In this article:
The attractiveness of the cheese market was appreciated by Russian businessmen a few years ago, when domestic production began to grow. Modern tendencies persist to this day: the product is in demand on the market.
For the production of high-quality cheese, it is necessary to strictly observe the technology, to maintain the product with the optimal temperature in the room.
We draw up documents for the enterprise for the production of cheese
Before starting production activities and purchasing equipment, you should take care of obtaining the necessary permits and draw up the relevant documentation.
This cost estimate will include:
- obtaining the right to purchase (lease) land and build;
- company registration;
- conclusion of contracts;
- licensing and product certification.
All this should be taken care of in advance, otherwise unforeseen circumstances may arise already in the process of making hard cheese.
As for the choice of legal form, it would be preferable to carry out activities through an LLC (with a simplified form of taxation) or an individual entrepreneur. Both options will significantly reduce taxes on the payment of taxes.
Since cheese (cheese) is a product of the dairy industry, its certification is a mandatory procedure.
For example, on Russian cheese you need to get a declaration of conformity code OKP 92 2511. It is issued to the manufacturer or to the contract, indicating the exact number of the lot.
You must provide the following documents:
- application;
- constituent documents of the applicant;
- Contract;
- phytosanitary registration certificate;
- label layouts;
- veterinary certificate.
We purchase a mini workshop for the production of hard cheese
To establish the production process, it is necessary to purchase specialized equipment, which will consist of:
- long-term pasteurization baths, 100 liters;
- paraffiner, volume 75 l.;
- IPKS baths, 200 l;
- cheese press;
- two molds for cheese;
- 2 refrigerating chambers;
- desktop.
Long pasteurization bath
paraffiner
IPKS bath
Basic requirements for raw materials
The taste of hard cheese depends on the quality of the main components.
Compliance with the following conditions is mandatory:
- milk should come exclusively from healthy cows;
- the level of active acidity on the pH meter should not be lower than 6.8;
- lack of antibiotics;
- basic level of fat content, within 3.5 - protein content not less than 3.0% - acceptance temperature not higher than 12 ° C
Contracts should be concluded with milk suppliers, in which the above requirements for milk quality, quantity, payment terms, deferment (if necessary), delivery methods are prescribed.
Russian cheese production technology
Cheese production technology is a complex biochemical process that occurs under the influence of microflora and enzymes and requires strict sequence in the process of its manufacture.
Cheese production steps:
- milk preparation;
- coagulation of milk and obtaining a homogeneous mass;
- cheese maturation;
- salt cheese.
Hardware flow diagram
The hardware technological scheme of cheese production is shown in the following photo:
In cheesemaking, special requirements are imposed on the quality of raw materials.
Milk preparation
It should contain a sufficient amount of protein, thus increasing the yield of the product and reducing the consumption of raw materials. First of all, milk must be cleaned and cooled to prevent the development of microflora and its subsequent spoilage. In this process, milk purifying filters or separators are used.
Milk is cooled to a temperature of 7-8°C on plate coolers of the required capacity.
Milk maturation
The maturation of milk occurs from 12 to 24 hours, during this period it gains acidity.
Excerpt necessary for both raw purified milk and pasteurized. In pasteurized milk, a starter culture of lactic acid bacteria (or a rennet component) should be added.
The use of fresh milk with the addition of mature milk is allowed (ratio 2 to 1).
After that, the milk should be cooled to the clotting temperature. Its normalization is carried out on cream separators, and pasteurization - on pasteurization and cooling units at temperatures of 74-76 ° C for about 20 seconds. With the help of heat treatment, vegetative forms of microorganisms are destroyed, enzymes are inactivated and milk is prepared for clotting (up to a temperature of 32°C). The acidity of milk before the coagulation process should be at least 20-22 degrees Turner.
Rennet coagulation
In a cheese bath, it is prepared for rennet coagulation, namely, a bacterial starter is added; chloride and calcium solution. If necessary, add rennet. For the manufacture of Russian cheese, sourdough from lactic acid and aromatic streptococci is often used (in the amount of 0.8-1.1%).
Quite often in manufacturing process use mature milk (a fifth of the total) in order to increase the calcium content and the quality of the clot. The addition of rennet guarantees the formation of a strong clot in a short time.
The process of milk coagulation occurs at a temperature of 32 ° C for half an hour. The resulting clot is cut and dried for 45 minutes, and the third part of the whey is removed. In order to accelerate dehydration, it is recommended to carry out a second heating of the cheese grain (t 40 ° C - 30 min.).
Dry the cheese mass after the second heating for 50 minutes.
Thus, the duration of the entire treatment is about 2-3 hours. The grain size should be 5-6 mm.
The process of salting cheese and the formation of the product
Salting hard cheese is carried out at the very end of the drying of the cheese grain, after removing 70% of the whey. Concentrated salt brine is added to the grain, stirring for 30 minutes. Now you can proceed to the molding of the product.
With the help of a pump, the cheese grain is fed to the whey separator, from where it is poured into molds.
Self-pressing should occur within an hour, subject to a single turning. After that, on specialized equipment (press), the cheese mass is pressed for another 4 hours, where its active acidity increases significantly.
The cheese is dried for 10 days, after which it is covered with a paraffin-polymer alloy.
It is also necessary to carry out technochemical control of cheese production for compliance with generally accepted standards.
Cheese production business plan
The cost of raw materials, premises and equipment for a cheese mini-factory
To start production activities, a mini-factory needs production room, with an area of 300 square meters with engineering and technical communications. It will house a cheese production shop, a warehouse for finished products and living quarters for employees. It can be purchased or rented.
Assume a monthly rental cost of 5,000 rubles.
The cost of the production line will be 207,880 rubles (capital costs).
Working capital will consist of:
- purchases of raw materials;
- monthly FOT.
To prepare 1 kg. hard cheese (containing 45% water) requires 9 liters of milk. The average cost of 1 liter is 16 rubles. Starter from lactic acid and aromatic streptococci: 1 dose for every 1000 liters.
Based on the monthly output - 5,000 kg. hard cheese, the costs will be:
- Milk - 35,000 liters x 13 rubles = 455,000 rubles;
- Starter cultures - 45 pieces of 30 rubles each = 1350 rubles;
- Payment utilities per month will be 10,000 rubles.
Thus, the cost of the finished product will be 466,350 rubles per month. (5,596,200 rubles per year).
Recruiting staff:
- director - 30,000 rubles;
- technologist - 22,000 rubles;
- cheese maker - 18,000 rubles;
- storekeeper - 15,000 rubles;
- 3 workers - 30,000 rubles.
Total payroll: 115,000 rubles per month (1,380,000 rubles per year).
Revenue and profit from the sale of cheese
Calculation of annual revenue: monthly production x cost of 1 kg. cheese = 5,000 x 250 rubles x 12 months. = 15 million rubles.
Gross annual profit(revenue-cost) = 9,403,800 rubles.
Total expenses, taking into account the initial investment in equipment - 7,184,080 rubles.
Profit before tax (gross profit - total costs) = 2,219,720 rubles. Profit after tax (15%) - 1,886,762 rubles. This will be the amount of net profit.
profitability ratio(net profit/revenue) will be 20.06%.
It should be noted that in the case of the acquisition of a functioning mini-shop, it becomes possible to save up to several million rubles.
The main directions of cheese sales
It is necessary to determine the pricing policy and intended markets for the produced hard cheese at the initial stage of developing a business plan for a mini-factory.
In the first months, you can sell products in the region where production capacity. And only then, as the volume of output increases, it will be possible to increase the sales market in other areas.
Enterprises that produce mainly hard cheeses subsequently expand their range by making cottage cheese, sour cream, glazed curds, etc.
The main advantage of such products is the short production time (one to two days). Thus, the profitability of the enterprise increases.
According to sales statistics, medium-priced hard cheeses are in the lead. Elite varieties of high fat content cannot overcome even 10% of the total consumption. It turns out that target audience will be a buyer with an average level of income.
Therefore, it will be more profitable to produce hard varieties of cheese of the middle price segment.
Of course, the main consumers will be shops and supermarkets, cafes and restaurants, with which long-term and mutually beneficial cooperation should be established. Later, after overcoming the payback period, it may even conquer the international market by selling products for export.
There are two types of cheese production:
1. PRODUCTION TECHNOLOGY OF HARD CHEESES WITH A LOW SECOND HEATING TEMPERATURE
(Hard rennet cheeses are produced from carefully sorted, fat-normalized (taking into account protein content) pasteurized milk with the introduction of various bacterial starter cultures. The production technology, microbiological processes of cheese maturation cause a relatively deep breakdown of proteins, which contributes to obtaining specific properties. Appearance hard cheeses(except Swiss) - the crust is strong, even, without damage and without a thick subcrustal layer, covered with paraffin, polymer, combined compositions or polymer films. Sickle prints are allowed on the surface of cheeses. The color of the dough is from white to slightly yellow, the same throughout the mass.
The main factors determining the specific features of cheeses of this group are:
The use of bacterial starters, consisting mainly of mesophilic lactic streptococci;
- the temperature of the second heating of the cheese grain - 32-42C (depending on the type of cheese and the ability of the cheese grain to dehydrate);
- a certain level of active acidity of the cheese mass at each stage of production, units. pH: after pressing - 5.2-5.9 in mature cheese - 5.2-5.4;
- moderate content in cheeses table salt (1,5-2,5%);
- the use of several temperature conditions in the process of maturation (10-12C, 14-16C, 10-12C).
TECHNOLOGICAL PROCESS
2. Cleaning and cooling of milk. It is carried out to prevent the development of microflora and spoilage of milk. It is recommended to use milk purifying filters to purify milk, and for more large enterprises- separators-milk cleaners. Cooling of milk is carried out to a temperature of 6-8C on plate coolers of appropriate capacity.
3. Reservation and maturation of milk. Reservation of milk lasting 12-24 hours ensures uninterrupted operation of the enterprise. Milk sent to the production of cheese must be ripe (aged at t 10-12C for 10-14 hours in order to increase acidity). Exposure applies to both raw purified and pasteurized milk. Pasteurized milk must be fermented with pure cultures of lactic acid bacteria. It is allowed to use fresh milk with the addition of a share of mature milk (up to 50%).
4. Normalization and pasteurization of milk. Cooling to clotting temperature. Normalization of milk is carried out on separators-cream separators for the fat of the normalized mixture. If necessary, protein normalization is performed (up to ppm protein 3.2%). Pasteurization of milk is carried out on pasteurization-cooling units at t 74-76C with a holding time of 20-25 seconds. The purpose of heat treatment is the destruction of vegetative forms of microorganisms, the inactivation of enzymes that are in their native state, and the preparation of milk for clotting. In the recovery section, the milk is cooled to the clotting temperature (32-34°C).
5. Coagulation of milk, clot processing. In the cheese bath, milk is prepared for rennet coagulation (introduction of bacterial starter; calcium chloride solution; if necessary, ripened milk; rennet). Special attention it is necessary to pay attention to the sourdough, since the entire ripening process depends on it in the production of cheese. A starter consisting of mesophilic streptococci must be active; is introduced in the amount of 0.5-0.8%. It is convenient to use a direct DVS starter, which does not require pre-cultivation of the production starter. Calcium chloride is needed to increase calcium ions in milk, which in turn bind proteins, which contributes to better clot formation. Sometimes in production, milk of increased maturity is used in an amount of 15-20% of the total amount, also in order to increase the amount of calcium ions, and, consequently, the quality of the clot. Rennet ensures the formation of a strong clot in a short time. Coagulation of milk is carried out at t 32-34C for 25-30 minutes.
The resulting clot is subjected to cutting with lira, crushing and kneading for 10-15 minutes in order to set the cheese grain (7-8 mm in size) and dehydrate it. 30% of serum is removed. To accelerate dehydration, the second heating of the cheese grain is carried out under the following modes: t 38-41C, duration 15-30 minutes. To increase the hydrophilicity of the grain, its partial salting is used, which ensures an increase in the content of bound moisture in the cheese. Kneading cheese grain after the second heating for 30-50 minutes is also carried out for its dehydration and grain normalization in terms of moisture. Acidity in the process of processing cheese chamois is regulated by diluting whey with water in an amount of 5-20%. The grain size at the end of processing is 4-5 mm.
6. Molding. For this group of cheeses, plastic molding is traditionally used. The finished cheese grain is pumped into the machine for molding the cheese mass for 15-25 minutes to form a layer and cut it into pieces of the required size. 7. Self-pressing. Pieces laid in cheese molds are subjected to self-pressing for 25-30 minutes - pressing under their own weight. At the end of self-pressing, the cheeses are marked with plastic numbers.
8. Pressing. In presses, pressing is carried out for the purpose of final dehydration of the curd and removal of free moisture, obtaining a well-closed surface and a compacted surface layer. Pressing is carried out from 1.5 to 4 hours. 9. Salting. The most rational way of salting hard rennet cheeses is salting in circulating brines with a concentration of 18-22% and a temperature of 8-12C for 3-5 days. For this group of cheeses, partial salting of the cheese mass in the grain is allowed. Salting gives the cheese certain flavors. During salting, microbiological and biochemical processes are regulated, and the consistency of the product is formed.
10. Cheese maturation, care. Before ripening, the cheese is dried for 2-3 days. In the process of maturation, as a result of the vital activity of microorganisms, profound transformations occur. constituent parts cheese, flavoring and aromatic substances accumulate, the taste of the product is formed. Cheese maturation must take place in maturation chambers under certain conditions (temperature, relative humidity). During the entire ripening time, careful care of the heads is necessary. The total duration of maturation is 1.5-2.5 months.
11. Packing cheese. After maturation, the cheeses are washed, dried, labeled, coated with a paraffin alloy using paraffin wax, or packed in polymer films.
2. PRODUCTION TECHNOLOGY OF HARD CHEESES WITH A HIGH SECOND HEATING TEMPERATURE
(Hard rennet cheeses are produced from carefully sorted, fat-normalized (taking into account protein content) pasteurized milk with the introduction of various bacterial starter cultures. Technology Swiss) - the crust is strong, even, without damage and without a thick subcrustal layer, covered with paraffin, polymer, combined compositions or polymer films. Sickle prints are allowed on the surface of the cheeses. The color of the dough is from white to slightly yellow, the same throughout the mass.
The main factors determining the specific features of cheeses with high temperature second maturation are:
The use of bacterial starters, consisting of mesophilic (for cheeses certain types) and thermophilic lactic streptococci and lactic acid bacilli;
- the use of pure cultures of propionic acid bacteria and active propionic acid fermentation during the maturation of cheeses;
- the temperature of the second heating of the cheese grain - 47-58C (depending on the type of cheese and the ability of the grain to dehydrate);
- reduced moisture content of cheese after pressing (38-42%);
- a certain level of active acidity of the cheese mass at each stage of production, units. pH: after pressing - 5.5-5.8, in three-day cheese - 5.3-5.4, mature - 5.5-5.7;
- reduced content of table salt in cheeses (0.8-2.5); - the use of several temperature regimes in the process of ripening cheese (mainly 10-12C and 20-25?C).
TECHNOLOGICAL PROCESS
Increased maturity and acidity of the processed milk and a high level of lactic acid process (Russian), and for Cheddar also maturation (cheddarization) of the cheese mass in blocks before salting and foaming. The production of hard cheeses with a high temperature of the second heating is less than 5% of the total output in Russia. Due to the long ripening time (more than 90 days) of the cheese. The consequence is the slow turnover of the capital of the cheese factory.
1. Acceptance and evaluation of milk quality. In cheesemaking, special requirements are imposed on the quality of raw materials. Raw materials must be of good quality in microbiological terms; a high content of solids, especially protein, is desirable, which increases the yield of the product and reduces the consumption of raw materials Raw milk should quickly coagulate under the action of rennet, form a clot that separates the whey well.
2. Cleaning and cooling of milk. It is carried out to prevent the development of microflora and spoilage of milk. To purify milk, it is recommended to use milk purifying filters, and in larger enterprises - milk purifiers. Cooling of milk is carried out to a temperature of 6-8°C on plate or tubular coolers of appropriate capacity.
3. Reservation and maturation of milk. Reservation of milk lasting 12-24 hours ensures uninterrupted operation of the enterprise. Milk sent to the production of cheese must be ripe (aged at t 10-12C for 10-14 hours in order to increase acidity). Exposure applies to both raw purified and pasteurized milk. Pasteurized milk must be fermented with pure cultures of lactic acid bacteria. It is allowed to use fresh milk with the addition of a share of mature milk (up to 50%). 4. Normalization and pasteurization of milk. Cooling to clotting temperature. Normalization of milk is carried out on separators-cream separators for the fat of the normalized mixture. If necessary, protein normalization is performed (up to 3.2% ppm protein). Pasteurization of milk is carried out on pasteurization-cooling units at t 74-76C for 20-25 seconds. The purpose of heat treatment is the destruction of vegetative forms of microorganisms, the inactivation of enzymes that are in their native state, and the preparation of milk for clotting. In the recovery section, the milk is cooled to the clotting temperature (32-34C).
5. Coagulation of milk, clot processing. The acidity of milk before curdling should be 19-22T. In the cheese bath, milk is prepared for rennet coagulation (introduction of bacterial starter; calcium chloride solution; if necessary, ripened milk; rennet). For Russian cheese, starter is used from strains of lactic acid and aroma-forming streptococci in the amount of 0.7-1.2%. For Cheddar - sourdough from strains of Str. cremoris, str. lactis, Lbm. plantarum in the amount of 1.5-2.0%. Calcium chloride is needed to increase calcium ions in milk, which in turn bind proteins, which contributes to better clot formation.
Sometimes milk of increased maturity is used in production in the amount of 15 - 20% of the total amount, also in order to increase the amount of calcium ions, and, consequently, the quality of the clot. Rennet ensures the formation of a strong clot in a short time. Milk clotting is carried out at t 32-34C for 30-35 minutes. The resulting clot is cut, set and dried for 35-45 minutes for Russian cheese and 45-50 minutes for Cheddar. Grain size 7-8 mm. 30% of serum is removed. To accelerate dehydration, the second heating of the cheese grain is carried out under the following modes: t 39-41C, duration 20-30 minutes. Drying of cheese grain after the second heating is carried out for 40-50 minutes. The duration of the entire treatment is 120-150 minutes. The grain size at the end of processing is 5-6 mm.
RUSSIAN CHEESE
Partial salting of Russian cheese is carried out at the end of drying the cheese grain before molding (50-70% of the whey is removed before this). Concentrated brine is applied to the grain. Salted grain is kept for 25-30 minutes with stirring.
FORMING
Ready for molding cheese grain is pumped to the whey separator, from where it is fed in bulk into molds. Self-pressing in the forms of cheese mass lasts 50-60 minutes with a single turn. Pressing lasts 3-4 hours, then the cheeses are repressed, then pressed for 2-3 hours until the active acidity of pH 5.2-5.3 increases. (Total pressing time 5-8 hours). Duration of cheese salting in brine is 2-3 days, brine temperature is 10-12C The cheese is dried for 8-10 days, then covered with paraffin-polymer alloy. The total duration of maturation is 60 days.
CHEDDAR
The processes of cheddarization, molding and pressing of cheese are carried out at a room temperature of 30-35C in order to intensively develop the lactic acid process. A 25-30 cm thick layer formed in the molding apparatus is kept under a whey layer for 30-40 minutes. Then the cheese layer is pressed, cut into blocks (25x24 cm), stacked in several rows on carts, subjected to cheddarization. Blocks are turned 4-6 times every 15 minutes. Cheddarization (ripening of the cheese mass for 90-100 minutes to pH 5.2-5.3) of the cheese mass is carried out in blocks before salting. As a result of ripening, the consistency of the cheese mass becomes layered-fibrous.
CRUSHING, SALTING
In the crushing device, the cheese mass bars are crushed into pieces of 1.5-2 cm, evenly salted.
FORMING
The cheese is molded into rectangular blocks and placed in perforated moulds. Self-pressing is carried out for 20-30 minutes. Pressing lead 8-14 hours. Drying 2-3 hours. The cheese is packed in polymer films under vacuum with heat shrink. Ripening 90 days.
Information provided by NPK "Progressive Technologies". The company supplies a wide range of equipment for the production of processed and sausage cheeses. We offer both fully equipped production and packaging lines, as well as disparate equipment, ranging from cheese mass melters to automatic packaging machines in a variety of consumer containers. The company's technologists will tell you in more detail about the production technology and correctly select the required equipment.
Phones in Moscow:
Secretariat: 933-60-63; fax: 933-60-64.
Company website: WWW.PROTEX.RU, E-mail: [email protected]
Cheese is one of the most valuable food products. It contains almost all the substances necessary for the human body in an easily digestible form. Protein digestibility cheese is 95%, fat - 96% and carbohydrates - 97%.
Cheeses are divided into four main classes: hard (Russian, Dutch, Swiss, etc.), semi-hard (spicy, Latvian, Roquefort, etc.), soft (amateur, Slavic, etc.) and brine (suluguni, farmer's, Imeretinsky, brynza , Adyghe, etc.). Each of these classes, in turn, is divided into separate subclasses and groups.
Regardless of the class of cheese and the volume of processed milk cheese production includes the following process steps:
- acceptance and preparation of milk for clotting;
- production of cheese grain;
- molding;
- pressing (self-pressing);
- salting;
- maturation and storage.
At the stage of acceptance and preparation of milk for clotting, the milk is weighed, the necessary analyzes are carried out to determine its quality, purification, milk cooling, storage, pasteurization and separation.
The production of cheese grain is carried out in cheese-making baths and cheese producers (boilers). In these devices, a number of operations are performed: normalization of milk (if it was not carried out at the stage of preparing milk for clotting), heating to a clotting temperature, adding the necessary components (rennet, bacterial starter culture, calcium chloride, etc.). Cutting the clot, selecting a part of the whey, kneading and setting the curd.
There are two main ways of molding cheese - from a layer under a layer of whey and in bulk. In accordance with this, in the first case, molding devices of various designs (horizontal and vertical) are used, in the second case, whey separators. At small cheese production the formation of cheese from the layer is carried out in cheese-making baths, and in bulk - perforated ladles are used. Thus, molding devices and whey separators are excluded.
At the stage of pressing, various presses are used - horizontal, vertical, tunnel, carousel, etc. Self-pressing is carried out in forms with periodic turning them over.
Ambassador cheese carried out in brine pools (with or without containers) filled with brine. Other methods of salting: rubbing with dry salt, injection, etc. are not widely used.
Ripening and storage of cheese is carried out in chambers in which the necessary humidity and temperature conditions are maintained. Cheese heads are placed on shelves in stationary racks or mobile containers. During the ripening period, cheeses are subjected to periodic washing and drying. Cheeses are ripened and stored in polymer films or coated with special alloys.
The above stages of cheese production consist of a number of operations performed manually or mechanized (automated). The production of each type of cheese is characterized by specific technological modes set out in technological instructions. One of the main factors affecting the quality of cheese and its competitiveness is the technical level of the enterprise.
To date, due to a number of objective and subjective reasons, a difficult situation has developed with the equipment of cheese factories modern technology. As a rule, typical plants with a capacity of 2.5; 5.0 and 10.0 tons cheese per shift were built in the 70-80s and equipped with complete cheese-making equipment of the Hungarian company Elgep. This equipment was developed in the late 60s and was supplied to the country almost until 1990. In the 1980s, within the framework of the CMEA, Hungary developed and tested individual models of machines and apparatuses of a new generation, which, according to the main technical specifications were not inferior to world standards, but they were no longer supplied to our country. Thus, the majority of standard plants are equipped with obsolete Hungarian equipment. Wear of this equipment reaches 80-90%.
The second supplier of cheese-making equipment was the enterprises of the Ministry of Nuclear Industry, which were not the developers of machines and apparatus for cheese-making, but made it according to the documentation transferred by the former Minpischemash. This equipment for large enterprises does not correspond to the modern technical level in terms of the degree of mechanization and automation, workmanship, productivity, because the documentation of the equipment developed and manufactured by the enterprises of the Minpischemash during the 70-80s was transferred. Work on the creation of a system of machines for cheese making, which began in 1989-1992, was suspended due to the termination of budget financing. The situation with the establishment cheese making equipment, is characterized as follows:
- lack of budget funding for research and development;
- lack of a unified policy in the development of equipment and coordination of work in this direction;
- production of machines and devices in the form of single samples for a paid order, instead of a planned serial production;
- a large number of enterprises ready to produce cheese-making equipment and, as a result, no difficulties in placing an order for its manufacture;
- a large selection of imported equipment with a higher level of mechanization and automation;
- lack of funds from the majority of enterprises for the purchase of new machines and apparatus;
- a significant reduction in the time for the development of technical documentation for equipment due to the exclusion of a number of coordinating and approving organizations, which is one of the positive factors in the current situation.
Analyzing the technical level cheese making equipment, one should always keep in mind a wide range of capacities of enterprises producing cheese (from 1-2 tons to 100 tons of milk processing per shift). Naturally, the level of mechanization and automation at these enterprises should be different and determined by economic feasibility.
The intensive development of equipment for the cheese-making industry falls on the 60-80s, when machines began to appear one after another, radically transforming one of the technically backward branches of the dairy industry into a highly mechanized one that meets modern production requirements. This equipment still forms the basis of cheese making. Practically over the past 12-15 years, fundamentally new machines and devices have not appeared either in our country or abroad. Only the modernization of previously created equipment, the improvement of individual components and mechanisms, and the replacement with modern elements of automation are carried out.
Apparatus for the production of cheese grain
Apparatuses of periodic action of two types are used: cheese baths and cheese makers (boilers). The division into these two types in some cases is conditional - devices with a capacity of 10 m3 or more, as a rule, are hybrids of bathtubs and boilers.
Attempts to create devices of continuous action, which would find distribution in the industry, were not successful. The latest design of a continuous apparatus is a conveyor-type machine manufactured by Alpma (Germany).
A modern apparatus for the production of cheese grain, regardless of type, is characterized by the following features:
- closed container;
- centralized in-place washing of the inner surface of the container and tools;
- non-removable universal cutting and kneading tool;
- automatic selection of a given amount of whey;
- program control (in time) of cheese grain production operations.
After about 20 years ago, horizontal cheese makers of the Danish company Pasilak, and then the Swedish company Alfa-Laval, appeared at the enterprises of the industry, fundamentally new designs of apparatus for the production of cheese grain were not proposed. The devices have reached the highest level of development, and further work is carried out in the direction of changing individual units and elements without affecting the entire structure.
At present, OSCON OJSC is engaged in the development and manufacture of cheese baths and cheese makers, which produces cheese baths with a capacity of 2.0; 5.0% 10.0 m3 and a cheese vat with a capacity of 10.0 m3.
Experimental Machine-Building Plant VNIIMS (EMZ VNIIMS) has developed and produces cheese baths with a capacity of 0.6; 1.2 and 2.5 m3, and JSC "OSCON" - 2.0; 5.0 and 10.0 m3, the characteristics of which are given in table 1.
Apparatus for molding and pressing cheese
Appeared in the 60s, the apparatus of the company "Tebel" for molding cheese under a layer of whey later became the basis for the creation of almost all batch machines, although before that various designs of apparatus were used. For example, the FAB movable bottom molding machine developed by VNIIMS and mass-produced.
A modern molding machine, like its prototype, has the same main components: a container with a movable bottom (plates or tapes), a pre-pressing mechanism, a device for cutting the cheese layer into bars. The improvement of the apparatus took place in the direction of increasing the level of automation and mechanization of individual manual operations (removing the plates of the movable bottom, loading them into the apparatus, sanitizing the plates and tape, as well as the inner surface of the container for the cheese mass, unloading cheese on the conveyor) or expanding the scope of use (establishing a mechanism for separating whey from cheese grains for the purpose of molding in the apparatus and cheeses molded in bulk). All this made it possible to create a highly efficient machine of complex design.
Tebel-type molding machines are produced by Oskon JSC, Kompleks JSC and EMZ VNIIMS.
In addition to batch molding machines, continuous vertical molding machines are widely used abroad. The best known are the Kazo-Matic devices from Alfa Laval. The vertical type of the molding machine has a number of advantages compared to the Tebel type machines: a smaller production area is required, it is easier to manufacture and operate, and the degree of automation is higher. The disadvantages are the high height, the difficulty of obtaining the required pattern for cheeses, molded from the reservoir, the need for an intermediate tank (buffer tank) between the cheese maker (cheese bath) and the molding machine. In our country, the development of vertical-type molding machines in the 80s was carried out by VNIIMS, VNIEKIprodmash, the North Caucasian branch of VNIIMS. However, for a number of reasons, they were not mass-produced.
For cheeses molded in bulk (Russian, Uglich, etc.), whey separators of drum and tray types are used. In large enterprises, some firms install whey separators on horizontal or vertical molding machines designed for cheese molded from the reservoir. This method expands the scope of use of devices for all types of cheese molding. Two modifications of drum whey separators (EMZ VNIIMS) are produced in our country for 23 m3/h and 50 m3/h.
Of all the cheese-making equipment, the most diverse in terms of design are, perhaps, presses for cheese: from primitive lever presses to automated complexes for pressing cheese. At the enterprises of the country, the most common is vertical pneumatic press(two- and four-section). Such a press is produced by EMZ VNIIMS and OAO OSCON
Tunnel presses are replacing vertical presses with manual loading and unloading of cheese molds. various designs with manual and automatic loading and unloading of these forms. As a working body for pressing, pneumatic cylinders and flexible hoses of large diameter are used.
To install tunnel presses, 2-2.5 times more production area is required than for vertical presses with the same pressing time. The advantages of tunnel presses are expressed in more mechanization and automation with simple devices for loading and unloading them.
At large enterprises, molding machines and presses are combined into a single complex with a high level of mechanization and automation using various mechanisms, devices and auxiliary equipment. The most automated complexes include a device for pressing cheese, machines for washing cheese molds (sanitization of the mold and press is carried out from the factory washing station), transport modules, devices for loading and unloading the mold and presses, a device for applying lids to molds, pumps for pumping cheese mass and whey. The domestic machine-building industry does not produce such complexes.
The connecting element of all equipment used at the stage of molding and pressing are molds (individual or group). For a long time, two-element (body and lid) cheese molds have been used abroad, which contributed to the successful comprehensive mechanization and automation of molding and pressing.
Molding and pressing stage cheese should be considered as a single one, in which there is no clear distinction between the processes of molding and pressing. Therefore, along with traditional devices for molding and pressing, machines are produced in which these two operations are combined. An example of such an apparatus, widely used in industry, is a baropress manufactured by EMZ VNIIMS (table 4). The baropress is a structure consisting of containers with a set of molds for cheese and rubber diaphragms (the number of containers is determined depending on the capacity of the apparatus for producing cheese grain), a vacuum station, a drive system for distributing the cheese mass among the containers and draining the whey. After filling the molds with cheese mass, diaphragms are placed on the containers. Molding and pressing is carried out by these diaphragms when vacuum is created in the containers.
For cheeses, the production technology of which does not provide for pressing, but only self-pressing (brine, soft), EMZ VNIIMS produces sets of group molds with mobile tables.
Equipment for salting cheese
The main method of salting cheese is salting in salt basins using containers and lifting mechanisms (hoist, overhead crane, etc.). In this case, mechanized loading of cheese on the shelves of the container and its unloading, loading of the container into the pool and its unloading is possible.
Abroad, for the mechanization of these operations, a system of canals, which are an integral part of the basins, is widely used. heads cheese through the channels with the brine flow they swim into the container, which, after filling the tier, lowers by one step. Alternately filling the tiers of the container with cheese ends when the topmost tier is filled. After that, the channel leading to this container is blocked and opened to the next container. The container is unloaded in the reverse order.
In the late 80s, new methods of salting appeared cheese: injection (needle and needleless) and salting by applying salt to the heads in an electrostatic field. However, these methods do not exclude subsequent salting out in brine and require further study. Containers for salting cheese with stainless steel shelves are produced by EMZ VNIIMS.
Equipment for ripening, storage and processing of cheese
Ripening and storage of cheese at the cheese factories of the country is carried out either on stationary racks or on special containers with wooden shelves. The movement of such containers and their stacking in the ripening chambers is carried out by electric forklifts. Cheese is loaded into the container and unloaded manually.
In the former Lithuanian branch of VNIIMS (Kaunas), a set of devices was developed on the basis of an existing shelf measuring 1000x850 mm. These devices made it possible to mechanize and automate loading and unloading and transport work in the cheese store. However, it did not reach serial production.
Foreign highly mechanized equipment systems for maturation and storage cheese are based, as a rule, on the use of shelves with a single-row arrangement of cheese on them. The use of such shelves greatly simplifies the design of devices and mechanisms for loading and unloading them, facilitates various manipulations with such shelves during their transportation and processing.
The processing of cheese during the ripening period consists in washing it, drying it and wrapping it in a film or applying a protective coating (alloy). For washing cheese, EMZ VNIIMS produces a machine of the RZ-MSCH brand, and for drying - a machine of the brand 44A.
The application of a protective coating is carried out on parfiners. EMZ VNIIMS produces the Ya7-OPK carousel paraffiner.
For packing cheese a large number of designs of vacuum packaging machines of various organizations are produced in the film. EMZ VNIIMS produces the VUM-5M machine for these purposes.
Equipment for small businesses
The need to produce machines and apparatus for this category of enterprises arose about 10 years ago, when collective farms and state farms began to create their own processing shops, since it was economically profitable not to hand over milk to cheese factories, but to process it on the spot.
Small enterprises conditionally include workshops and cheese dairies that process up to 10 tons of milk per day. The creation of equipment for such enterprises has its own specifics. As a rule, the equipment is located in existing premises, which have to be adapted to the requirements of the dairy industry, often they do not have boiler rooms, maintenance personnel, as a rule, are not familiar with the production technology. cheese, It has low qualification etc. Therefore, in each specific case, an individual approach to the choice of equipment is required (taking into account the volume of milk processing, the type of cheese produced, the availability of steam, electricity, staff qualifications, etc.). The range of manufactured equipment for small businesses is very wide and is based on cheese baths with a capacity of up to 2.5 m3 with electric or steam heating, lever and pneumatic presses, fermenters, salting containers, mobile tables, cheese molds, racks for ripening and storing cheese, pumps for pumping milk, etc. In addition, industry-wide low-capacity equipment is also required - pasteurizers, milk coolers, separators, milk and whey storage tanks.
EMZ VNIIMS for small businesses produces cheese baths, lever and pneumatic presses, salting pools, fermenters, cheese molds, mobile tables, washing machines cheese, racks, various containers (for washing forms and inventory, for storing cleaning solutions, etc.), paraffiners and a vacuum packaging machine. Similar equipment is manufactured by JSC "OSCON" and other organizations.
When creating new domestic equipment for cheese making, it is necessary to achieve the optimal ratio of "price - the level of mechanization and automation".
Currently, many cheese factories are not able to short term(primarily in terms of financial conditions) to carry out a comprehensive re-equipment, replacing worn-out and obsolete Hungarian equipment, which is equipped with enterprises with a capacity of 25 tons of milk or more, processed per shift for cheese. Therefore, when developing new machines and apparatuses, one should return to the implementation of the MASUM system (modular-aggregate system for the unification of machines). This system was developed by VNIIMS, and its implementation began in the 1980s. MASUM allows for the phased creation of modules and their use in industry, gradually increasing the technical level of the cheese factory, without waiting for the development and production of the entire complex of equipment.
The creation of machines and apparatus for molding and pressing cheese of a high technical level is impossible without solving the problem of cheese molds. Currently, metal molds made from Uglich perforation are widely used in the industry. These forms are multi-element (body, perforated liners, bottom, cover). Assembly and disassembly of such forms is possible only manually, which does not allow comprehensive mechanization at the stage of molding and pressing. The creation of two-element forms (body and cover) is one of the main tasks, without which it is impossible to eliminate many labor-intensive manual operations in cheese production.
Those highly mechanized equipment complexes, the need for which is limited in the country (for the 5-10 largest enterprises), it is advisable to purchase abroad rather than develop it on our own.
The existence of several firms involved in the development of cheese-making equipment, and the presence of competition between them, are a good basis for creating machines and apparatus that meet the practical requirements of the cheese-making industry.
Magazine "Food business",
Reprinting without the written permission of the editors is not allowed.
Oddly enough, but the cheese that we all love to eat can be compared to a person. Just like a person, cheese is born, matures, ages and dies.
By the way, like people, cheeses have their own hierarchy: patriarchs, aristocrats and commoners.
The technology for making hard cheese has hardly changed for centuries.
In small and medium-sized cheese dairies, where traditions are honored, cheese is still made by hand. At large enterprises, cheese production processes are mechanized and automated, and the equipment is equipped with program control.
The initial ingredients from which any hard cheese is made is milk. The technology for making different varieties of hard cheese from milk has much in common, so before you start cooking cheese, you need to study general provisions and then apply different recipes.
1. Milk pasteurization. As you know, there are three modes of pasteurization:
- prolonged, when milk should be heated to 65 ° C and kept for 30 minutes;
- short-term - milk is heated to 75 ° C and kept for 20 minutes;
- instant, when the milk is heated to 90 ° C and not kept.
According to various recipes, hard cheese can be prepared with pasteurized milk, and with fresh, as well as with steam, that is, immediately after milking.
Depending on what kind of milk you use when making cheese, the cheese acquires its own special characteristics and taste.
2. Formation of a clot. After you add a milk-clotting enzyme or starter to milk, a gel forms.
Depending on the temperature at which the starter or enzyme was added to the milk, the result of coagulation (coagulation) of milk will be different.
Depending on the cheese recipe, the resulting coagulate is subjected to various types processing in order to separate whey, cut, heat, mix. This process is called syneresis.
3. Cutting the clot. The coagulum is ready for cutting after a period of 25 minutes to 2 hours, depending on the cheese recipe.
To determine the exact time of cutting the clot, a clean finger test is performed. This traditional method, which is used by cheese makers.
The meaning of the test for a clean finger is to dip a finger, probe (spatula) or thermometer into the top layer of the clot and lift it up, as a result of which the clot breaks up, forming a break line.
A clean break with non-spreading edges and green serum at its base indicates that the clot can be cut.
A soft uneven break line with white serum indicates a weak clot strength. On the sides of the break, one can judge the quality of the clot: a granular structure indicates that the clot is too dense.
4. Getting the cheese mass. As a result of the processes performed with cheese, a curd mass is obtained. In fact, this is a ready-made cheese, in which you can this stage add various spices, salt, herbs, nuts, etc. The cheese mass is either weighed or pressed.
5. Cheese pressing and self-pressing. At the stage, it is laid out in special forms and subjected to pressing.
You can buy molds for cheese in the online store with delivery.
Pressing can take place in several stages and can be different in terms of pressure.
6. Cheese maturation. At this stage, the cheese should be transferred to a cellar, or some other special room for maturation, where it will need to be carefully looked after.
If you are preparing pickled cheese, then it can both ripen and be further stored in brine.
In the process of ripening, the cheese must be turned over, sometimes washed, brushed. Depending on what kind of cheese is being made, it can even be smoked, wiped with alcohol, sprinkled with spices and perform other manipulations.
It is important that a certain level of humidity and temperature is maintained in the room throughout the entire ripening process, since the final result depends on this.
You can buy a package for cheese maturation in the online store.
To date, among the entrepreneurs of our country, it has gained great popularity as a business. A mini-workshop for the manufacture of this product does not require investments of tens of millions of rubles. Cheese itself is present in the diet of almost all families, which confirms the considerable demand for it.
That is why opening your own business for the production of this dairy product is a very promising and profitable business.
Who can start a cheese business?
It is most profitable for farmers to open their own mini-workshop. In this case, the production of cheese can be carried out from its own raw materials. This will make the final product cheaper, and therefore in demand.
But is cheese production as a business only available to a farmer? Any entrepreneur can open a mini-workshop. Of course, he will have to negotiate the purchase of milk from farmers, but in this case it will be possible to make a significant profit. The main thing is to plan your actions correctly and rationally.
Preparatory stage
How to start your own cheese making business? First of all, you will need to think over a business strategy. It will be needed not only for beginners, but also for experienced entrepreneurs. A business plan will help analyze all initial costs, give a correct assessment of supply and demand in the market, as well as plan the future profitability and profitability of the event. In addition, a pre-developed strategy will allow you to select the right range of products, determine their prices and find buyers.
Sales market
Before organizing a cheese mini-workshop as a business, you need to start looking for buyers. To do this, you need to plan in advance the ways of marketing future finished products. They may be different. So, the sale of cheeses is possible by:
Selling in your own store;
- sales in the food market in their area;
- conclusion of contracts with wholesale warehouses;
- deliveries of the product to the retail trade network;
- deliveries of cheese to cafes and restaurants of their city and region.
It is advisable to choose more than one option from the list. This will make it possible to sell the product faster and get a fairly large profit.
Range selection
Natural cheese is represented by a large number of varieties. They differ from each other in their appearance, taste and other characteristics. So, according to the manufacturing process, cheeses are classified into rennet and sour-milk. The first of them are made using. In the second method, cheeses are made by fermenting milk with the help of sourdough.
The preparation of each of the available varieties involves the use of its own technology and special equipment. It is this moment that determines the importance of choosing the direction of business. Also, a novice entrepreneur will need to take into account the level of their own qualifications. For those who are interested in cheese production as a business (mini-workshop), the technology for their first production should be chosen, most likely, the most uncomplicated. Such a process will not require significant time costs and special art of its implementation.
The easiest way to cook cheeses related to soft varieties. For them, it is only necessary to curdle the milk, and then strain and compress the portions needed for sale. The main advantage of soft varieties is their short production time. Such cheese does not require ripening and is ready to eat in a couple of days or within a week. According to a long-term maturing technology, it will take a month and a half to make them. However, it should be borne in mind that such a product must be sold within 14 days.
You can also organize the production of hard cheese as a business. In this case, the mini-workshop will produce products in a longer time frame, but its cost is much higher.
Company registration
If you decide to organize the production of cheese as a business, the mini-workshop in which this product will be made can only be opened after the appropriate paperwork is completed. You will also need to obtain a permit to operate.
What is the best organizational form to choose when starting cheese production as a business? It is recommended to open a mini-workshop to a society with limited liability. The fact is that the bulk of retail chains and big stores prefers to work with legal entities. This makes it possible to make tax deductions, thereby reducing taxes. Working with IP does not provide such an opportunity. After all, according to their status individual entrepreneur is an individual.
Payment of mandatory payments to the budget
When choosing a taxation system, a novice businessman should pay attention to the simplified tax system. In this case, two payment options are acceptable:
- 6% of revenue;
- 15% of income.
The second system of taxation becomes profitable at high production costs.
Certification
What other documents will require the organization of cheese production as a business? A mini-workshop producing a dairy product cannot be opened without the appropriate certification. The issuance of this document is carried out by Rostest in accordance with the current technical regulations. The obtained certificate makes it possible to label products in accordance with the law. Without this, cheeses simply will not get on store shelves.
To obtain a certificate, you will need to collect a package of documents. It should include:
- certificates for raw materials, which are provided by suppliers of milk and sourdough;
- expert opinion issued by Rospotrebnadzor.
It is necessary to take care of the availability of all these documents even before cheese production as a business is established. In this case, the mini-workshop will work without interruption, and the entrepreneur will not have any difficulties with the guardians of the law.
Room selection
Very profitable and attractive is the production of cheese as a business (mini-workshop). How to open this case? To do this, in addition to processing the relevant papers, you will need to choose a convenient room. Its area should not be large. For example, if up to 100 kilograms of cheese are produced per day, then a workshop of 20 square meters is enough. meters. On such an area it is quite compact to accommodate the necessary technological equipment.
Communications and arrangement
What else needs to be considered in the premises where cheese production as a business will start? A mini-workshop, the plan of which should contain several zones, must be equipped with utilities. After all, the product is impossible without the presence of water supply, sewerage, ventilation and heating. The division into zones will make it possible to sequentially place technological equipment in the workshop and perform each of the stages of the cheese-making process in a separate area.
When choosing a room for rent, the amount of which will be 30-50 thousand rubles per month, you need to pay attention to the presence of natural light. Also, a system should be installed in the workshop fire safety. It should also be taken into account that the production of cheese must be organized in a room whose walls are tiled. In the absence of this finish, you will have to allocate money for construction work.
Workshop equipment
An aspiring entrepreneur should be aware that he will need to purchase a special processing line in order to start cheese production as a business.
A mini-workshop, the equipment of which is necessary for the production of a quality product, is equipped with:
A cheese manufacturer, that is, a place where raw materials are cooled and pasteurized, and a clot is also formed;
- bath, necessary for the formation of cheese heads;
- maturation chamber, in which the required temperature and humidity are set, allowing to obtain a product;
- a dosing device with which packaging is carried out liquid products in individual packaging.
Who is engaged in the production of technological lines?
The choice of equipment for a mini-workshop for the production of cheese is not so great. As a rule, entrepreneurs purchase such lines abroad. The domestic manufacturer is PK Molexpert LLC, located in Barnaul.
However, entrepreneurs who open cheese production as a business (mini-workshop) buy Italian equipment more often. These are the low volume lines offered by Sfoggia. This company, which is the most famous in Europe, develops and manufactures quality equipment for the production of small quantities of hard and fresh cheeses. In addition, Sfoggia's lines allow the production of butter and yogurt, pasteurized milk, etc.
What is the peculiarity of these installations? In them, the milk is pasteurized, cooled, and then the cheese mass is fermented and cut. Further, on special tables with their own heating, the product is formed and goes through the self-pressing stage.
Why is this line attractive for those who open cheese production as a business (mini-workshop)? Italian equipment greatly simplifies the process of product preparation due to automation and its subsequent cooling. In addition, the line is equipped with a special recording tool that allows you to print out data on already performed operations, which facilitates the work of the operator.
The company manufactures various models of cheese makers for 120 and 360 liters. At the same time, the equipment is able to operate on electricity, gas, hot water, steam, as well as on diesel fuel.
Italian mini-cheese factories allow you to get 12 kg of the finished product from 100 liters of cow's milk. And if the raw material is goat or sheep, then all 20 kg. What is attractive is that the remaining whey from the cheese can be turned into ricotta curd. Moreover, from cow's milk it will turn out 5 kg, and from goat or sheep - 8 kg.
The Italian line is chosen by businessmen and according to the available technical characteristics. For example, a model with a capacity of 360 liters can process up to 1400 liters of milk within 16 hours. This is a reliable and durable equipment that has proven itself both in Europe and in the vastness of our country.
Personnel issues
When opening a mini-workshop for the production of cheese, one or three people will need to be hired to maintain the line and one technologist who knows all the features of the technological process. The service of a manager involved in the supply of raw materials and the sale of the finished product will not be superfluous. But this function can be taken over by the owner of the cheese production.
It should be borne in mind that the success of the business started will depend on the staff hired. That is why this issue deserves the most serious approach.
Raw material quality
For successful work the market will need to produce a product of high quality. And this will require the implementation certain conditions which concern, first of all, purchased milk. Raw materials must be taken only from farmers who have healthy animals that have passed veterinary control. It should not contain even a small percentage of antibiotics. In addition, good raw materials have a three percent fat content, and its acidity index should not be less than 6.8. It is better to fix all requirements for milk when signing a supply contract.
Production costs
When opening a mini-workshop for the production of cheese, you will need to make certain financial investments. Approximately they will be (thousand rubles):
For the purchase of a production line - 300;
- workshop repair - 200;
- training of employees - 30;
- other expenses, including registration - 100.
As a result, the total amount of preliminary investments will amount to 630 thousand rubles.
Monthly production costs (thousand rubles):
Received income
How profitable is cheese production as a business (mini-workshop)? Feedback from entrepreneurs suggests that by releasing one hundred kilograms of product every day, it is possible to sell up to 2200 kg of hard and soft cheeses monthly. With an average selling price of 200 rubles. per kg, the revenue will be 440 thousand rubles.
The amount received will be enough to cover the costs of production and payment of tax. The net profit of the entrepreneur will be about 65 thousand rubles. Thus, with the sale of all manufactured products, the payback of production can be achieved within ten months after the start of work.
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