring additives in the production of pasta. The most commonly used tomato paste and tomato powders.

Improvers are surfactants. They help to improve the quality of pasta, which stick together less during drying and better retain their shape during cooking.

In order to enrich pasta, you can use heat-resistant water-soluble vitamins B 1 , B 2 , PP.

The quality of pasta largely depends on the technological process.

Modern pasta production is a single automatic production line. It consists of the following main operations: preparation of raw materials, dough preparation, pasta molding, drying, packaging.

2. Range of manufactured products

Depending on the shape, pasta is divided into the following types: tubular, thread-like, ribbon-like and figured. In turn, each of these types of products is divided into types.

Tubular products, depending on the size of the cross section, are divided into types: straws (diameter up to 4 mm); special) diameter from 4.1 to 5.5 mm), ordinary (diameter from 5.6 to 7 mm), amateur (diameter more than 7 mm). The wall thickness of tubular products must be no more than 1.5 mm (up to 2 mm is allowed in an amount of not more than 5% of the mass of products in a packaging unit).

Tubular products include (Fig. 3): pasta - a tube with a straight cut at least 15 cm long; horns - a curved or straight tube with a straight cut from 1.5 to 10 cm long; feathers-tube with an oblique cut from 3 to 10 cm long.

Figure 3 - a - pasta, b - horns, c - feathers

Filamentous products (vermicelli) are divided into types according to the size in the section (Fig. 4); cobweb (diameter no more than 0.8 mm); thin (diameter no more than 1.2 mm); ordinary (diameter not more than 1.5 mm); amateur (diameter no more than 3 mm).

Figure 4 - Filamentous products. a - long, b - short

Ribbon-like products (noodles) are produced in various names (Fig. 5): smooth or corrugated, with straight, wavy or sawtooth edges, etc. Any width of noodles is allowed, but not less than 3 mm, its thickness should be no more than 2 mm.

Figure 5 - Tape-like products. a - long, b - short.

Figured products (Fig. 6) can be produced in any shape and size, but the maximum thickness of any part in the fracture should not exceed: for pressed products - 3 mm, for stamped products - 1.5 mm.

Figure 6 - Figured products - a - shells, b - scallops; c - stamped, d - curls, d - soup fillings

Depending on the length, pasta is divided into long (from 15 to 50 cm) and short (from 1.5 to 15 cm). Pasta is made only long; vermicelli and noodles - both long and short; horns, feathers, figured products - only short ones.

Finally, according to the method of forming, short products are divided into short-cut and stamped.

3. Main stages of pasta production

Preparation of raw materials. It consists in sifting flour, separating metal-magnetic impurities from it, heating (flour temperature must be at least 10 ° C), mixing different batches of flour in accordance with the instructions of the factory laboratory.

The water intended for dough kneading is heated in heat exchangers and then mixed with cold tap water to the temperature specified in the recipe.

The preparation of additives consists in mixing them in water intended for dough kneading. When using chicken eggs, they are pre-washed, and if melange is used, then it is pre-thawed.

Cooking pasta dough. It consists of dosing the ingredients (flour, water and additives) and kneading the dough.

Dosing is carried out using dispensers that supply flour and water with additives dissolved in it in a continuous flow into the kneading trough in a ratio of approximately 1:3.

In the kneading trough, flour and water are intensively mixed, the flour particles are moistened and swollen - the dough is kneaded. However, unlike bread or biscuit dough, pasta dough by the end of the kneading is not a continuous connected mass, but a lot of moistened scattered lumps and crumbs.

Pressing dough. The goal is to compact the kneaded dough, turning it into a homogeneous, bound, plastic dough mass. and then give it a certain shape, mold it. Forming is carried out by forcing the dough through holes made in the metal matrix. The shape of the holes of the matrix determines the shape of the pressed out raw products (semi-finished product). For example, round holes will produce vermicelli, rectangular holes will produce noodles, etc.

Cutting raw products. It consists in cutting raw products pressed out of the matrix into segments of the required length and preparing them for drying. This preparation, depending on the type of manufactured products and the drying equipment used, consists either in laying out raw products on mesh conveyors, frames or tray cassettes, or in weighing long strands of raw products on special drying poles - bastuns.

Pressed out products before cutting or during cutting are intensively blown with air to obtain a dried crust on their surface. This prevents wet products from sticking to the drying surfaces and from sticking together during drying.

Drying products. The goal is to fix their shape and prevent the development of microorganisms in them. This is the longest and most important stage of the technological process, the correctness of which depends primarily on the strength of the products. Very intensive drying leads to the appearance of cracks in dry products, and very slow drying can lead to souring of products.

At pasta enterprises, convective drying of pasta is used - blowing the dried product with heated air.

Cooling of dried products. This process is necessary in order to equalize the high temperature of the products with the air temperature of the packaging compartment. If the pasta is packed without cooling, then the evaporation of moisture will continue already in the package, which will lead to a decrease in the weight of the packaged products.

Most preferably, the slow cooling of dried products in special bins and chambers, called storage stabilizers.

The cooled products are subjected to rejection, during which the products that do not meet the requirements for their quality are removed, after which the products are packaged.

Package. It is produced either in small containers (boxes, bags) manually or by filling machines, or in bulk" in large containers (boxes, boxes, paper bags)

4. Main technological schemes for the production of pasta

The production of any type of pasta always consists of the stages listed above, however, the type of products produced, as well as the availability of this or that equipment at the factory, determine the technological scheme for the production of these products at any particular factory. Pasta factories currently produce long products according to three schemes, and short products according to two. What are the distinguishing features of each of these five schemes?

Scheme of the production of pasta with drying in tray cassettes. According to this scheme (Fig. 7), pasta of any diameter with a length of 20-25 cm is produced.

A strand of raw pasta emerging from the press matrix 1 is placed into tray cassettes using a rolling table 2 and cut. At many enterprises, this operation is mechanized, it is performed by spreading and cutting machines.

Figure 7 - Scheme of the production of pasta with drying in tray cassettes

Cassettes filled with raw products are transferred to trolleys 5 or trolleys and transported to the drying department. Heatless drying cabinets 4 are installed here, to which trolleys with filled cassettes are tightly substituted, or cassettes are manually transferred from the trolley to the drying cabinet. Drying consists in the fact that the air flow from the fan of the dryer passes through the pasta placed in the cassettes. Upon completion of drying, the finished products in trolleys or on trolleys enter the packing department, where the products, after cooling and sorting, are packed manually or placed in bulk in large containers. Empty cassettes in trolleys or trolleys are fed to the press, where the process is repeated again.

The main disadvantages of the cassette method for the production of pasta are that a lot of manual labor is expended and the pasta always turns out to be curved. However, until now, according to this scheme, the bulk of pasta is produced in our country. This is explained by the fact that the cassette method does not require complex and expensive equipment (drying cabinets, trolleys and trolleys are made in the workshops of pasta enterprises) and large areas.

In recent years, in order to reduce manual labor to a minimum with the cassette method of pasta production, a number of enterprises have created mechanized production lines. On fig. 8 shows a diagram of one of these lines. The strand of pasta pressed out by the screw press 1 enters the 2 spreading and cutting machine, where the pasta is mechanically stacked and cut into 3 tray cassettes. The filled cassettes are stacked manually in piles on two 5 chain conveyors passing on both sides of the dryer. The dryer consists of several cabinet dryers installed in a row. When moving stacks slowly

Figure 10. Mechanized production line for the production of pasta with drying in tray cassettes

cassettes conveyors dry the pasta. Dry pasta is removed from the cassettes on the packing table 6, and empty cassettes are fed to the cutting and laying machine for the next filling with raw products.

Scheme for the production of long pasta on automated production lines with hanging drying. According to this scheme, a relatively small amount of pasta is still being produced in our country. However, due to the high degree of mechanization and automation of all technological processes carried out by continuously operating machines and units that are part of the lines, this method of producing high-quality pasta (special pasta and sticks, vermicelli and noodles) is becoming more widespread in our country. At present, according to this scheme, the lines of the Italian company Braibanti and similar domestic lines B6-LMG, B6-LMV and LMB are operating in the pasta industry.

On fig. 9 shows a diagram of the B6-LMV line. A continuous-acting press 2 presses strands through a rectangular matrix, which are hung on bastuns by a special machine (self-weighting) 1. In this state, they go to dry. First, the pasta strands are dried in the pre-dryer 5, where moisture is intensively removed from the semi-finished product, and then in the final dryer 4, in which moisture is slowly removed from the products. In dryers, bastuns with products are moved by conveyors located in several tiers. Dried products on bastuns enter the stabilizer-accumulator 5, and then are removed from the bastuns by machine b and fed to packaging. Empty bastuns are fed by a chain conveyor to self-weighting. Usually the lines are equipped with packing machines for packing products into boxes.

Figure 11. Automated production line B6-LMV for the production of long pasta

Scheme of the production of long products on automated production lines with pre-drying on frames and final drying in cylindrical cassettes. According to this scheme, long pasta is made on automated production lines of the French company Bassano. There are two such lines in our country. The line includes a pasta press, spreader, pre-dryer, final dryer, storage stabilizer and a group of packaging machines. The main advantages of this scheme are the absence of dry waste and the production of absolutely straight products of the same length. This is achieved by the fact that the pasta cut into segments of the same length, after preliminary drying on the frames, undergoes final drying inside the rotating cylindrical cassettes. In this way, the products are dried by continuous rolling on the inner surface of the cylindrical cassettes, which makes them absolutely straight.

Scheme of the production of short-cut products on complex-mechanized production lines. The line (Fig. 10) consists of two main elements: screw pasta press 1 and continuous dryer 2.

The extruded products are continuously cut by some sort of short cutter and fed to the top belt of the steam conveyor dryer. Gradually pouring from the upper belt to the underlying one, the products are blown with heated drying air.

Rice. 12. Scheme of a complex-mechanized production line for the production of short-cut products

Dried products are cooled most often in vibration coolers 5 or simply on belt conveyors of sufficient length, which feed them to the packaging department.

A high degree of mechanization, circuit flexibility, and high productivity made it widespread in our country in the postwar years.

The scheme of production of short products on automated production lines. The production of pasta according to this scheme differs from the production according to the previous higher degree of mechanization and automation of processes, higher quality of the resulting products due to the use of longer drying, carried out in three stages - preliminary drying, preliminary and final drying.

In addition to dies and cutting mechanisms for producing short-cut products, the lines are usually equipped with slit-like dies for producing a dough tape and stamping machines, which also makes it possible to produce stamped products on them.

The line (Fig. 11) consists of a screw pasta press 1, a pre-dryer 2, a preliminary dryer 5 and a final dryer, a storage stabilizer 11, as well as auxiliary and transporting devices: bucket elevators 3, b and 9, product spreaders 4 and 7 and belt conveyors 10 and 12.

Figure 13 Bribanti automated production line for the production of short products

5. The main units of pasta production - a pressing device and dies

Screw presses are classified according to the number of mixer troughs (one-, two-, three- and four-trough), by the number of pressing devices or pressing screws (one-, two- and four-screw), by the presence and place of vacuuming the dough (in the dough mixer or in the screw chamber). ), according to the shape of the matrix and the design of the tube.

Currently, our pasta enterprises operate domestic pasta presses LPL-1M, LPL-2M and LMB. The latter are installed in automated production lines LMB, as well as automated production lines of the Italian company Braibanti, and the French company Bassano - press VVK 140/4.

The Rostov-on-Don Machine-Building Plant has started production of presses of the B6-LPSh series with a capacity of 500,. 750 and 1000 kg/h finished products.

In order to understand the principle of operation of the press and the purpose of its individual components, let us consider the technological scheme of a single-trough single-screw pasta press with a round matrix, shown in Fig. 14

The technological units of the press are flour 1 and water 2 dispensers, a dough mixer consisting of a trough 3 and a shaft 4 with blades, a pressing device including a screw cylinder with a water jacket 6 and a screw 7, a press head, a replaceable matrix 10, a cutting mechanism 11 and a blower 12. The rotation of the dough mixer and auger shafts is usually carried out from a single drive 5.

MATRIX Dough kneading, compaction of the resulting crumbly mass and molding of raw products are currently carried out in a single unit - in a continuous screw pasta press, the main working body of which is a matrix. The shape of the matrix holes determines the type of pressed products. By changing the matrices, it is possible to obtain almost any kind of pasta on the same press. Thus, presses and dies are the main equipment for kneading and pressing pasta dough.

In addition to this equipment, various machines and mechanisms for cutting raw products are used in the dough-forming departments of pasta factories (we will focus on them in the next chapter), as well as a number of auxiliary machines, which we will consider in this chapter.

The matrix, along with the pressing device, is the main working body of the pasta press. It determines the productivity of the press, the type of products (shape and dimensions of the cross section), and to a large extent affects the quality of the product (degree of surface roughness, bonding strength of pasta tubes, etc.). The matrices are made of metals that are not susceptible to corrosion, have sufficient strength and wear resistance, with low adhesive ability. Such metals are bronze, brass, stainless steel.

There are two types of matrices - round (disk) and rectangular. With the help of round dies, all types of long and short-cut products are formed, as well as dough strips for the manufacture of stamped products from them. Rectangular dies are used for molding long pasta (pasta, vermicelli, various types of noodles) produced on automated production lines.

Round matrices. Matrices, depending on the thickness, are used without supporting devices or with supporting grate devices. In matrices with underlay grates, strips are left that are located above the ribs of the grate, and in matrices with overhead (suspended) grates, the central part is occupied by a bolt with which the grate rib is attached. In this regard, there are fewer holes on grate dies than on non-grate ones.

The diameter of the matrix depends on the performance of the press. In LPL presses with a capacity of about 400 kg / h, matrices with a diameter of 298 mm are used. In LPSh presses, matrices with a diameter of 350 mm are installed.

The thickness of the matrix must meet the conditions of strength. In screw pasta presses, for each centimeter of the matrix surface area, the dough presses with a force of up to 100 kg or more. Matrices with a diameter of 298 mm, having a thickness of less than 60 mm, are used with support grates.

The backing grate also consists of a shell 1 made of strip steel with steel ribs 2 welded to it. Such grates are most often two- and four-ribbed. The outer diameter of the shell is equal to the diameter of the matrix. The grate is installed on the annular support of the matrix holder, on which the matrix is laid.

Matrices with lining grates allow you to mold products that are cut in the suspended state - pasta, feathers, vermicelli, noodles.

Figure 15 - Round matrices: a - grateless; b, c - grate

The overhead (suspended) grate consists of a steel rib 1 inserted into the slot of the bolt 2. The bolt is inserted into the hole of the matrix 4 and attached to it from below with a nut 5. In this case, the matrix is installed on the annular support of the press die holder (as well as without grate).

Matrices with overhead grates allow you to mold all types of both short-cut and long products.

Rectangular matrices. There are single lane and double lane. Single-strip dies are used in Bassano automated production line presses, in which the products being pressed out form one strand. Two-lane matrices are used in presses of automated production lines with hanging drying to obtain two strands hung simultaneously on two bastuns.

In each strip, the forming holes are placed in several rows so that they are located in one layer on the bastuns or on the roller table (Fig. 17). The number of rows in the matrix depends on the size of the cross-section of the products: in the matrices for special pasta and wide noodles in each strip, the holes are placed in two rows, for straw pasta - in three, for thin pasta - in seven rows.

Rectangular dies for automated production lines are produced with a length of 995 and a width of 100 mm. The thickness of the matrix can be from 31 to 50 mm.

Hole profiles. Matrix forming holes are of three types: with inserts for forming tubular and some types of figured products; without inserts for forming all types of products, except for tubular and stamped, and slit-like for forming a dough strip,

Figure 17 - Rectangular matrices: a - single-lane; b - two-way

intended for the manufacture of stamped products from it.

Holes with inserts are the most complex in design and consist of two main elements: a forming channel drilled in the body of the matrix, and an insert fixed in it.

6. Environmental indicators of production

The main harmful factors for food industry enterprises, and in particular for a pasta factory, are noise, dust and wastewater.

Measures necessary for environmental protection are usually divided into three groups:

a) technological measures related to changes in technological processes and the design of machines in the interests of environmental protection;

b) planning activities, including a set of technical solutions for the placement of machines and apparatus in departments, workshops, as well as the whole enterprise in the territory adjacent to the residential area

c) sanitary and technical measures, including the calculation of the coefficients of the required efficiency of treatment facilities and the selection of the necessary types of apparatus for the treatment of wastewater and emissions into the atmosphere, noise protection.

Harmful factors affecting the environment from the pasta factory are:

flour dust; the movement of flour through material pipelines (pipes through which flour enters by means of aspiration (blowing method) is accompanied by the release of flour into the air, which is taken into the air duct of the aspiration network and sent to the cyclone. However, sometimes there is not enough air in the cyclone and its emissions into the environment exceed the MPE ( maximum allowable emissions), (according to SN-1042-7З) is equal to 0.5 g/s;

Noise: the operating equipment is a source of constant noise, permissible sanitary norms of MPE noise: 35 dBA during the day, 25 dBA at night;

Wastewater should not exceed the sanitary standards for contamination with organic pollutants, the amount of which should not exceed the allowable 3 mg/l.

Conclusion

So, in my work, I tried to talk about the features of pasta production technology.

Physiologists have proven that the human diet should consist of 37% flour products, i.e. bread, baked goods, and pasta. Consumption of 100 g of pasta per day covers all human needs for proteins, 50% in starch, it has also been indicated that the proteins, fats and carbohydrates contained in pasta are highly digestible.

Unfortunately, in our city there is only one pasta factory located on the street. January 9. The range of products of our factory is not high enough, but the products are of high quality, and most importantly - low price. In the Russian market, the undisputed leader is the products of the Chelyabinsk macaroni factory "Makfa".

So, in conclusion, I would like to say that pasta production occupies an important and not the last place both in the human diet and in the basket of an ordinary consumer.

List of used literature

1. Medvedev G.M. Technology and equipment for pasta production. – M.: 1984. – 280 p.

2. Chernov M.E. Equipment for pasta industry enterprises. – M.: 1987. – 232 p.

3. Smirnova N. A., Nadezhdina L. A. “Commodity science of grain flour and confectionery products.” M.: 1990 - 241 p.

3. V. I. Teplov, V. E. Boryaev “Commodity research of food products.” M.: - 1989

In this article:

The profitable operation of the pasta business depends on two things - equipment and flour. The raw materials and pasta vacuum press must certainly be of excellent quality.

The cost of production is minimal, the technology is simple, and the profit is significant.

Organizational moments of business

When opening the production of pasta, the first step is to register as a business entity, after selecting the most preferred legal form.

In the process of registering an enterprise, you will need to specify the following code OKVED: 15.85- production of pasta.

Room search

The main requirement for the future production workshop is the area - it should be enough to install a production line and equip a small warehouse for storing flour and finished products in proper conditions. It is recommended to allocate at least 90 square meters for storage facilities. After the acquisition of an industrial building (rent) and the repair carried out in it, you can begin to resolve paper issues.

Documentation

Before starting the production process, it is imperative to take care of obtaining a production certificate from the sanitary and epidemiological service, which will be a permit for the operation of the premises for the purpose of manufacturing food products.

You should also collect a package of documents for obtaining permits from the executive authority, the environmental service and the fire department. Specialists of these organizations will travel to the site of the future production workshop, study the compliance of the conditions with the approved rules, and ultimately issue a verdict.

The production of pasta must comply with GOST R 52378-2005. The certificate is granted on the basis of an expert opinion after the first launch of the production line and the study of samples of the manufactured product, which is completely ready for use.

After receiving all the documents, you can proceed to the main stage - the purchase of production equipment.

Equipment for the production of pasta

In our country, in order to organize mini factories for the production of pasta, some domestic machine-building plants produce devices that ensure the performance of these operations. Compared to imported equipment (for example, popular Italian), it is several times cheaper. A wide range of units allows you to choose the most suitable model in terms of price, quality and performance. In addition, spare parts will be cheaper, and repairs will be made in a short time.

The technological mini-line for the production of pasta products includes the following equipment:

flour sifter;
pasta press machine;
drying cabinet;
packing machine.

If you have enough funds, you can purchase expensive Italian pasta equipment (for example, Realpast). This version of the production line will be preferable for large factories with a production capacity of up to 600 kg. at one o'clock. The indisputable advantage of the equipment is the ability to produce non-standard pasta for our country. (beshbarmak, lasagna, etc.)

The estimated price of the pasta line will be 3-3.5 million rubles.

This equipment allows to produce a wide range of pasta products: spaghetti, cones, shells, all kinds of spirals, etc. (about 500 varieties in total). The transition of a vacuum press to the production of another type of pasta is carried out by replacing the matrix within a few minutes. It is possible to purchase a fully equipped line with a capacity 100 kg. at one o'clock.

Features of the technological process for the manufacture of pasta

The technological scheme of the production process is shown in the figure.

Flour preparation

This stage includes weighing, mixing, sieving and magnetic cleaning of the main ingredient. Mixing of different batches of raw materials must necessarily be of the same grade, it is carried out in order to improve quality indicators. In the process of storing flour in warehouses, it is far from always possible to monitor the microclimate in the room. Therefore, mixing the flour will ensure the necessary consistency of the raw material relative to moisture. Otherwise, there may be failures in the operation of the vacuum press and the entire production line as a whole.

Screening

Foreign particles accidentally found in the flour must be removed (villi, twigs, threads, paper, dried lumps of flour).

Magnetic cleaning

With the help of special magnets in the equipment, metal impurities are removed, which can sometimes get into the flour as a result of its production and transportation.

Cooking pasta dough

In terms of its composition, pasta dough is the simplest variety of all possible options that are used in the production of flour products. Most often, the only ingredients are flour and water. In the case of making various additives (eggs, dyes), the cost of production begins to rise, which significantly reduces the profitability of production.

In the process of kneading pasta dough, a minimum amount of water is added to the flour. Its initial appearance has a crumbly structure, which, in the course of further pressing, begins to turn into a homogeneous mass, completely suitable for forming the necessary shape of products.

Dosing and mixing ingredients

The kneading is carried out in continuous dough mixers, which are often part of vacuum presses.

It is important to note that they are of a lot of trough type (used for production of more than 150 kg per hour). According to the recipe, flour and water enter the equipment through dispensers.

Compaction and shaping of the dough

The process of dough compaction and direct molding of products is carried out on screw vacuum presses. Flour and water are fed into the inlet of the dough mixer in a continuous stream and mixed with the blades of the kneaders. Through the passage hole, the dough enters the screw of the pressing device, the rotation of which contributes to its movement to the pressing head. Here it is compacted, turning into a dense mass.

To facilitate the process of molding and pressing, the temperature of the dough can be heated - so it will become more plastic and pliable. Vacuum processing involves the removal of air bubbles. After molding in a matrix, finished pasta is obtained at the exit. To prevent the dough from overheating and breaking its elasticity, cold water is supplied to the press jacket.

Cutting raw pasta

The process is carried out after pressing out the finished dough, which is subject to blowing, cutting into individual products and their layout.

The speed of the drying press, the quantitative consumption of raw materials and the appearance of pasta depend on the quality of these operations. After that, the finished products are prepared for drying. Blowing is carried out to prevent sticking of pasta and for more precise cutting.

Formed and dried pasta is subject to prolonged drying on the surface of conveyor dryers.

The quality indicators of the finished product, namely strength, acidity level, structural integrity and appearance of pasta, directly depend on the correctness of this stage of production. Excessively intensive drying process often leads to cracking of products, too long - to them souring. In the case of drying in layers, the pasta may become deformed.

Packaging and storage of finished pasta

Before packaging, the finished product must be kept for at least 4-5 hours in cardboard boxes, after which it can be packaged. Some models of modern equipment use hydrothermal technology - if a cooler is available, packaging can be started immediately. Pasta can be produced packaged (no more than 1 kg.) And by weight. In the first case, cardboard boxes, paper and plastic bags are used as packaging.

Loose products are placed exclusively in shipping container: wooden or cardboard boxes that are pre-lined with clean wrapping paper. Packed pasta is placed in boxes tightly enough, and the gaps are filled with paper. Finished products should be stored in cardboard boxes (paper bags) until they are sold directly to retail chains. It is not allowed to exceed the temperature in warehouses over 13 degrees, and humidity - more than 12%. For storage and transportation of the manufactured product, it is necessary to purchase racks and trolleys.

To achieve high quality products, it is desirable to hire an experienced technologist who will monitor the technological process and product composition. After all, it is on his professional qualities that the competitiveness of the mini-factory and the profitability of the business as a whole essentially depend.

Pasta business plan

Equipment costs

To organize your own production of pasta, you need to purchase the following equipment:

flour sifter - 9,000 rubles;
dough mixer - 23,000 rubles;
pasta press - 180,000 rubles;
drying cabinet - 31,000 rubles;
packing machine - 65,000 rubles.

Total equipment costs amount to 308,000 rubles.

Personnel costs

For the effective functioning of the mini-factory, the following personnel will be needed:

manager 20,000 rubles;
2 workers to service the production line - 20,000 rubles each;
technologist - 15,000 rubles;
driver - 12,000 rubles.

The total monthly payroll is 67,000 rubles.

The amount of tax on salary equals: 67,000 x 30% \u003d 20,100 rubles.

In order to save money, the duties of a manager-manager can include the formation and provision of accounting (tax) statements.

Feedstock

Flour and water are used as the main ingredients for the production of pasta. For 1 kg. the finished product requires 950 grams of feedstock.

The planned volume of pasta production per month is 2200 kg: 100 kg x 22 working days, where 100 kg is the rate of production per day, 22 days is the number of working days per month.

At the wholesale price for 1 kg. flour at 12 rubles, we calculate the cost of raw materials that are necessary for the production of pasta: 11.40 rubles x100 kg. x 22 days \u003d 25,080 rubles, where 11.40 r is the price of 0.950 kg. flour of the highest grade;

Fixed monthly costs

rent of premises - 8,000 rubles;
utility bills - 10,000 rubles;
raw materials - 25,080 rubles;
transport costs - 12,000 rubles;
Payroll for personnel - 67,000 rubles;
payroll tax - 20,100 rubles;
packing bags - 4,000 rubles.

The total expenditure part is 146,180 rubles + 308,000 = 454,180 rubles.

Revenue part

Retail price 1 kg. loose pasta is 30 rubles, and in a pack - 40 rubles. Including VAT (20%), income from 1 package of pasta will be: 40 - 8 = 32 rubles.

Gross revenue based on 100% sales of pasta produced per month: 2200 kg. x 32 rubles. = 70,400 rubles.

Profit after tax (15%) -59,840 rubles (net profit).

Profitability of production: (70,400 rubles / 146,180 rubles) x 100% \u003d 48.2%

We will determine the effectiveness of current costs based on the indicator of product profitability: Sp = 25,080 rubles;

Pp \u003d (70,400 rubles - 25,080 rubles): 2200 kg \u003d 20.60 rubles

Rp \u003d (20.60 rubles / 40 rubles) x 100% \u003d 51.5%.

Thus, from the above calculations, it can be concluded that the pasta business is a profitable activity. With a release rate of 2,200 kg. per month of finished products, the gross profit from the sale of products will be 70,400 rubles.

Establish sales of finished products

During the first months of operation, it is desirable to use production capacities not fully due to the search for your own consumer segment. As for the price, at first it should be intermediate between the competitive and the actual cost of production. Only in this way (not at the expense of quality) can we win the trust of the population and gradually increase production volumes. With the full implementation of the manufactured products, it is desirable to gradually increase the range of the finished product (spaghetti, various types of horns, etc.).

Consider possible sales options:

conclusion of contracts with food bases and large food and wholesale warehouses;
organization of deliveries to retail chains;
sale of products to public catering enterprises (restaurants, cafes, bars, cafes and canteens);
regular participation in tenders for the supply of pasta to various institutions (gardens, schools and summer camps).

You need to be prepared that the newly created enterprise will have problems with the sale and marketing of products. Wholesalers are reluctant to purchase products that are not accepted by consumers. In this regard, it makes sense to try to create your own dealer network or supply pasta for sale to local market outlets.

Pasta must certainly have high quality indicators in terms of composition, cooking and taste properties. The color and appearance of the packaging makes a positive first impression. The competitiveness of manufactured products and the level of profitability of the business as a whole will largely depend on such characteristics.

An advertising company can significantly increase sales. Announcements in the media, a TV commercial, billboards and other outdoor advertising means will be especially effective in this case, as well as periodic promotions (when buying two packs, the third one is free).

If you correctly approach the organization of the production process, then the investment will pay off within one year. The profitability of this type of business is very high, but at the initial stage it is extremely difficult to overcome competition and establish sales of finished products.