How fat-free cottage cheese is made in production. Technological line for the production of cottage cheese

In this article:

Cottage cheese has firmly taken pride of place in the diet of every person, its demand is due to the presence of a mass of useful properties. This business plan discusses the organization of the production of medium-fat cottage cheese using the example of a mini-factory. Strict observance of technological standards in the production process contributes to the manufacture of tasty and high-quality products.

Thus, in the case of the rational use of funds, the acquisition of reliable equipment and the selection of qualified personnel, the business has every chance to develop effectively and bring monthly profit to its owner.

Organization of curd business

After choosing the form of economic activity (LLC or sole proprietorship), it is necessary to obtain permission to conduct business from the executive authority.

Wherein OKVED code will be as follows: 15.51.14 - production of cottage cheese and curd cheese products.

Then the relevant documents must be issued by the sanitary and epidemiological station and the fire inspection.

It is necessary to locate production facilities in your own or rented building, which must meet the following requirements:

• availability of running water, electricity and sewerage;
• the area of ​​the main workshop should be at least 30 square meters;
• lining the walls with tiles more than 2 meters high;
• waterproof, non-slip and acid-resistant floors;
• light colors of the walls of household, auxiliary and storage rooms;
• ventilation, availability of means of protection against rodents and cockroaches;
• opportunity to equip your own laboratory.

Licensing

It is necessary to obtain a license that gives the right to carry out production activities.

To do this, a certain package of documents should be submitted to the licensing authority (Gospishcheprom), consisting of an application of the established form, copies of constituent documents and a receipt for payment of the state duty. After examining the future production workshop, a permit is issued in the form of an act, the validity of which is at least 5 years.

Certification

After the launch of the mini-factory and the production of the first batch of cottage cheese, it will be necessary to certify the products without fail.

The document will confirm the proper quality and safety of products. It is also necessary to be prepared for systematic visits by representatives of the sanitary and epidemiological station, who very often examine samples of bacteriological washings of equipment and walls. Therefore, certificates of the condition of the cows from which milk is supplied should be available.

Standards

Cottage cheese must meet established standards, namely:

• GOST R 52096-2003 - cottage cheese;
• GOST R 52096-2003 - the shelf life of cottage cheese.

It is advisable to carry out proper quality control of the supplied raw materials in our own production laboratory, which has modern control devices.

The cost of maintaining it will more than pay off in the near future, since high-quality raw materials facilitate the technological process and guarantee high consumer properties of the finished product. In this regard, the development and approval of its own specifications will be especially effective for the production of products that will be in demand among consumers.

Features of cottage cheese production technology

Methods for the production of cottage cheese

Depending on the method of formation of a clot during the production cycle, the following methods for the production of cottage cheese are distinguished: acid and rennet.

The first method is used to produce low-fat cottage cheese and a low-fat product, during which acid coagulation of proteins occurs through fermentation of milk by bacteria. A distinctive feature of the finished product, which is made in this way, is a delicate texture, since the spatial structure of the clots is not very strong.

With the rennet-acid method, the clot is formed due to the direct influence of rennet, as well as lactic acid. In this way, cottage cheese of high and medium fat content is obtained.

Consider the production of cottage cheese in the traditional way

Feedstock- benign fresh and skimmed milk, which is sent for pasteurization (temperature 79-80°C). Such a temperature regime has a direct impact on the properties of the clot, on which the quality and yield of the finished product depend. For comparison, at a low pasteurization temperature, the clot will turn out to be not dense enough, because almost all proteins go into whey, and the yield of cottage cheese is significantly reduced. Thus, by adjusting the modes of pasteurization, clot processing and selecting variants of rennet starter cultures, it is possible to obtain clots with the necessary moisture-retaining characteristics.

A distinctive feature of the production of cottage cheese in a separate way is the addition of pasteurized cream, due to which the fat content of the finished product increases several times.

The technological process of cottage cheese production consists of the following stages:

Raw material preparation

Milk is subjected to purification on separators-milk cleaners (Fig. 5) and heated to a temperature of 37°C. Filtration through gauze (at least 3 layers) is also allowed. In the process of making fatty or semi-fat cottage cheese, milk is subject to pasteurization at a temperature of 80 ° C in plate (tubular) pasteurization and cooling units.

Milk cooling

Then the milk must be cooled to the fermentation temperature (about 30°C). To obtain sour-milk curd, an acid is required, which is formed by a biochemical method, namely due to the influence of a culture of microorganisms.

Leaven

Such a starter is prepared on pure cultures of mesophilic, thermophilic or lactic streptococci. Before adding it directly, the surface layer must be carefully removed with a clean and thoroughly disinfected bucket.

After that, the starter is added, which has the appearance of a homogeneous consistency (no more than 5% of the total volume). If there is a need for accelerated fermentation, then a combined ferment is added to the milk: 2.5% based on mesophilic streptococci, and 2.5% from thermophilic streptococci. The average duration of milk fermentation is 10 hours, and with accelerated fermentation - no more than 6 hours.

It is important to note that as a result of the pasteurization and sterilization processes, the amount of calcium in milk inevitably decreases (up to 50%), which in turn leads to a deterioration in the ability to rennet.

Thus, in order to restore the salt balance, calcium chloride is added to the milk prepared for fermentation (35-40%, i.e. 350-400 grams per 1000 kg of fermented milk), i.e. 400 g per 1000 kg of fermented milk.

Introduction of rennet and obtaining a clot

After this, rennet (for example, food beef or pork pepsin) can be added. Within 15-25 minutes, it is necessary to mix the milk thoroughly, then leave it alone until a dense clot is formed, which should be checked for a break (the norm is a smooth edge with a smooth surface).

Particular attention should also be paid to serum: it should be transparent with a greenish tinge.

The clot is cut into cubes, the approximate dimensions of which are 20x20x20 cm.

Self-pressing

After that, they are left for 1 hour in order for the whey to separate (drained from the bath) and the acidity level increased. The cubes themselves are placed in calico bags, and they fill a little more than half. Tying up and laying in the bath takes place with the aim self-pressing.

A similar process can also be carried out in press trolley or on UPT installation for pressing and cooling curd.

The practically finished product is subject to self-pressing from 1 to 4 hours. Ultimately, cottage cheese must have a mass fraction of moisture, which is provided for by regulatory documentation. After that, you can proceed to the stage of packaging, labeling and cooling the finished product.

Cottage cheese packaging

Cottage cheese is transported on a belt conveyor and fed to filling machines.

Packaging of products will be carried out in briquettes, which, due to vacuum, extend the shelf life of ready-to-eat cottage cheese and are environmentally friendly.

Business plan for the production of cottage cheese

As the main line for the production of cottage cheese, we consider the equipment of a domestic manufacturer with the ability to produce 100 kg. at one o'clock. Schematically, the line is shown in the following figure:

In the production shop, it looks like:

The technological line we have chosen consists of the following units:

• cottage cheese bath;
• press trolley;
• curd cooler;
• pasteurization bath;
• pipeline, pump and other auxiliary elements.

The cost of the production line is 1,216,000 rubles, while it provides for the production of various types of products, in particular glazed curds. In addition to the basic configuration, there is a need to purchase:

• filling machine - 865,000 rubles (Fig. 11);
• refrigerating chamber with a monoblock (Polair) - 135,000 rubles (Fig. 12).

The manufacturer will carry out installation and commissioning works free of charge. Thus, the cost of purchasing production equipment will be 2,216,000 rubles. In the absence of this amount to equip the cottage cheese production workshop, you can borrow credit resources from a financial institution or attract investors.

The productivity of the technological line is 50 kg. at one o'clock. With an 8-hour working day, the monthly output of finished products will be 8,800 kg. per month. (8 hours x 50 kg. x 22 working days).

For such planned volumes, it is necessary to purchase raw materials in the amount of 654,675 rubles:

• milk - 50,000 liters x 13 rubles - 650,000 rubles;
• rennet sourdough for cottage cheese - 50 pieces of 60 rubles each = 3,000 rubles;
• calcium chloride - 1,675 rubles.

Thanks to the use of a modern production line, it is realistic to achieve a high degree of automation of the technological process, and therefore significantly reduce the level of labor intensity. Therefore, it is possible to reduce the cost of production, which in turn will have a positive effect on the financial results of the mini-plant. So, 3 people will be enough to service the equipment:

• 2 workers - 12,000 rubles each;
• 1 technologist - 16,000 rubles.

It is desirable to create an additional staff unit, whose job responsibilities will be to determine the quality of the supplied raw materials and the manufactured finished product: laboratory assistant - 15,000 rubles.

His immediate responsibilities can also include monitoring compliance with the sanitary and hygienic conditions of the production cycle.

The total monthly payroll will be 55,000 rubles.

The estimate of monthly capital investments will consist of the following items of expenditure:

• preparation of the premises (cosmetic repairs) - 80,000 rubles;
• monthly rent - 30,000 rubles;
• SPD registration - 28,000 rubles;
• purchase of raw materials -654,675 rubles;
• packaging cost - 35,000 rubles;
• freight transportation costs - 15,000 rubles;
• utility bills - 10,000 rubles;
• labor costs - 55,000 rubles;
• advertising - 5,000 rubles.

The total cost of production is 912,675 rubles per month and 10,952,100 rubles per year.

Annual revenue: monthly output x 12x retail price of 1 kg. cottage cheese = 8,800 x 160 rubles. x 12 months = 16,896,000 rubles.

Gross annual profit (revenue - cost) \u003d 16,896,000 - 10,952,100 \u003d 5,943,900 rubles.

Profit before tax, taking into account the initial investment in equipment = 5,943,900 - 2,216,000 = 3,727,900 rubles.

The amount of profit after tax (15%) is 3,168,715 rubles per year (net profit).

Let's determine the profitability ratio of production (net profit / gross profit) - 53.3%.

Thus, if there is a given amount of investment, the organization of the production of cottage cheese will be a fairly profitable business with a monthly profit of 254,059 rubles.

Sales of finished products

Establishing the production of cottage cheese will be especially effective if you have your own raw material base. At the same time, at first, you can find reliable contractors - farmers who will supply fresh milk daily. Commercial risk and competition in the cottage cheese market can lead to non-standard situations in the activities of the mini-factory, so it is necessary to make short-term management decisions, namely:

• packaging of cottage cheese in colorful packaging weighing 300, 500 or 800 grams;
• setting a retail price more acceptable compared to similar products (at the stage of product recognition);
• cooperation with retail chains, deliveries to small stores, creation of a branded outlet;
• advertising (media, billboards, outdoor stands);
• periodic promotions.

In the case of profitable activities, it is possible to gradually increase the volume of output of finished products and expand its range (to produce glazed curds, granular cottage cheese with jam, etc.).

Characteristics of products, raw materials and semi-finished products. Cottage cheese is a protein sour-milk product made by fermenting cultures of lactic acid bacteria with or without the use of a milk-clotting enzyme and calcium chloride of pasteurized normalized whole or skimmed milk (mixing with buttermilk is allowed), followed by removal of a part of the whey from the clot and pressing the protein mass.

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 in cottage cheese, and especially high-grade proteins, determines its high nutritional and biological value. Curd contains a significant amount of minerals (calcium, phosphorus, iron, magnesium, etc.) necessary for the normal functioning of the heart, central nervous system, brain, bone formation and metabolism in the body.

Depending on the mass fraction of fat, cottage cheese is divided into three types: fatty, semi-fat and low-fat.

As a raw material, benign fresh milk is used, whole and skimmed, with an acidity of not more than 20 °T. In terms of fat, milk is normalized taking into account the content of protein in it (according to protein titer), which gives more accurate results.

Curd products include various curd masses and curds, cakes, creams, etc.

Features of production and consumption of the finished product. There are two ways to produce cottage cheese - traditional (regular) and separate. The separate method of cottage cheese production allows to speed up the process of whey separation and significantly reduce losses. The essence of the separate method lies in the fact that the milk intended for the production of cottage cheese is pre-separated. Low-fat cottage cheese is produced from the obtained skimmed milk, to which the required amount of cream is then added, which increases the fat content of the cottage cheese to 9 or 18%.

According to the method of clot formation, two methods of curd production are distinguished: acidic and rennet-acid. The first is based only on acid coagulation of proteins by fermenting milk with lactic acid bacteria, followed by heating the clot to remove excess whey. In this way, low-fat and low-fat cottage cheese is produced, since when the clot is heated, significant fat losses occur in the whey. In addition, this method ensures the production of low-fat cottage cheese with a more delicate texture. The spatial structure of clots of acid coagulation of proteins is less strong, is formed by weak bonds between small particles of casein, and releases whey worse. Therefore, to intensify the separation of whey, heating of the clot is required.

With the rennet-acid method of coagulation of milk, a clot is formed by the combined action of rennet and lactic acid. Under the action of rennet, casein at the first stage passes into paracasein, at the second - a clot is formed from paracasein. Casein, when converted to paracasein, shifts the isoelectric point from pH 4.6 to 5.2. Therefore, the formation of a clot under the action of rennet occurs faster, at a lower acidity than during the precipitation of proteins with lactic acid, the resulting clot has a lower acidity, the technological process is accelerated by 2...4 hours. During rennet-acid coagulation, calcium bridges formed between large particles provide high clot strength. Such clots are better at separating whey than acid ones, since the compaction of the spatial structure of the protein occurs faster in them. Therefore, heating of the clot to intensify the separation of whey is not required.

The rennet-acid method is used to produce fatty and semi-fat cottage cheese, which reduces the waste of fat into whey. With acid coagulation, calcium salts go into the serum, and with rennet, they remain in the clot. This must be taken into account when producing cottage cheese for children who need calcium for bone formation.

Stages of the technological process. The production of cottage cheese in the traditional way includes the following stages:

Acceptance of milk;

Normalization of milk to the required composition;

Cleaning and pasteurization of milk;

Cooling milk to fermentation temperature;

Introduction of sourdough and rennet into milk;

Fermentation of milk;

Clot cutting;

Serum separation;

Curd cooling;

Packing;

Packaging and storage of finished products.

Characteristics of equipment complexes. The technological process of cottage cheese production in the traditional way is carried out with the help of equipment complexes for receiving, cooling, processing, storing and transporting raw materials.

Metal containers (tanks) are used to store received milk. Milk and products of its processing are pumped over by pumps. The acceptance of raw materials is carried out using scales (milk meters), milk separators, plate coolers, pasteurizers, filters and auxiliary equipment.

The leading complex of the line consists of curd makers with pressing baths, curd curd baths, curd pressing and cooling units.

The final set of line equipment provides packaging, packaging, storage and transportation of the finished product. It contains filling and packaging machines and equipment for expeditions and warehouses for finished products.

The machine-hardware diagram of the line for the production of cottage cheese in the traditional way is shown in fig.

Rice. Machine-hardware diagram of the line for the production of cottage cheese in the traditional way

Milk from container 1 is first supplied to the balancing tank 2, and then by pump 3 to the recuperation section of the pasteurization-cooling unit 5, where it is heated to a temperature of 35 ... 40 ° C and sent to the separator-purifier 4.

Normalized and purified milk is sent for pasteurization at 78 ... .80 ° C with a holding time of 20 ... 30 s. The pasteurization temperature affects the physicochemical properties of the clot, which, in turn, affects the quality and yield of the finished product. So, at low pasteurization temperatures, the clot is not dense enough, since whey proteins almost completely go into whey, and the yield of cottage cheese decreases. With an increase in pasteurization temperature, the denaturation of whey proteins increases, which are involved in the formation of a clot, increasing its strength and increasing water-holding capacity. This reduces the intensity of whey separation and increases the yield of the product. By regulating the modes of pasteurization and clot processing, by selecting strains of starter cultures, it is possible to obtain clots with the desired rheological and water-retaining properties.

Pasteurized milk is cooled in the recovery section of the plate pasteurization-cooling unit 5 to the fermentation temperature (up to 28...30 °C in the warm season, up to 30...32 °C in the cold season) and sent to special baths 6 for fermentation. The starter for the production of cottage cheese is made on pure cultures of mesophilic lactic acid streptococci and added to milk in an amount of 1 to 5%. The duration of fermentation after fermentation is 6-8 hours.

With the accelerated method of fermentation, 2.5% of the starter prepared in the starter 10 on cultures of mesophilic streptococcus and 2.5% of thermophilic lactic acid streptococcus are added to milk. The fermentation temperature with the accelerated method rises in the warm season up to 35 ° C, in the cold - up to 38 ° C. The duration of milk fermentation with the accelerated method is 4.0 ... 4.5 hours, i.e. is reduced by 2.0 ... 3.5 hours, while the release of serum from the clot occurs more intensively.

To improve the quality of cottage cheese, it is desirable to use a direct method of preparing starter cultures on sterilized milk, which makes it possible to reduce the dose of starter application to 0.8 ... 1.0% with its guaranteed purity.

With the rennet-acid method of producing cottage cheese, after adding the starter, a 40% solution of calcium chloride is added (at the rate of 400 g of anhydrous salt per 1 ton of milk), prepared in boiled and cooled to 40 ... 45 ° C water. Calcium chloride restores the ability of pasteurized milk to form a dense, well-separating clot under the action of rennet. Immediately after that, rennet or pepsin is added to milk in the form of a 1% solution at the rate of 1 g per 1 ton of milk. Rennet is dissolved in boiled and cooled to 35 ° C water. A solution of pepsin in order to increase its activity is prepared on acidic clarified whey 5-8 hours before use. To speed up the turnover of curd baths 6, milk is fermented to an acidity of 32 ... 35 ° T in tanks, and then pumped into curd baths and calcium chloride and an enzyme are added.

The end of ripening and the readiness of the clot is determined by its acidity (for fatty and semi-fat cottage cheese it should be 58 ... 60 ° T, for low-fat - 66 ... with the release of a clear greenish serum. Fermentation with the acid method lasts 6.. .8 hours, rennet-acid - 4.. .6 hours, using active acid-forming starter - 3...4 hours.

To speed up the release of serum, the finished clot is cut with special wire knives into cubes with a face size of 2 cm. In the acid method, the cut clot is heated to 36 ... .38 ° C to intensify the release of whey and kept for 15 ... 20 minutes, after which it is removed . With rennet-acid, the cut clot is left unheated for 40 ... 60 minutes for an intensive release of serum.

For further separation of whey, the clot is subjected to self-pressing and pressing. To do this, it is poured into calico or lavsan bags of 7 ... 9 kg (70% of the bag capacity), they are tied up and placed in several rows in a press trolley 7. Under the influence of its own mass, whey is released from the clot. Self-pressing takes place in the workshop at a temperature not exceeding 16 °C and lasts at least 1 hour. The end of self-pressing is determined visually by the surface of the clot, which loses its luster and becomes matte. Then the curd is pressed under pressure until tender. In the process of pressing, the bags with cottage cheese are shaken several times and shifted. In order to avoid an increase in acidity, pressing must be carried out in rooms with an air temperature of 3.. .6 ° C, and after it is completed, immediately send the curd for cooling to a temperature not higher than 8 ° C using coolers of various designs; the most perfect of them is the two-cylinder cooler 8.

The finished product is packed on machines 9 in small and large containers. Cottage cheese is packed in cardboard boxes with liners made of parchment, polyethylene film. In small packages, cottage cheese is packed in the form of bars weighing 0.25; 0.5 and 1 kg, wrapped in parchment or cellophane, as well as in cardboard boxes, bags, glasses made of various polymeric materials.

Cottage cheese is stored until sale for no more than 36 hours at a chamber temperature not higher than 8 ° C and a humidity of 80.. .85%. If the shelf life is exceeded due to incessant enzymatic processes, defects begin to develop in the curd.

Curd makers with a pressing bath are used to produce all types of curd, while the laborious process of pressing curd in bags is eliminated. The cottage cheese maker consists of two double-walled bathtubs with a capacity of 2000 liters with a crane for draining whey and a hatch for unloading cottage cheese. Pressing baths with perforated walls are fixed above the baths, on which the filter cloth is stretched. The pressing vat can be hydraulically raised or lowered almost to the bottom of the fermentation vat.

Ready cottage cheese is sent for packaging and then to the refrigerating chamber for additional cooling.

In order to reserve cottage cheese in the spring and summer periods of the year, it is frozen. The quality of thawed cottage cheese depends on the method of freezing. Cottage cheese with slow freezing acquires a grainy and crumbly texture due to the freezing of moisture in the form of large ice crystals. With rapid freezing, moisture simultaneously freezes in the form of small crystals in the entire mass of the curd, which do not destroy its structure, and after defrosting, the original consistency and structure characteristic of it are restored. There is even an elimination after defrosting of an undesirable granular consistency due to the destruction of grains of cottage cheese by small ice crystals. The cottage cheese is frozen in packaged form - in blocks of 7 ... 10 kg and briquettes of 0.5 kg at a temperature of -25 to -30 ° C in thermally insulated continuous freezers to a temperature in the center of the block of -18 ° C and -25 ° C for 1.5 ... 3.0 hours. Frozen blocks are placed in cardboard boxes and stored at the same temperatures for 8 and 12 months, respectively. Defrosting of cottage cheese is carried out at a temperature not exceeding 20 ° C for 12 hours.

The machine-hardware diagram of the cottage cheese production line in a separate way is shown in fig.

Rice. Machine-hardware diagram of the line for the production of cottage cheese in a separate way using a separator-curd separator

The device and principle of operation of the line. With this method of production, milk intended for the production of cottage cheese is supplied from tank 1 by pump 2 to surge tank 3, and from it - by pump 2 to the recovery section of the plate pasteurization-cooling plant 4 for heating up to 40 ... 45 ° C. The heated milk enters the cream separator 5, where it is separated into skimmed milk and cream with a mass fraction of fat of at least 50 ... .55%. The resulting cream is fed first into an intermediate container 6, and then by a pump 7 into a plate pasteurization and cooling unit 8, where they are pasteurized at a temperature of 85.. .90 ° C with a holding time of 15.. .20 s, cooled to 2.. .4 ° C and sent to a double-walled container 9 for temporary storage until mixed with curd.

Skimmed milk from the separator enters the plate pasteurization-cooling unit 4, where it is first pasteurized at a temperature of 78 ° C with a holding time of 15 ... 20 s, and then cooled to 30 ... special mixer. The leaven prepared in the starter 10 is fed by pump 7 into the tank 11 for fermentation. Calcium chloride and enzyme are also supplied here, the mixture is thoroughly mixed and left for fermentation until the acidity of the clot is 90 ... 116 °T, and if the accelerated method of milk fermentation is used, then 85 ... .90 °T. When separating a clot with a lower acidity, the separator nozzles may become clogged.

The resulting clot is thoroughly mixed and pumped 12 is fed into the plate heat exchanger 13, where it is first heated to 60...62 °C for better whey separation, and then cooled to 25...32 °C, due to which it is better separated into the protein part and serum. From the heat exchanger 13, the clot is fed under pressure through a strainer 14 to the cottage cheese separator 15, where it is separated into whey and cottage cheese.

When producing fatty cottage cheese, dehydration by separation is carried out to a mass fraction of moisture in a clot of 75 ... 76%, and when producing semi-fat cottage cheese, to a mass fraction of moisture of 78 ... 79%. The resulting fat-free cottage cheese is fed with a special pump 16 first to the cooler 17 for cooling to 8 ° C, pounded on a roller until a homogeneous consistency is obtained. The cooled cottage cheese is sent to the 19 kneading machine, where the pasteurized chilled cream is fed from the 18 tank with a dosing pump 7 and everything is thoroughly mixed. The finished cottage cheese is packed on 20 machines and sent to the storage chamber.

Introduction

1. Curd. Characteristics, meaning and production technology

1.1 Curd. Definition of cottage cheese. Types of cottage cheese

1.2 The technological process of making cottage cheese

2. Recipes for cottage cheese products

2.1 Curd mass with sour cream

2.2 Curd mass with berries or fruits

2.3 Curd cream

2.4 Curd balls

2.5 Cottage cheese pancakes

3.1 Chemical composition and nutritional value of the main and auxiliary raw materials

4. Preparation and production of products

5. Types of control over the release of cottage cheese products

5.1 The concept and types of product quality control

5.2 Technochemical control over the release of cottage cheese products

6. Standardization and certification of curd and curd products

7. Organization of the workplace and use of equipment

Conclusion

List of references

Applications

Introduction

According to the Roman writer and scientist Mark Terentius Varro, cottage cheese was known in ancient Rome. Milk was then fermented with a clot, which was removed from the stomach of calves, kids or lambs that ate only mother's milk.

Cottage cheese was eaten both salted and unsalted, sometimes mixed with milk, wine or honey. For quite a long time, cottage cheese in Rus' was called cheese, and dishes made from it were called cheese (remember the cheesecakes familiar to everyone). It is not known where this name came from, but it was so firmly entrenched in cottage cheese that it did not disappear even after the appearance of hard (rennet) cheeses in Russia. Cottage cheese has always been one of the most revered products among the Slavs. It was eaten almost daily. The raw material for the preparation of cottage cheese was ordinary yogurt, a pot with which was placed for several hours in a not very hot oven. Then the pot was taken out and its contents poured into a linen cone-shaped bag. The whey was strained, and the bag with cottage cheese was placed under the press. However, cottage cheese prepared in this way could not be stored for a long time, and refrigerators were not yet known at that time. In the period when the milk yield was good, and especially during Lent, the peasants accumulated quite a lot of cottage cheese. So that it does not disappear, the people came up with a rather original way of preserving it. Ready (from under the press) cottage cheese was again placed in the oven for several hours, then under the press, and so on twice. When it became completely dry, it was packed tightly in clay pots and poured ghee on top. In the cellar, such cottage cheese could be stored for months, they took it with them on a long journey. In the last century, the Rostov district of the Yaroslavl province was famous for cottage cheese. From there he was taken to Moscow. In the Ryazan province, cottage cheese from the village of Dedinovo was considered the best. They sold cottage cheese by the pound. Moreover, the drier it was, the more expensive it was.

Now the production of cottage cheese has been established, if not in every settlement, then in every, even a small city, for sure.

The Chelyabinsk City Dairy Plant was founded in 1935. The decision to create a plant was made in order to provide the population of the Southern Urals with dairy products. The first dairy product that the plant began to produce was kefir. At that time, all operations were performed manually. Today the company successfully operates in the market of dairy products in the Chelyabinsk region, Yekaterinburg, Tyumen.

Dairy products are the main source of amino acids and living microorganisms that are essential for human life. "First Taste" (very successful brand Chelyabinsk City Dairy Plant) - the taste of life. The processing technology of the trade mark "First Taste" allows keeping microorganisms alive in dairy products, which is impossible in products that undergo high-temperature processing (sterilization).

The object of this work is cottage cheese and cottage cheese products; subject - the technological process of manufacturing cottage cheese and products from it.

The purpose of the work is to consider in detail such a product as cottage cheese, its characteristics, production. To achieve this goal, it is necessary to solve the following tasks:

define cottage cheese, reveal its characteristics, meaning and production technology;

consider some recipes for cottage cheese products;

consider the characteristics of the main and auxiliary raw materials, identify useful properties, determine their nutritional and energy values;

describe the processes of preparation and manufacture of products;

consider the types of control over the release of products from cottage cheese;

cottage cheese certification standardization product

highlight the main stages of standardization and certification of cottage cheese and cottage cheese products;

describe the organization of the workplace and the use of equipment.

1. Curd. Characteristics, meaning and production technology

1.1 Curd. Definition of cottage cheese. Types of cottage cheese

Fermented milk products are products produced by fermenting milk or cream with pure cultures of lactic acid bacteria, with or without the addition of yeast or acetic acid bacteria. Some fermented milk products are obtained as a result of only lactic acid fermentation; in this case, a fairly dense, homogeneous clot with a pronounced sour-milk taste is formed. Other products are obtained as a result of mixed fermentation - lactic acid and alcohol.

Fermented milk products are of great importance in human nutrition due to their medicinal and dietary properties, pleasant taste, and easy digestibility.

Cottage cheese is a traditional protein fermented milk product with high nutritional and therapeutic dietary properties. In almost all medical menus prescribed by doctors, cottage cheese is one of the first. But it is also useful for healthy people of any age. Cottage cheese is a concentrate of milk protein and some other components of milk. The importance of protein in our lives is well known: it is the material from which all body cells, enzymes, and immune bodies are built, thanks to which the body acquires resistance to diseases. The human body receives proteins along with food, breaks them down to amino acids, and from them builds molecules of new proteins that are unique to our body. To do this, he needs a set of 20 amino acids. Of the latter, methionine and tryptophan are the most deficient in food products, which play an important role in the processes of the nervous system, hematopoietic organs and digestive organs. The main supplier of these amino acids is cottage cheese. Along with proteins, minerals are also necessary for the normal functioning of the body, the most important of which are calcium and phosphorus compounds. They form the basis of bone tissue and teeth. By the way, this explains the fact that during the period of formation and growth of the body, children and adolescents need additional amounts of calcium. At the same time, calcium is necessary for the normal functioning of the heart muscle and the central nervous system, and brain and bone tissue needs phosphorus. By the amount of calcium and phosphorus salts, as well as their physiologically favorable ratio among themselves, cottage cheese stands out favorably among other food products: it contains about 0.4% of them. It should be added that calcium saturation makes cottage cheese an indispensable product for tuberculosis, bone fractures, diseases of the hematopoietic apparatus, rickets. Cottage cheese helps to excrete urine, so it is recommended for hypertension, heart disease, kidney disease, etc.

In modern conditions, it is produced by fermenting pasteurized whole or skimmed milk and removing some of the whey from the resulting clot. Cottage cheese from unpasteurized milk can only be used for the production of products subject to mandatory heat treatment (vareniki, cheesecakes, etc.), as well as for the production of processed cheeses. The composition of cottage cheese includes 14-17% proteins, up to 18% fat, 2.4-2.8% milk sugar. It is rich in calcium, phosphorus, iron, magnesium - substances necessary for the growth and proper development of a young organism. Cottage cheese and products made from it are very nutritious, as they contain a lot of proteins and fat. Curd proteins are partially associated with phosphorus and calcium salts. This contributes to their better digestion in the stomach and intestines. Therefore, cottage cheese is well absorbed by the body.

Methionine and choline, contained in the components of cottage cheese, prevent atherosclerosis. Children, pregnant women and nursing mothers especially need cottage cheese, since the calcium and phosphorus salts in it are spent on the formation of bone tissue, blood, etc. Cottage cheese is recommended for patients with tuberculosis and suffering from anemia. It is useful in diseases of the heart and kidneys, accompanied by edema, as calcium helps to remove fluid from the body. Fat-free cottage cheese is recommended for obesity, liver disease, atherosclerosis, hypertension, myocardial infarction. With gout and other diseases, when meat and fish proteins are contraindicated, they are replaced with cottage cheese protein.

Cottage cheese has a pure sour-milk taste and smell without extraneous shades. The consistency is tender and homogeneous, for fatty cottage cheese it is slightly smearing, for low-fat cottage cheese it is allowed to be heterogeneous, crumbly with a slight release of whey. The color is white, uniform throughout the mass. Cottage cheese is produced in the following types:

fatty - fat content 18%, acidity 200 - 225 T;

bold - fat content 9%, acidity 210 - 240 T;

low-fat - acidity 220 - 270 T;

table - fat content 2%, acidity 220 T;

dietary - fat content 4%, 11%, acidity 220 T;

dietary fruit and berry - fat content 4%, 9%, 11%, low-fat, acidity 180 - 200 T.

with fruits - fat content 4%, non-greasy, acidity 200 T.

1.2 The technological process of making cottage cheese

The technology for the production of cottage cheese is based on the fermentation of milk with sourdough in order to obtain a clot and its subsequent processing. The clot is obtained by acid and acid-rennet coagulation of milk proteins.

Based on this, there are two main ways of coagulation:

acid;

acid rennet.

Production of cottage cheese by the acid-rennet method

With this method of producing cottage cheese, a clot is formed not only as a result of lactic acid fermentation, but also with the help of introduced rennet. The scheme for the production of cottage cheese by the acid-rennet method is shown in Figure 1.

Figure 1. Scheme of the production of cottage cheese by the acid-rennet method

Reservoir for normalized milk; 2 - pump; 3 - intermediate tank; 4 - lamellar pasteurization apparatus; 5 - separator-milk cleaner: 6 - bath for curd clot; 7 - press trolley; 8 - cooler for cottage cheese; 9 - packaging machine; 10 - storage room.

For the production of cottage cheese, benign fresh milk without defects is used. Normalized milk is purified from mechanical impurities and sent for pasteurization. Pasteurized milk is cooled to the fermentation temperature and sent to special baths for the production of curd. For the convenience of unloading the clot from them, the baths are mounted on the site.

For fermentation of milk, a ferment prepared on pure cultures of mesophilic lactic streptococcus is used. After adding the starter, the milk is thoroughly mixed.

Rennet is not introduced simultaneously with the starter, but only after some exposure of the fermented milk. Fermented milk is kept until it reaches an acidity of 32-35°T. After that, a solution of calcium chloride is added to it in order to restore the ability of pasteurized milk to form a dense, well-separating clot under the action of rennet. A solution of rennet is added to thoroughly mixed milk. After that, the milk is thoroughly mixed and left alone to form a clot.

The duration of milk fermentation with the correct conduct of the technological process with the use of starter cultures on mesophilic cultures is 6-8 hours, with the accelerated method 4-4.5 hours.

During the production of cottage cheese, moisture is removed from the resulting clot (whey along with dry substances dissolved in it - lactose, mineral salts, whey proteins, etc.). To speed up the release of serum, the clot is cut into small pieces, which significantly increases its surface, opens many capillaries and pores, and also shortens the path of whey to the surface.

For this purpose, the clot at the moment of readiness is cut into cubes and left alone for a while. During this time, serum is intensively released from the broken clot, the cubes are somewhat compacted and at the same time acidity increases in them. The whey separated during the exposure time is removed from the bath with a siphon or released through a fitting.

The clot partially freed from whey is unloaded from the bath and sent for self-pressing. To facilitate the release of whey, self-pressing and pressing of the clot takes place in small portions placed in strong bags. The bags are tied and placed in several rows in a press trolley, where, under its own weight, the serum is released from the clot.

At the end of self-pressing, bags with curd are evenly laid out on the perforated bottom of the trolley in several rows, a plate is lowered on them and the curd is pressed until tender. To speed up the release of whey, the bags in the press trolley are shaken and shifted during pressing (move the top bags down and the bottom bags up).

In order to avoid an increase in acidity, pressing should be carried out not in the production workshop, but in rooms with an air temperature not higher than 8 ° C. For this, press carts are transported from the workshop to special chambers. The end of pressing is determined by the moisture content in the curd. The whole process of removing whey from the clot poured into bags lasts at least three hours.

After the end of the pressing, the curd is immediately cooled to 6-8 ° C to prevent the growth of acidity in it. To cool cottage cheese at dairy plants, Loktyukhov coolers, rotary drums, in which the curd is pressed and cooled, as well as more advanced two-cylinder OTD coolers, are used. In enterprises with a small volume of cottage cheese production, after pressing it in the same bags, it is placed in refrigerators. Ready cottage cheese is packaged in large and small containers.

The technology for producing cottage cheese using the acid-rennet method has a number of serious drawbacks and fundamentally slows down the growth of its production. The whole process of its production is very long and takes at least 11 hours. Operations to remove whey from the clot take not only a lot of time, but also require a lot of manual labor, which entails a decrease in labor productivity. With whey, a significant amount of fat is removed from the clot.

Production of fat-free cottage cheese by the acid method

Fat-free cottage cheese, as a rule, is produced by an acid method. Its production is organized not only at dairy plants, but also at grassroots enterprises and is carried out on the same equipment that produces fatty curds using the acid-rennet method. The scheme for the production of cottage cheese by the acid method is shown in Figure 2.

Skimmed milk used for the production of cottage cheese must be fresh, of good quality and have an acidity of no higher than 21 ° T. It is pasteurized, cooled to the fermentation temperature and sent to baths. With thorough kneading, the starter is added to the skimmed milk and left in a calm state to form a clot.

Figure 2. Scheme of the production of cottage cheese by the acid method

Reservoir for normalized milk; 2 - pump; 3 - intermediate tank; 4 - lamellar pasteurization apparatus; 5 - separator-milk cleaner; 6 - bath for curd clot; 7 - press trolley; 8 - cooler for cottage cheese; 9 - packaging machine; 10 - storage room.

To speed up the separation of whey, the clot is cut horizontally and vertically with knives into cubes with an edge size of 20 mm and then left alone for 10-15 minutes. The process of syneresis accelerates with increasing temperature, which causes a stronger contraction of the protein clot and a more intense release of whey from it. Therefore, the cut clot is heated (boiled) to 36-38 ° C.

In this case, during the production of cottage cheese in double-walled baths, hot water is supplied to their inter-wall space. For uniform heating of the entire mass, the clot is gently mixed. If cottage cheese is produced in single-wall baths, then hot whey with a temperature of 60-65 ° C is added to it for heating. With an increased acidity of the clot, it is better to heat it with boiled hot water. Hot whey or water should be poured into the bath gradually with stirring to avoid local overheating of the clot.

Overheating of the clot contributes to the formation of a dry and rough consistency of cottage cheese. Insufficient heating of the clot slows down the separation of the whey, which can cause an increase in acidity and also adversely affects the quality of the product. After reaching the specified temperature, the heating is stopped, the clot is left alone for 10-15 minutes for better dehydration. Then part of the whey is removed and the clot is poured into bags. Its acidity before bottling should be 80-85°T.

Fat-free cottage cheese is used mainly as a raw material in the production of processed cheeses and is therefore packaged in large containers.

Separate method for the production of cottage cheese

In order to speed up the process of separating whey and significantly reduce fat loss, a technology was developed for the production of fatty cottage cheese in a separate way.

The essence of the separate method lies in the fact that the milk intended for the production of cottage cheese is pre-separated. Low-fat cottage cheese is produced from the obtained skimmed milk, to which the required amount of cream is then added to increase the fat content of the cottage cheese.

The production of fat and semi-fat cottage cheese in a separate way can also be carried out on conventional equipment (cottage cheese baths, press trolleys, etc.). Fat-free cottage cheese is produced by the acid-rennet method. From a low-fat clot, whey is separated much easier and faster. The scheme for the production of fatty and semi-fat cottage cheese in a separate way is shown in Figure 3.

Cottage cheese is pressed in bags until a certain moisture content is reached, then it is sent to a rolling mill, where it is well ground until a homogeneous consistency is obtained. After that, it enters the kneading machine, where the calculated amount of chilled cream is fed. After thorough mixing, the resulting product is sent for packaging.

Figure 3. Scheme of the production of fatty and semi-fat cottage cheese in a separate way

7 and 10 - reservoirs; 2 - pump for milk; 3 - lamellar pasteurization plant; 4 - cream separator; 5 - pump for cream; 6 - pasteurizer for cream; 8 - starter; 9 - dosing pump; 11 - membrane pump; 12 - plate heat exchanger: 13 - cottage cheese separator; 14 - receiver; 15 - pump for cottage cheese: 16 - cooler; 17 - mixer.

When producing cottage cheese in a separate way, it is necessary to perform additional operations for the separation of milk, as well as for mixing low-fat cottage cheese with cream. However, the advantages that this method has are significant, suffice it to say only about saving fat.

When cottage cheese is produced in a separate way on existing equipment, a number of operations are performed manually, there is no production flow, and the use of bags for curd pressing creates great inconvenience. All these shortcomings are eliminated by using special separators.

Ready cottage cheese is packaged on automatic machines. On these lines, 500-600 kg of cottage cheese are produced per hour; they are intended for large dairy plants that process at least 30 tons of milk per shift into cottage cheese.

The main advantage of this line is the complete mechanization of the technological process, which is carried out continuously and in a closed stream. As a result, all manual operations for the production of cottage cheese are excluded (with the exception of equipment washing). The most time-consuming process - the separation of whey from the clot - occurs continuously with the help of a separator. As a result, the sanitary and hygienic conditions of production are improved, labor productivity is increased, costs are reduced and the quality of the finished product is increased.

Flow-mechanized method of cottage cheese production

The method consists in the fact that a clot is formed during the production of cottage cheese under the action of lactic acid, which is added to milk in the form of acid whey. Fermentation of milk and the release of whey from the clot occurs in multi-section continuous curd makers. They can produce fatty, semi-fat and fat-free cottage cheese. The scheme of the flow-mechanized method for the production of cottage cheese is shown in Figure 4.

With a flow-mechanized method of producing cottage cheese, milk is prepared for fermentation in the usual way. Purified, normalized and pasteurized milk is cooled and sent to vertical tanks, where the milk undergoes partial fermentation. To do this, leaven is added to it and, after thorough mixing, is left to increase acidity.

To ensure the continuity of the process, milk from each tank is supplied to the curd maker in the amount of 25-50%, and fresh milk is supplied to the tank instead. The mixture of fresh and partially fermented milk again reaches the desired acidity within a short period of time. Thus, partial fermentation of milk before its processing is carried out by a continuous-cyclic method.

Figure 4. Scheme of a flow-mechanized method for the production of cottage cheese

Drive: 2 - automatic dispenser: 3 - pipeline for milk: 4 - receiver: 5 - multi-section drum: 6 - screw partition; 7 - bandage; 8 - removable mesh: 9 - lattice shield: 10 - pallet; 11 - cutting device; 12 - carrier frame; 13 - tray; 14 - rollers with a bracket.

The sour whey used to form the curd clot must be prepared in advance. To do this, the whey obtained by pressing the cottage cheese is heated and the leaven is added to it. The whey is fermented in the tank for 2-3 days, over the next 7-10 days the whey is fermented by dilution (new portions of fresh whey are added to a certain amount of acidic whey). Before sending the acid whey to the curd maker, it is pasteurized and cooled.

A multi-section cottage cheese maker is a cylindrical body, divided by helical partitions into separate sections. The first section is the receiving section, into which partially fermented milk and coagulant (sour whey or lactic acid solution) enter through pipelines. The following sections serve to form a clot and achieve the required density. The last two sections are designed for pressing the curd clot.

Partially fermented milk enters the receiving section of the curd maker by gravity or is supplied in portions by a pump. The supply of milk is carried out with continuous rotation of the curd maker and occurs through each of its revolutions. Simultaneously with milk, sour whey enters the receiving section to increase acidity.

When milk is mixed with sour whey, a curd clot is formed. The resulting curd clot, during the rotation of the curd maker, moves from section to section, while it is compacted, since as a result of the siperesis process, whey is released from it. In the last sections, the clot during rotation moves along the filter surface, where it is pressed. The whey released from the clot flows through the filter mesh into the pan. Ready cottage cheese is unloaded from the last section through a special tray and sent for cooling.

The production of cottage cheese in multi-section cottage cheese makers has a number of advantages compared to the usual method of its production. The whole process of producing cottage cheese in them is carried out continuously in a relatively short period of time and allows you to increase the removal of finished products on existing areas. At the same time, all technological operations are mechanized, including the most laborious one - the separation of whey from a clot. As a result of the elimination of bags for pressing cottage cheese, the cost of auxiliary materials is reduced and the sanitary culture of production is increased.

Production of cottage cheese at a cottage cheese manufacturer

Fat, semi-fat and fat-free cottage cheese are produced at the cottage cheese maker.

Prepared in the usual way (for the production of cottage cheese), milk enters the baths, where ferment is added to it. Upon reaching the required acidity, the usual doses of solutions of calcium chloride and rennet are added to the milk, after which they are left for fermentation.

The scheme for the production of cottage cheese at a cottage cheese manufacturer is shown in Figure 5.

Figure 5. Scheme of cottage cheese production at a cottage cheese manufacturer

Bath for fermentation of milk; 2 - a hatch for unloading cottage cheese into carts; 3 - crane for whey descent: 4 - racks; 5 - traverse; 6 - hydraulic cylinder; 7 - pressing bath; 8 - filter cloth; 9 - rod; 10 - branch pipe; 11 - mechanism for opening and closing the hatch; 12 - self-priming pump: 13 - hydraulic drive.

The resulting clot is cut with a special device included in the kit of the curd manufacturer into cubes with an edge size of 20 mm and the clot is left alone to separate the whey, which is removed from the bath using a whey separator. The selector is a perforated cylinder covered with a filter cloth. The released whey through the filter cloth and the perforated surface enters the sampler and leaves the bath through the nozzle.

After partial draining of whey, clot pressing begins. To do this, with the help of a hydraulic drive, the pressing bath is lowered down. The speed of immersion of the pressing bath into the clot depends on its quality and the type of curd produced. During pressing, the released whey passes through the filter cloth and the perforated surface into the pressing bath, from where it is periodically pumped out by a pump. Depending on the type of product produced, the duration of pressing is: for fat cottage cheese 4-5 hours, bold 3-4 hours and fat-free 2-2.5 hours.

At the end of pressing, the perforated bath rises and the finished product is unloaded through the hatch into the trolleys. The trolley with cottage cheese is lifted up and overturned over the cooler hopper. The cooled cottage cheese goes to packaging. The finished product produced in the cottage cheese manufacturer is of good quality with a specific layered structure.

The production of cottage cheese in a curd maker with a pressing bath has a number of advantages. It allows you to mechanize all labor-intensive processes and reduce the cost of manual labor at the same time. As a result of the elimination of bags for pressing, the loss of raw materials and finished products is reduced.

Freezing cottage cheese.

In order to reduce the seasonality of cottage cheese production, part of the cottage cheese produced in the summer is stored for long-term storage (up to 6 months).

Usually cottage cheese is frozen in wooden tubs. Freezing cottage cheese in tubs and its subsequent defrosting require a lot of manual labor, cause significant losses of cottage cheese and reduce its quality. The process of freezing a large mass of cottage cheese in a tub is very slow. As a result, ice crystals, initially formed between the curd particles, gradually increase and reach significant sizes. When defrosting cottage cheese, in this case, water cannot be evenly distributed in the product and partially flows out of it, which reduces the quality of the cottage cheese.

2. Recipes for cottage cheese products

2.1 Curd mass with sour cream

Number according to the collection of recipes No. 602 "Curd mass with sour cream"

Product name	Gross, g
Curd

Cooking technology

The sweet or salty ready-made curd mass is placed in a portioned dish in a slide, a recess is made in it, into which sour cream is placed. Cumin (1.6 g per serving) can be added to the salted curd mass, which is pre-sorted, washed, poured with hot water and left for 1-1.5 hours to swell, then the water is drained.

GOSTs and TUs for products included in the recipe "Cheese mass with sour cream" are presented in table 1.

Table 1 - GOSTs and TUs for products included in the recipe "Curd mass with sour cream"

2.2 Curd mass with berries or fruits

Number according to the collection of recipes No. 603 "Curd mass with berries or fruits"

Cooking technology

The finished curd mass is placed in a portioned dish in a slide, slices of fresh berries or fruits or berries are placed on top. When preparing the curd mass with canned fruits or berries, the mass laid in a slide is poured over with syrup, and then decorated with fruits or berries.

GOSTs and specifications for products included in the recipe "Curd mass with berries or fruits" are presented in table 2.

Table 2 - GOSTs and TUs for products included in the recipe "Curd mass with berries or fruits"

2.3 Curd cream

Number according to the collection of recipes No. 612 "Curd cream"

Product name
Butter
Nuts (kernel)

Cooking technology

Softened butter is rubbed with egg yolks and sugar until a fluffy homogeneous mass is formed.

Vanillin dissolved in hot water and salt are added to the pureed cottage cheese, mixed with the egg-butter mass and cream or sour cream whipped into thick foam is gradually added. The finished cream is placed in portioned dishes in the shape of a cone or pyramid, sprinkled with chopped nuts (almonds, walnuts or pistachios) and cooled.

On vacation, the cream is made out with slices of fresh or canned fruits or jam.

GOSTs and TUs for the products included in the recipe "Cream curd" are presented in table 3.

Table 3 - GOSTs and TUs for products included in the recipe "Curd cream"

	Product name	Name, number of GOST or TU
		GOST R 52096-2003 Cottage cheese. Specifications
		GOST R 52121-2003 Edible chicken eggs. Specifications
	Butter	GOST R 52969-2008 Butter. Specifications
		GOST 21-94 Sugar-sand. Specifications
		GOST R 52092-2003. Sour cream. Specifications
	Nuts (kernel)	GOST 16833-71 Walnut kernel. Specifications
		GOST R 53118-2008: Jam. General specifications
		GOST 16599-71 Vanillin. Specifications

2.4 Curd balls

Number according to the collection of recipes No. 613 "Cottage cheese balls"

Cooking technology

Cottage cheese is wiped, combined with butter, grated cheese, red ground pepper, salt are added and mixed. From the resulting mass, balls the size of a walnut are formed, sprinkled with crushed breadcrumbs.

On vacation, the balls are decorated with parsley.

GOSTs and TUs for products included in the recipe "Curd balls" are presented in table 4.

Table 4 - GOSTs and TU for products included in the recipe "Curd balls"

2.5 Cottage cheese pancakes

Number according to the collection of recipes No. 617 "Cheesecakes from cottage cheese"

Cooking technology

2/3 flour, eggs, sugar, salt are added to the mashed cottage cheese. You can add vanillin 0.02g per serving, after dissolving it in hot water.

The mass is well mixed, shaped into a bar 5-6 cm thick, cut across, breaded in flour, shaped into round meatballs 1.5 cm thick, fried on both sides, and then placed in an oven for 5-7 minutes.

Sugar-free cheesecakes can be prepared with cumin (0.5g per serving).

Cumin is sorted, washed, poured with hot water and left for 1-1.5 hours to swell, then the water is drained. Cumin is introduced into the mashed cottage cheese along with the rest of the ingredients.

Syrniki are released in 3 pieces. per serving with sour cream, or jam, or sour cream and sugar, with milk or sour cream, or sweet sauces.

Syrniki with cumin are released with sour cream or sour cream sauce.

GOSTs and TUs for products included in the recipe "Cheesecakes from cottage cheese" are presented in table 5.

Table 5 - GOSTs and TUs for products included in the recipe "Cheesecakes from cottage cheese"

3.. Characteristics of the main and auxiliary raw materials

3.1 Chemical composition and nutritional value of the main and auxiliary raw materials

Food products are different in chemical composition, digestibility, the nature of the impact on the human body. Food products are characterized by their nutritional, biological and energy value.

Nutritional value is a general concept that includes the energy value of products, the content of nutrients in them and the degree of their assimilation by the body, organoleptic qualities, good quality (harmlessness).

The energy value is determined by the amount of energy that the food substances of the product give: proteins, fats, digestible carbohydrates, organic acids.

The biological value primarily reflects the quality of the proteins in the product, their amino acid composition, digestibility and assimilation by the body.

The nutritional and energy value of the main and auxiliary products that make up the dishes considered in this work, namely: "Curd mass with sour cream", "Curd mass with berries or fruits", "Curd cream", "Curd balls" and "Cheese from cottage cheese", - are presented in table 6 - the nutritional and energy value of the main and auxiliary products.

Table 6 - Nutritional and energy value of the main and auxiliary products

Product name	Nutritional value (chemical composition) per 100g of product									Energy value, kcal
				Carbohydrates, g	Dietary fiber, g	Organic acids, g		Vitamins, mg	Micro and macro elements, mg
fresh apricots
Pear jam
table margarine
Butter
Wheat flour
Nuts (kernel)
Curd
Rye bread

3.2 Conditions and terms of storage of the main and auxiliary products

Conditions and terms of storage of apricots

The main purpose of storing fresh fruits is to create conditions for slowing down the biochemical, physical and other vital processes that occur in fruits after harvest, delay the onset of aging and death of the fruit, and thereby more fully preserve the chemical composition and commercial quality of these products.

Stone fruits are classified as short-term storage products: shelf life - from 1-2 days to a month.

The most perishable are cherries, cherries and apricots. The main condition for the storage of stone fruit is to maintain a constant temperature of 0-1°C relative air humidity of 90-95% with moderate air exchange.

To extend the shelf life of apricots up to 2 months, the fruits are placed in the RGS with an oxygen content of 2-3% and carbon dioxide of 3-5%.

Conditions and terms of storage of fermented milk products: cottage cheese, sour cream

Cottage cheese is a product that is not very stable in storage, even at low temperatures. At 0°C, it can be stored for up to 7 days. For longer storage, the cottage cheese is frozen. Oily typically at 12°C, non-oily at 18°C; at these temperatures, frozen cottage cheese is stored for 4-6 months.

Sour cream is stored at a temperature of +2 to +4°C for 72 hours.

Conditions and terms of storage of oil and fat products: margarine and butter

Margarine should be stored in refrigerated warehouses or refrigerators at an air temperature of -20 to 15°C with constant air circulation. It is not allowed to store margarine with products that have a sharp specific smell. Guaranteed shelf life of bulk margarine at temperatures from -20 to -10°C is 90 days, from -9 to 0°C - 75 days, from 0 to 4°C - 60 days, from 5 to 10°C - 45 days; packaged in parchment - 60, 45, 35.20 days, respectively; packaged in laminated foil - 75, 60, 45, 30 days, respectively. Bulk soft margarine in cups or boxes made of PVC at a temperature of 0 to 10°C can be stored for no more than 75 days. The guaranteed shelf life of margarine with preservatives increases at a storage temperature of 5 to 15°C by 10 days.

Butter is a relatively perishable product. It is recommended to store it at a temperature of 10-12 ° C, in a dark place. The shelf life of butter with fillers is somewhat less than usual and varies, depending on the conditions, from 10-20 to 90 days.

Conditions and terms of storage of flour

Flour is stored in warehouses and bases of bakery products, trade enterprises and organizations, in warehouses and premises of catering establishments, retail trade enterprises. The storage room for flour must be dry, clean, well ventilated, not infested with pests of grain stocks, well lit. Walls must be whitewashed at least twice a year. Flour sacks are stacked on wooden pallets or wooden grates. Stacks are placed separately by type of flour, grades, numbers (for cereals), dates of receipt. The height of the stack with cereals and flour depends on the season, storage conditions, type, grade and humidity of the product. flour with a moisture content of up to 14% is put in a stack of such a height (number of rows of bags): at an air temperature in the composition higher than +10 ° C - 10 rows, from +10 to 0 ° C - 12 rows, the lowest from 0 ° C - 14 rows. Flour with a moisture content of 14-15.5% is put into stacks, respectively, two rows of bags less. The height of the stack for millet, corn and oatmeal, corn and oatmeal with a moisture content of up to 13%, depending on the air temperature, should not exceed 8-10 bags. The height of a stack of products with a moisture content of 13-14% is reduced by two rows of bags.

As a rule, the height of a stack of flour in warehouses and bases of trade enterprises does not exceed 6-8 rows of bags. The optimal relative humidity of flour storage air is 60-70%. Favorable temperature for flour storage is from +5 to +15°C. For long-term storage of these products, the temperature should be as low as +5 to -15°C. A sharp fluctuation in temperature and relative humidity of the air negatively affects the storage of flour. Warehouses should be especially carefully ventilated in the spring, when the temperature difference between the outside and storage air is significant. The duration of storage of flour depends on their type, grade, humidity, packaging, storage conditions. Wheat flour of the highest and first grades, seeded rye, rice and barley flour is well preserved. Flour with a high fat content has a shorter shelf life.

Conditions and terms of storage of cheese

Cheese is a living product that is constantly in the process of development, so certain conditions must be observed during its storage. If stored poorly, the ripening process is accelerated, its development is not correct, the cheese may dry out, the appearance may deteriorate and the cheese itself will become unusable.

The ideal storage conditions for cheese are:

constant temperature from 6 to 8 C degrees;

constant humidity level of about 90 percent;

ventilated room.

Too low a storage temperature kills the cheese (for example, if the cheese is frozen, it will crumble when thawed), and too high - kills its structure. Similarly, humidity is bad for cheese: too high causes it to spoil, and too low to dry it out.

Conditions and terms of storage of eggs

Eggs intended for storage must be whole, clean and fresh (5-6 days old, and with some storage methods - on the day they are laid).

As the eggs are stored, their dietary properties decrease.

In special recesses on the inner panel of the refrigerator door, it is recommended to store only those eggs that are intended for food in the next 3-7 days (an increase in temperature near the door when it is opened, as well as a higher temperature on it compared to the temperature in the depth, contribute to the bioprocesses inside the egg and the appearance of microcracks in the shell). Therefore, the rest of the eggs are best stored in the depths of the top shelf of the refrigerator compartment (under the freezer), where their shelf life can be more than two weeks, if each egg is wrapped in paper and turned over once a week.

Eggs absorb odors from strong-smelling objects, so do not store them near onions, smelling fish, spices, kerosene, gasoline, acetone, naphthalene, etc., and do not store them in an unventilated room. .

4. Preparation and production of products

The vast majority of food raw materials are complex multicomponent systems consisting of organic and inorganic substances. Culinary processing of raw materials leads to a significant change in its composition. Actually, these changes lead to the fact that the initial set of raw materials turns into a finished product with certain organoleptic properties and nutritional value inherent in it.

At various stages of the technological process, various processes take place: mechanical, thermophysical, chemical, microbiological, etc.

Mechanical restoration

The initial stage in the preparation of culinary products, as a rule, is mechanical processing, as a result of which various types of raw materials are converted into semi-finished products.

During mechanical processing, inedible or nutritionally low-value components are separated. The main mass of the product is crushed and, as a result, further operations are greatly facilitated. Mechanical processing is accompanied by such processes as destruction, screening, pressing, mixing, etc.

Destruction (grinding). An external force applied to a rigid body causes it to deform.

The main methods of grinding are cutting, grinding, homogenization, breakdown.

Cutting. When grinding a food product, its dissection into separate large parts minimally disturbs the microstructure. If the dissection of a piece of food is not accompanied by its sorting, then the chemical composition may hardly change. Keeping the cells of the food product intact ensures that the ratio of structured and dissolved components in the food is maintained.

Grinding. When grinding a food product by grinding, crushing and destruction of the bulk of the cells occurs. When the microstructure of the food product is disturbed, the cell sap and its constituent enzymes, in particular hydrolytic ones, convert various substances in accordance with their specificity. Grinding makes it easier to isolate a certain group of substances by pressing.

Homogenization. Grinding food to a homogeneous, homogeneous state is similar to grinding, but is accompanied by a more intense mechanical effect.

Breakdown (beating). The main purpose of the breakdown is to facilitate chewing when eating food.

Sorting. In food production, various bulk materials are processed, which sometimes need to be separated by size and shape or by density.

Screening is a mechanical sorting on sieves having the same holes of different shapes.

Pressing. The application of an external force to capillary-porous bodies first causes partial destruction with shape refinement, and then a decrease in the volume of the body as a result of compression and separation of the liquid.

The methods of mechanical processing of food raw materials also include:

Cutting - dividing food into pieces of a certain size and shape using a cutting tool or mechanism

Chopping - cutting vegetables into small narrow pieces or thin narrow strips.

Beating - intensive mixing of one or more products in order to obtain a loose, fluffy or foamy mass.

Breading - applying p / f breading to the surface (flour, sugar crumbs, sliced ​​​​bread, etc.)

Rubbing - grinding products by forcing through a sieve to obtain a uniform consistency.

Stuffing - filling with minced meat specially prepared products.

Forcing is the introduction of vegetables or other products specified in the recipe into special cuts in pieces of meat, carcasses of birds, game or fish.

Loosening - partial destruction of the connective tissue structure to speed up the heat treatment process.

Thermal processes

Surface heating. In this case, the surface of the product is heated by contact with water, steam, hot fat, air or infrared rays.

Bulk heating. During volumetric heating, the energy of electromagnetic oscillations or electric current is converted into thermal energy in the product itself, and its entire mass is heated almost simultaneously.

Cooling. The product is cooled as a result of heat transfer to the environment. Products can be cooled in natural and artificial conditions.

Evaporation. When solutions boil, the concentration of dissolved substances increases due to the conversion of part of the solvent into vapor.

Condensation. It is the process of converting a vapor or gas into a liquid.

Considering the whole variety of processes, it should be noted that they have in common the presence of one of two possible types of transfer at each stage of the transformation of raw materials into finished products: energy transfer and mass transfer.

5. Types of control over the release of cottage cheese products

5.1 The concept and types of product quality control

Quality control refers to the verification of the conformity of the quantitative or qualitative characteristics of a product or process, on which product quality depends, to established technical requirements.

Product quality control is an integral part of the production process and is aimed at checking the reliability in the process of its manufacture, consumption or operation.

The essence of product quality control at the enterprise is to obtain information about the state of the object and compare the results obtained with the established requirements recorded in the drawings, standards, supply contracts, technical specifications. NTD, TU and other documents.

Control involves checking products at the very beginning of the production process and during the period of operational maintenance, ensuring that in case of deviation from the regulated quality requirements, corrective measures are taken to produce products of good quality, proper maintenance during operation and full satisfaction of customer requirements. Thus, product control includes such measures at the place of its manufacture or at the place of its use, as a result of which deviations from the norm of the required level of quality can be corrected even before defective or non-compliant products are released. Insufficient control at the stage of serial production leads to financial problems and entails additional costs. Quality control includes:

incoming quality control of raw materials, basic and auxiliary materials, semi-finished products entering the warehouses of the enterprise;

production step-by-step control over compliance with the established technological regime, and sometimes inter-operational acceptance of products;

systematic monitoring of the condition of equipment, premises, hygiene of employees;

finished product control.

5.2 Technochemical control over the release of cottage cheese products

The functions of technochemical control include:

quality control of incoming: milk, dairy products, as well as containers, supplies and materials;

control of technological processes of milk processing and production of dairy products;

quality control of finished products, containers, packaging, labeling and the procedure for the release of products from the enterprise;

control of consumption of raw materials and outputs of finished products;

control of the mode and quality of washing, disinfection of dishes, apparatus and equipment, as well as the sanitary and hygienic state of production;

control of reagents used for analysis and the order of their storage;

control over the state of measuring instruments.

Assessment of the sanitary and hygienic condition of the workshop, production site is carried out on the basis of data from technochemical and microbiological control of the quality of washing dishes, inventory and equipment, as well as on the basis of a visual inspection of the condition of the workshop, site and personal hygiene of workers.

Technochemical control of milk in the production of cottage cheese

) In milk intended for the production of cottage cheese from pasteurized milk, organoleptic indicators, fat content, acidity, density, protein content are determined from each container using cobalt sulfate solution as a standard.

In the production of fat-free cottage cheese, the mixture is examined for density, acidity, solids content by the express method or protein content.

) Control of normalization of milk. After thorough mixing, samples of pasteurized milk are taken from each container, in which the following are determined: fat content, density, acidity and protein content (by the method of formal titration), fixing the data in a journal.

The normalization of the mixture in the production of fat and semi-fat cottage cheese, taking into account the actual content of protein and fat in the original milk, is carried out according to the coefficients of the ratio between fat and protein. The coefficient is set for a certain period of time for each enterprise or zone. The method for determining the coefficient of conversion of protein to the fat content of the mixture is as follows: 3-4 control workings are carried out, in which the mixture is normalized according to the approximate coefficients of the ratio between fat and protein of the mixture, equal to: for fatty cottage cheese - 1.1; for bold - 0.55.

) Before fermentation of milk determine its temperature and the acidity of the starter. After adding the starter, the acidity of the milk is determined again.

) In the process of fermentation (coagulation) of milk, if necessary, check the temperature, its acidity and, at the last, the moment of adding a solution of calcium chloride and an enzyme preparation (rennet powder or pepsin) to the milk.

) Checking the concentration of calcium chloride solution and the activity of enzyme preparations added to milk when it reaches a certain acidity is carried out: for the first - every time after preparing a fresh solution, for the second - in each new jar entering the workshop.

) To determine the moment of cutting the clot, its acidity is checked. Then the acidity of the clot is determined at the moment of draining it into bags and in the process of self-pressing.

) The fat content in whey is determined in the average sample taken per day, and if necessary, the content of solids, density and acidity are determined. According to the same indicators, whey is checked after separation. To compile an average sample, whey is taken in proportion to its amount after draining from the container, after self-pressing and pressing the curd mass.

) At the end of the technological process, an average sample is taken from each batch of cottage cheese (i.e. made from milk of one container), in which organoleptic indicators are determined, acidity according to GOST 3624-67, fat content according to GOST 5867-69 (for fatty and bold cottage cheese ), moisture according to GOST 3626-47 or express method, periodically pasteurization of the product according to GOST 3623-56.

) In the production of fat and semi-fat cottage cheese (when low-fat cottage cheese is mixed with cream), before mixing the components, the following are determined: in cream - organoleptic indicators, fat content and acidity, and in fat-free cottage cheese - acidity and moisture content.

The quality of the finished product is checked in each batch according to the same indicators as in the production of cottage cheese using conventional technology.

Technochemical control of cottage cheese in the production of curd products

) Cottage cheese before using it for the production of curd products is subjected to organoleptic evaluation and analysis for fat content (for fatty and semi-fat cottage cheese) and moisture, acidity and periodically for pasteurization of the feedstock.

) The quality of the remaining components included in the composition of curd products according to the recipe is periodically monitored for compliance with their GOSTs and technical conditions.

) After mixing all the components in a kneading machine, a sample of the curd mass is taken for each batch before packaging, in which the following are determined: organoleptic indicators; fat content according to GOST 5867-69; acidity according to GOST 3624-67; moisture according to GOST 3026-47 or express method; periodically reaction to pasteurization in accordance with GOST 3623-56.

The obtained indicators are also referred to the finished packaged product. The number of components that make up the curd products is periodically checked by the actual filling, and the sucrose content is checked by the actual filling or by the refractometric method.

Periodically, but at least once a decade, the content of sucrose is controlled in sweet curd products according to GOST 3628-47, and in salted curd products - the salt content according to GOST 3627-57.

) Data on the control of technological processes for the manufacture of curd products are recorded in a journal.

6. Standardization and certification of curd and curd products

Tasks, basic principles and rules for carrying out work on state standardization in the Russian Federation are established by GOST R 1.0-92 "State standardization system of the Russian Federation. Basic provisions" and GOST R 1.2-92 "State standardization system of the Russian Federation. Procedure for developing state standards".

To develop standards for cottage cheese and cottage cheese products for the consumer, it is necessary to provide the following information:

name of the product (when using heat treatment, indicate the method of its heat treatment immediately before packaging and / or after packaging in consumer packaging);

the value of the mass fraction of fat in percent (not indicated for ice cream and glazed curds) for milk-containing products, including milk fat;

grade (if available);

name and location of the manufacturer [legal address, including the country, and, if not the same as the legal address, address (a) of production (a)] and an organization in the Russian Federation authorized by the manufacturer to accept claims from consumers in its territory (if any);

manufacturer's trademark (if any);

the value of the net weight or volume of the product;

composition of the product.

The ingredients that make up the glaze are listed in the general list of ingredients:

food additives, flavors, biologically active food supplements, ingredients of non-traditional products;

the nutritional value. In the information on the nutritional value of products that contain sucrose, in addition to the amount of carbohydrates, indicate the content of sucrose in 100 g (ml, cm of the product;

storage conditions;

date of manufacture and date of packaging;

expiration date (except for ice cream);

shelf life (for ice cream);

implementation period;

methods and conditions for preparing ready-made meals (for semi-finished dairy products and concentrates);

terms of use. Indicate only for therapeutic and prophylactic, gerodietetic products and for the nutrition of people with a specific professional and sports load; if necessary, indicate contraindications;

designation of the document in accordance with which the product is manufactured and can be identified;

conformity information. GOST R 51074-2003 Food products. Information for the consumer. General requirements

In order to protect the population from low-quality food products that can harm health and the environment, food products are certified for compliance with sanitary norms and standard requirements. The purpose of certification is to confirm that products are safe and of good quality. Food products of domestic and foreign production, intended for sale on the Russian market, must be certified.

In order to protect the population from low-quality food products that can harm health and the environment, food products are certified for compliance with sanitary norms and standard requirements. The purpose of certification is to confirm that products are safe and of good quality. Food products of domestic and foreign production, intended for sale on the Russian market, must be certified. Mandatory certification of food products is carried out for goods included in the Unified List of Products Subject to Mandatory Certification.

Certification of milk and dairy products is carried out for compliance with technical regulations (Federal Law of June 12, 2008 No. 88-FZ "Technical Regulations for Milk and Dairy Products"). The technical regulation imposes requirements for safety, packaging, labeling, requirements for special technological processes in the production, storage, transportation and disposal, and other aspects of the production of dairy products.

The list of milk and dairy products that are subject to technical regulation of this Federal Law includes: raw milk and raw cream, drinking milk and drinking cream, fermented milk liquid products, cottage cheese and curd products, sour cream and products based on it, cow's milk butter , butter paste, creamy-vegetable spread and creamy-vegetable baked mixture, cheese and cheese products, dairy, milk-containing canned food, ice cream and ice cream mixtures, functionally necessary components, milk-based baby food products, secondary products of milk processing.

The Technical Regulations for Milk and Dairy Products determine the requirements for the organization of washing and disinfection of industrial premises and equipment, for functionally necessary components used in production, requirements for baby food products, identification of milk and products of its processing, etc.

7. Organization of the workplace and use of equipment

The location of production workshops should ensure the flow of technological processes; technological communications (milk pipelines) - the shortest and most direct flows of raw materials and finished products.

The department for the preparation of starters should be located in the same production building with the main consumer shops, isolated from the production premises and as close as possible to the starter consumer shops. The room for the preparation of starter cultures should not be walk-through. At the entrance to the starter department, a vestibule for changing sanitary clothing and a disinfectant rug should be provided. The starter department must have a set of separate rooms in accordance with Section 13 of these SanPiN.

Preparation of solutions of food components from flour, sugar, protein supplements, etc. should be carried out in a separate room.

The walls of the main production workshops, as well as the starter department and laboratory, must be lined with glazed tiles (or other materials approved by the state sanitary and epidemiological service) to their full height, but not lower than 2.4 m, and above, to the bottom of the supporting structures, painted with water-based and other coatings approved for this purpose by the State Committee for Sanitary and Epidemiological Supervision of Russia; walls in storage chambers for finished products, thermal and cold storage rooms, as well as in the offices of shop managers, craftsmen, etc., can be painted with emulsion and other permitted paints; in warehouses for storing raw materials and materials, lime whitewashing of walls should be provided.

At workplaces near process equipment, leaflets on compliance with sanitary and hygienic and technological regimes, posters, warning notices, equipment washing schedules and modes, results of assessing the condition of workplaces, and other materials intended for production personnel should be hung out.

The temperature and relative humidity of the air in industrial premises, chambers and warehouses for the storage and maturation of products must comply with the sanitary standards for the design of industrial enterprises, the sanitary requirements for the design of dairy industry enterprises and the technological instructions for the production of dairy products.

Technological equipment, apparatus, utensils, containers, inventory, film and products made of polymeric and other synthetic materials intended for packaging milk and dairy products must be made of materials approved by the state sanitary and epidemiological supervision authorities for contact with food products.

Bathtubs, metal utensils, sinks, trays, gutters, etc. must have smooth, easy-to-clean interior surfaces, free of crevices, gaps, protruding bolts or rivets that make cleaning difficult. The use of wood and other materials that are difficult to clean and disinfect should be avoided.

The working surfaces (coverings) of food processing tables must be smooth, without cracks and gaps, made of stainless metal or polymeric materials approved by the state sanitary and epidemiological supervision authorities for contact with food products.

Technological equipment and apparatus must be painted on the outside with light-colored paint (except for equipment made or lined with stainless steel) that does not contain harmful impurities. Painting of utensils and inventory with paints containing lead, cadmium, chromium is not allowed.

The arrangement of technological equipment should be carried out in accordance with the technological scheme, ensuring the flow of the technological process, short and direct communications of milk pipelines, excluding oncoming flows of raw materials and finished products.

When arranging equipment, conditions must be observed that ensure free access for workers to it, sanitary control over production processes, the quality of raw materials, semi-finished products and finished products, as well as the possibility of washing, cleaning and disinfecting premises and equipment.

Equipment, apparatus and milk pipelines must be installed in such a way as to ensure complete drainage of milk, washing and disinfecting solutions. All parts in contact with milk and dairy products must be accessible for cleaning, washing and disinfection. Metal milk pipelines must be detachable.

Glass thermometers without a protective frame are not allowed to be used.

Tanks for the manufacture and storage of milk, cream, sour cream and other dairy products (except for those used for the production of cottage cheese) must be equipped with tight-fitting lids.

Apparatuses, bathtubs and other equipment in which dairy products are manufactured are connected to the sewerage with a jet break through funnels with a siphon.

Direct connection of the equipment to the sewerage system and the discharge of water from them to the floor are not allowed.

Intra-factory transport and intra-shop packaging should be assigned to certain types of raw materials and finished products and marked accordingly.

Conclusion

Thus, summarizing this work, we can draw the following conclusions:

In this paper, such a product as cottage cheese is considered in detail.

Cottage cheese is a lactic acid product prepared by fermenting milk with lactic acid bacteria and removing whey. Depending on the source of raw materials (whole or skimmed milk), fat, semi-fat and skimmed cottage cheese are distinguished. According to the standard adopted in Russia, fatty cottage cheese contains no more than 65% water, no less than 18% fat and 11% protein; acidity 200-225°T (°Turner); calorie content of 100 g of cottage cheese is 230 kcal (960 kJ). Cottage cheese - a product that is full in biological composition, is well absorbed.

There are main ways to produce cottage cheese:

acid;

acid rennet;

separated.

The range of dishes and cottage cheese products is very wide. In this paper, the following recipes are considered: "Curd mass with sour cream", "Curd mass with berries or fruits", "Curd cream", "Curd cheese balls" and "Curd cheese pancakes".

Also, the characteristics of the main and auxiliary raw materials for the manufacture of the above dishes are presented, useful properties are identified, their nutritional and energy values ​​are determined; describes the processes of preparation and manufacture of products;

The types of control over the release of products from cottage cheese are considered.

Highlight the main stages of standardization and certification of cottage cheese and cottage cheese products.

The organization of the workplace and the use of equipment in the production of cottage cheese and cottage cheese products are described.

List of references

1. Federal Law of June 12, 2008 N 88-FZ "Technical Regulations for Milk and Dairy Products

2. Instructions for technical and chemical control at the enterprises of the dairy industry

Z.P., Korolkova E.P. Merchandising of food products: A textbook for the beginning. prof. Education: Proc. allowance for Wednesdays. prof. Education - 2nd ed., Sr. - M.: Publishing center "Academy", 2003. - 272p.

Collection of recipes for dishes and culinary products. Normative documentation for public catering establishments: Educational and methodological manual / Comp. A.V. Rumyantsev - 3rd ed., revised. and additional - M.: Publishing house "Business and Service", 2002. - 1016s.

Chemical composition of food products. Reference tables of the content of basic nutrients and the energy value of dishes and culinary products. - M .: Light and food industry, 1984. - 328s.

Golubeva L.V., Polyansky K.K., Chekulaeva L.V., Technology of products for preserving milk and milk raw materials, 2002.

Kastornykh M.S., ed., Commodity research and examination of edible fats, milk and dairy products, M .: 2003.

Kruglyakov G.N., Kruglyakova G.V., Merchandising of food products, Rostov-on-Don, 2000.

Krus G.N., Khramtsov A.G., Technology of milk and dairy products, M.: Kolos, 2002.

Kunizhev S.M., Shuvaev V.A., New technologies in the production of dairy products, M .: DeLi print, 2004.

Cottage cheese is a protein fermented milk product made from milk by fermentation, followed by the removal of a part of the whey clot and pressing the protein mass. Cottage cheese is made from whole, normalized or skimmed milk. Cottage cheese happens: fatty - 18%, bold - 9%, low-fat.

Organoleptic indicators.

The taste and smell are clean, sour-milk, the texture is tender, homogeneous, for fatty it is allowed to be soft, for non-fat it is crumbly. Color - white, with a creamy tint.

Microorganic indicators.

Bacteria of the Escherichia coli group are not allowed in 0.01g of the product. Salmonella is not allowed in 25g of the product. Staphylococcus aureus is not allowed in 0.1g of the product.

The composition of cottage cheese protein includes essential amino acids, methionine and choline - are recommended for diseases of the cardiovascular system. Milk fat of cottage cheese is digested by 95%.

Methods for the production of cottage cheese.

1 Acidic.

2 Acid-rennet.

3 Separate (adding high-fat cream to the curd).

In acid: casein coagulation occurs under the action of lactic acid. With this method, the clot has a good consistency, however, in the production of fatty cottage cheese, whey is more difficult to separate. The most cost effective.

Acid rennet? coagulation occurs under the action of lactic acid and rennet and lipepsin. Rennet enhances the process of separating whey from the clot.

General technological scheme.

1 Acceptance and preparation of raw materials.

2 Purification of milk from mechanical impurities. t 25-45 degrees C.

3 Homogenization P - 6 MPa, t - 50 degrees C.

4 Cooling milk to t - 4 degrees C, stored for no more than 6 hours.

5 Normalization and heating. It is carried out taking into account the mass fraction of protein, depending on the normalization coefficient for each type of cottage cheese.

6 Pasteurization t -78 degrees C, 10-20 sec. Elevated pasteurization regimens will promote protein denaturation, which increases density, and impairs whey separation.

7 Storage of milk. Cooling to 4 degrees C, storage no more than 6 hours.

8 (Acid). Fermentation t - 30 degrees C in the summer, 32-35 - in winter. Mesophilic lactic streptococci are used. When using symbiotic starter cultures, fermentation at t - 32 degrees C.

8’ (Acid-rennet). Addition of calcium chloride and milk-clotting enzymes to milk. Calcium chloride is introduced: 400 g of anhydrous calcium chloride salt per 1 ton of milk, in the form of a 40% solution. After that, we add rennet at the rate of 1 g per 1 ton of milk.

9 Souring. The end of fermentation is determined by the acidity of the clot. For 18% and 9% cottage cheese - acidity 61grad T, for low-fat 65gradT, fermentation 6-10 hours (for acid-rennet). For acidic 18% and 9% - 75 degrees T, non-fat - 85 degrees T, the duration of fermentation is 8 - 12 hours.

10 Curd treatment and cooling. Cutting into curd grains, whey begins to separate (syneresis), while the whey is removed from the curd bath.

11 Self-pressing and curd pressing. Pressing is carried out when the mass fraction of moisture reaches 65 - 73%. For pressing, the curd grain is placed in lavsan bags, tied up and placed on a harness. . Under the influence of its own mass, whey continues to stand out, this process lasts no more than an hour at t - 15-17 degrees C. The end of the process is determined visually by the disappearance of gloss from the surface of the clot. The curd is then pressed using various installations where cooling and pressing takes place. At the same time, the temperature of the curd is 8-10 degrees C. Additional cooling to t - 6-8 degrees C.

12 Packaging. Consumer packaging - parchment, foil, cups; transport packaging - aluminum packaging, plastic boxes up to 15 kg.

13 Storage. No more than 36 hours at t< 8градС.

Curd defects and methods of their prevention.

Defects of taste and smell.

1 Feed taste - transmitted from milk, in the autumn-winter period, a slight feed smack and low-fat cottage cheese is allowed.

2 Unclean, old, musty taste and smell. Due to poorly washed containers, storage in a poorly ventilated area, the development of microorganisms.

3 Too sour taste. Non-compliance with the temperature regimes of fermentation, increased lactic acid fermentation; lengthening of terms of self-pressing and pressing, untimely cooling.

4 Acetic-sour taste and smell. Development of acetic acid bacteria due to elevated storage temperatures.

5 rancid taste. With the development of butyric acid bacteria in the curd, which secrete the enzyme lipase, they develop if the pasteurization regimes are not observed.

6 Bitter taste. Due to the quality of raw materials.

Consistency defects.

1 Rough, dry, crumbly. Increased heating temperature during the processing of the clot and its excessive crushing.

2 Rubbery texture. It is typical for cottage cheese produced by the acid-rennet method, with the introduction of increased doses of rennet.

3 Smeared consistency. When fermenting cottage cheese.

4 Bloating. Caused by yeast, with insufficient cooling of the curd at an elevated storage temperature.

5 Isolation of serum. Insufficient pressing.

6 Mudiness and moldiness of cottage cheese. It is observed with loose packaging, with a loose fit of the lid to the curd, and in violation of temperature and humidity conditions.

A fermented milk product, known in Russia as cottage cheese, and in European countries as “young cheese”, is popular in our country. Delicious, satisfying and healthy, it has been instilled in Russians since childhood. Now there are many manufacturers of this food product on the market, but despite this, the business for its production has great prospects. The consumption of dairy products per person in the Russian Federation is 252 kg/g. For comparison, in the USSR in 1990, the norm was 386 kg / g. In the countries of the USA and Western Europe now - 390 kg/g.

The data shows that the domestic market has room to grow. New manufacturers are required - a good product will always find a buyer. In the article, we will present a business plan for opening a line that produces cottage cheese, study the features of the business, and conduct economic calculations of the payback of the business.

Demand for curd products in Russia

Cottage cheese is a fermented milk protein product obtained from fresh milk. It is bought by all categories of the population - it is suitable for both children and diet food.

The market for curd products in Russia is studied annually. Recently, the volumes of production and consumption are unstable (there are recessions and rises), but in general, the indicators are growing. In 2015, 1 average Russian bought and ate 9 kg of this product (compared to 2011, an increase of 0.7 kg).

Experts predict that by 2020-2022. sales will grow by 10-13% every year (medium forecast).

Long-term prospects are bright: the physiological norm of consumption is 18 kg per year (against 9 kg in 2015). The demand will continue to grow - this is a chance for new manufacturers.

Market assessment

In 2017, 493.1 thousand tons of cottage cheese were produced (21% more than in 2016). Most of the goods were created in the European part of Russia (CFD). The Central Federal District accounted for more than 41% of the total production.

Average price increase for this product from 2015 to 2018 amounted to 16.4% (up to 193.9 thousand rubles per 1 ton). The average price of 1 kg of a fatty product in 2018 is 290.4 kg (retail).

The largest companies:

• LLC "Danone Industry";
• JSC "Wimm-Bill-Dann";
• LLC "Dairy business";
• OOO "Molvest";
• CJSC "Yantar"

Several well-known regional manufacturers:

• "Ostankino Dairy Plant"
• RostAgroComplex,
• Dmitrovsky Dairy Plant.

The competition is high, consumers are more likely to look for a high quality product.

Initial investment in branded cottage cheese production

Items that will require the most expenses: equipment for cottage cheese and raw materials. The salary is high enough (the exact amount depends on the position) to motivate employees to work responsibly and hold on to the place.

Table 1. The amount of initial costs for the business of cottage cheese production.

We will open a business in a city with a population of up to 1 million people. In additional expenses - the cost of utility bills, advertising, cosmetic repairs.

Technological scheme of own production

The factory production scheme is as follows:

1. Raw milk is being prepared. After assessing the quality, the milk is pasteurized (treated at high temperature for 30 minutes).
2. Separation is carried out (separation of cream from the milk mass).
3. Sourdough is added to milk. Within a few hours, fermentation occurs, that is, the process of product formation itself. There are several ways (more on that below).
4. After protein coagulation, whey is squeezed out of the resulting clots. They are left for a certain time to completely remove residual liquid from them.
5. The clots are left in a special bath or trolley for pressing. Using a wire knife, the curd mass is cut into small cubes (0.2 m each).

After cooling, the product is packed in containers (briquettes, flasks, boxes) and stored in a refrigerator.

How high-quality cottage cheese is made in production

Making cottage cheese at home is easy. You will need milk, sour cream and a container for fermentation. Milk must be boiled, then cooled to 30 ° C and put sour cream into it (calculated as 100 g per 2 liters of milk). The mixture is left in a warm place for 9 hours for ripening. After the resulting mass is transferred to cheesecloth, squeezed and hung for self-pressing and final removal of whey.

Several methods are used in industry:

• Traditional. It is similar to the technology for the production of cottage cheese at home.
• Acid-rennet. Lactic acid and rennet are used for fermentation.
• Separated. The most common in the industry for the production of cottage cheese with full automation.

Traditional curd technology

With this method, a practically fat-free product is made.

First, raw milk is prepared: it is separated to normalize the fat composition and pasteurized. Milk is heated to 78 ° C for half an hour - this is how pathogenic microorganisms are removed while maintaining beneficial properties.

After the mass is cooled to 28-32°C. Rennet and calcium chloride are added to it for subsequent fermentation.

After protein folding, the resulting clots are separated, pressed and cooled (to stop the fermentation process). The protein product is packaged and stored in refrigerators.

The cottage cheese production technology has several drawbacks, the main of which are the duration of the process and the need for manual labor. There is a risk of intestinal infections getting into the cottage cheese. The best option for the production of cottage cheese at home.

Acid-rennet

Medium/high fat cottage cheese is prepared with this method. The main ingredients are rennet and lactic acid. In a certain proportion (from 1 to 5% of the total mass), sourdough is mixed with milk - lactic acid streptococcus. If you do not have your own laboratory in production, you can buy the starter in special laboratories, if available, you can make it yourself according to a certified method.

After that, rennet is added to the mixture - a catalyst for the process of protein coagulation. The enzyme is prepared in advance - for 6 hours in water heated to a temperature of 35°C.

After the formation of clots, they are also pressed, whey residues are removed from them. The product is packaged and sent to the refrigerator for cooling and storage.

Separated

This method of making cottage cheese in production was developed in the Soviet Union and has been used since the 1960s. Its essence is the manufacture of a low-fat product with further connection with cream to achieve the desired fat content.

The separate method is used in large-scale production: it optimizes costs, minimizes fat loss and fully automates the process. Special tables have been developed that calculate the exact consumption of cream. This method helps speed up the whey separation process.

Pasteurization of milk is carried out in special production lines, fermentation - in containers with automatic mixers. The resulting clots are subjected to heat treatment to destroy harmful microorganisms, then they enter the separators to separate the whey. At the end, the cottage cheese is mixed with cream in the right proportions.

Equipment for the production of cottage cheese

The business plan considers an automated line for the production of cottage cheese A-TL-3 worth about 1.5 million rubles. Produces according to traditional or acid-rennet methods. Equipment for the production of cottage cheese meets the requirements of GOST.

The production of cottage cheese at factories is carried out in the presence of:

• cottage cheese producers of the Republic of Tatarstan, 2 pcs.;
• curd curd pressing unit UTS-500;
• semi-automatic boot ATL;
• filling machine (12-25 packs / min);
• rotary pump.

2-3 people are required for service. It can produce up to 1.8 tons (75 kg/h) per day.

The filling machine can pack the product into briquettes, plastic bags or plastic containers.

Also, for the production of cottage cheese, a pasteurization bath will be required. It is needed for the preparation of milk and refrigeration units for storing the finished product.

Raw material

The production of cottage cheese requires milk and sourdough.

Even at the preparatory stage, it is necessary to study the market well for suppliers of raw milk, to find suitable producers / sellers of milk.

It will be required in large quantities and constantly, so look for a supplier near your workshop. This, firstly, will reduce logistics costs, and secondly, it will ensure regular delivery of milk (lower the risk of supply disruptions).

It is better to cooperate only with trusted suppliers who have quality certificates, permission from Sanepidnadzor.

Before starting work, the entrepreneur must already have contracts for the supply of milk.

There are many manufacturers of starter cultures now - it is easy to find a product at the right price and in the required quantity.

room

All requirements for the production premises are specified in SanPiN 2.3.4.551-96 "Production of milk and dairy products".

The space of a mini-factory should be divided into several rooms - a working workshop with equipment (at least 30 sq. M), administrative rooms, an area for workers, a bathroom.

It is obligatory to have all communication systems - electricity, water (according to GOST 2874-82), ventilation, heating.

The walls in the production hall are tiled, the floors are waterproof, non-slippery, inert to acids.

It is recommended to order the development of an architectural project with a master plan and justification for decisions on the arrangement of the workshop.

Staff

Modern machines are automated, doing all the work itself. This reduces the workforce and labor costs. But the staff needs to be trained, taught to operate the equipment. When purchasing a production line, it is possible to agree on the training of employees from the seller. A minimum of 2 people are required to operate.

We also need experienced specialists who know how to process milk and make high quality cottage cheese (2 people).

A minimum of 1 driver is required (can be hired with your own car). It is important to find a sales manager who will create a distribution network for the product. An accountant at the initial stage of development can be hired by outsourcing. For loading and unloading work will require a handyman.

A working staff of 8 people is enough to launch and develop a small production of high-quality cottage cheese.

Documentation of business

First, select the form of economic activity for doing business - an individual or legal entity, individual entrepreneur or LLC.

Businessmen planning to open a large plant need to work in the form of an LLC - then they can conclude profitable contracts for raw materials and sales (with wholesalers). An individual entrepreneur can sell goods to his friends, deliver to small stores.

When registering, indicate the OKVED code 15.51.14 "Production of cottage cheese and curd cheese products."

To get started, get permission from the Fire Inspectorate and the Sanitary and Epidemiological Station. Based on the results of all checks, a license will be issued (valid for 5 years).

The first batch of goods is sent for certification. If the requirements of GOST 31534-2012 are met, the entrepreneur will receive a quality certificate, which he will be able to present to counterparties when organizing sales.

Distribution channels for finished products

Curd is a perishable product. It is necessary to start its production when distribution channels are established.

If the business operates in the form of an LLC, potential buyers will be:

• Retail Stores;
• trade and retail grocery chains;
• wholesale bases engaged in resale;
• manufacturing companies that manufacture products based on / with the addition of our product;
• catering establishments (canteens, cafes/restaurants).

Individual entrepreneurs will be able to sell goods to friends and acquaintances through word of mouth and organize sales "from the car" - that is, to purchase special vehicles and sell them in residential areas. Soon there will be loyal customers who are determined to buy specifically his product.

Promotion

The level of competition in the segment is high, and for success, a businessman needs to make sure that consumers recognize and want to buy his product. Firstly, you need to produce a high quality product, and secondly, think over marketing activity in advance. There are several low-cost ways to promote:

• advertising in the media (in particular, in newspapers);
• promotion in social networks, order advertising in VKontakte groups;
• flyers and other POS materials for distribution and posting in high traffic areas.

Selling in neighborhoods with your car is useful not only for sales, but also for promotion. So you can teach customers to look in grocery stores specifically for their product. This method requires additional costs, but it is effective.

Profitability and payback: financial plan

The initial investment will amount to 3.88 million rubles.

The productivity of the equipment per hour is 75 kg, 600 kg of product can be produced in an 8-hour day. For a month (22 days) it is realistic to produce 13.2 tons.

To prepare 1 kg of fermented milk product, 6.67 kg of milk is needed. This means that 88 tons of raw milk will be required per month (1 kg costs 15 rubles). Accordingly, the amount of monthly expenses is approximately 1.8 million rubles. (including other articles).

The average cost of 1 kg is 150-200 kg (wholesale). For a month, you can sell products for 2.24-2.64 million rubles.

Net monthly profit will be 440-840 thousand rubles. The difference between these values ​​is large, since the range of wholesale and retail prices on the market is large (the price depends on the fat content and quality of the product).

Payback period - from 5 to 9 months.

Table 2. Economic rationale for a business idea.

When concluding long-term supply contracts, the business is attractive for investment. However, there are many manufacturers and intermediaries on the market. To attract customers, you may have to offer goods at lower prices - because of this, the payback period will increase.

With the development and improvement of positions, you can expand. Start producing curd products, open your own farm - this will allow you to increase the range and reduce the cost.

The opening of a mini-factory for the production of cottage cheese, with proper development, will allow the entrepreneur to receive a source of large income with the prospects for further transformation into a large enterprise. And besides, there will always be dairy products at home, the freshness and usefulness of which will not be in doubt.