pasta production technology. Own business: pasta production

Raw materials used in the production of pasta

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

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

Water is an integral part of pasta dough. It determines the biochemical and physico-chemical properties of the dough.

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

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

The quality of pasta largely depends on the technological process.

Product range

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

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

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

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

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

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

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

Main stages of pasta production

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

A characteristic feature of modern pasta production is the widespread use of production lines that combine all technological operations into a single complex, from the receipt of raw materials to production and ending with the shipment of finished products to the warehouse. In separate sections of these lines, automatic regulation and control of processes is carried out. The functional diagram of pasta production is shown in fig. 1.6.

The technological scheme for the production of pasta includes the following processes:

Preparation of raw materials for production;

kneading dough;

Formation and separation of raw products;

stabilization;

Packaging of finished products.

Preparation of raw materials. Flour preparation consists of mixing, sifting, magnetic cleaning and weighing. Egg and milk additives are stored in refrigerators. The preparation of eggs for production consists of disinfection, as eggshells are often contaminated with bacteria, and rinsing with water. To do this, they are immersed in a 2% solution of lime, then in a 2% solution of baking soda, and then washed with cold water. To avoid getting spoiled eggs, break them into a separate bowl in small portions (3-5 pcs.). The resulting egg mass must be filtered through a sieve with cells no larger than 3x3 mm. Before use, the melange is thawed by placing the jars in warm water at a temperature of 40-45 ° C for 3-4 hours. Tomato paste is stored in sealed containers made of non-corrosive metal at a temperature of 0 to 20 ° C, avoiding freezing. Vitamins are stored in a dry place in a packaged form. The packaging should only be opened immediately before assembling the vitamin mixture.

For uniform distribution of additives in the dough, they are mixed with water in vats with mixers. To avoid coagulation of proteins, the water temperature for mixing egg additives should be no higher than 45 ° C, for powdered milk - no higher than 55, for other additives - 55-65 ° C.

Rice. 1.6. Generalized pasta production scheme

Pasta dough differs significantly from all test masses for food purposes. It is kneaded steep and consists mainly of flour and water.

At first, the dough is a loose mass with grains of small lumps. Then, during the subsequent processing under pressure in the screw chamber of the press, it gradually turns into a thick dough mass.

Conclusions. The term "kneading" for pasta dough is used conditionally. In pasta screw press tistozmishuvachi do not get a completely finished dough. Here, only the ingredients of the dough are pre-mixed to form a grain-like mass. The preparation of the dough begins with the dose of ingredients.

In the tistozishuvalne trough flour comes from the dispenser in a thin layer continuously. Here, the flow of flour, when falling, meets water, in the form of thin jets or splashes comes from another dispenser. From the first moment of collision of these components, the process of water binding with flour colloids and their swelling begins.

Flour and water are dosed in the ratio necessary to ensure the desired recipe and performance.

The kneading of the dough takes place continuously, which ensures the continuous operation of the dispensers in the same mode. In the kneader of screw presses, fragile dough with different particle sizes is obtained. The purpose of kneading the dough is not only the uniform distribution of the mixed components, but also the provision of certain physical properties that determine the high quality of the finished products.

In modern pasta presses, dough kneaders are used with dough vacuuming during the kneading process. In the first trough, intensive pre-kneading of the dough is carried out. In the second and third (under vacuum) the final kneading of the dough and its vacuum processing are carried out.

In the Braibanti presses, the tistozmishuvach also consists of three or four departments. In the first one, preliminary mixing of the dough components is carried out, in the subsequent ones, the final kneading, and in the last one, vacuuming. The Pavana presses have two kneading chambers and two under vacuum. In the presses of the company "Euler" (Switzerland), the tistozmishuvachi have one compartment with a vacuum device at the end of the chamber, but in this compartment there are two kneading bodies of the screw type. A tistozmishuvach with a cylindrical chamber 3 m long is installed in the Aktiva twin screw press.

In screw press mixers, powdered dough is obtained in the form of small grains or lumps. This dough is suitable for direct pressing. That is why screw presses are conditionally referred to as mixing machines, since they do not knead the dough, but only moisten the flour evenly by spraying with water. Next, the dough is processed in the channel of the screw chamber of the press, where its crystal-like mass under the action of the screw blade is gradually compacted and plasticized, acquiring the structures and properties necessary for subsequent formation. In the screw chamber, the final stage of the formation of the structure of pasta dough takes place, which differs significantly from the structure of bread dough.

Cooking pasta requires a significant amount of energy. This can be done in small pulses over a period of time, or in large doses over a short period of time.

An increase in the speed of the kneading blade leads to a strengthening of the dough structure. This is due to the fact that the pasta dough after kneading is a three-phase dispersed system and the role of the solid dispersed phase is played by moistened hitches - flour grains and starch grains. The dispersion medium is plasticized gluten, the third gaseous phase is the inclusion of air. Such a heterogeneous system, unlike a homogeneous one, is capable of compacting and strengthening.

Depending on humidity,%, there are three types of dough kneading: hard - 28-29, medium - 29.5-31.0, soft - 31.5-32.5. The most common medium batch. The dough in this batch is dribnogrudkuvate, quite loose. Products after pressing retain their shape well, do not crumple and do not stick together during decomposition and in bulk in several layers. In soft kneading, the dough is plastic, easily formed, the products have a smooth surface, but dry slowly. At the lower limit of moisture, products dry faster, but have a worse appearance.

Dough of hard kneading is kryhtopodibne, little knitted. It is difficult to process it, the process is slower than in other batches. It is rarely used, only for stamped products of complex shape.

Soft kneaded dough with large lumps does not fill the crimping auger well. Raw products from it easily wrinkle, stick together, stretch. Therefore, it is used only for the preparation of very flexible products that need to be figured into a skein, bow, "swallow's nest" and others.

Depending on the range of products, the quantity and quality of flour gluten, the following dough moisture indicators are adopted,%:

Pasta:

hanging drying 31.0-32.5;

with a diameter of 6 mm or more 29.0-31.0;

less than 6 mm in diameter (drying cassette) 29.5-31.5;

pressed vermicelli and noodles 29.0-31.0;

figured products, horns (pressed) 29.5-31.5.

Temperature significantly affects the structural-mechanical and rheological properties of the dough, which largely determine the results of pressing raw products. The temperature of the dough depends not only on the temperature of its components, but also changes in the dough mixer and in the screw chamber, where the mechanical energy of the working bodies of the dough mixer and the press is almost completely converted into heat energy, due to which the dough is additionally heated. In addition, the screw chamber may have a heating or cooling device, which also makes its own adjustments to the dough temperature.

There are three types of kneading depending on the water temperature, ° C: warm - 55-65, hot - 75-85 and above, cold - 20-25.

Vacuum processed dough, a significant technological effect is achieved: the rheological characteristics of raw products and the appearance of products are improved, strength is increased and the culinary properties of pasta are significantly improved.

If, before or during pressing, air bubbles are not removed from the dough, then in raw semi-finished products, small air bubbles under pressure, when heated and dried, expand and destroy the microstructure of the product. It is even visually noticeable how non-vacuum raw pasta with a perfectly smooth and yellow surface gradually acquires a matte shade during drying, similar to slightly matte glass covered with small white drops. The reason for the change in the color and appearance of pasta is air, which remains in the mass of the dough during pressing in the form of compressed microbubbles, which loosen the structure of the surface of the products during drying.

After vacuum processing, such a change in color and appearance of pasta is not observed. In addition, dough deaeration improves pasta quality indicators: it increases the density and strength of dry products, improves culinary properties, and the like.

Formation of pasta. Now two methods of forming pasta are used: pressing and stamping. The most common method is pressing.

The production of stamped products is also associated with pressing. A strip of dough, from which products of complex spatial shape are stamped, is produced by pressing the dough through a thin slot of the pasta press matrix.

Pressing. For the formation of pasta, continuous screw presses are used, an integral structural part of which are devices for continuous dough preparation - tistozmishuvachi.

The dough components are continuously dosed into the kneading chamber of the dough mixer in a strictly defined volume with the help of special tools. Here the dough is formed, which then enters the screw chamber of the press through the holes. There it is subjected to intensive mechanical processing from the side of the helical blade of the screw, gradually compacted, becomes a thick elastic-plastic and viscous mass. The dough formed in the screw chamber is forced further into a small pre-matrix space, ending with a pressing die, through the holes of which it is pressed out due to the pressure created in the screw chamber. This pressure develops due to the resistance of the forming holes of the die to the expiration of the steep pasta dough. Its value depends on the humidity and temperature of the dough, the speed of pressing, the cross-sectional area of ​​the holes and their configuration, the nature of the expiration of the dough through the holes, and a number of other interrelated factors.

The shape of products obtained by pressing depends on the configuration, the cross section of the molding holes of the matrix. There are mainly two types of holes: solid and with liners with different configurations. Solid holes give filamentous products, and holes with liners - tubular. The inserts with their shoulder pads (in some feather-shaped shoulder pads are placed at an angle of 120 ° C, in others they are T-shaped) rest on the edges of the input side of the matrix holes. The movement of the pressed threads and tubes can be endless, since the pressing by the screw is continuous. The threads are cut into pieces according to the type of products using special cutting mechanisms. The main working body of the pasta press, which determines the type and type of pasta, is the matrix.

Screw pasta presses, thanks to the heating of the dough up to 40-45 ° C, make it possible to press the dough at high speed, which places certain requirements on the quality of matrices made of bronze, brass or with plastic inserts.

The temperature of the dough significantly affects its rheological behavior and colloidal processes and biochemical transformations. The temperature of the pasta dough does not exceed 40-45 ° C. Overheated above 55-80 ° C, the dough gradually turns white, loses its plasticity, becomes inelastic and breaks. During the pressing of such a dough, the working pressure increases significantly, the surface of the products becomes rough, dark or powdery-white in color, the products themselves are easily torn under their own weight. Raw and overheated products are unstable during drying and storage, cracked, brittle and brittle.

Low dough temperature is also undesirable: the process of hydration of gluten proteins is delayed, the dough loses its plasticity, becomes more elastic, and roughness increases on the surface of raw products. Energy costs for pressing cold dough increase dramatically.

The dough reaches its best properties in the temperature range of 50-55 ° C. It becomes as plastic as possible, the surface of the products remains smooth or slightly matte at a significantly increased pressing speed. The productivity of the press increases without increasing the energy consumption for pressing. This also affects the improvement of the quality of finished products: their strength increases, vitreousness is stored in the crack, excellent color, elastic consistency during cooking.

Processing of raw products includes blowing them with air for drying, cutting to a given length and decomposition on a drying device. The purpose of the combination of these operations is to prepare the mass of pressed products for a longer and more important stage of production - drying. The quality of processing of raw products largely determines the results of drying.

Raw products for quick drying of their surfaces are blown with air in order to reduce plasticity and provide them with elasticity and resistance to deformation, especially sticking and curvature. To perform the cutting operation of most products, blowing with a jet of air is used perpendicular to the fibers of the products. For cutting vermicelli and noodles on a hanger in order to obtain straighter products, drying is best done by blowing air along the fibers at a certain length.

Drying is carried out with air, taken from the premises of the workshop. Do not blow cold air on products, as moisture may condense on cooled products. Blowing should be carried out in such a way that cracking of the surface layer of products does not occur. Hanging-drying long pasta is cut with self-rising cutting devices, and products for cassette drying - with the help of special folding cutting machines.

Such important indicators as the productivity of drying equipment, raw material consumption and product quality depend on the quality of cutting and decomposition. During pressing, pasta under the matrix reaches a length of 1.5-2.0 m, then it is mechanically picked up and placed on cassettes, after which they are cut manually or mechanically.

Short-cut products (vermicelli, noodles, horns, curly products, soup fillings) are cut by special mechanisms with one or more knives that cut products directly at the die hole or at some distance from the die. The speed of movement, the number of knives and the cutting method vary depending on the type of products.

Vermicelli and noodles are cut on a hanger at some distance from the matrix after the products dry out a little during blowing. It is reasonable to carry out this in combination with drying raw products by impregnation of air along the fibers. Decomposition provides, during drying, uniform access of air to all parts of a large mass of dried products.

Short-cut raw products from the place of their formation to the dryers are transported by pneumatic transport or by gravity along inclined surfaces. If the production is located on one floor or the dryers are located on the upper floors, and the presses are below, pneumatic transport is used to move small assortment of raw products (vermicelli, noodles, soup fillings, etc.) for drying. From a technological point of view, this is not only some drying of the product, but also the prevention of sticking of individual particles of the product.

Long products for drying in a suspended state are placed in even rows on Bastun with the help of automatic machines, self-winding, which are part of the production lines.

For the production of pasta on presses with round dies, a cassette dryer with double wooden cassettes 500 mm long with slots on the side walls and tables are used. As soon as the length of the fiber reaches 1.5-2 m, a table with cassettes laid on it is rolled under it and all the fiber is manually cut off at the matrix. Then, through the slot of the cassettes, the fibers are cut into pieces 250 mm long.

During cassette drying, various options for mechanizing the cutting and decomposition of tubular products are used. For cutting all types of short pasta, pressed through a round matrix, a universal cutting device is used. The cut pasta is poured out on the directed trays onto the conveyor belt. The cutting unit is mobile, installed under the press and easily moved with the help of rotating wheels.

Drying is the final stage in the production of pasta. An effective method of controlling the drying process is regulation according to the parameters of the drying object itself. Therefore, for a scientifically based drying regime, it is first necessary to know the properties of the material being dried. To prevent distortion and cracking, one should strive for uniform drying of products both along its cut and along its length. An exemplary mode will be in which the internal moisture flow will not lag behind the moisture output from the surface of the products. It is very difficult to implement such a regime, since during drying a significant moisture gradient is formed in the mass of products, at which the moisture inflow from the deep layers is much less than evaporated from the surface of the products. Therefore, it is very important to maintain such a gradient value at which the drying intensity would be greatest.

During drying to pasta dough, the following rule applies: while the dough is plastic, it can be dried quickly (stress and cracking due to it may not be observed even if the difference in moisture content in the center and on the surface is significant).

For drying pasta, the most common three-hundred-milk, or pulsating air drying mode: with constant drying capacity, with variable drying capacity, with preliminary heat treatment of raw products. In each mode, the main goal is to prevent cracking of products.

The three-stage drying regime consists of three stages, or stages. The first stage is pre-drying. Its purpose is to stabilize the shape of raw products, preventing souring, mold and stretching. Drying lasts from 0.5 to 2 is only underway compared to hard modes. During this time, one-third to one-half of the moisture that must be removed from the pasta is released.

Such intensive dehydration in a relatively short time is possible only at the first stage of drying, when the pasta is still plastic and there is no risk of cracking.

The second stage is anxiety. By increasing the relative humidity of the air, softening of the skin is achieved - moistening the surface layer, as a result of which the moisture gradient decreases and the tension that arose in the first stage is relieved. This process is best carried out at relatively high temperatures and relative humidity, at which the rate of moisture diffusion increases and the residence time is reduced.

The third stage - the final drying - is carried out with a soft mode, since the products are in the zone of elastic deformations. During this period, the rate of evaporation of moisture from the surface should be the same as the rate of moisture brought to the inner layers from the outer ones. At this stage, drying alternates with non-curing.

The three-stage drying regime is widespread in Italy even in those days when drying was carried out in natural conditions, alternating drying in the sun and laying in cellars. Later, this mode was justified theoretically and began to be used in the industrial production of pasta.

Pasta packaging. It is undesirable to pack pasta immediately after drying, as their temperature is relatively high. In addition, the products continue to equalize moisture along the cut. The moisture content of the entire pasta mass, as well as of each product, remains non-uniform after drying: on the surface of the product it is drier, in the thickness it is more moist. In products to be dried in a hard mode, due to uneven linear folding, internal stresses arise. Their size may still be insufficient to cause destruction of the products, but if they fall on the packaging immediately after drying, then the inevitable mechanical operations can increase the stress and degrade the quality of the products.

To relieve internal stress, the technological process introduced proofing or stabilization of products in appropriate devices for relaxing internal stresses caused by the clotting of products during drying, and their gradual cooling to the air temperature in the packaging room. Chilled products do not dry out.

Packaging includes the supply of products to packing tables or bins, sorting, checking products on magnetic separators (for short-cut products), packing, sealing on a vibrator, weighing, clogging the lid, marking. The main manifestation of the good quality of products is the absence of zlipan, that is, tubes of pasta, vermicelli strands or strips of noodles glued to each other. Tubes of pasta should be free to separate from each other during light shaking. Unfinished products must be sent for final drying.

Roughness, damage to products by cracks is determined organoleptically, by comparison with reference samples.

Particular attention is paid to the defeat of products by mold. Often, it begins to develop inside the pasta tube in the form of a network of thin moldy threads. On the surface of products affected by mold, spots and stripes of different colors appear - from white to green.

Signs of non-standard products: the presence of ingots and lumps, mold, the presence of impurities, increased acidity and humidity, severe curvature and increased roughness, dark color.

Each batch of short-cut products after passing through a magnetic separator is subject to a control check for the presence of metal impurities. If they exceed the norm, the batch is subject to repeated magnetic testing. To do this, the magnet is preliminarily cleaned of retained metal impurities, after which the products are re-passed through the magnetic separator.

Pasta is produced in packaged and unrevealed. Products are packaged in boxes or bags made of paper, cellophane, varnished cellophane or other packaging films that are harmless to human health. All types of packages must be enclosed in an outer container. Deviation in net weight is allowed ± 5 g. The outer packaging of pasta must ensure their safety during transportation and storage. The packaging of long pasta is different from the packaging of short cut pasta. The first includes strict requirements for strength. The deflection of the pasta tube over a length of 250 mm should not exceed 3-4 mm.

The storage area for pasta should be clean, dry, well ventilated, and not infested with barn pests. Products packed in cardboard boxes and bags are placed in stacks, the height of which should not exceed six boxes or seven bags.

Pasta defects

The cause of pasta defects is the poor quality of the flour. fortifiers and flavoring additives, non-observance of the recipe and manufacturing technology, violation of regimes and terms of storage. The most common pasta defects include foreign taste and smell, rancidity, darkening, rough surface, deformation and sticking of products, the presence of broken products and crumbs, cracks (Table 1.4).

Table 1.4

DEFECTS pasta

Name	Causes
Foreign taste and smell	They may have products for the manufacture of which flour with the presence of these defects was used, stale eggs and egg products. Poor-quality milk and dairy products, sour tomato paste and tomato puree, etc. Foreign smell may occur in case of non-compliance with the commodity neighborhood (sorption of vapors and gases). Pasta can acquire the smell of petroleum products, fish, etc.
Rancidity	It is found mainly in enriched pasta. This is the result of the oxidation of fats, and above all those containing polyunsaturated fatty acids. Such fats are found in flour, dairy and egg products. The process of oxidation of pasta fats is accelerated at high humidity and at high storage temperatures. A bitter taste of pasta can be caused by flour made from wheat with a high content of wormwood, vyazel and other weeds.
Darkening	It can be caused by the formation in the semi-finished products (dough) of dark compounds - melanins as a result of the enzymatic oxidation of phenolic compounds that are found in flour (tyrosine, phenylalanine, tannins, etc.). Most often browning occurs in products made from bread flour or pasta flour from soft wheat.
Rough surface	Appears with insufficient content of gluten in pasta flour, as well as with low humidity of the dough

The end of the table. 1.4

Name	Causes
Presence of broken products and creaks	It is due to the high temperature of the dough during pressing, excessive drying temperature and drying of raw products, rapid cooling of finished products. This defect may appear due to careless packaging, transportation
Presence of cracks	The result of the rapid cooling of pasta after drying, as well as a sharp temperature drop during storage
Moisturizing	Occurs when storing pasta at high relative humidity (above 75%), as well as during sudden temperature changes
Acidity	It is caused by the staleness of raw materials, the long duration of kneading dough, shaping and drying raw products. May occur during long-term storage of products at high humidity and temperature
Presence of dark patches	Associated with the presence of shell particles, aleurone layer and wheat germ in the flour
	Caused by mold fungi at high humidity products. Especially if it is stored at temperatures above 18-20 ° C

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

Pasta business. Organizational moments

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

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

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

Target consumers and types of sale of pasta

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

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

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

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

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

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

Raw material

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

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

Equipment for the production of pasta

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

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

Expenses

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

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

Profitability

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

Net profit

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

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

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

The pasta business is currently a profitable investment. The demand for these products is constant, according to a sociological survey, 40% of Russians eat pasta three times a week. When organizing activities, not only an automated pasta line is important - production is a more complex process, it includes the preparation of premises, the selection of qualified personnel, the selection of suppliers of high-quality raw materials, and effective marketing activities.

What you need to know about pasta

Classic pasta is made from two main ingredients - flour and water. Depending on the quality of the flour, there are varieties of pasta:

Basic ingredients for pasta

• "A" - durum wheat;
• "B" - soft flour (made from crushed wheat);
• "B" - baking flour.

Products differ in shape:

• long - from 14 cm;
• short curly - up to 14 cm;
• small soup products;
• baking sheets.

To expand the range of pasta products, the company can improve the recipe by introducing new ingredients - eggs, mineral and vitamin supplements, new types of flour.

Organization of production

How to open a pasta production line? First you need to take care of the production capacity. The workshop where the line will be located must be dry, heated, with a good ventilation system, all engineering communications are connected. The production area must be at least 100 m 2, it is necessary to provide a room for an office and household rooms, as well as a warehouse for raw materials and finished products. If you do not have your own premises, it would be advisable to rent, rather than purchase a new one, the monthly fee will be 15 thousand rubles, utility bills - 15 thousand rubles.

To maintain the line, two workers and a chief technologist will be needed, in addition, a loader, storekeeper, manager and driver will be needed. With a small volume of production, vacancies can be combined. The monthly wage fund, when working 22 days in one shift, will amount to 60 thousand rubles.

According to the main recipe for classic pasta, flour of the highest or first grade will be required, depending on the class of products. The consumption rates of raw materials per 1 kg of finished products are 0.950 kg. The wholesale price of flour is 12 rubles per kilogram, respectively, the cost of production will be 11.40 rubles, excluding the cost of water. It is advisable to use purified water, to do this, install industrial filters, then the cost of water will be included in utilities.

Equipment for the production of

The main component of the technological process is an automatic line for the production of pasta. The cost of acquiring it makes up a large proportion of all investments. Both domestic and foreign manufacturers are represented on the Russian market. Italian equipment (Realpast) is in the greatest demand, but it is also the most expensive, cheaper analogue - Chinese-made lines (Milltech). Domestic ones are in no way inferior to foreign competitors, the Makiz line of the Ural Machine-Building Plant has proven itself perfectly.

Components of Makiz Pasta Mini Line:

flour sifter

• press machine;
• conveyor dryer;
• pneumatic conveyor;
• stabilizer-cooler;
• storage hopper;
• bag holder.

A flour sifter is necessary to remove impurities, foreign bodies and metal particles that have accidentally entered. Characteristics:

The press machine is used to make dough. Equipped with an evacuated hopper for mixing ingredients, thanks to which air bubbles are removed from the mass, this further improves the taste and structural qualities of finished products. Characteristics:

• power - 14 kW;
• productivity - 240 kg / h;
• electricity - 380 V;
• dimensions - 1860 * 1950 * 750 mm;
• weight - 550 kg.

Pneumatic conveyor is a device for transferring products from a press machine to a conveyor dryer, an integral mechanism of a pasta production line.

Mini Pasta Production Line

The conveyor dryer carries out high-temperature drying of products. This unit has an automated control system that maintains the required humidity, temperature, and controls the time the products stay in the dryer. Characteristics:

• power -84 kW;
• electricity - 380 V;
• productivity - 200 kg / h;
• dimensions - 1500 * 1300 * 6400 mm.

The storage bunker is designed for the collection and temporary storage of finished products, its volume is 1000 kg.

The bag holder is part of the packing mechanism - it packs products in paper bags, unloading the storage hopper.

The price of the line for the production of Makiz pasta is 350 thousand rubles.

Economic benefits of production

Payback is the main issue in deciding on the organization of production, since any entrepreneur is interested in making a profit. Net profit is obtained by subtracting the cost of production and fixed costs from gross revenue.

Cost calculation: 100 kg of finished products per day, 22 working days per month, the cost of raw materials for 1 kg is 11.40 rubles. 11.40*100*22 = 25080 rubles

Fixed costs:

• rent - 15,000;
• utilities - 15,000;
• transport costs -12,000;
• packaging - 4000;
• salary - 60,000;
• raw materials -25080 rubles.

The total cost of production is 131,080 rubles.

Gross revenue: the price of 1 kg of pasta is 32 rubles, per month it turns out 72 * 100 * 22 = 158,400 rubles.

Profit - 158,400 - 131,080 \u003d 27,320 rubles.

It will take one year to fully pay back the cost of the pasta production line. And if you organize work in two shifts, then the desired results can be achieved in six months.

Video: Pasta making machine