The method of storage of molasses taken from the centrifuges of the last product. Production and storage of starch syrup

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

On 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 stored in closed warehouses on pallets at a relative 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 must 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.

Melas storage warehouse (tank farm 20000 m3).
Tank farm parameters:
1. The diameter of the molasses storage tank is 34200 mm, the height is 16880 mm.
2. the maximum level of molasses filling is 16000 m.
3. specific gravity molasses 1.45 t/m³
4. to reduce foaming, the filling of the tanks is provided from below.
5. to reduce the risk of crystal formation at the site of the product exit pipes from the tank, a set of tanks for storing molasses should be carried out through valves 2. Emptying should be carried out through valves 1 (during the operation of the plant and molasses entering the tank.) and also for the final emptying of the tank, the molasses should be removed from the tank through the valve 2.
6. The molasses storage tank must have: protection of internal surfaces, structures and communications from damaging effects acid environment and organic acids contained in molasses.
· inspection manhole ∅600-2 pcs, closed hermetically at a height of 500 mm from the bottom of the tank to the bottom of the hatch;
· DN15 ball test valves over the entire height along the stairs at a vertical distance of 1000 mm from each other. 2 lower test cocks at a height of 500 and 1000 mm from the bottom of the tank.
· to steam the tank, provide an annular bubbler ∅76 at a height of 300 mm from the bottom.
· for heating molasses in the tank, provide horizontal ring registers from a pipe ∅108. Place the registers at a height of 150 mm from the bottom
molasses heating to carry out hot water. Water supply and drainage Du150. If necessary, provide for the use of return steam as a heat carrier.
· Provide steam supply DN50 and condensate discharge DN32 from molasses heating registers.
provide temperature control in the tank at a height of 200 and 500 mm from the bottom
inspection hatch
6. molasses dispensing tank must have; protection of internal surfaces, structures and communications from the damaging effects of an acidic environment and organic acids contained in molasses.
· revision manhole ∅600-1 piece, closed hermetically at a height of 500 mm from the bottom of the tank to the bottom of the hatch;
· Ball test valves Du25 — 2 pieces at a height of 500 and 1500 mm from the bottom of the tank.
· provide a mechanical float indicator of the level of molasses in the tank.
branch pipe for filling the tank Du150
branch pipe for emptying the tank Du150
inspection hatch
· heat exchanger for heating molasses in the tank. Heating is carried out with hot water. If necessary, provide for the use of return steam as a heat carrier.
hot water supply pipe to the heat exchanger Du100
hot water outlet from heat exchanger Du100
branch pipe for supplying steam to the heat exchanger Du50
· Branch pipe of removal of condensate from the heat exchanger Du20
black pipe Du200

EQUIPMENT LIST
A. Molasses tank
B. Dispensing tank
C. Railway tank
D. underground tank for unloading molasses from railway tanks
E. pump molasses into tanks
F. pump molasses into the dispensing tank
G. flush pump after cleaning, rinsing and steaming the tank.

Molasses (beet molasses, slang malas) - valuable product, thanks to which you can significantly improve the palatability of the main diet. What kind of food is this and how to use it in feeding cows and pigs will be discussed in this article.

What is molasses

Molasses is a by-product of sugar production. This is the brown syrup (molasses) that remains after sugar crystallizes. Sugar beet is washed, crushed and subjected to diffusion (leaching of sugar and its dissolution in water). This solution is heated to 73-78°C. containing sugar raw juice separated from the crushed beet mass (pulp). The pulp is pressed and is also used in feeding farm animals.

Raw juice is purified from sediment using limestone and carbon dioxide. The purified juice contains about 12-15% dry matter and is evaporated to obtain thick syrup. Then sugar crystallizes from this syrup. The remains of the syrup from which the sugar was obtained is molasses. About 35 kg of sugar, 540 kg of raw beet pulp and 40 kg of molasses are obtained from a ton of sugar beets. For more information about the sugar production process, see:

Molasses quality and storage

At the factory, molasses is stored in a very concentrated form and very thick. In order to be able to ship molasses, it is heated to 40°C and diluted with water. It is on how much water was added (i.e. what concentration of sugar was reached, table 1), and depends molasses quality.

It is believed that high-quality molasses - with a sugar content of 40% or more. But, of course, it depends on the quality of the raw materials used by the manufacturer and the production technology itself. And do not forget that the sugar industry does not produce molasses, but sugar, i.e. it is in the manufacturer's interest to leave as little sugar as possible in the molasses.

The volumetric weight of molasses is about 1.25 kg (1 liter of molasses = 1.25 kg) and can be checked by this parameter. Quality molasses must have a uniform consistency when shipped, with no areas that are too thick or too watery.

Table 1. Molasses quality: different sugar concentrations

Index	Meaning
% sugar in molasses
Total sugar content (%)*, in terms of sucrose	min. 40	min. 42	min. 47
	68 — 70	72 — 74	76 — 79

*for natural humidity

Because molasses has liquid consistency, its use and storage is complicated. occurs in containers for liquids. If raw materials are stored in a large container, for example, a 1000-ton one, then denser particles are collected at its bottom (the first 50-200 tons from this barrel will be thicker), but this does not mean that there will be more sugar at the bottom - the sugar content at the same time remains the same. To store molasses in such large containers, it should contain 44-49% sugar.

Storage capacity beet molasses should have openings for filling and unloading with a diameter of at least 8-10 cm. The barrel is positioned so that it is convenient to drive up to it, and it is also convenient to select raw materials for feeding.

In winter, molasses that is stored outside can lose its flow property. In order to improve the fluidity of molasses in winter, it is enough to add 10-15% of water to it through the apparatus high pressure before the start of frost. Molasses does not freeze, but thickens, so equipment is needed to heat the molasses tank when needed.

In hot summers, you need to make sure that full containers are not in direct sunlight. Molasses containers should be stored in the shade, preferably indoors. The reason for this is that at high temperatures there is a danger of alcoholic fermentation of molasses. But if, nevertheless, the food has fermented, it can still be fed to animals.

Under normal conditions, this feed raw material can be stored for a very long time. For ease of use, dilution of molasses with water in a ratio of 1:1 is recommended.

The chemical composition of molasses and its nutritional value

Molasses is a high-energy and highly digestible feed raw material. The dry matter content of molasses ranges from 60 to 80%, and is usually around 65%. The chemical composition of molasses- these are soluble saccharides - mainly sucrose, as well as in a small amount glucose, fructose and raffinose, minerals(about 10% raw ash) and non-protein nitrogen compounds. Molasses contains about 35-45% sugar. The saccharides contained in it are absorbed by ruminants and pigs by more than 90%. The amount of energy depends on the amount of sugar. Sugar-rich beet molasses contains about 8 MJ PEL or 13.5 MJ ME of a pig per kg of dry matter. The crude ash content of molasses ranges from 8% (very low) to 13% (very high).

Table 2. Chemical composition of molasses

Index	Unit. rev.
Dry matter
per kg dry matter
raw ash
Crude protein
crude fat
BEV
Starch
Sugar
Calcium
Gassing HFT	ml/200 mg SV
Phosphorus
Sodium
Magnesium
Potassium

Source: Potthast, C. et al. 2011, Sugar Industry, 136 (10): 663-669

Molasses can be fed in limited quantities to various animal species (ruminants, horses, pigs). Due to its high content of easily digestible sugar, molasses is also used as an ensiling additive for crops that are difficult to ensil.

Molasses in cow feeding

Molasses has a positive effect on the productivity of cows:

• increases the digestibility of dry matter and organic matter of the diet
• stimulates microbial activity in the rumen
• has a positive effect on animal feed intake, improves the taste of the diet
• increases and milk yield.

Beet molasses shows this effect especially on diets rich in grass silos, in which there are few easily digestible carbohydrates.

Table 3. Nutritional value of molasses for cows (per kg dry matter)

Index	Unit.	Meaning
Digested Crude Protein nXP
Rumen nitrogen balance RNB
Exchange energy of cattle, ME	MJ	11,9
Net Lactation Energy NEL	MJ
Non-digestible protein 5*

Table 4. Maximum allowable intake of molasses in the diet (kg per head per day)

Animal species	Maximum amount of molasses, kg
cash cows	1.5 to 2.5
young growth	0.5 to 1
fattening	1 to 2
Goats and sheep

In feeding cows, goats, sheep, molasses is limited to no more than 15% of dry matter. This means no more than 0.4 kg of dry matter of molasses for every 100 kg of animal weight per day (a cow weighing 650 kg should receive a maximum of 2.5 kg of molasses per day). When feeding more molasses and a lack of structural fiber in the diet, there is a threat of acidosis. It is generally recommended to feed 1-2 kg of molasses per head per day. If beet pulp or other sugar-rich ingredients are included in the diet, the amount of molasses should be reduced to a maximum of 1.5 kg per head per day.

Make sure that the diet is balanced and appropriate for the stages of lactation (limiting the content of starch and sugar to 20-25%, not less than 15-18% crude fiber).

The introduction of molasses into the diet is carried out gradually so that the microorganisms of the rumen can adapt. The most favorable way to feed molasses is to include it in a homogeneous fully mixed diet. Thanks to this, stable work of the scar is achieved throughout the day.

Molasses is very effective when fed in combination with straw-rich diets (e.g. for dry cows). It greatly improves the attractiveness of the diet by enhancing its palatability. When fed with straw, it is crushed and watered with molasses (can be diluted 1:1) in a ratio of 50-100 g/kg of straw.

Molasses in pig feeding

In pig feeding, the maximum proportion of molasses can be 15% of the dry matter of the ration. For piglets with 15 kg of live weight, the introduction of molasses is limited to 10% of the dry matter of the diet. Only molasses containing a lot of sugar is suitable for feeding pigs.

For pigs, molasses also has high palatability. It can be fed both to fattening pigs (up to 0.7 kg per head per day), and pregnant (up to 5% of the total diet) and dairy sows (up to 3% of the total diet). Due to the high proportion of non-protein nitrogen, when calculating the diet, it must be taken into account that only 50% of the protein contained in molasses will be absorbed by the animals.

Table 5. Nutritional value of molasses for pigs (per kg dry matter)

Index	Unit.	Meaning
Exchange energy, ME	MJ	13,1
Lysine
Methionine + Cystine
Threonine
tryptophan
Digestible phosphorus		< 0,1

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. Below is the preparation various kinds raw materials used for the production of flour confectionery products.

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 is made from flour different varieties or with the addition of starch, then the flour is mixed simultaneously with its sifting. IN winter time 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 for cooking 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 the next amount 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. In order not to form lumps, a little is first poured into the powder warm water, stir well, and then add the rest of the water and, stirring, bring 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.

Condensed milk used for the preparation of confectionery products is preheated to 40 °, and then filtered through a sieve with meshes of 0.5 mm.

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 puff, butter biscuit and cream, butter sometimes they replace it with clarified butter (1 kg of butter corresponds to 840 clarified butter). 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 consisting of 30% lard, 30% beef fat and 40% vegetable oil, can be heated to a high temperature without smoke. You can use refined sunflower, cottonseed or soybean oil, and kitchen fats, because 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, airy, almond and yeast dough. Before use, check the freshness of the eggs with an ovoscope. At long-term storage eggs, the yolk shell becomes fragile and easily torn. These eggs cannot be used for the preparation of such 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, average weight eggs 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, stored in tin cans at a temperature from -18 to -25 °. Defrost the melange immediately before use. Preliminarily, a jar of melange is doused with a chloride solution, and then washed 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 filter. 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. The yeast is dried at a temperature not exceeding 35 °, since at more than high 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, rubbed on a grater, ground in micromills and sieved 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.

Fine table salt is sifted through a sieve, and salt in large crystals pre-dissolve, and then filter the solution through a sieve with cells of 0.5 mm.

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.

STORAGE OF MOLDS AND PREPARING IT FOR PRODUCTION

Molasses is delivered to bakeries in railway or truck tanks, from where it is pumped to storage tanks, where it is stored at a temperature of 8-12 ° C in conditions that protect the tanks from exposure to sunlight and precipitation. To ensure a constant storage temperature of molasses, the tanks are placed in a special room equipped with an automatic temperature controller.

To reduce the viscosity, molasses is heated to a temperature of 45 ° C during intra-factory transportation. Before use, it is passed through a sieve with cells with a diameter of not more than 3 mm.

STORAGE OF FAT PRODUCTS, OTHER RAW MATERIALS AND THEIR PREPARATION FOR PRODUCTION

Oil and oil paste from cow's milk stored in a cold dark room. Under the action of light, atmospheric oxygen and elevated temperature, the oil goes rancid. Butter and butter paste from cow's milk is stored at a relative humidity of at least 85% and a temperature of -6 ± 3 "C - 9 months; at a temperature of 3 ± 2 "C, storage of ghee in flasks is allowed for up to 1 month.

hard margarine stored in warehouses or refrigerators at temperatures from -20 to 15 "C with constant air circulation. Margarine should not be stored together with products that have a sharp specific odor.

liquid margarine stored in bins of stainless steel at a temperature of 35-48 ° C no more than 2 days. Each tank is equipped with a water jacket and a propeller agitator, the periodic rotation of which prevents the separation of the margarine emulsion.

Boxes, drums and barrels with margarine during storage should be stacked: for mechanized stacking - on pallets, for non-mechanized stacking - on slats and grates (pillars) in stacks with gaps between them for free air circulation, at a distance of at least 0.5 m from the walls . Barrels and drums are stacked in a vertical position.

Confectionery and bakery fats, depending on the temperature (from -20 to 15 °C) and the content of antioxidants (antioxidants), are stored for 1-9 months.

Guaranteed shelf life of liquid baking fat from the date of manufacture is 10 days at a temperature of 15-20 °C. It is stored in thermally insulated tanks or other containers equipped with heating devices and agitators.

In preparation for production solid fats free from containers, inspect, clean the surface from contamination. Then the fats are cut into pieces and their internal state is checked.

If fats are consumed in a melted state, then after cleaning the surface, the fat is placed in a tank with a water jacket or steam coil, agitator and filter. The temperature of the melted margarine should not be higher than 40-45 ° C, otherwise the mass will separate into fat and water, which will cause an uneven distribution of fat in the dough. The pipeline through which the fat is transported must be provided with thermal insulation or a heating device.

Creamy-vegetable, vegetable-creamy spreads and baked mixtures are stored at temperatures from -25 °C to 5 °C inclusive; vegetable fat spreads and baked mixtures - from -20 °С to 15 °С inclusive.

Spreads and melted mixtures should not be stored together with products that have a strong specific odor.

The stowage requirements for boxes of spreads and ghee are the same as the stowage requirements for margarine boxes above.

Vegetable oils are stored in a dark room, in closed containers (barrels or tanks) at a temperature of 4-6 °C. Under the influence of atmospheric oxygen, light and elevated temperature, vegetable oils deteriorate.

The effect of fat added to the dough on the quality of bread can be enhanced if the fat is added in the form of an aqueous emulsion using an appropriate emulsifier (phosphatide concentrate, surfactants, etc.).

The resulting emulsion must be finely dispersed, stable over time and suitable for transportation through pipelines. For this purpose, it is advisable to use installations with hydrodynamic vibrators (Fig. 13), which create sound vibrations in the emulsifiable mixture.

Figure 13 -. Hardware-technological scheme of the installation for the preparation of fat emulsion:

/ - mixing tank; 2 - tank for emulsification RZ-KhChD-315; 3 - hydrodynamic vibrator AGA; 4- filter; 5-pump ShF-2/25A(RZ-3); 6-capacity RZ-HCHD for storage

emulsions
On installations of this type, manufactured at food engineering plants or manufactured in mechanical repair shops, it is possible to prepare emulsions of fat added to the dough, and emulsions for lubricating baking forms and sheets.

Eggs are stored separately from other products in refrigerators at a temperature of 0 to 20 ° C and a relative humidity of 85-88%: table eggs - from 8 to 25 days; washed - no more than 12 days.

In industrial refrigerators, eggs are stored at a temperature of -2 to 0 "C and a relative humidity of 85-88% for no more than 90 days.

When processing a large number eggs are processed in a separate room equipped with three-section baths and tables with special devices (special knives) for breaking eggs.

For decontamination, eggs, rammed in a separate room, are placed in mesh boxes or buckets and washed thoroughly with water. Then they are kept sequentially for 5-10 minutes in a solution of soda, bleach and running water. Clean eggs are broken into 3-5 pieces. over a separate cup and check for smell. If the egg is benign, then the contents of the cup are poured through a sieve into a common dish.

The easiest way to determine the freshness of an egg is to see it through an ovoscope.

In large enterprises, special equipment is used to sanitize eggs and separate the yolk from the protein.

Liquid chilled egg products(melange, yolk, protein) are stored in clean, well-ventilated rooms at a temperature not exceeding 5 ° C - no more than 24 hours; frozen egg products at a temperature not exceeding -18 ° C - no more than 16 months; at a temperature not higher than - 12 ° C - no more than 10 months; at a temperature not higher than -6 "C - no more than 6 months.

Before use, jars with melange are thawed in water at a temperature of 45 ° C for 2-3 hours and carefully opened with a special knife. Thawed melange is filtered through a sieve with cells up to 3 mm in diameter and used within 3-4 hours, as it quickly deteriorates.

Egg powder arrives at the bakery in barrels, cartons or cans. Keep egg powder recommended in a dry, clean and well-ventilated room with a relative humidity of no more than 75% and a temperature of no more than 20 ° C - no more than 6 months; at a temperature not higher than 2 °C - no more than 2 years. Egg powder is very hygroscopic and quickly deteriorates under the influence of light, moisture and oxygen.

Egg powder is sifted before use, and then diluted in three or four times the amount of water with a temperature not exceeding 45 "C. Water is added to the powder, gradually stirring the mass. The resulting emulsion is filtered through a sieve with cells with a diameter of 2 mm. In dry form, egg powder is not used , since its particles do not have time to swell in the dough, which causes the appearance of specks in the products.

Jam, jam and preserves are delivered to the bakery in metal cans or wooden barrels, jam can also be packed in boxes. These products are stored in a dry room at a temperature of 0-20 ° C and a relative humidity of 75-80%. Under these conditions, jam packed in boxes is stored for up to 6 months, and packed in barrels - up to 9 months. Storing jams, marmalades, and marmalades in a warm, humid environment can cause them to ferment or mold.

Before use, jam is passed through a sieve with cells with a diameter of not more than 2 mm.

Spices are kept dry. clean room in a tightly closed container. Do not store spices together with other strong-smelling substances.

Before use, cumin, anise and other spices are sifted and passed through magnetic traps. When using crushed spices (such as cinnamon), it is recommended to grind them in portions to preserve the flavor.

Vanillin is stored in tin boxes for up to 1 year. Before adding to the dough, vanillin is dissolved in 96% alcohol in a ratio of 2: 1 or in hot water temperature 80 "C.

Essential oils and essences are stored in tightly closed bottles with ground stoppers, which are placed in baskets filled with sawdust. Essences are flammable and volatile. At temperatures up to 25 ° C, they can be stored for 6 months.

Raisins are stored in boxes. Before use, it is sorted out, impurities and branches are removed, and then washed by hand or on a special machine. After washing, the raisins are placed on a sieve to remove moisture droplets.

Nuts and almonds are stored in bags, they are sorted out before use.

Transportation of the main and additional raw materials

Mechanical transport installations include slopes and ramps, hand trucks, forklifts, conveyors of various types.

Descents and slopes. To unload bags of flour, salt and other goods from wagons and vehicles to warehouses, as well as to transfer goods from floor to floor, descents are used, which are straight and spiral.

Direct descents (inclined planes, trays, pipes) are used to move goods simultaneously in vertical and horizontal directions. The slope of the descent is usually 20-25°. Inclined planes and trays are made of smooth planed wooden boards 30-50 mm thick.

Spiral screw descents are used when transporting goods vertically down. They are a helical gutter (cast iron or wood), which is reinforced around a vertical column. Its outer diameter is most often 1.5-2.0 m.

Cast iron descents are made from separate helical links, put on a common axle and connected by bolts. The downward movement of loads can also be carried out by free fall along the pipe. In bakeries with multi-story placement of technological equipment, dough is usually fed to dough dividers through a vertical pipe.

Hand trucks and forklifts. For the transportation of goods within the enterprise, hand trucks (rail and railless), as well as forklifts are used.

Rail trolleys are used only when transporting cargo over a long distance in a straight line.

Trackless trolleys are used for intra-factory transport with relatively small but difficult routes. By design, hand trucks can be two-, three- or four-wheeled.

In flour warehouses of small and medium-sized enterprises, lifting and transport trolleys are used.

D For the mechanization of work in flour warehouses, forklifts and electric forklifts are used. Electric forklifts are most widely used, as they are more convenient to operate, have smaller dimensions and do not pollute the air with exhaust gases. The electric forklift is designed for both moving and stacking bags of flour and other goods. It works as follows: the load is placed on a pallet (platform), the loader moves towards the load, the forks fit under the pallet, then the frame together with the forks leans back by 8-10 °, and the load rises. The inclination of the forks towards the loader ensures a stable position of the transported load. If it is necessary to stack the load, the forks of the electric forklift are raised. The maximum lifting height for loaders of various brands ranges from 1500 to 2800 mm.

The electric forklift is driven by a DC motor powered by a battery. For the movement of the forks along the frame and the inclination of the frame, a hydraulic drive is used. The hydraulic drive pump is powered by a separate electric motor. The loader batteries must be charged every 7-8 hours of operation. The electric forklift is operated by a specially trained driver.

CJSC "Techlen" manufactures shelving trolleys (hairpins, lining, containers) oven for all types of baking ovens of domestic and foreign production from black or stainless steel, welded and collapsible. Carts can have from 3 to 30 levels - guides for trays and trays. To increase the carrying capacity of the levels, they are reinforced with transverse (rod) and longitudinal (tape) ties. If necessary, levels are made in the form of lattice shelves (for laying forms).

To fix the trays and trays on the trolleys, vertical locking rails are used, located on the back (welded) and / or on the front (rotary) side. Less commonly used stops on guides. For orientation in the furnace, the trolleys have a lower landing unit on a ball or an upper suspension device by a hook. Additional strength and increase in the service life of the carts is achieved by reinforcing the frames with corner scarves in the places of welded joints.

Carts are equipped with swivel wheels made of cast iron or heat-resistant phenolic plastic produced by Italian and German companies.

TO
pipelines. According to the design of the working carrier body, belt, scraper, bucket, screw, etc. conveyors are distinguished.

Belt conveyors(Fig. 3. 7, a) are widely used, as they are more economical, operate smoothly and silently, and are simple in design. These conveyors consist of an endless belt, drive and take-up drums and a frame supported along the length of the belt by rollers or a smooth deck.
4.2 Equipment for kneading and cutting dough
Dough mixers (dough mixers)

Dough mixers are designed for kneading dough from various types of flour. The device of dough mixing machines is very different. The capacity is very different, from 10-25 liters to 300 or more liters. Dough mixing machines are used in bakeries, workshops Catering, restaurants, cafes. Some kneading machines are equipped with a timer for counting the dough kneading time, in addition, there are devices for reversing the rotation of the kneading body at the end of work to remove the dough from it. The spiral kneading body, rotating around its own axis, making a circular motion around the axis of the bowl, effectively kneads the dough throughout the entire volume of the bowl.

The dough mixing machine is selected depending on the productivity of the oven and the type of dough. For yeast and sweet dough spiral kneaders are used. For bakery enterprises of small productivity (up to 120 kg / h), machines with a fixed bowl are usually used. If the assortment of bakery enterprises has a large volume of one type of product, and, accordingly, it is necessary to knead one type of dough, then dough mixers with rolling bowls are used. Equipment used at this stage technological process should ensure the uninterrupted operation of the bakery, so it is better to focus on imported equipment.
Dough preparation unit I8 HTA 12/1

(with single-channel unloader)

Continuous paddle kneading machine is designed for kneading sourdough and dough from wheat and rye flour during production bakery products at enterprises bakery industry. The machine can be equipped with a two-channel flour unloader, which will allow feeding m uku of different varieties in certain ratios.

Figure 14 - Dough mixer I8 HTA 12/1
Table 2 - Technical characteristics of the Mixer I8 HTA 12/1

Dough mixer "PRIMA - 300"

"Prima-300" is a two-speed automatic dough mixing machine with a spiral kneading body, a central cutter, a rolling rotating cylindrical thick-walled stainless steel bowl with a capacity of 300 liters. Designed for intensive kneading of a wide range of wheat, rye and mixed types of dough for bread, bakery and confectionery products, including yeast-free and yeast-free puff products. The maximum load for each recipe is determined empirically. "Prima-300" can be operated in 1-3 shifts under conditions industrial production bread, bakery products. Intensive kneading on "Prima-300" fundamentally improves the quality of baked products, increases the volume of products, the crumb becomes more elastic, the porosity is uniform and fine, the crust is more intensely colored, slows down perseverance.
Figure 15 - Dough mixer "PRIMA - 300"

The automatic control system based on the SIMATIC S7-200 industrial controller and the SIEMENS touch control panel provides:

• 
  creation, storage, use, adjustment of up to 100 10-step mixing programs
• 
  work in automatic mode
• 
  
• 
  monitoring of emergencies with automatic transfer of the machine to a safe state
• 
  
• 
  control of the load on the drives of the working bodies of the machine during operation
• 
  measurement and indication of dough temperature, connection to a technological computer (optional).

Structural elements that ensure reliable operation and ease of use of "Prima-300":

• 
  all structural elements in contact with the dough are made of stainless steel
• 
  two speeds of rotation of the kneading body, reverse rotation of the bowl at low speed
• 
  
• 
  kneading body rotation drive group V-belt transmission
• 
  bowl rotation drive ensures smooth start of the rotation drive motor and eliminates damage to the drive mechanism in case of tooth-to-tooth gears by moving the drive gear into engagement after fixing the bowl in the working position
• 
  nozzles on the lid of the bowl for loading bulk and liquid components in automatic and manual modes, a sight glass for visual control of the mixing process
• 
  

Table 3 - Specifications Dough mixer

"PRIMA - 300"

The volume of the bowl used, l	300
	200
	5
	5-8
	17.6
Rated voltage, V	3NPE~380
Overall dimensions, mm	1805x1260x1343
	1280
- weight of bowl D-300, kg, no more	250

Automated dough preparation complex based on the dough mixing machine "Prima-300" "Prima-300AR"

A
automated dough preparation complex "Prima-300AR" based on the dough mixing machine "Prima-300" is designed to automate the process of kneading all types of dough from wheat,

Figure 16 - Automated dough preparation complex based on the dough mixing machine "Prima-300" "Prima-300AR"

rye-wheat flour prepared using a steamless technology, as well as for the final kneading sponge dough in the bakery industry. With minimal cost, it is integrated into the dough preparation schemes existing at enterprises.
Allows you to use the fleet of 330 l bowls already available at the enterprise for preparing, transporting dough, fermenting dough after

final kneading (if such a technological operation is available), transportation of the finished dough.

The complex operates in two modes:
1. Automatic mode (unmanned technology)


- sourdough dough technology in case of sourdough preparation.
The complex is controlled in automatic mode from the touch panel of the control panel of the "Prima-300" dough mixer.
2. manual mode
Applicable when using:
- unpaired test technology
- sourdough dough technology for bowl preparation of sourdough, bowls T1-XT2D with a capacity of 330l are used.
The control of the complex in manual mode is carried out from the touch panel of the control panel of the "Prima-300" dough mixer. The control of the following operations: raising and lowering the bowl of the complex, raising and lowering the platform of the dough loader and starting the dough kneading program is also possible from the control panel of the unloader.
The control system of the complex controls the operation of all actuators, displays the performance of all current operations and technological parameters, issues sound and light alerts when the bowl is raised and lowered, monitors emergency situations with automatic transfer of actuators to a safe state.

The volume of the bowl used, l	300
Maximum dough weight, kg/batch	200
Minimum dough weight, kg/batch	5
Duration of one batch, min	5-8
Rated power consumption, kW	17,6
Overall dimensions, mm	1805x1260x1343
Weight (without bowl), kg	1280

Table 3 - Specifications "Prima-300"

Table 4 - Specifications Dough unloader

Load capacity, kg, no more	450
Rollover/return time, s, no more	120
Bowl rotation angle in loading/unloading position	110±2
Height from floor to bottom of tray when capsizing, mm, not less
Overall dimensions in the initial position, mm	3090x1460x1170
Overall dimensions when capsizing, mm	3090x1660x2020
Rated power consumption, kW	1,5
Weight, kg	650

DOUGH MIXER "PRIMA - 375"

Automatic dough mixing machine with two spiral kneading bodies, a central cutter, a rolling rotating cylindrical thick-walled bowl made of stainless steel with a capacity of 375 l is designed for operation in 1-3 shift modes in the conditions of industrial production of bread, bakery and confectionery products.
The kneading machine, unlike traditional intensive kneading spiral kneading machines, is equipped with two kneading bodies with individual drives. This kneading scheme allows you to increase the productivity of the machine by reducing the kneading time from 25% to 50%, depending on the recipe of the kneaded dough.
The function of smoothly changing the speed of rotation of the kneading bodies and the bowl makes it easy to select the optimal kneading modes to obtain the necessary rheological properties for all types of dough. Thanks to the intensive kneading of a wide range of wheat, rye and mixed types of dough for bread, bakery and confectionery products on Prima-375, the quality of baked products is fundamentally improved:

Picture 17 - dough mixing machine "PRIMA - 375"

The temperature of the dough during kneading rises by no more than 2 C/min.
The automatic control system based on the industrial controller SIEMENS SIMATIC S7-200 with a color touch control panel provides:

• 
  input, editing, storage and playback in automatic mode of up to one hundred 10-step dough kneading programs with the ability to set technological parameters in each step
• 
  testing and diagnostics of the operability of machine components and assemblies
• 
  monitoring of emergencies with automatic shutdown cars
• 
  automatic archiving: batches, emergency events with fault diagnostics, accounting of machine operating time
• 
  control of the load on the drives of the working bodies of the machine
• 
  Possibility of joint work with dosing stations of bulk and liquid components
• 
  connection to a technological computer with the possibility of remote control (optional)
• 
  control of the dough loader and the dough unloader, if these devices are available.

"Prima-375" has:

• 
  mixer rotation drives and a bowl rotation drive with a function of smoothly changing their rotation speeds
• 
  reverse rotation of the bowl at low speed
• 
  all structural elements in contact with the dough are made of stainless steel
• 
  hydraulic drive for lifting - lowering the traverse and fixing the bowl, components and assemblies of the hydraulic system - from the best European manufacturers
• 
  built-in temperature sensor with indication on the touch panel
• 
  drives of rotation of kneading bodies - group V-belt transmission
• 
  bowl rotation drive with soft start of the engine, which excludes damage to structural elements in case of tooth-to-tooth drive gears when rolling the bowl
• 
  bowl D-375 with the possibility of installation in a position with an inclination of about 45 degrees C for sanitization
• 
  nozzles on the lid of the bowl for loading bulk and liquid components in automatic and manual modes
• 
  bowl lid with a viewing glass, the design of which makes it possible to practically eliminate flour spray during kneading
• 
  power cabinet with a control panel with the possibility of installation on the machine body both on the right (standard) and on the left
• 
  convenient access to all units, mechanisms and units for maintenance
• 
  motor-reducer of the bowl rotation drive, which works without changing the lubricant during the entire service life
• 
  the best samples of foreign-made ballasts, providing minimal maintenance and high reliability in operation

Spare parts are included in the scope of delivery.
Table 5 - Technical characteristics of the dough mixer

"PRIMA - 375"

The volume of the bowl used, l	375
Maximum dough weight*, kg/batch	250
Minimum dough weight, kg/batch	20
Rated power consumption, kW	49
Rated voltage, V	3NPE~380
Overall dimensions, mm	1940x1425x1625
Weight, kg, no more (without bowl D-300)	1570
- weight of bowl D-375, kg, no more	270

Dough mixer "Prima-300R" with dough loader

It is intended for the dough technology of dough making at the bowl preparation of dough, at the enterprises of the baking industry, bowls T1-XT2D with a capacity of 330l are used.
The dough mixing machine "Prima-300R" performs the final kneading of sponge dough with subsequent automated unloading of the dough by overturning the dough mixing part of the machine. The dough loader is aggregated with the Prima 300R dough mixing machine and operates from its hydroelectric station. The use of a loader allows you to speed up the process of loading the sponge in comparison with traditional bowl lifters. The dough mixing machine "Prima-300R" with a dough loader is integrated into existing dough preparation schemes at enterprises, saving space.

Figure 18 - Dough mixer "Prima-300R" with dough loader.

The complex operates in two modes:
1. Dough mixer "Prima -300R"
Two-speed semi-automatic dough mixer for intensive dough kneading. The kneaded dough is unloaded by lifting and overturning the machine.
2.Dough loader
It is an actuating mechanism and can only function in conjunction with the Prima-300R dough mixing machine. Designed for reloading dough from rolling bowls Т1-ХТ2Д into the bowl of a dough mixing machine for subsequent kneading of dough. The control is carried out from the control panel of the dough mixing machine "Prima-300R" and provides: raising and lowering the platform of the dough loader, control of the kneading modes and mechanized unloading of the dough.

Figure 19 - Dough mixer "Prima-300R" with dough loader