Preparation of raw materials for the production of confectionery.

Bulk storage of liquid raw materials

Bulk storage of raw materials of liquid consistency is carried out in accordance with certain rules and taking into account the characteristics of a particular type of raw materials,

Fruit and berry raw materials when used in large quantities, it requires significant areas for its storage and compliance with certain conditions. Therefore, many large enterprises have railroad warehouses located at a short distance from the main enterprise (10 km). Raw materials are delivered to production in tanks of various capacities with thermal insulation. The tank is filled from tanks by gravity through a pipe with steam heating. At the factory, raw materials (mashed potatoes, pulp) flow from the tank by gravity into a deep container.

Bulk storage warehouses (Fig. 4.5) can be located in the basement, 5 km away from the factory. Subject to a temperature of 0-10 ° C, the raw material will be stored for a year. I At the same time, weekly monitoring of the content of sulfur dioxide (preservative) is necessary. If its amount becomes below the norm (0.1-0.2%), additional sulfitation is carried out directly in storage containers. Puree is delivered to the factory in special tanks with a capacity of 2.5 tons. The car with the tank stops near the tank. The tank with raw materials is removed by a forklift and installed on an inclined frame. Then the drain pipe opens, the raw material flows by gravity into the receiving tank of the screw pump 1V-20/10 and is pumped into tanks with a capacity of 1.8 tons, made of stainless steel 4 mm thick. As needed, raw materials are fed for processing.

The tank (Fig. 4.6) is an all-welded cylindrical tank with elliptical bottoms, installed on a concrete foundation. The inner surface and planes of the fittings are covered with glass enamel for protection against corrosion, which is resistant to acidic environments, has high sanitary and hygienic properties and mechanical strength. Non-enamelled parts and components in contact with the product are made of stainless steel. Fasteners are protected by a special anti-corrosion and decorative coating.

Warehouse for bulk storage of apple, strawberry, apricot puree can be organized directly at the confectionery factory. Raw materials are delivered in barrels by rail. After the quality control of the average sample of the raw material and the determination of its suitability for processing, it is stored in containers. For this purpose, the barrels are placed on a rack, opened, the contents are poured into one of the containers and pumped into storage tanks.

Before filling the container, fumigate with sulfur dioxide. When filling out, a passport is drawn up indicating the date of loading, type of raw material, sulfur dioxide content, solids, mineral impurities, acidity. During storage, constant monitoring of these parameters is necessary. Filled containers are sealed (close the lid, valves). The amount of raw material is determined by measuring tube.

Molasses - the main raw material in the production of most confectionery products, therefore, its significant stocks are required. Usually, molasses is stored in special metal tanks installed on the territory of the factory or in other premises (Fig. 4.7). When storing molasses indoors, the factory requires large areas for storage, but the length of pipelines is reduced and a relatively constant temperature is ensured during storage. Molasses is transported to enterprises in railway tanks with a capacity of 50 tons, in tankers - 3.5 -5 tons. It is delivered to small enterprises in barrels with a capacity of 250 - 300 kg and in smaller containers.

When delivering molasses in tanks, the receiving devices must be buried for at least 2 m. The molasses is drained by gravity into the tanks. Steam is required to heat the molasses when unloading tanks in winter.

The tanks are equipped with coil heating, providing a temperature of about 40 ° C, while the viscosity of the molasses decreases, which allows it to be pumped.

In order to more economical use of storage space, tanks of rectangular or square section are used. There must be a distance of at least 0.8 m from the top of the tanks to the protruding parts of the ceiling.

At a number of confectionery enterprises, areas for bulk transportation, storage and transfer to fat production have been organized.

confectionery fat is transported in metal containers equipped with an internal coil and a fitting for supplying steam or hot water, draining the product and draining condensate or water. On the top cover there is a hatch for pouring fat. To receive and store liquid fat, a metal tank with coil heating with a capacity of 6 m 3 can be used.

There are installations for bulk reception, storage and transportation of liquid fat, equipped with an automatic device for maintaining a constant fat temperature of 40-45 ° C and an automatic signaling device. The fat storage tank is made of stainless steel and has a capacity of 2 m. The propeller mixer ensures the homogeneity of the fat, the steam-water jacket provides heating

Milk And dairy are delivered in bulk to the enterprises in tank trucks and pumped into aluminum containers with a cooling jacket, an insulating layer, wooden lining and a protective casing.

The temperature of cold water entering the jacket should not exceed 12 - 14 °C. Filling of milk is carried out through a branch pipe on a cover of capacity, selection of milk - from below. The vacated container should be washed periodically. Wash water is used to prepare syrups. Thorough washing is carried out periodically with a mixture of warm water and detergent. Dirty water is drained into the sewer.

Chocolate glaze, cocoa butter, cocoa mass are transported in a car boiler with a capacity of 5 tons and in other ways (Fig. 4.8).

The introduction of bulk transportation, storage and transfer to the production of raw materials at confectionery enterprises improves the culture of production, saves production space, and makes it possible to release workers.

Molasses (starch, maltose, refined) may be transported and stored only in clean containers with tight-fitting lids. Store molasses in a cool place.

Before being used in production, the molasses is passed through a sieve with a mesh size of not more than 3 mm. Molasses is preheated to (42 ± 2) ° C to reduce viscosity. It is allowed to dilute with water to obtain a solution of a certain density within 1, 2.

Honey is stored in a cool, dry room at a temperature of 5-10°C packed in wooden barrels, glass containers (up to 1000 g), milk flasks, cans and cans made of tin or tin-plated iron. Before being used in production, honey is passed through a sieve with a mesh size of 3 mm.

Vegetable oils are stored in closed dark rooms at a temperature of (19 + 2) degrees. Oils delivered to bakeries in railway tanks or tank trucks are poured into receiving tanks, from which they are sent to production through pipelines.

Before being used in production, the oil is passed through a sieve with a mesh size of not more than 3 mm.

Liquid margarine is transported in tank trucks with thermal insulation, containers, flasks, subjected to special treatment and approved for the transport of food products. Liquid margarine is stored at a temperature not exceeding 17% for no more than 48 hours from the moment of production.

Solid fats, margarine and cow butter are stored in refrigerated warehouses or refrigerators with constant air circulation at a temperature not exceeding 10%. Solid fats, margarine and cow's butter are used in melted form.

It is allowed to use unmelted fats for the preparation of certain types of products, for example, puff pastry products.

Liquid fat for the baking industry is used in accordance with the technological recommendations for its use. Shelf life at a temperature of (17 ± 2) ° C is not more than 10 days.

To receive fats in a container, the T1-HUZH installation has been developed. It is designed for mechanized kindling of solid fat products, as well as for transporting liquid fat into storage containers. The T1-HUB unit (Fig. 16) is designed for bulk reception, storage and pumping of liquid fat.

Rice. 16. Scheme of installation for storage of liquid fat T1-HUB: 1 - tank for fat storage; 2 - device for pumping fat; 3 - filter for air purification; 4 - compressor; 5 - supply tank.

Liquid fat is delivered to the enterprise in bulk in tank trucks, pumped to storage devices, where it is stored at a constant temperature (40-45 ° C) and agitated to prevent its delamination.

Starch syrup is one of the main raw materials in the confectionery industry. It is used in the production of certain types of flour confectionery. It is used as an anti-crystallizer for syrup. By introducing it, you can change the hygroscopicity of confectionery and semi-finished products. The molasses should be a thick, clear liquid. For molasses, an uncharacteristic taste and smell, as well as the presence of mechanical impurities, is not allowed. Physico-chemical indicators of molasses are shown in table 19

Table 19 - Physical and chemical indicators of molasses

At confectionery factories, molasses is stored in bulk. Molasses are brought to the production in specialized tanks, pumped into a container for storing molasses (pos. 17), then using a pump (pos. 13), molasses is pumped into a container for weighing and filtering (pos. 18). After weighing, the molasses is pumped with a pump into a supply tank (pos.19).

Preparation of citric acid

Citric acid is a tribasic hydroxy acid.

The enterprise receives citric acid for the enterprise in paper bags of 40 kg. Citric acid is stored in closed warehouses on pallets at a relative air humidity of not more than 70%.

In accordance with GOST 490-2006, according to organoleptic indicators, they must meet the following requirements table 20

Table 20 - Organoleptic characteristics of citric acid

As necessary, citric acid is sifted through a sieve with a mesh size of 3 mm (pos.16). The sifted raw material is collected in an intermediate container (a plastic box with a lid) and transported to production. Dosed manually.

Preparing for the production of flavors

They are synthetic fragrances. Synthetic flavors give products the same flavor as natural flavors.

Flavorings arrive at the enterprise in plastic canisters weighing from 5 kg to 30 kg. They evaporate quickly and are highly flammable, so they should be stored in a separate, well-ventilated room at a temperature not exceeding 15ºC and a relative humidity of not more than 75%. Before use, the flavors are filtered through a sieve (pos. 20) with cells no larger than 0.5 mm or through two layers of gauze (pos. 16). Transfer to another container is not allowed.

The quality of confectionery products largely depends on the raw materials used for their preparation. Therefore, the confectioner must know the properties of each product well, be able to prepare it and use it correctly. The preparation of various types of raw materials used for the production of flour confectionery products is considered below.

Flour. Before kneading the dough, the flour must be sifted in special sifters or manually through a sieve. When sifting, random impurities are removed, the flour is enriched with air, which facilitates kneading the dough and contributes to its better rise. If confectionery products are prepared from flour of different grades or with the addition of starch, then the flour is mixed simultaneously with its sifting. In winter, if the flour has a low temperature, it is brought into the room in advance so that it heats up to 12 °. In the manufacture of dough, especially yeast, its temperature during kneading affects the quality of the products.

Starch. Just like flour, starch is sifted and added to some types of dough. This gives the product a greater friability. The starch provided in the recipes can be replaced with the same amount of wheat flour.

Milk. Whole milk is mainly used to make yeast dough and creams. It should be immediately sold, and if necessary, stored - heated to a boil, cooled and stored at a temperature of 1-5 °. Before use, the milk is filtered through a sieve with 0.5 mm cells. Whole natural milk can be replaced with condensed or powdered milk, while 1 kg of whole natural milk is replaced with the following amount of other products (in g):

Condensed whole with sugar (with a decrease in the norms of laying sugar by 176 g) ...................................... 400

Condensed fat-free with sugar (with 140 g less sugar and 30 g fat) ...... 330

Dry whole .............................................................. ................................................. ................................................130

Powdered milk is sifted and dissolved in warm water before use. To do this, determine according to the table how much milk powder should be taken to replace the required amount of natural milk. Water is taken so much that its weight together with the powder is equal to the weight of the replaced milk. This is 870 grams of water per 130 grams of milk powder. To prevent lumps from forming, a little warm water is first poured into the powder, stirred well, and then the rest of the water is added and, stirring, brought to a boil.

Example. Let's assume that to make a cinnamon pie, 5 kg of flour, 1 kg of sugar, 1 kg of margarine, 2 kg of milk, 1.075 kg of eggs, 0.2 kg of yeast, 0.050 kg of salt are required. It is necessary to replace natural milk with condensed skimmed milk with sugar.

It is known that 1 kg of milk is replaced by 0.330 kg of condensed skimmed milk with sugar. Therefore, it will take 0.330? 2 = 0.660 kg. At the same time, it is necessary to reduce the amount of sugar by 0.140? 2 = 0.280 kg take it not 1 kg, but only 1.000 - 0.280 = 0.720 kg. Accordingly, the margarine bookmark should be increased by 0.030? 2 = 0.060 kg. With such a replacement, the yield of the product will decrease, since instead of 2 kg of milk 0.660 + 0.060 = 0.720 kg of substitutes is taken, the sugar content is reduced by 0.280 kg, therefore, about 1 kg of raw materials is not reported. In this regard, in order to maintain the yield rate, condensed milk is diluted with the same amount of water.

The condensed milk used for the preparation of confectionery products is preheated to 40°C and then filtered through a 0.5 mm sieve.

Butter. Butter increases the calorie content of products, improves their taste, enhances aroma. If the surface of the oil is contaminated, the oil is cleaned. Unsalted butter can be replaced with salted butter (salted butter cannot be used in the manufacture of creams). In the manufacture of all confectionery products, except for puff, butter biscuit and cream, butter is sometimes replaced with melted butter (1 kg of butter corresponds to 840 gtop of flax). Store the oil at a temperature of 2-7 ° in a dark room. Under the influence of light and oxygen in the air, the oil deteriorates. When using oil with the M brand (oil obtained by continuous separation according to the method of engineer Meleshin), the cream formulation changes somewhat in accordance with departmental instructions and orders. Oil obtained on oil-making or other batch-type machines and marked with the letter K is intended for confectionery production.

Margarine. For the preparation of confectionery, it is prepared in the same way as butter.

Deep fats. These fats are used when frying in a large amount of fat pies, donuts and brushwood. Mixtures of vegetable and animal fats are most suitable for this purpose. A mixture of 30% lard, 30% beef tallow and 40% vegetable oil can be heated to a high temperature without producing smoke. You can use refined sunflower, cottonseed or soybean oils for deep-frying, as well as kitchen fats, since they contain almost no moisture and withstand heating to high temperatures. When frying in vegetable oil, special care should be taken to ensure that the fat does not overheat more than necessary.

Before frying products, deep-frying is heated until the water contained in it has completely evaporated and “blue smoke” appears above its surface, which usually indicates the process of decomposition of fat impurities that has begun. This kind of heating of fat is called calcination.

Eggs. Eggs are used in the production of some creams, air, almond and yeast dough. Before use, check the freshness of the eggs with an ovoscope. With prolonged storage of eggs, the yolk shell becomes fragile and easily torn. These eggs cannot be used for the preparation of products where it is necessary to separate the yolks from the proteins.

Contaminated eggs are washed before use. They are placed in a bucket with holes in the walls and at the bottom, or in a basket and immersed in warm water. After 5-6 minutes, they are washed by raising and lowering the dishes into the water. Heavily contaminated eggs are washed with a brush. To remove germs, eggs are disinfected after washing by dipping them in a 2% bleach solution, and then washed in the shower. Dry the eggs in the same bowl for 5-10 minutes. Eggs are processed in an isolated room or in a specially designated place.

Before use, the eggs are split on a special device or on a sharp, hard object. Eggs should be beaten into dishes (no more than 3-5 pieces), and then, having determined their good quality, poured into a common cauldron. Beaten prepared eggs are filtered through a sieve with 3 mm cells.

The weight of one egg ranges from 40 to 60 g, the average egg weight is 43 g (yolk 20, protein 23 g). Eggs can be replaced with various egg products or dry whites or yolks. However, in the manufacture of creams, it is impossible to replace eggs with other products. 1 kg of eggs can be replaced with 1 kg of melange, or 350 g of yolk and 650 g of protein, or 278 of egg powder.

Melange - a mixture of proteins and yolks, or separately proteins and yolks, is stored in cans at a temperature of -18 to -25 °. Defrost the melange immediately before use. Previously, a jar of melange is doused with a chloride solution, and then washed with warm water. Cans are opened with special can openers. The frozen melange is taken out of the jar, cut into pieces and thawed for 15-20 minutes on a food warmer at 40-45°. The prepared melange is filtered and used immediately, as it quickly deteriorates.

Egg powder is sifted before use, and then dissolved in water (0.35 liters of water per 100 g of powder). For better dissolution of the powder, first pour in a little warm water (35-40 °), rub it thoroughly and, continuing to stir, pour in the remaining water. After 25-30 minutes, the powder swells and can be used. The weight of one medium-sized egg corresponds to 12.5 eggs powder and 30.5 gvoda.

Sugar. Granulated sugar. Pass through a 3 mm sieve before use.

Powdered sugar is used for finishing confectionery and for preparing some types of dough. In the absence of ready-made powder, it is easy to prepare it from refined sugar, which is ground in a grinder or in a mortar, and then sifted through a fine sieve. You can replace 1 kg of sugar with 1.33 g of caramel molasses, or 1.46 kg of syrup, or 1.2 kg of honey.

Honey and caramel syrup. Before use, honey and molasses are heated to 40-45 ° and filtered through a sieve with 2 mm holes. You can replace 1 kg of molasses with 1.1 kg of syrup or 0.75 kgsa-hara.

Soda and ammonium carbonate. They are sifted through a sieve or dissolved in cold water and filtered. Ammonium is preliminarily crushed in a mortar. Store carbonic acid, ammonium in a hermetically sealed container, as it is volatile.

Yeast. Yeast is stored in a dry room at a temperature of 2-8 ° and a relative humidity of 70-75%; packs of yeast are laid out at a distance of 3-5 cm from each other. Before use, the yeast is freed from paper, dissolved in warm water and filtered through a sieve. For drying, the yeast is rubbed through a sieve onto a baking sheet or board covered with paper, with a layer of no more than 2-3 mm. Yeast is dried at a temperature not exceeding 35 °, since at a higher temperature they lose their activity. Mix 100 dry yeast with 1 kg of flour and dilute in 3 liters of warm water (27 °). After an hour, they can be used to make dough. Dry yeast is taken by weight 3 times less than fresh. If the dry yeast has been stored for a long time, the bookmark is increased, since the activity of the yeast decreases during storage.

Spices. Spices are used in small quantities, otherwise you can spoil the taste of products. Before use, the spices are dried at 50-60 °, then ground in a mortar, grated, ground in micromills and sifted through a sieve with 1.5 mm mesh openings. Aromatic substances are stored in a dry room, in a tightly closed container, each type separately, as they easily transfer their aroma.

Small table salt is sifted through a sieve, and the salt in large crystals is pre-dissolved, and then the solution is filtered through a sieve with 0.5 mm cells.

Crystalline acids are filtered through a sieve with a mesh size of no more than 2 mm, and liquid ones are filtered through a cloth, gauze or sieve with cells of no more than 0.5 mm. Citric acid is dissolved in hot water (70-80 °) in a ratio of 1:1. In the manufacture of confectionery, the dosage of dissolved acid indicated in the recipe is doubled. Citric acid can be replaced with tartaric acid in a ratio of 1:1 or malic acid in a ratio of 1:1.2.

Gelatin and agar-agar are soaked in cold water before use and the excess water is drained. After an hour, strongly swollen gelatin or agar-agar is diluted with hot water and brought almost to a boil. Dense jellies are obtained with a content of gelatin or agar-agar in the amount of 4-5%. Gelatin jellies are elastic.

Manufacturer: PJSC "Dneprovsky starch plant" (Ukraine)

Package:
Railway tanks
tank trucks
Drums 55kg
Metal barrels 290kg

Additional shipping information:
Starch syrup (glucose syrup) is sold in bulk or packaged in drums. Starch syrup (glucose syrup) is packaged in carton-winding drums of 55kg (880kg on a pallet). Minimum lot 1 pallet. Starch syrup (glucose syrup) can be purchased from warehouses in Dnepropetrovsk, Kyiv and Lvov.

Production technology:
Low-sugar molasses is a product of incomplete hydrolysis of starch, with a glucose equivalent content of 26 - 35%. Low sugar starch hydrolysates are characterized by high viscosity, binding and anti-crystallization action, they are foam and emulsion stabilizers. Such molasses are used in the production of aerated confectionery, hard candies, where low sweetness, mild flavor and non-hygroscopicity are very important.

Application:
Molasses reduces the rate of crystallization of sugar syrups, and when it is introduced in large quantities, crystallization does not occur. This property of molasses is used in the production of caramel, toffee and other non-crystalline masses. Molasses can also change the hygroscopicity of confectionery semi-finished products and products (gingerbread, etc.), which prevents them from drying out quickly. Molasses contributes to an increase in the volume of yeast products, an increase in the porosity and elasticity of the crumb, slows down the process of hardening of finished products, gives color and is an anti-crystallizer.

Packing and storage:
The molasses can be delivered to the consumer by road tanks, barrels, cans, cardboard-winding drums with a capacity of 25, 50, 200 liters, 1 m3 containers, intended for use in the food industry. Automobile tanks are sealed, barrels, cans, containers are sealed. When transported by road (molasses carriers), molasses is poured into a sectional thermal tank with a capacity of 25 tons at a temperature of 50 ... Depending on the weather, the temperature of the IG-42 during loading may vary. For long-term storage of molasses, it is necessary to provide insulated containers made of stainless steel with external electric heating (water jackets can also be used for heating) at a temperature of 50…55ºС. The heating is calculated in such a way as to exclude heat losses to the production premises or the environment, if the storage is designed outdoors.

Qualitative indicators:
Organoleptic characteristics 1. Appearance Thick viscous liquid. The lollipop obtained as a result of boiling the caramel sample should be transparent 2. Color: visual assessment From colorless to pale yellow 3. Odor Characteristic of the product, without foreign smell 4. Taste Sweet, characteristic of molasses, without foreign taste Physical and chemical characteristics 5. Mass fraction of solids (%), not less than 78.0 6. Dextrose equivalent (content of reducing substances in terms of dry matter), % 28…32 7. Density, kg/dm3 (20°C) 1.42 8. Hydrogen indicator, pH 4.6 ... 6.0 9. Acidity - the volume of sodium hydroxide solution with a concentration of 0.1 mol / dm3 (0.1 N.) for the neutralization of acids and acid salts in 100 g of dry matter of molasses, cm3, not more than 12 ,0 10. Content of sulfur dioxide (SO2), (mg/kg), not more than 15.0 11. Mass fraction of total ash in terms of dry matter, % 0.40 (0.25) 12. Caramel sample temperature, ° С 145 13. The presence of free mineral acids is not allowed 14. The presence of visible foreign mechanical impurities is not allowed 15. Calorie content, kcal/100 gr. 310 Average carbohydrate composition (% by weight of dry matter) 16. Glucose 6…10 17. Maltose 6…10 18. Maltotriose 9…14 19. Higher sugars 70…75 Viscosity ×103, mPa s 20. 25 °С 160 21 35 °С 82 22. 45 °С 23 23. 55 °С 7 Microbiological indicators 24. The amount of MAFAM (CW/1 g), no more than 1 × 103 25. Bacteria of the Escherichia coli group (coliforms), in 1 g are not allowed 26. Pathogenic microorganisms, incl. bacteria of the Salmonella genus in 25 g are not allowed 27. Yeast (FSC/1 g), not more than 100 28. Mold (FSC/1 g), not more than 100

Application advantages:
. Exceptional molasses purity
. Ease of use / manufacturability
. Cost reduction
. Good fermentability
. Glossy / shine / glazing
. Friable/crunchy taste
. Hygroscopicity
. Extended shelf life
. Taste improvement
. porous structure
Molasses reduces the rate of crystallization of sugar syrups, and when it is introduced in large quantities, crystallization does not occur. This property of molasses is used in the production of caramel, toffee and other non-crystalline masses. Molasses can also change the hygroscopicity of confectionery semi-finished products and products (gingerbread, etc.), which prevents them from drying out quickly. Molasses contributes to an increase in the volume of yeast products, an increase in the porosity and elasticity of the crumb, slows down the process of hardening of finished products, gives color and is an anti-crystallizer.
. The production of starch syrup is not limited to the harvest period, but can continue throughout the year.
. The fermentation activity of yeast increases.
. Decreases dwell time. Reduces dough viscosity.
. The volume of products is slightly increased.
. Elasticity, form stability, porosity of products improve.
. Starch molasses is an analogue of caramel molasses, therefore, it does not require changes in technology or instrumentation of technological processes.
. The use of starch syrup does not affect the processes of coloring, flavoring, acidification, kneading and stretching the caramel mass, caramel molding and final cooling of the finished caramel.
. The reduced viscosity of starch syrup improves the molding of jelly sweets made according to the traditional recipe.