Business plan for cottage cheese production. Making cottage cheese from milk for sale at home

Introduction

Cottage cheese is one of the oldest dairy products. It can be assumed that people began to eat it much earlier than cheese and butter. This assumption is quite reasonable, because. as a result of the vital activity of lactic acid bacteria, which are always found in milk, spontaneous souring of milk is possible. In this case, a clot is formed, which is compacted as a result of natural syneresis. One of the first products that the ancients considered cottage cheese was the Hippaka product - a clot of mare's milk. No less natural is the assumption that in ancient times a person also accidentally learned about rennet fermentation, using the stomachs of slaughtered animals as containers for milk.

About products such as cottage cheese, obtained as a result of sour and rennet fermentation of milk, there is information in the works of ancient poets, in the works of philosophers and scientists. Homer, Aristotle, Hippocrates, Palladium, Columella wrote about these products. Columella, who lived in the 1st century AD, wrote in particular detail, indicating practical advice on how to ferment milk, and requirements for its quality.

In the writings of ancient authors, it is indicated that the remains of curdled milk from the stomachs of lambs and kids, the mucous membrane of the stomach, were used for fermentation. Even then, various vegetable substances and wine vinegar were also used to ferment milk.

Thus, historically there were two main methods of fermentation of milk during the production of cottage cheese: acid and acid-rennet. Both of these methods have survived to this day.

With the acid-rennet method, the production of cottage cheese for many centuries has been using pieces of raw and dried stomachs of calves and lambs as rennet. Enzyme preparations appeared about 100 years ago, when liquid rennet starters were first sold in France. Dry rennet was obtained at the end of the 19th century.

According to available data, in 1888-1890. pure cultures of lactic acid bacteria began to be used.

In industrial conditions, cottage cheese began to be produced at the end of the 18th and at the beginning of the 19th centuries, which was associated with the organization of urban dairies.

Commodity dairy farming in Russia arose at the end of the 18th century, when large landowner farms organized cheese dairies with the production of not only cheeses for the market, but also melted butter, sour cream and cottage cheese. The first cheese factory was opened in 1975. In the Lotoshchino estate of the eponymous district of the Smolensk region.

With the development of capitalism in Russia and the growth of the urban population, the demand for dairy products increases, and therefore the dairy industry takes on a commercial, entrepreneurial character. Peasant artels and milk buyers open small handicraft dairy factories, often in peasant huts, adapted premises, with minimal equipment.

The founder of the scientific formulation of the dairy business in Russia was A.A. Kalantar, who worked at the Edimonovskaya school since 1882. and organized here the first milk testing laboratory with scientific research. He wrote a number of manuals and popular science guides on dairy farming, cheese making, butter making.

It should be noted that the further back in history the appearance of a product goes, the lower the general technical level of its production at the present time. It is this that can explain the fact that primitive production techniques are still preserved at the hotel dairies, the duration of the technological cycle is still long.

Cottage cheese is a fermented protein product made by fermenting pasteurized normalized whole or skimmed milk (mixing with buttermilk is allowed), followed by the removal of a part of the whey from the clot and pressing the protein mass. Officially, it is customary to classify curd produced in the traditional way according to its fat content. In accordance with this, fat, semi-fat and non-fat cottage cheese are distinguished (non-fat cottage cheese is often called fat-free). Cottage cheese from unpasteurized milk is produced in case of milk with high acidity; before eating, the cottage cheese must be subjected to heat treatment (obtaining cheesecakes, dumplings, production of processed cheeses). Cottage cheese has pure sour-milk taste and smell; for the first grade, a slightly pronounced aftertaste of feed, packaging, light bitterness is allowed. The consistency is tender, homogeneous; for fatty cottage cheese of the first grade, somewhat loose and smearing is allowed, for low-fat - crumbly, with a slight release of whey. The color is white, slightly yellowish, with a creamy tint, uniform throughout the mass; for fatty cottage cheese of the first grade, some uneven color is allowed. A significant content of fat and especially high-grade proteins in cottage cheese determines its high nutritional and biological value.

When the clot is dehydrated on separators, the curd has a pasty consistency, and therefore it is sometimes referred to as non-traditional, although it is traditional in terms of composition and raw materials. Cottage cheese obtained in a separate way, even without the use of separators, is also conditionally called non-traditional.

Non-traditional types include cottage cheese made from buttermilk, whey of dry dairy products, as well as grain cottage cheese with cream.

According to the method of coagulation of milk proteins, cottage cheese is divided into acid and acid-rennet. Sour curd is usually made from skimmed milk.

In this case, the protein coagulates under the action of lactic acid, which is formed in the process of lactic fermentation, which develops as a result of the introduction of starter cultures into milk.

When evaluating the quality indicators of cottage cheese, along with the fat content, the moisture content in the finished product, as well as its acidity, is important.

Depending on the acidity of cottage cheese of all kinds, they are divided into the first and highest grade.

It should be noted that the composition of cottage cheese, and especially its protein part, is certainly influenced by different methods of its production. It can be noted that casein, freed from calcium, prevails in acid curd, and both casein and its calcium salt are contained in acid-rennet curd. The degree of use of milk proteins in the production of cottage cheese also depends on the methods of coagulation. The content of calcium and phosphorus salts in cottage cheese is in the ratio most favorable for human absorption

Table 1

The high biological value of cottage cheese is determined by the content of all essential amino acids in it: lysine, histidine, argenine, threonine, valine, miteonine, isoleucine, leucine, phenylalanine.

It should also be noted that the content of amino acids in fatty and low-fat cottage cheese is different. This is due to the fact that in the production of fatty cottage cheese, it includes proteins of the shells of fat globules, which have a slightly different amino acid composition.

Sour cream is produced by fermenting pasteurized cream with pure cultures of lactic acid bacteria, followed by maturation of the resulting clot. Among other fermented milk products, sour cream stands out for its high nutritional value. Due to the changes that occur with the protein part during the fermentation process, sour cream is absorbed by the body faster and easier than cream of the corresponding fat content. Some lactic acid bacteria in the process of fermenting sour cream are able to synthesize B vitamins, therefore, in sour cream, compared to milk, the content of these vitamins is also higher. Sour cream has a pure sour-milk taste with pronounced taste and smell characteristic of a pasteurized product. Its consistency is homogeneous, moderately thick, without grains of fat and protein. Sour cream of traditional chemical composition with a mass fraction of fat of 30% is divided into the highest and first grades. For the first grade, slight aftertastes are allowed: melted butter, containers (wood), the presence of slight bitterness. According to the consistency, not thick enough, slightly lumpy, granular, the presence of slight ductility is allowed. Other types of sour cream are not divided into varieties.

1. Production technology

1.1 Initial technological operations

Cooling, in essence, determines the behavior of milk in the process of further technological processing. The cooling temperature should be considered the main factor on which such quality indicators of milk depend, such as its bacterial contamination and acidity. The lower the cooling temperature, the longer the quality of the milk remains. During the cooling process, the quality of the feedstock does not change. The purpose of cooling is to maintain the original properties. The World Health Organization recommends cooling milk to 4°C no later than one hour after acceptance. Maintaining the temperature of chilled milk during taring prevents the development of microorganisms, and therefore slows down the increase in acidity.

1.1.1 Reception of milk

After the milk is received by the enterprise, it is necessary to ensure the preservation of its native properties, the minimum contamination of it with microflora. To do this, milk after receipt is cleaned of mechanical impurities and cooled. Purification is carried out by filtration or using centrifugal separators of milk cleaners. For filtering, you can use gauze-cotton, lavsan filters. Mechanical filtration does not provide complete purification of milk, only large particles are retained, incoming new portions of milk come into contact with contaminated ones on the filtrate and are additionally seeded with microflora

Business in the food industry is a profitable direction, which, with a competent approach, will provide the entrepreneur with a consistently high income. The only drawback here is the rather impressive start-up costs that the entrepreneur will have to bear to start production. To minimize all financial risks, choose a profitable business. This includes the production of cottage cheese - a product in demand among consumers! The technology for the production of cottage cheese is simple, equipment and raw materials are quite affordable on the market, there is little competition - it is worth trying to implement this business idea.

Cottage cheese is a fermented milk product obtained by fermenting milk and separating it from whey. Cottage cheese is included in adult and baby food. It is a source of easily digestible protein and calcium - an indispensable product in a healthy diet.

How to open a mini-factory for the production of cottage cheese in Russia for a novice entrepreneur?

Our business valuation:

Starting investment - 3500000 rubles.

Market saturation is average.

The complexity of starting a business is 8/10.

Business formalization

In your business plan, include a paragraph on formalizing the business. All legal issues will certainly take a beginner a lot of time - you have to collect a whole package of documents and obtain permission to conduct activities from the supervisory authorities. If you are not versed in all the intricacies of registering food industry plants, it is better to entrust the matter to specialists!

It is necessary to choose the form of economic activity - LLC or IP. The first option is better, because it will allow you to conclude profitable contracts for the supply of raw materials and cooperate with wholesale buyers. And if you plan to make homemade cottage cheese on your own farm, you can choose an individual entrepreneur - the level of sales, in this case, will be small. OKVED code: 15.51.14 - production of cottage cheese and curd cheese products.

SES and the Fire Inspection put forward serious requirements for the organization of premises, the chosen technology, and the quality of finished products. Therefore, study the norms and standards in order to know all the features of business registration. Supervisory authorities will regularly check the plant to identify any violations.

You cannot start a food production business unless you obtain the appropriate license. After checking the prepared premises and equipment, you will be issued a permit in the form of an act. Its validity period is 5 years.

When the production of grained cottage cheese is launched, the first batch of goods will need to be sent for certification. The document will confirm the high quality of fermented milk products.

What products can be produced?

Within the walls of the plant, it is possible to produce not only cottage cheese, but also other products that belong to this category. In advance, you need to think over the “range” that you will offer to wholesale buyers. The modern line for the production of cottage cheese allows you to produce different types of cottage cheese products! This is what distinguishes the "curd" niche from others - there are great opportunities for the development of the enterprise.

In general, the product line of the curd factory can be represented as follows:

Sour-milk cottage cheese - fat-free, fatty, classic, fatty.
Curd products - curds, pastes, creams, desserts.

It makes no sense for a novice entrepreneur to plan a wide product line at once - in the future, difficulties may arise with the sale of finished products. But at least 5-7 types of cottage cheese must be provided for the opening of the plant! Engage a qualified technologist to develop the recipe - then it will be checked by the SES and licensing authorities.

The development of recipes and the preparation of a unique specification are quite costly stages in the launch of a mini-factory. In some cases, it takes a lot of time - up to six months.

Curd production technology

Before you buy equipment for the production of cottage cheese, you need to decide on the technology that will be introduced at the plant. Most likely, in order to offer customers a large range of products, it will be necessary to provide several technologies.

Depending on the method of coagulation of proteins and the formation of a curd clot, the following methods of curd production can be distinguished:

Acid. The technology allows the production of fat-free cottage cheese. In this case, fermentation of milk occurs by bacteria. The result is a product of delicate texture without clots. The acid method for the production of cottage cheese allows the production of curds, curd masses.
Acid-rennet. Here, special rennet and lactic acid are used to ferment milk. This technology is more often implemented in the food industry. The production of cottage cheese by the rennet method makes it possible to obtain a product of medium and high fat content. Cottage cheese is dense, granular, with a characteristic sour-milk taste and aroma.

Depending on the sequence of technological operations and regimes, the production of cottage cheese at factories is carried out according to one of several technologies - traditional and separate. In recent years, it is the separate method that has become widespread - it is simpler and more economical in terms of the use of raw materials.

How is cottage cheese made in production?

We can distinguish the main stages that are inherent in any of their technologies:

Preparation of raw materials - normalization, pasteurization and cooling of milk.
Fermentation of milk with lactic acid bacteria or rennet.
Processing of the resulting curd clot - pressing and cooling.
Packaging of the finished product.

Modern industrial production of cottage cheese involves its packaging in large or small containers. It is worth deciding on the type of packaging immediately in order to order all the necessary materials and containers. The product in a large container will be delivered to wholesale buyers who will sell cottage cheese by weight. Barrels with a volume of not more than 50 kg, flasks of 35 kg, large plastic bags packed in cardboard boxes can be used here. For packing small-packaged cottage cheese, parchment paper or foil, plastic containers are used. As a rule, the product is packed in 125g, 250g, 500g.

If you have planned the production of soft cottage cheese in small containers, you should think over the packaging design in advance - the product name, logo, container design. Product branding will require significant investments. To minimize costs at the start, it is possible at first to cooperate with customers who are interested in buying cottage cheese by weight.

Raw materials for the production of cottage cheese

The main raw material for the production of cottage cheese is milk. It is advisable to find suppliers at the stage of drawing up a business plan so that in the future there will be no interruptions in the supply of raw materials to production. Collaborate with farms that are geographically closer to the enterprise - delivery costs are reduced. Milk must be accompanied by quality certificates and a certificate from the local veterinary station. Please note that the SES will check the quality of not only the finished product, but also the quality of the raw materials used. Collaborate only with trusted suppliers!

The most profitable in economic terms is the production of cottage cheese on its own raw material base. But opening a farm for a novice entrepreneur is too expensive. It is worth thinking about this a little later - when the enterprise reaches zero.

In addition to milk, you will also have to purchase starters for the production of cottage cheese. Now many companies offer them - choose the product that fits the chosen technology.

How to equip the workshop?

Significant costs will be spent on preparing the cottage cheese workshop for work. Requirements for the organization of space are clearly spelled out in the regulations of the SES and the Fire Inspectorate. Sewerage, electrical wiring, heating, plumbing - these are mandatory conditions! The entire space will be divided into several zones - the acceptance of raw materials, the workshop with equipment itself, warehouses for storing finished products with cooling, laboratories where microbiological control of raw materials and finished cottage cheese will be carried out, service and office premises. It will take at least 200 m 2 of free space.

To save money, look for an empty building on the outskirts of the city - the cost of rent is cheaper. In addition, it will be easier to deliver raw milk here, since farms are located outside the settlement. Great, if you start renting a building that is already prepared for the operation of a food enterprise, then you won’t have to spend money on repairs.

For the manufacture of cottage cheese, a whole technological complex is required. The purchase of equipment is the most significant item of expenditure. To minimize manual labor, pay attention to automatic equipment! The production of cottage cheese in a separate way is carried out using the following machines and devices:

Milk storage tanks.
Pasteurizer.
Tanks for normalization of milk.
Bath for making cottage cheese.
Press trolley.
cooler.
pasteurization bath.
Filling and packaging machine.

To equip the workshop will require at least 2,500,000 rubles. And it will be a low-capacity line - 50 kg/h. Really save if you buy a used line.

To service the production process line, you will need to hire 6-10 employees - a master, a technologist, laboratory assistants, loaders. All employees will be required to undergo a medical examination and safety briefing.

Sales plan for finished products

The production of cottage cheese in the traditional way will only begin to bring consistently high profits when the distribution channels are debugged! Look for interested buyers already at the stage of developing a business plan. Then you can start working already having orders from customers - greatly simplifies the work and does not allow the plant to stand idle.

Who can be a buyer of finished products?

Wholesale bases that sell goods to retail stores.
Retail Stores.
Supermarket chains.
Food enterprises that use cottage cheese as a raw material.
Public catering - cafes, restaurants, canteens.

It is more profitable to cooperate with large wholesalers. But at first, you should not refuse contracts with small grocery stores - now it is important to promote products on the market.

Expenses and income, business development prospects

To start making cottage cheese from milk, impressive costs will be required - at least 3,500,000 rubles. Capital investments will be used to register a business, equip a workshop, and purchase raw materials.

It is rather difficult to calculate the sales proceeds - this will be influenced by the chosen technological scheme for the production of cottage cheese, the capacity of the line, the established price for the products sold, and the cost of purchasing raw materials. As practice shows, all the costs of launching a mini-factory pay off in 2-4 years. As the level of sales grows, you can think about expanding the enterprise - for example, launching a line for the production of other types of fermented milk products (sour cream or yogurt).

Promotion of own products in the consumer market becomes an important task - profit will largely depend on this. If you cooperate with wholesale buyers, then many advertising channels become ineffective - here you need more competently composed commercial offers. But if the release of small-packaged cottage cheese is planned, advertising is definitely needed - TV, radio, Internet, newspapers and magazines.

Many enterprises organize the sale of cottage cheese directly from the factory. A great way to promote your products to the public! But own retail outlets for the sale of the finished product, while the process of production of cottage cheese is not fully debugged, it is not always advisable to open - due to a small product line. But as the enterprise develops, you can think about opening, for example, stalls in local food markets. This is what many food companies do.

The beneficial properties of cottage cheese (the presence of calcium salts, balanced protein, the ability to digest quickly) allowed him to take an important place in the human diet. The production of cottage cheese attracts many businessmen due to its relevance, lack of complexity. Such a business can be developed in different volumes, starting with the smallest ones.

Cottage cheese is a fermented milk protein product (fatty, semi-fat, fat-free) with a delicate taste. It has a positive effect on the gastrointestinal and cardiovascular systems of the body.

It has a number of healing properties:

prevention of atherosclerosis due to the content of methionine and choline;
prevention of liver diseases due to the content of amino acids;
protection against atherosclerosis due to the content of B vitamins;
strengthening of bone tissue due to the content of calcium and phosphorus;
normalization of the nervous system, metabolism.

The organization of production and marketing of products can be established at home. To do this, it is enough to have milk, sour cream, dishes and a small room (it can be a kitchen) available.

The tasks become somewhat more complicated when the business is enlarged. An increase in space, investments, time, documentation is required. But the income also increases accordingly.

Curd manufacturing technology

In the manufacture of the product, it is important to comply with technological standards. The raw material is cow's milk. The production is based on the ability to coagulate the protein under the influence of introduced starter cultures. There are different ways to produce this product.

It is based on fermentation of dairy products by bacteria. The final product is defatted. For the production of this method, good quality milk is used up to 20 degrees Turner (°T).

Degree Turner - the amount of ml 0.1n. sodium hydroxide (or potassium) solution needed to neutralize 100 ml of milk. Turner degrees measure the acidity of milk to evaluate its freshness and naturalness. High-quality milk is characterized by indicators of 16-20 ° T., and a product with higher rates is considered off-grade.

Preparation for fermentation includes the following steps:

Normalization of the fat composition of milk (standard ratio of fat and protein, corresponding to the expected composition of the cottage cheese). Milk is normalized by mixing with a product of a different fat content (skim, cream) or by separation.
The fight against mechanical impurities (particles of feed, bedding, hair). The simplest way is filtration using gauze, synthetic fabric or non-woven material. More reliable is the centrifugal cleaning method by means of separators-milk cleaners.
Pasteurization. It is heating to a temperature of 78 ° C for 30 minutes to get rid of germs.
Cooling to the desired temperature (28-32 degrees).

Fermentation of cottage cheese is carried out in special baths in the following sequence:

the introduction of a special rennet enzyme, necessary for coagulation of milk, as well as calcium chloride for the fermentation process;
actually, the fermentation process;
cutting the clot into cubes along the edge of 2 cm with a wire knife, independent separation of whey;
self-pressing when moving from the bath to the bags;
forced pressing for the final removal of whey;
cooling to stop lactic acid fermentation up to 4-8 degrees in the refrigerator or when using a special cooler;
packaging in bars of different weights, automatic or semi-automatic;
storage in refrigerators until sale.

This method has a number of disadvantages:

the method is based on manual labor;
the process is quite long (up to 12 hours);
a lot of fat is removed from the clot along with the whey;
the method is open, not completely protected from the entry of microorganisms.

By the way the clot is formed, acid methods are distinguished (using lactic acid fermentation), rennet acid (accelerated as a result of the introduction of rennet and calcium chloride).

A clot is an elastic formation of curdled milk.

Production of cottage cheese by the acid-rennet method

The acid-rennet method is based on the formation of a clot of medium and high fat content, which is provided by rennet and lactic acid. With this method, leaven from 1 to 5% is introduced into the cooled mixture. It is made using lactic acid streptococcus. These are bacteria that cause lactic acid fermentation. Sourdough can be made in special microbiological laboratories and biofactories.

Next, rennet or pepsin is added, prepared in about 6 hours in boiled 35-degree water. This enzyme activates the separation of whey from protein components, acting as a catalyst for the production of cottage cheese.

For 3 hours after the start of fermentation, the milk should be stirred at intervals of half an hour. This is necessary to prevent the settling of fat.

Determination of the degree of readiness (break test)

The end of the spatula should be inserted into the clot at an angle, carefully lifted.
Result:

The kink is even, its edges are shiny, a transparent light green serum stands out - the clot is ready.
The fracture is flabby, watery, the serum is cloudy - the clot is not yet ready.

The acidity of the finished clot is 58-60°T. The process takes approximately 6-8 hours. To reduce the fermentation time to 4-5 hours allows increasing the temperature to 35-37 °.

In addition to the curd itself, the clot contains moisture with whey proteins. It accounts for about 70%. To remove it, the clot is divided into parts, for which wire knives are used. The resulting cubes are left for half an hour to remove the remaining whey.

The method was introduced for the first time in Chelyabinsk in 1961. The basis is the production of low-fat cottage cheese, followed by the addition of cream to increase the fat content to the desired percentage (9-18). The method provides accelerated whey separation while reducing losses. All calculations are performed using the developed tables.

The method has many advantages:

Reduced fat loss.
The process is completely mechanized. Special separators are used to separate the curd.
Special production lines have been developed and mechanized, where milk is pasteurized, cooled, fermented for 8-10 hours in containers with mixers.

Acidity with this method reaches 95-100°T. The clot is fed into the heat exchanger, where it undergoes heat treatment. This contributes to the separation of serum, the destruction of microorganisms.

Then, with the help of a pump, the clot is fed into the separator to separate the curd from the existing whey. It is removed, the curd is discharged into the receiver.

Chilled cottage cheese is fed into the mixer for mixing with cream in the required proportions. Further, the cottage cheese is automatically packaged. This is a mild dietary product.

Making thermostatic curd

With the thermostatic method, already fermented milk is poured into packages. The packages are moved to thermostatic chambers, and the whole process of curd preparation takes place inside the package.

The temperature required for ripening is maintained inside the chamber. The cost of the product is reduced, the productivity is correspondingly increased.

How fat-free cottage cheese is made in production

Fat-free cottage cheese is considered to be with a minimum content of fat in its composition: 0.1-1.9%. The technology of its production is based on achieving such percentages. The basis of its production is low-fat milk. Therefore, the separation of milk can become the initial stage of production.

Then one of the methods of fermentation is applied. From skimmed milk, the same product is obtained, in which, if necessary, the necessary amount of cream can be added to achieve the desired percentage of fat content.

How grained cottage cheese is made in production

One type of low-fat cottage cheese is grained. This product is made from curd raw materials with the addition of table salt and cream. There is no heat treatment. Consistency stabilizers (food additives) are not added. After all, they prevent the separation of whey, improving the viscosity of the product, which is not necessary in the case of the manufacture of grain mass.

Technological scheme of cottage cheese production

The curd product is produced in stages:

Storage at temperatures up to 8 ° should not exceed 36 hours.

Documentation of the curd business

Permission to conduct business for the production of cottage cheese is issued by executive authorities (city state administration, district state administration). The following steps are required to set up a business:

The choice of the form of organization of production: LLC, IP. If the scale of the planned production is not large, then it makes sense to choose an IP. Registering it is much cheaper and easier.
Selection of the OKVED code - 15.51.14 "Production of cottage cheese and cheese-curd products".
Room selection.
Obtaining permits from SES and fire inspection. Submit the following documents to these authorities:

on state registration (copy);
on the lease of premises (space);
list of equipment, list of employees;
taxpayer certificate (copy);
production flow chart;
passport for the ventilation system;
disinfection agreement.

The right to production activity is confirmed by a license. To purchase it, you should prepare documents for the State Food and Beverage Industry:

statement;
copies of the requested constituent documents;
receipt of paid state duty.
After studying the production workshops, a permit for production activities is issued for a period of 5 years.
Product certification. It is carried out after the release of the test batch. This document confirms the safety and quality.

Required documents for certification:

statement;
founding documentation;
Contract;
label samples;
veterinary certificate;
registration certificate.

Assistance in certification matters can be provided by a specialized intermediary company.

Products must comply with GOSTs. All manufacturers of curd products in their work must be guided by the adopted "Technical Regulations for Milk and Dairy Products".

SES, fire inspection, other bodies control, including:

sanitary and hygienic regime;
maintenance of equipment, inventory;
medical examinations of employees.

Production control provides monitoring of product quality and safety indicators.

Production of cottage cheese in mini-factories

For effective business development and optimal profit, it is important to rationally use financial investments and use reliable equipment with the involvement of highly qualified personnel. This is feasible when choosing such a form of production as mini-factories. The development of the project will cost about 70 thousand rubles. For the total investment in the mini-factory, approximately 5.5 million rubles will be needed. Given the stability of work, this amount will pay off in at least 2 years.

All-Russian classifier of types of economic activity (OKVED) for the production of cottage cheese and cheese-curd products: 15.51.14. The necessary documents are issued in the fire and sanitary-epidemiological inspection.

Premises for the organization of production

The following requirements are imposed on the premises (leased or owned):

having at least 30 sq. m. area for the main workshop;
the availability of the possibility to create a laboratory with the necessary quality control devices;
mandatory systems: electricity, water supply, sewerage;
equipment for ventilation and heating systems;
implementation of sanitary standards, means for protection against rodents, cockroaches;
tiled wall covering at least 2 meters high;
light color schemes of the walls;
the flooring is waterproof, acid-resistant, non-slippery;
equipping with the necessary technological equipment;
compliance with environmental regulations.

All requirements are covered in SanPiN.

Production staff

For the production of a product at a mini-factory, a staff of 3-4 to 8-10 people is enough.

Approximate required specialties:

workers;
technologist;
laboratory assistant;
accountant;
sales manager.

The need for a particular specialist is determined by the volume of production. A laboratory assistant, for example, is needed to determine the quality of raw materials and finished products, to monitor sanitary and hygienic parameters. All employees undergo training, medical examination, hygiene training.

Curd making equipment

The following set of equipment is required for the production of cottage cheese:

Type of equipment	Purpose
tanks	Milk storage
Separator	Separation of cream from milk
Baths	Fermentation process, pasteurization
Wire knives	Clot cutting
Press trolley	Product pressing
Refrigerators	Cooling of the manufactured product
Filling machine	Dosage, packaging, labeling
Other auxiliary elements	Piping, pumps, coolers…

There are special automated lines that carry out the entire production process. The mechanization of the process allows you to attract a minimum of labor (2-3 people) and, accordingly, save money.

The mini-plant allows for the automation of the technological process, reducing the labor intensity and cost of production.

How to organize the supply of raw materials for the production of cottage cheese

The raw material for cottage cheese is natural milk of high quality and varying degrees of fat content. In the presence of its own raw material base, production efficiency increases. Farmers can become permanent suppliers of milk.

Benefits of working with farmers:

reduction of costs for the delivery of raw materials with the territorial choice of nearby farms for permanent cooperation;
product quality assurance, confirmed by the certificate of the local veterinary station.

The organization of raw materials supply includes:

search for a counterparty - supplier;
conclusion of a supply agreement with him.

The contract must include:

purchase price;
product quality parameters;
frequency, timeliness of deliveries;
conditions for the return of products, deferred payments;
conditions for terminating the contract.

When choosing a supplier, consider the following criteria:

the quality of the supplied raw materials;
comparative analysis of prices;
reputation of the supplier;
optimal location.

Acceptance of raw materials is carried out according to the invoice in the presence of a quality certificate.

To increase production volumes with a decrease in the cost of production, the production of cottage cheese from powdered milk (whole and skimmed) is practiced. This allows you to reduce milk deficiency during the off-season. Appropriate technologies have been developed.

Distribution channels for finished products

In order to have regular buyers of finished products, it is important to take the following steps: advertising the product, improving packaging, packing different volumes, and diversifying the assortment. It is optimal to find wholesale buyers.

Systematic promotions and a system of discounts contribute to the establishment of sales. Effective is cooperation with retail chains (shops, cafes), opening their own outlets.

Business Profitability

The cottage cheese business is always profitable, which is explained by the demand for products. The production of cottage cheese is cost-effective and pays off quickly. However, at the start, financial investments will be required. On average, with an investment of 4.3 million rubles. and the production of cottage cheese in volumes of 90 kg / hour, investments will pay off in 19-25 months. The profitability of production as a whole is 7-10%.

The main advantages of the curd business:

demand for the product in the market;
ease of production technology;
availability of raw materials and equipment;
in case of difficulties in registration, it is possible to attract specialists.

When organizing your own business, it is important to consider the following points:

the need for financial investments at the start;
the importance of establishing contact with suppliers of raw materials and consumers of products;
with large volumes of production, the importance of involving a professional technologist and other specialists in cooperation.

The annual increase in the range of curd products, its demand among the population opens up new niches for business development in this direction: expansion of production volumes, product lines. For example, adding curd mass, curds, creams, cakes. Production of semi-finished products: cheesecakes, dumplings, etc.

Delicious, fresh, airy cottage cheese is always in demand among residents of a large metropolis and a small provincial town. Opening a business for the production of a fermented milk product is not difficult, since the manufacturing technology does not require the use of a large number of ingredients and kitchen utensils. Nowadays, even a small subsidiary farm brings a good income, especially when making products with pleasure.

Features of opening a "curd" business

Before opening your own business, you must register with the Federal Tax Service or its regional representative office as an entrepreneur who wants to establish a business (IP). The newly minted IP will have to conclude agreements with Rospotrebnadzor, Sanitary and Epidemiological Station, and the Fiscal Tax Service. A number of reporting and daily documentation is subject to completion and maintenance, among which the logs of receipt and expenditure of funds and raw materials are of particular importance. Individual entrepreneurs must strictly comply with the clauses of contracts for the removal (disposal) of solid, household and medical waste, as well as in accordance with the instructions that determine the disinfection of a courier car.

For the manufacture of cottage cheese, a minimum set of kitchen utensils is required, which greatly simplifies the production process of the product and reduces its cost by eliminating additional expenses for the purchase of specialized tools. The cottage cheese maker's set is a set consisting of the following devices:

2 pans of various sizes;
skimmers;
1 sieve.

At the same time, one should take into account the fact of cottage cheese production at home according to the simplest recipe, which requires the presence of the 1st pan and gauze. Aluminum pans should be used as opposed to enameled ones for 1 simple reason: milk in enameled pans burns when heated and acquires an unpleasant burnt aftertaste, which negatively affects the taste of the finished product.

Choice of ingredients for making crumbly cheese

Milk is considered the main ingredient in homemade cottage cheese production. Some recipes for making crumbly cheese require the addition of additional ingredients - sour cream or kefir. It should be remembered that all products that make up the cottage cheese must be natural: store-bought pasteurized milk is not suitable in this case. There are no special requirements for the equipment of the premises for the production of cottage cheese. The main thing is that the kitchen is spacious, clean, has enough space and working surfaces of tables and stoves for various technological operations.

Two employees (cooks) need to purchase a health book and undergo a medical examination. If an individual entrepreneur wants to produce not only ordinary, but also low-fat cottage cheese, he should purchase a special filtering apparatus - a milk separator. The principle of operation of the device is called the separation of milk into skimmed emulsion and cream. A production separator separates fermented milk into curd and whey, but such a device is unsuitable at home.

Curd mass preparation technology

As mentioned above, the technology for making homemade cottage cheese contains several recipes. We bring to your attention a couple of simple types, following the step-by-step instructions of which even an inexperienced cook can cook delicious cottage cheese.

Recipe "Minimum"

Milk is taken and poured into an enamel pan in the required volume.
The pan is placed in a warm place for 30 hours. It is not recommended to interfere with milk during the fermentation process, since exposure to the product with a spoon worsens the quality of the formation of curd clots.
After the specified time has elapsed, the container with milk is placed on a slow fire in order to avoid overheating of the liquid, which will adversely affect the process of separating the curd mass from the whey.
It is worthwhile to separate the cottage cheese from the whey using a water bath: a container of milk is placed in a larger saucepan filled with water, the level of which is set at the middle mark of the height of the inner saucepan of a smaller volume.
The temperature of the heated fermented milk is determined by touching the container with your hand. Separated liquids should not be mixed, because action degrades the quality of whey separation from the final cheese product. If the mixture is overheated, the curd will be dry and too crumbly. In the case of bringing the fermented milk emulsion to the optimum heating temperature, the curd product comes out sour in taste and is easily separated from the liquid part.
The heating process is carried out within half an hour.
The pan is removed from the fire, left alone in order to allow the 2-component product to cool until half cooked. The best indicator of separability from whey is dry cheese, cooled for 6-8 hours.
At the end of the cooling period, the clearly visible curd mass is laid out in a colander with a slotted spoon. The second method of separating cottage cheese and liquid is the method of pouring the contents into cheesecloth located above a jar or 2nd pan. One person drains the curd mixture, and the second one tightly holds a piece of gauze, stretching it in both directions.
The cottage cheese obtained in this way is allowed to drain for 1-1.5 hours. If the curd mass was placed in gauze, then the cloth is tied and hung over the sink or bathtub. If homemade cottage cheese is in a colander, then the device is placed on the opening of the pan so that the whey can finally flow out.
It is not worth keeping cottage cheese in gauze or a colander for more than 1.5 hours, because it loses its softness and tenderness of texture, becomes hard and dry.

Quick recipe

In a jar of milk, add a little sour cream or kefir, based on the calculation: 50 gr. to 1 litre.
We put in a warm place for 12-24 hours for ripening.
After the time necessary for the formation of curd clots, we take a jar of curd mass and put it in a larger saucepan (volume and diameter).
Pour water flush with the upper border of yogurt in a jar. We take out the product from the container with water.
Put the pot on the fire and bring the water to a boil.
We turn off the gas after the liquid boils.
We put a jar of fermented milk in hot water for half an hour.
Then we take out the bottle and let it cool for 40-45 minutes.
Pour the contents of the bottle into a colander or 2nd saucepan through cheesecloth.
We tie the gauze in a knot and hang it over the sink or bathtub.
We leave the finished cottage cheese to drain for 1.5 hours. The product is ready.

The IP will have to pay expenses on a monthly basis for the following items:

the increased cost of paying for utilities: the use of gas, electricity;
wages to hired employees: 2 cooks and a courier delivering goods to consumers' addresses;
payment for the cost of a technical device for separating milk sections - a separator;
payment of the cost of travel to the point of sale of finished products - the fair, including payment of the local market fee;
expenses for attracting buyers: release of a commercial on the Internet, on television and radio;
expenses for the purchase of high-quality feed for cows living in the subsidiary farm, especially in the cold season.

Promotion and business profitability

Distribution of finished products should be started by friends and acquaintances, who will make up good advertising for individual entrepreneurs, the so-called "word of mouth". Further, as you attract and accumulate capital, you should apply to create an advertisement in a web studio. It became possible to carry out a marketing campaign to promote goods independently, using the profiles of social networks Facebook, Twitter, Vkontakte, Instagram as an advertising platform.

The profitability of home-made cottage cheese production is quite high. Based on the calculation of the production of 1 kg of curd mass from 3 liters of milk, then when receiving 10-20 liters of milk from cows, 6 kg of cottage cheese can be prepared daily. The cost of 1 kg of a fatty curd product on the market is about 260 rubles, and for a fat one - about 300. Thus, the monthly revenue will reach 45-50 thousand rubles. By-products of the curd craft are also in demand - whey and cream, produced using a separator. The production of homemade crumbly cheese does not create any particular difficulties, and the income is enormous.

This type of business is well suited for people who have their own subsidiary plots. The "curd" business, ideally, leads to an increase in net profit and an increase in one's own well-being.

Anna Goncharuk, [email protected]

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Continuation of Lek #2

Technology of cottage cheese, curd products and sour cream

Cottage cheese is a protein fermented milk product, the main part of which - casein - contains all the essential amino acids. Fat cottage cheese contains almost equal amounts (18% each) of proteins and fat, as well as milk vitamins. Cottage cheese is rich in calcium, phosphorus, magnesium and other valuable minerals. Of the fermentation products of milk sugar, cottage cheese contains lactic acid and aromatic substances that give it a specific sour taste and sour-milk smell. Cottage cheese has as much protein as meat, and its cost is much lower. In addition to direct consumption, cottage cheese is used to prepare various dishes, culinary products and a wide range of curd products. The addition of sugar increases the calorie content of curd products and improves their taste.

Cottage cheese and curd products are produced from pasteurized milk using mesophilic lactic acid bacteria as a starter culture. It should have a clean, delicate sour-milk taste and smell, and a delicate texture. The consistency of cottage cheese depends on the production technology; it can have a layered structure or be a homogeneous homogeneous mass. The fat content in fat cottage cheese is not less than 18%, in bold - not less than 9%; humidity of fat - no more than 65%, bold - 73, non-fat - 80%. Acidity of cottage cheese of fatty premium - 200, grade I - 225 ° T; bold premium -210, I grade - 240 ° T; low-fat cottage cheese of the highest grade - 220 and grade I - 270 ° T.

There are two ways production of fat and semi-fat cottage cheese: regular - from normalized milk and separate - from skimmed milk, followed by enrichment of skimmed cottage cheese with cream. Below is a technological scheme for the production of cottage cheese.

Separate way has a number of advantages. Significantly reduced fat loss in production; saving fat per 1 ton of fat cottage cheese is 13.2, bold - 14.2 kg. The separation of whey from the clot is facilitated, a great opportunity is created for the mechanization of technological operations and, consequently, an increase in labor productivity. Finally, an important advantage of the separate method for the production of cottage cheese is the improvement in the quality of the product as a result of reducing the acidity: the addition of fresh pasteurized cream to low-fat cottage cheese reduces its acidity, and at the same time, chilled cream reduces the temperature of the curd, which prevents a further increase in the acidity of the finished product.

The listed advantages of the separate method make it economically more profitable, despite the need for additional operations (separation of milk and mixing of fat-free cottage cheese with cream).

Normalization of milk by fat and protein titer. It is produced only when producing fatty cottage cheese from whole milk, with a separate method, this operation is replaced by milk separation and subsequent mixing of the resulting cream with low-fat cottage cheese.

Milk pasteurization. Pasteurization temperature 72-74°C, exposure 20 s. In this mode, whey proteins do not undergo noticeable thermal denaturation and completely pass into whey when curd is produced.

Pasteurization at a temperature of 78-80°C with a holding time of 20-30 seconds increases the reliability of pasteurization of milk and curd obtained from it and slightly increases the yield of the product due to heat-labile whey proteins coagulating at this temperature.

Fermentation of milk. Starter from pure cultures of mesophilic streptococci in the cold season is introduced into milk at a temperature of 30-32°C (calculated for possible cooling), and in the warm season - at 28-30°C. With the accelerated fermentation method, when a mixture of cultures of mesophilic and thermophilic streptococci is used, the milk temperatures are set to 38 and 35 ° C, respectively.

The use of streptococcal sourdough in the production of cottage cheese is based on the fact that its acid-forming ability guarantees the production of a finished product with acidity within the requirements for a premium product, i.e. not more than 200°T. Excessive acidity reduces the quality of cottage cheese, it is transferred to grade I or becomes non-standard.

However, despite the use of only streptococcal starter, heat-resistant lactic acid bacilli are found in the finished product. They are constantly present in cottage cheese and just cause the most common defect of fresh cottage cheese - excessive acidity. The source of contamination of cottage cheese with lactic acid sticks is the transfer sourdough.

To eliminate the cause causing the appearance of this defect, it is recommended that during fermentation, not 5% (to the volume of milk) of secondary, but 2% of primary streptococcal ferment, be introduced into milk. In this case, during the entire process of curd production, lactic streptococci (1.4-2 billion/g) prevail in fermented milk and clot, and the number of heat-resistant sticks barely reaches 30 million/g and cannot significantly (beyond the norms of the highest grade ) increase the acidity of the curd.

To improve the quality of cottage cheese, it is also proposed to use directly laboratory starter (prepared with sterilized milk) in an amount of only 0.8%. At the same time, there is no significant slowdown in the fermentation process, but a high-quality product is guaranteed.

With rennet-acid method for the production of cottage cheese, in addition to bacterial starter culture, rennet is added to milk at the rate of 1 g/t of milk. Rennet reduces the acidity of the clot, increases its density by the time of processing. Simultaneously with rennet, a 40% solution of calcium chloride (500 g of anhydrous salt per 1 ton of milk) is added to fermented milk. After the addition of rennet and calcium chloride, the milk is left alone until complete fermentation.

Fermentation of milk. In fermented milk, as a result of the vital activity of lactic acid microorganisms, an increase in acidity occurs. The chemistry of the effect of lactic acid on the caseinate-calcium phosphate complex of milk in the process of fermentation of milk during the production of cottage cheese is similar to that described earlier in the technology of fermented milk products. But in the manufacture of cottage cheese, the introduced rennet also acts in parallel, so there is a joint acid and rennet coagulation of casein. Partial conversion of casein to paracasein under the influence of rennet essentially precedes acid coagulation. Since casein shifts its isoelectric point from pH 4.6 to 5.2 upon conversion to paracasein, clot formation occurs at a lower titratable acidity than with pure acid precipitation, which ultimately leads to a lower acidity of the resulting curd. In addition, calcium bridges formed between paracasein particles are involved in the formation of the clot structure during the rennet-acid precipitation method, as occurs during rennet coagulation in the production of rennet cheeses. The presence of calcium bridges, strengthening the structure of the clot, leads to the formation of a denser clot, which in turn prevents it from being sprayed during mechanical crushing, to a certain extent favorably affecting the increase in the yield of curd.

With the rennet-acid method of producing cottage cheese, the fermentation process lasts 4-6 hours from the moment the starter is added to milk, with the accelerated method using active acid-forming starter - 3-4 hours, and with preliminary acidification of milk with whey - 3-3.5 hours. Acidity milk in the production of fatty and semi-fat cottage cheese reaches 66-70, low-fat - 58-60 ° T. The end of milk fermentation is determined by the break test and by the type of whey released from the clot. If, when separating the clot with a spoon or spatula, even fracture edges with shiny smooth surfaces are formed, then the clot is ready for further processing. The serum that stands out at the fracture site should be transparent, light green in color.

Clot processing. It is very important to correctly determine the end of fermentation of milk before starting processing. When processing an insufficiently fermented clot, the loss of cottage cheese increases, since part of it in the form of “dust” passes into whey. From the fermented clot, a sour curd of a smearing consistency is obtained. With proper fermentation of milk, a clot is formed in the form of a dense gel that spontaneously releases whey (the process of syneresis). Cutting the clot, increasing its surface, accelerates the release of serum.

The finished clot is cut with wire knives into cubes about 2 cm in size along the edge; first cut along the length of the bath into horizontal layers, then along the length and width into vertical ones. The clot cut in this way is left alone for 1 hour for an increase in acidity, which contributes to the most complete release of whey.

Separation of whey from clot. It is known that in the isoelectric state, protein substances have a minimum of solubility and a minimum of swelling. Spontaneous separation of whey from the clot in the process of syneresis most actively occurs at pH 4.6-4.7, i.e., at the isoelectric point of casein, and for paracasein (with rennet coagulation) at pH 5.0-5.2. With the mixed rennet-acid method for the production of cottage cheese, the isoelectric point of the clot is shifted towards paracasein and the optimal pH value is about 4.7-5.0.

When the serum that is freely released as a result of syneresis is removed, part of it is retained in the clot. For the final separation of the whey from the clot and obtaining cottage cheese with a standard moisture content, self-pressing is used, and then forced pressing. Self-pressing of the clot, laid out from the bath into bags made of synthetic fabric (lavsan), calico or gauze, is carried out on press trolleys, which also have a device for forced pressing. Self-pressing continues for at least 1 hour, while the bags with cottage cheese are shifted. The room temperature should not exceed 160C. After self-pressing, the bags with the product for the final pressing of the curd are evenly laid out along the bottom of the press trolley and covered with a metal perforated plate, which takes pressure from the press screw through a special frame.

This method is the simplest, but also the most laborious. Currently, curd makers with a pressing bath are mainly used.

The cottage cheese maker (Fig. 1) is intended for fermenting milk, obtaining a curd clot, cutting it, removing free-separated whey and final pressing the curd mass. It consists of double-walled bathtubs with a crane for the release of whey and a hatch for unloading the curd. A pressing bath with perforated walls is mounted above the curd bath, on which a filter cloth is put on; inside this bath there is a pipe for pumping out whey.

Milk is poured into a fermentation bath, leaven and enzyme are added. The resulting curd clot is cut, as mentioned above, and after a while, part of the released whey is drained using a sampler lowered into the bath. At the end of the whey drain, the sampler is removed and the hydraulic drive is turned on, lowering the pressing bath down at a speed of 2-4 mm/min.

In this case, the whey passes through the filter cloth and perforated lining into the bath, from where it is periodically pumped out by a pump. At the end of the process, the pressing bath is lifted, the hatch is opened and the curd is unloaded into the trolley.

The use of curd makers with a pressing bath, in comparison with the usual method of pressing in bags, gives a great economic effect: labor costs are reduced, the process is mechanized, and the need for production space and filter material is reduced. All this ultimately increases labor productivity and reduces the cost of the product.

Recently, continuous production of cottage cheese has been mastered by separating fermented milk on a special cottage cheese separator (Fig. 2). The working part of the separator is a drum with a set of conical plates (52 pieces). The drum is covered with a protective spherical casing, which rests through an intermediate casing on an annular bowl, which serves to catch curd ejected from nozzles with a diameter of 0.5 to 0.7 mm. The drum rotates at a speed of 5500 rpm.

Hydrogen" href="/text/category/vodorod/" rel="bookmark">hydrogen ions, which should not exceed 4.50.

Previously, it was indicated that the most favorable conditions for separating whey from a clot occur at a pH value close to the isoelectric point of casein, when the most complete connection and compaction of its particles occurs. When separating fermented milk, sediment particles that are in an electrically neutral state, under the influence of centrifugal forces, can form a mass of dense consistency in the peripheral part of the drum, which will not be ejected through the separator nozzles, and the nozzles will inevitably clog quickly. To avoid this, it is necessary to cross the boundary of the isoelectric state of casein in the direction of a more acidic reaction during fermentation. It has been experimentally established that the serum should have a pH in the range of 4.5-4.3.

In this case, the casein particles, the size of which is calibrated with a mesh filter (Fig. 3), begin to acquire a positive charge, i.e., opposite to the charge of casein particles in fresh milk. Like-charged particles, when in contact with each other, do not form a dense mass and therefore are easily removed from the separator drum without clogging the nozzles.

Curd cooling. Pressed cottage cheese must be immediately cooled to 3-8 ° C in order to stop lactic acid fermentation with an increase in excessive acidity. Cooling, depending on the type of technological equipment used for the production of cottage cheese, is carried out by various methods.

With the method of laying the curd into bags, pressing can be combined with cooling by placing the press trolleys in a cold store. For this, a special press cooler is also used, which is a tubular drum into which bags with curd mass are loaded and chilled brine is passed through the pipes; when the drum rotates slowly, the bags move, the whey is separated and the curd is cooled simultaneously.

When using a curd maker with a pressing bath, cooling of the curd is combined with pressing: for this, a coolant is passed into the interwall space of the bath. The finished curd is cooled in a refrigerator or on a special cylindrical cooler. In the cooler designed by Loktyukhov, a brine with a temperature of -7°C circulates inside the cylinder. On the surface of the cylinder on one side through a gap of 0.4-0.5 mm, a thin layer of cottage cheese is applied with a roller; on the opposite side of the cylinder, the cooled layer of cottage cheese is cut off with a knife from the surface and falls into the trolley, in which it is fed for packaging.

One- and two-cylinder curd coolers OTV-500 and OTD-650 are more perfect (Fig. 4).

The cooled cottage cheese is continuously removed by knives from the surface of the cylinder and, moved by two screw turns of the drum, enters through an opening in the cylinder cover. Brine circulates in the cylinder jacket through a spiral channel.

The curd cooled from 28 to 10°C is supplied for packaging.

Packing, packaging and storage of cottage cheese. Fatty, semi-fat and low-fat cottage cheese for retail sale is packaged in bars weighing 250, 500 and 1000 g. The temperature of the cottage cheese sent for small packaging should not exceed 6 ° C. It is packaged on OFZ machines (Fig. 5) and semi-automatic filling machines with forming nozzles. Curd bars wrapped in parchment or colorless cellophane are placed in cardboard or wooden boxes. Packaged cottage cheese is cooled and stored until sale in refrigerators at a temperature of about zero, but not higher than 4 ° C.

It should be borne in mind that at the indicated storage temperature, the quality of cottage cheese decreases due to enzymatic processes, further breakdown of lactose and protein substances. As you know, the activity of enzymes does not stop even at low positive temperatures. Therefore, cottage cheese after two to three days of storage at 4-6 ° C is transferred from the highest grade to the first; with prolonged storage, its quality deteriorates even more.

For long-term storage and reservation of summer cottage cheese, it is frozen. The reversibility of this process is most complete if freezing is carried out at low temperatures. Under these conditions, the water in the curd freezes in the form of small crystals without disturbing its structure. In contrast, slow freezing is accompanied by a redistribution of moisture in the curd with the formation of large crystals. When frozen curd is defrosted, its original consistency and structure are restored. Moreover, some shortcomings in the consistency of cottage cheese (for example, graininess) are eliminated during defrosting. This is due to the fact that small ice crystals formed during freezing inside the grains of cottage cheese destroy them, a fine-grained structure is created, which tastes like a homogeneous mass.

Cottage cheese in small packages (0.5 kg) and in blocks (10 kg) is frozen in freezers at a temperature of ° C or in quick freezers.

Grain curd. We have been producing this kind of curd on an industrial scale since 1965. Cottage cheese with cream has a grainy structure and a pleasant sour-milk taste. 100 g of grained cottage cheese contains 16-20 g of protein, 6 g of fat, 0.8-2.0 g of minerals and other substances.

Rice. 6. Technological scheme for the production of cottage cheese with cream:

1- tank for milk; 2- centrifugal pump; 3 - balancing tank; 4- pump of the pasteurization plant; 5 - pasteurization unit; 6 - cream separator; 7-tank for collecting cream; 8-pump for supplying cream to the homogenizer; 9- homogenizer; 10- pasteurizer for cream; 11 - tank for aging and storage of cream; 12 - cream supply pump to the dosing machine; 13 - bath with stirrer; 14 - pump for supplying grain for drying; 15 - vibrating unit for drying grain; 16 - carts; 17 - trolley lift; 18 - grain and cream dosing machine; 19 - starter for mother starter; 20 - installation for industrial leaven; 21 - pump for feeding the starter into the bath; 22 - centrifugal pump for water supply; 23 - tank for water preparation; 24 - cooling unit.

Due to the fact that cream, as in the separate method of producing cottage cheese, is added to a low-fat product, it concentrates on the surface of the grains, and this product tastes like high-fat cottage cheese. The process flow diagram is shown in fig. 6. Fresh conditioned milk is pasteurized in a plate installation at 72-74°C with a holding time of 18-20 s and separated. In skimmed milk, leaven is introduced in an amount of up to 5%, consisting of homofermentative lactic streptococci and aroma-forming cultures. At the same time, rennet is added at the rate of 0.5-1.0 g and calcium chloride solution at the rate of 400 g per 1 ton of milk. Two modes of fermentation are used: short-term and long-term. In short-term mode, the fermentation temperature is 30-32°C, the duration of the process is 6-8 hours; with prolonged, respectively, 21-23 ° C and 12-18 hours.

The readiness of the clot is determined by the increase in the acidity of the whey. The clot should be strong with smooth edges at the break, the serum is separated in the form of a clear greenish liquid.

The finished clot is cut with wire knives into cubes 12-13 mm in size along the edge (first cut lengthwise into horizontal layers, then across the width into vertical ones), after which it is left alone for 20-30 minutes to isolate the serum and compact the clot. Then, water at a temperature of 46-48°C is added to the bath in such an amount as to increase the content level in the bath by 50-60 mm. Water raises the temperature of the clot by 2-3°C, reduces the acidity of whey from 40-42 to 36-38°T. After adding water, the grain is thoroughly mixed and gradually heated by introducing hot water into the interstitial space of the cheese bath; the temperature of the contents in the bath should rise by 1° for every 10 minutes and reach 33°C.

Subsequent heating to 48-55°C should be carried out faster so that the temperature rises by 1° for every 2 minutes. Upon reaching the specified temperature, the grain is kneaded for an hour to compact. The finished grain, pre-cooled with tap water, should retain its shape when lightly squeezed in the hand. Then the whey is removed and proceed to washing and simultaneous cooling of the grain. First, water at a temperature of 16-17°C is added to the grain, it is stirred for 15-20 minutes, then the water is drained; for the second washing, add water at a temperature of 2-4°C, keep the grain in the water for the same time, after which it is drained.

The washed grain is left in the bath for 1-2 hours, and then transferred to carts with a perforated bottom, in which it is placed for 10-12 hours in a refrigerator at an air temperature not higher than 5-10°C. Cream with a fat content of 20-30% and an acidity of not more than 17°T is added to the dried grain. The cream is pre-pasteurized at 33-35°C for 20-30 minutes, then cooled to 26-30°C, homogenized at a pressure of 12.5-15.0 MPa, finally cooled to 2-4°C. Salted cream is added to the total mass of the grain or in portions, into each cup during packaging.

Cottage cheese with cream is packaged in small containers - polymer cups with a capacity of 200, 250 and 500 g and in large stainless steel containers or 20 kg cardboard boxes with a paper lining covered with a polymer film.

Store grained cottage cheese at room temperature (16-20°C) should be no more than a day, and at 8-10°C - no more than 6 days. The storage stability of grained cottage cheese is somewhat lower than that of ordinary cottage cheese due to the fact that lactic acid, which, as you know, has a preservative property and counteracts the development of putrefactive processes, is removed from the first one by thorough washing.

When stored both at room conditions and in the refrigerator, yeast can intensively develop in cottage cheese. Long-term storage of grained cottage cheese is possible only in brine (10% NaCl) at 6-8°C for 5 months without a significant change in organoleptic properties.

curd products

From cottage cheese with the addition of sugar, salt, flavoring and aromatic substances (cocoa, coffee, candied fruits, dried fruits, raisins, cumin, dill, etc.) they produce curds, curd mass, cakes, creams, as well as semi-finished products - dumplings, cheesecakes, dough for cheesecakes, etc., for which wheat flour, chicken eggs, starch and other products are used as additional raw materials.

The commodity classification of curd products divides them into four groups - with a high fat content (20-26%), fatty (15%), bold (up to 8%) and fat-free; according to flavoring additives - sweet with sugar content from 13 to 26% and salty with salt content - from 1.5 to 2.5%. Curd curds and curd mass of these types can be produced with and without the addition of flavoring substances. The number of individual components that make up curd products is regulated by the recipe for certain types of these products and the requirements of the RTU.

The technological process for the production of curd products consists in preliminary grinding of curd on roller machines (Fig. 7) to obtain a homogeneous curd mass and its subsequent mixing in kneaders with the rest of the ingredients. The duration of mixing depends on the design and capacity of the machine, the speed of rotation of the agitator, as well as the temperature and consistency of the incoming components.

Upon completion of processing, the resulting mass is cooled in a cylindrical cooler or in refrigerators to a temperature not exceeding 6 ° C and then sent for packaging.

Pack curd products, with the exception of glazed curds, cakes, creams, in parchment or polymer packaging materials; glazed cheese curds - in aluminum or tin foil with a wrapping label; cottage cheese cakes - in cardboard boxes, the bottom of which is pre-lined with parchment with patterns on the edges. Curd creams are packaged in cups or tubes made of polystyrene or other polymeric materials approved for food packaging.

Rice. 7. Roller machine:

1- conveyor bunker; 2 - auger; 3 - receiving hopper; 4 - steering wheel for regulating the gap of the rolls; 5 - rolls; 6 - bed support.

Finished curd products must meet the requirements of the current RTU for acidity, fat, sugar and salt content, have a clean, sour-milk taste and smell, with a pronounced taste and aroma of added flavoring and aromatic substances, a homogeneous, tender, moderately dense texture, white color, with a cream shade or due to the addition of flavoring substances, such as cocoa, chocolate, uniform throughout the mass.

Of the most common taste defects of cottage cheese and curd products, one should name an overly sour taste that occurs when excess lactic acid accumulates, a yeast taste, especially in sweet curd mass and cheese curds, that appears as a result of alcoholic fermentation caused by yeast. Bitterness in the product is the result of contamination of the product with putrefactive bacteria. The acetic acid taste and smell are caused by the development of acetic acid bacteria. The breakdown of fatty substances under the influence of both putrefactive bacteria and molds also leads to the appearance of taste defects.

Of the defects in the consistency, graininess is most common, indicating a violation of the technology for the production and processing of cottage cheese.

In all cases, in order to prevent the appearance of defects in the product, it is necessary to maintain a high sanitary culture of the starter production and the technological process.

Pastes "Health" and acidophilic

Milk-protein paste "Health" is produced from pasteurized skimmed milk by fermenting it with sourdough prepared on pure cultures of lactic acid bacteria and adding cream, sugar, fruit and berry syrups, vitamin C (in the form of rosehip syrup) and salt. The product is intended for direct consumption as a highly nutritious protein concentrate or as a seasoning for dishes. It has a pure sour-milk taste with a pronounced aroma of added flavoring substances and is reminiscent of thick sour cream in consistency.

Pasta "Health" is produced in several types: 5% fat, low-fat and with fillers - salty (salt 0.2%) and sweet (sugar 10-13%); moisture content from 75 to 85%, depending on the type of pasta.

The technological process is as follows. Skimmed milk is pasteurized at a temperature of 80°C with a holding time of 20-30 seconds. Then it is cooled to a fermentation temperature of 36-38°C and 5-8% of the ferment prepared on a mixture of cultures of thermophilic and mesophilic races of lactic streptococci in a ratio of 1:1 is added. Fermentation is carried out to an acidity of 80-85°T for 10-12 hours. The finished clot is cut into cubes about 2 cm in size along the edge. The cut clot is left alone for 40-50 minutes.

The removal of whey and the pressing of the clot is carried out in the same way as in the production of cottage cheese.

To obtain a homogeneous consistency, the milk-protein base is passed through a colloid mill, and then syrup, cream, sugar or salt are added to it, depending on the type of paste. The finished product is packaged in various containers: wide-mouthed glass jars, bottles or containers made of polymeric materials.

Packaged products are cooled to a temperature not exceeding 8°C and stored for no more than 36 hours.

For the production of Zdorovye pasta, VNIMI has developed a production line, completed mainly from technological equipment used for the production of cottage cheese.

acidophilus paste- a therapeutic fermented milk product - is not only a protein, but also a bacterial concentrate of acidophilus bacilli. Pasta is produced from whole and skimmed milk, using pure cultures of acidophilus bacillus as a starter. Sugar and fruit and berry syrups are added to the paste.

They produce sweet acidophilic paste of 8 and 4% fat and non-fat.

Acidophilus paste is intended for direct consumption in food. In addition, it is recommended to use it as a therapeutic product for a number of gastrointestinal diseases.

Pasta can be made in two ways: by pressing the clot obtained by fermenting milk, and from pre-condensed milk, as shown in the diagram below.

Conditioned whole milk is normalized to a fat content of 2.3% for a 4% paste and to 3.4% for a paste with a fat content of 8%. Milk (normalized, skimmed) is pasteurized in pasteurization plants at a temperature of 85-90°C with exposure in baths for 15 minutes, and then cooled in the same baths to the fermentation temperature (40-42°C).

In the production of paste from pre-condensed milk, pasteurized milk is sent to a vacuum apparatus. Milk is thickened in the shortest possible time at a temperature of 50-55°C, increasing it at the end of thickening to 55-60°C. The content of solids in condensed milk normalized for fat must be at least 29% and in skimmed condensed milk at least 23%. Condensed milk is cooled to the fermentation temperature (38-40°C).

The milk is fermented with a starter prepared on an acidophilus stick, taken in an amount of 5% by weight of the milk. Fermented milk is thoroughly mixed; fermentation is carried out until a dense clot is obtained. The acidity of the clot from fat-normalized milk should be in the range of 80-90°T and from condensed milk 180-200°T.

The clot is laid out in calico or lavsan bags with a capacity of 12-14 liters for self-pressing at a temperature of 6-8°C, and then pressed (in press trolleys, curd presses) to the required humidity.

Sugar syrup with a concentration of 66% is added to the pressed and condensed paste and mixed in a kneader until a homogeneous consistency is obtained.

The paste is packaged in glass jars or containers made of polymeric materials and sent to a refrigerator for cooling to 8°C.

The finished product should have a taste and smell of pure sour milk, for condensed milk paste - with a flavor characteristic of condensed milk, a delicate, pasty, homogeneous texture. Moisture content in sweet paste 8% fat 60%, 4% fat 65%, low fat 80%; sugar content respectively 24, 20 and 12%. Acidity in all cases is not more than 200°T. It is not allowed to contain pathogenic microorganisms in the acidophilic paste; the titer of Escherichia coli should be at least 0.3 ml.

Sour cream

Sour cream is a national Russian fermented milk product containing 20, 25, 30 and 36% fat. In dietary sour cream fat 10, amateur 40%.

The technological process of sour cream production consists of the following operations: separation of milk and production of cream, normalization of cream for fat, pasteurization, homogenization, cooling of cream to the fermentation temperature, introduction of ferment, fermentation of cream, cooling and ripening of sour cream, packaging and storage of the finished product.

Milk is separated at 40-45°C to obtain cream with a fat content of at least 32%; the cream is finally normalized in terms of fat to 31.6%, based on the production after adding the starter in the amount of 5% of the finished product with a fat content of 30%. When developing a product with a 36% fat content, the cream is normalized to 37.9%. A corresponding calculation is also made for other fat contents of sour cream. Cream is pasteurized at 85-95°C with a holding time of 15-20 s.

Cream is recommended to be homogenized at a temperature of 50-70°C and a pressure of 7.0-8.0 MPa. Sour cream from homogenized cream has a denser consistency, as well as fermented milk drinks produced by a tank method using milk homogenization.

After homogenization, the cream is immediately cooled on a plate or tubular cooler to the fermentation temperature (in the warm season 18, and in the cold 22°C). Pure cultures of mesophilic streptococci (Str. lactis, Str. cremoris) and flavoring agents (Str. diacetilactis) are used as starter cultures. The amount of starter introduced significantly affects the duration of fermentation.

The fermentation of cream, depending on the temperature, lasts 14-16 hours. In the first 3 hours, the cream is stirred every hour, and then they are left alone until the end of fermentation. The end of fermentation is determined by the increase in acidity to 65-75°T in summer and 80-85°T in winter.

Freshly prepared sour cream can be packaged in small or large containers; in the same container cooling and ripening of sour cream is carried out. For cooling and ripening, large containers are also used - VDP baths, double-walled tanks, in this case ready-made sour cream is packaged. In any case, cooling is combined with the ripening of sour cream, which continues at 5–8°C for 24–48 hours. h. With the rapid cooling of fermented cream to 5-6 ° C, the ripening process can be reduced to 6-8 hours.

The essence of the ripening process during cooling of sour cream is the crystallization of milk fat glycerides, the hardening of the shells of fat globules and the joint acid coagulation of casein and heat-labile plasma whey proteins denatured during high-temperature pasteurization of cream. These are the main processes of structure formation of sour cream, which proceeds in time.

The fat phase of sour cream is more than 4/3 by volume, its physical state associated with crystallization, hardening and the formation of polymorphic structures is crucial for the consistency of sour cream. So, according to Tverdokhleb, preliminary deep cooling of cream to 2-6°C before fermentation and holding for 2-3 hours make it possible to achieve a high degree of solidification of fat and the formation of metastable forms of glyceride crystals, as occurs during the physical maturation of cream in the butter industry. This kind of cream processing improves the consistency of sour cream and reduces the ripening time.

In the consistency of sour cream, in addition to the hardening of milk fat glycerides during cooling and maturation, it is also reflected in the degree of dispersion of fatty particles. On the developed surface of the shells of fatty particles, especially after homogenization, protein substances are included in structure formation. With an acid reaction of the medium, i.e., at a pH below 4.6-4.7, casein again acquires a charge (opposite), colloidal dissolution and violation of the gel structure, liquefaction of the clot occurs. In this case, sour cream acquires a liquid consistency, which increases as the pH shifts from the isoelectric point, which is observed when sour cream is over fermented.

The consistency of sour cream, in addition, is greatly influenced by the concentration of proteins in the plasma of sour cream, which depends on the content of casein in the original milk. An increase in the content of casein even by tenths of a percent can have a significant effect on the consistency of sour cream, all other things being equal.

Denatured whey proteins may also be involved in the formation of the protein stroma during acid coagulation of casein. During the coagulation of protein substances, the resulting structures do not have sufficiently strong bonds, therefore, any mechanical effect both at the time of formation of the structure, and especially at the final stage of its completion, should be minimized.

Sour cream should be stored until sale in a refrigerator at a temperature not exceeding 2-40C and a relative humidity of 75-80%.

Sour cream sent for sale must comply with the requirements of the current RTU: taste and smell for the highest grade is pure sour-milk without foreign tastes and odors; for the first grade, slightly pronounced aftertastes of fodder, melted butter, containers (wood), the presence of slight bitterness are allowed; the consistency of sour cream of the highest grade is homogeneous, moderately thick without grains of fat and protein (cottage cheese), for the first grade it is allowed not thick enough, slightly lumpy, with grains and slight ductility. Acidity for the highest grade is 65-90, for the first grade 65-110°T.

The range of sour cream includes two more varieties - "Dietary" and "Amateur".

Features of the production technology of dietary sour cream are as follows. Fermented with a special starter of lactic acid bacteria capable of synthesizing vitamin B, pasteurized and homogenized cream with a fat content of 10% is poured into wide-mouthed glass bottles and glasses or into plastic glasses and then fermented in thermostats at 28 ° C to an acidity of 65-70 ° T, after which the sour cream is cooled in a refrigerator at a temperature of 5-6°C and kept for maturation for 12-16 hours. Sour cream cooling is completed when its temperature drops to 8°C, after which it is sent for sale.

For the production of amateur sour cream, the initial cream is obtained with a fat content of at least 44.5%, followed by a decrease in its sourdough to 40%. The cream is pasteurized at 87°C with a holding time of 20 minutes or at 92-99°C with a holding time of 10-20 minutes, which gives the sour cream a specific, so-called "nutty" flavor. Pasteurized cream homogenized at 50°C and a pressure of 10 MPa. Sourdough for amateur sour cream from strains of mesophilic and thermophilic races in a ratio of 1: 1 is introduced in an amount of up to 10% by weight of cream at 45-50°C. Upon reaching the required acidity (not lower than 55°T), the sour cream is cooled on a cylindrical cooler for cottage cheese to 4-6°C and packaged on automatic machines with packing of briquettes weighing 100 g in parchment or other material. Briquettes of sour cream packed in cardboard boxes are placed in refrigerators with a temperature of 0-6 ° C and kept for maturation for at least 6-12 hours. The finished product has a dense, uniform texture, retains the shape of a given briquette, the taste is pure sour-milk with a pronounced taste of pasteurized cream.