Puppet theater as an art form. Puppet show
Yoghurt is a fermented milk product produced by normalizing the fat content and concentration of milk powder in its composition. During manufacture, various food additives are introduced into the product in the form of vegetable proteins, flavoring components, thickeners and sweeteners.
Outwardly, yogurt is a product of a creamy consistency with the addition of individual berry or fruit pieces. Regular yogurt is the color of milk, while those containing fillers may be the color of added syrups.
Just because both children and adults like yogurt, it makes sense for an entrepreneur to go into business related to it and open a yogurt production plant in Russia. Even if it requires significant investment, the production of a product loved by everyone will very soon pay off the costs and become profitable.
Our business valuation:
Starting investment - 2,250,000 rubles.
Market saturation is average.
The complexity of starting a business is 7/10.
Technological features of yogurt production
Yogurt production technology is very similar to sour cream production technology. Also, yogurts have two cooking methods - thermostatic and reservoir. Moreover, products of a fruit and berry type can only be obtained by a thermostatic method.
tank method
The method for the production of yogurt consists of the following operations:
- acceptance of raw materials in the form of natural milk into the workshop, filtration;
- regulation of the fat component by adding milk powder or higher fat dairy products;
- passing the mixture through a homogenizer;
- pasteurization;
- lowering the temperature of the mixture;
- the introduction of sourdough;
- mixing with fillers and dyes;
- ripening;
- mixing;
- aging in the refrigerator;
- packing in sealed containers;
- manufacturer's labeling.
It is very important that all the constituent materials used in production are only fresh and of high quality. In order for yoghurt bacteria to multiply rapidly and productively process raw materials, it is necessary that the intermediate technological mixture be completely free of any foreign substances. All requirements for the yogurt production process must be in high level After all, the main consumers of this product are children. At every stage of preparation, with every new delivery of milk, quality checks must be carried out everywhere and every time.
The milk received by the shop is normalized according to the content of fat and solids. To increase the fat content, milk heated to 60 degrees is evaporated, while excess liquid is removed from it. Usually the amount of evaporated liquid is one fifth of the total initial volume of milk. To reduce fat content and normalize the content of dry substances in milk, powdered milk. Powdered milk additives are up to 3% of the total weight.
Normalization of fat can also be carried out by the method of separation of the milk mixture. The content of air in the milk mixture plays an important role. It should almost not be in yogurt, since both the shelf life of the product and the fermentation time depend on this.
- subjected to pasteurization and cooling;
- leaven is introduced into it, followed by mixing;
- aged for 3 hours;
- fillers are introduced into it;
- cools down;
- packaged and sent to the refrigerator in the warehouse.
thermostatic method
The production of yogurt by the thermostatic method differs both in technology and equipment. It may include the preparation of fruit additives or dispense with them. It is important that thermostatic yogurt is prepared for long-term storage and sale. To do this, packaging is carried out in special glasses of 150 ml, which are sealed on top with aluminum foil squares, on which the date of manufacture and expiration date are applied.
The sequence of operations, in contrast to the first manufacturing method, is also somewhat different:
- primary processing and filtration of raw materials from a dairy farm;
- fat normalization;
- passing through a homogenizer;
- pasteurization followed by lowering the temperature;
- sourdough additive;
- packing with marking;
- fermentation and storage in the refrigerator in the warehouse.
It turns out that the thermostatic method is almost the same as the reservoir method. The difference begins when the mixture is filled with additives of the fruit and berry composition. It is very important that the fillers are added while stirring the already cold yoghurt substance for ten to fifteen minutes.
The fermented mixture is placed in a thermostat and kept at 40 degrees. four o'clock. This is where the fermentation process takes place. Final procedures - checking the thickened product for acidity and viscosity. If all parameters comply with the standards, the fermented product is sent to the refrigerator, where its temperature drops to 5 degrees. By thermostatic method, yogurts are obtained with a short shelf life - up to 4 days. The temperature in the box of the trade enterprise should be kept at 6 degrees.
Ripening drinking yoghurt in fermenters
Technology for the production of more liquid, drinking yogurt somewhat different, but also not very complicated. You just need to follow the set parameters of the workflow and not deviate from them. The workshop requires the constant presence of a specialist - a technologist who is well acquainted with both technological maps and the operation of equipment.
Greek variant
The production of Greek yogurt has significant differences from the production of classic products. It contains more than in the classic regular yogurt, the protein component. It also has a low carbohydrate content. Now our domestic dairy companies have begun the production of this product. But they will not be able to completely saturate the market of fermented milk products with it in the near future.
A new separator has appeared on the market of dairy processing equipment, which has a low productivity, at which, in addition to Greek yogurt, it is possible to produce soft cottage cheese.
Even at low productivity, this machine is capable of producing 200 kg of product per hour with appropriate settings. Having small dimensions and low power consumption, it is very good for making dessert-type cottage cheese. The device is easy to operate and its price is quite acceptable for entrepreneurship. It is quite realistic to start a business in the production of yogurt with this equipment.
homemade yogurt
With all the complexity of the technology and equipment of the dairy industry, one should not forget that it is possible to make yogurt at home. Consider individual recipes for the preparation of this product.
- A liter of whole milk is taken.
- Dry yogurt starter is bought in a store or pharmacy (you can use live yogurt from a store that has not expired as a starter).
- Bring milk to a boil and boil for 20 minutes.
- Cool milk to 45 degrees.
- We pour out a small part of the milk and mix the sourdough into it.
- Pour the milk with the starter back into a large vessel and mix everything thoroughly again.
- We stand the composition at the same temperature for 6 hours. You can try to do this somewhere near the radiator.
Now on sale you can see special kitchen appliances - yogurt makers for making homemade yogurt. If there is this kitchen appliance at home, then fermented yogurt should be placed in it, setting the operating temperature to 45 degrees. It is this temperature that is most suitable for the vital activity of sourdough bacteria. It makes sense even before placing the product in the yogurt maker, pour the mixture into small jars with tight lids.
As soon as the yogurt is ready, it should immediately be put in the refrigerator. After all, when the drink is cooled, the growth of yeast bacteria stops and the “peroxidation” of yogurt will not occur. You can store homemade yogurt in the refrigerator for 4 days, but no more than a week. The specific recipe for making this milk drink at home may vary, but the general principles always remain the same.
Production Equipment Kits
Most modern factories use the tank method to produce yogurt. With the tank method, fermentation, fermentation, maturation of the mixture takes place in the same tank.
This requires a line of equipment that contains:
- two-layer tank made of chromium-nickel steel;
- milk pump;
- cream separator;
- normalizing device;
- cream container;
- homogenizing apparatus;
- flow cooler;
- emulsifier with a stirring mechanism;
- starter container;
- packing machine;
- fridge.
All technological stages are controlled by additional devices. The main control parameters include the fat content of raw milk and the temperature of the yogurt mixture during fermentation.
thermostatic method
It is characterized by the fact that fermentation and final maturity of the fermented milk product occurs already in packaging in special thermostatic chambers at a given constant temperature. In addition to thermostatic chambers, the equipment also contains all the working elements for the primary processing of milk, for fat normalization and mixers for uniform distribution of the starter throughout the volume of the yogurt mixture.
The productivity of a typical line for a working day is up to 15 thousand cups. If you organize work in two shifts, then productivity will also double. The power consumption of the technological line is about 18 kW/h. Water consumption per day of work is approximately 10 cubic meters.
A fairly wide range of equipment for the industrial production of yoghurts is presented on the domestic market, at prices that are quite acceptable to average entrepreneurs.
Just for mini-production Russian manufacturers Two types of these devices have been released:
- Dairy processing complex with a capacity of up to 2 thousand liters. product per day. The mini-workshop is designed for a staff of four people and is located in a room of 80 square meters. meters. The cost of this complex is 2,250,000 rubles.
- A yogurt production line that processes up to 4,000 liters of milk per day. The output of finished products is twice as much as at the previous complex - 4000 liters of yogurt. Five people will be required to service this equipment. It is located on the same area as the previous complex, but its price is already 3,500,000 rubles.
In order for the technological scheme for the production of yogurt to be complete, it is necessary to add large-capacity refrigerators to the specified equipment, which are best placed in an additional storage building.
It is not enough just to buy equipment for the production of yogurt. To open a mini-workshop, you will also need a modular room with plumbing, sewerage and power supply. All this must be located on a leased or purchased land.
Yogurt business plan
The business plan for the production of yogurt is drawn up taking into account the fact that the main method of producing the product is tank. Considering that the product is not completely natural during such manufacture, it is characterized by long-term preservation, and hence a long period of sale.
It's sour now dairy production fully automated and produces a product with or without fruit inclusions. Packing in cups and sealing them - everything is done by special robotic machines.
The business plan must take into account the necessary maintenance personnel. It should include up to 6 workers, an electrician and a lactic acid equipment technician. If you set up large-scale production, then up to 30 workers per shift may be required. For the production of 2,000 liters of product per day, a yogurt line worth 2,000,000 rubles will be required.
This business is not seasonal, however, during the summer months, demand from resellers for yoghurts decreases. This is due to the fact that the shelf life of fermented milk products in the warm season is sharply reduced, and there is a high risk of putting the goods out of service even before they are sold. This can happen both at the factory and during transportation to the seller and storage in the store.
A yogurt business with the right plan is bound to be highly profitable. The payback period of equipment in the organization of its continuous operation at full load usually does not exceed one and a half to two years. This is a high figure, typical only for business on products with a large and stable demand.
The owners of the patent RU 2280991:
The invention relates to the dairy industry. The method involves adding hydrocolloids to a mixture of pasteurized and chilled whole milk with skimmed milk powder, which are used as a complex stabilizing system, a sweetening component. The resulting mixture is pasteurized at a temperature of 94-98°C with a holding time of 2-10 minutes, cooled, starter is introduced from a combination of cultures of direct introduction, fermented for 4-7 hours. Then the mixture is reserved. The filler is introduced in the flow and, simultaneously with the filler, a vitamin or mineral nutritional supplement is added. Then the mixture is thermized at a temperature of 65-84°C with a holding time of 10-30 s and cooled. EFFECT: invention makes it possible to increase the nutritional value of yogurt, its shelf life, and reduce the complexity of the method. 3 w.p. f-ly, 3 tab.
The invention relates to the dairy industry and can be used in the production of yoghurts.
There is a known method for the production of a fermented milk product, mainly yogurt, according to which whole milk is mixed with skimmed milk powder, hydrocolloids are introduced into the resulting mixture, homogenized, subjected to heat treatment at 80-140 ° C for 3 to 15 minutes, then cooled to 20- 43°C, starter is added, fermented to pH 4.0-4.6, cooled, fruit filling is added, cooled down and packaged.
The disadvantage of this method for the production of a fermented milk product, mainly yogurt, is its laboriousness and obtaining a product with low nutritional value.
The closest in technical essence to the proposed method is a method for the production of yogurt, including homogenization of condensed whole milk or a mixture of whole milk with skimmed milk powder or condensed skimmed milk, the introduction of hydrocolloids, pasteurization at 80-98°C and exposure from 20 minutes to 1 hour 20 min, cooling to 32-43°C, fermenting, fermentation to pH 4.0-4.55, curd mixing to a homogeneous consistency, cooling, adding fruit filler with simultaneous mixing and cooling of the mixture to 40-20°C for 1 -3 hours, packaging and additional cooling for 8-16 hours.
The disadvantage of this method of yogurt production is its low nutritional value, short shelf life, high labor intensity of the method.
The aim of the invention is to increase the nutritional value of yogurt, its shelf life, reduce the complexity of the method.
The task is achieved by the fact that in the method for the production of yogurt, which includes the introduction of hydrocolloids into a mixture of whole milk with skimmed milk powder, homogenization of the mixture, pasteurization, cooling to 32-43 ° C, introduction of starter culture, fermentation to pH 4.0-4.55, cooling, adding fruit filler, packaging and additional cooling for 8-16 hours, before formulating the mixture, milk is pasteurized at a temperature of 80-90 ° C for 3 seconds and cooled, a complex stabilizing system is used as hydrocolloids, a sweetening component is added simultaneously with hydrocolloids, pasteurization of the mixture is carried out at a temperature of 94-98 ° C with an exposure of 2-10 minutes, combinations of cultures of direct introduction are used as a starter, fermentation is carried out for 4-7 hours, after cooling the mixture is reserved, the filler is added in a stream, simultaneously with the filler vitamin or mineral nutritional supplement, before packaging, the mixture is thermized at a temperature of 65-84°C with an exposure of 10-30 s and subsequent cooling to a temperature of 18-22°C.
The method for the production of yogurt is as follows: raw milk is taken by weight and quality, cooled to a temperature of 4±2°C and fed into a storage tank (no more than 6 hours), then the milk is heated to a temperature of 55±2°C and served on cleaning and normalization. Then the milk is pasteurized at a temperature of 85±2°C for 3 seconds and cooled. In the tank, whole milk is mixed with skimmed milk powder. Hydrocolloids are introduced into the mixture, which are used as a complex stabilizing system: "Hamulsion RABB 30", including hydroxypropyl distarch phosphate, milk protein, gelatin, guar flour or "Grinstead SB264", including amidated pectin, normalized with sugar, gelatin, hydroxypropyl distarch phosphate. Simultaneously with the hydrocolloids, a sweetening component is added to the mixture. The mixture is kept for (30 ± 5) minutes with occasional stirring until the stabilizing system is completely dissolved, then the mixture is heated to a temperature of 55 ± 2°C, homogenized, pasteurized at 96 ± 2°C with an exposure of 5 ± 2 minutes. The mixture is cooled to the fermentation temperature - 38±2°C and sent to the fermentation tanks. Combinations of direct addition starters (DVS) are introduced, the mixture is stirred for 15 minutes and left alone for 35±5 minutes, mixed again for 15 minutes and left alone until ripening. Fermentation is carried out for 6±1 hours and is stopped when a sufficiently strong clot is formed and active acidity pH 4.2±0.2. The fermented product is cooled to a temperature of 20±2°C and reserved. Fruit filler, which is used as aseptic processed and specially prepared fruits and berries, stored at a temperature of 4±2°C, is introduced into the fermented product in a stream. Simultaneously with the fruit filler, a vitamin or mineral nutritional supplement is added, the resulting mixture is fed for thermization at a temperature of 68±2°C with a holding time of 20 s and subsequent cooling to a temperature of 20±2°C. The finished product is served for packaging at a temperature of 20±2°C and cooled down for 10±2 hours. When the product reaches a temperature of 4±2°C, the technological process is considered complete. The shelf life of yogurt is 30 days.
When using the proposed method for the production of yogurt, the nutritional value of yogurt increases due to the introduction of a vitamin or mineral supplement at the final stage of the production process, as a result of which a product is obtained that is balanced in terms of vitamin or mineral composition. Moreover, the introduction of vitamin and mineral nutritional supplements is carried out in such quantities that, when using 200 g of yogurt, the intake of 30-50% of the recommended daily norm of the corresponding vitamins or minerals into the human body is ensured. This method allows you to increase the shelf life of yogurt due to the thermization process under gentle temperature conditions, which ensures the preservation of the viable microflora of yogurt and, consequently, its probiotic properties. The use of combinations of direct addition starters (DVS) in the technological process of yogurt production makes it possible to completely eliminate the laborious process of preparing industrial starters and, therefore, in general, reduce the complexity of the method.
Tables 1, 2 show examples of the proposed yogurt formulations.
| Table 1 - Yogurt recipe | |||
| Components | Recipe for 1000 kg | ||
| 1 | 2 | 3 | |
| 779,80 | 777,20 | 777,00 | |
| 17,00 | 17,00 | 17,00 | |
| 22,00 | 22,00 | ||
| 24,00 | |||
| 0,50 | 0,50 | 0,50 | |
| 0,50 | 0,50 | ||
| 0,50 | |||
| Sugar | 80,00 | 80,00 | 80,00 |
| Ascorbic acid | 0,20 | ||
| Vitamin premix (vitamin E, B 1 , B 6 , PP, B 12 , C, folic acid, biotin) | 0,80 | ||
| calcium lactate | 3,00 | ||
| Fruits and/or berries | 100,00 | 100,00 | 100,00 |
| Table 2 - Yogurt recipe | |||
| Components | Recipe for 1000 kg | ||
| 1 | 2 | 3 | |
| Whole milk with a mass fraction of fat 3.6% | 779,3 | 857,05 | 855,6 |
| Skimmed milk powder with a mass fraction of fat 1.5% | 17,00 | 17,00 | 17,00 |
| Stabilizing system "Grinstead SB264" | 22,00 | 22,00 | |
| Stabilizing system "Hamulsion RABB 30" | 24,00 | ||
| YC-180 direct sourdough starter | 0,50 | 0,50 | 0,50 |
| Bb-46 direct sourdough starter | 0,50 | 0,50 | |
| Bb-12 direct sourdough starter | 0,50 | ||
| Sugar | 80,00 | ||
| Aspasvit TS100 | 0,8 | ||
| Aspasvit TS200 | 0,4 | ||
| Vitamin premix (vitamin E, β-carotene, C, folic acid, biotin) | 0,70 | ||
| ferrous lactate | 0,15 | ||
| magnesium lactate | 4,0 | ||
| Fruits and/or berries | 100,00 | 100,00 | 100,00 |
Table 3 shows the organoleptic characteristics of yogurt according to the proposed recipes.
This method of yogurt production allows expanding the range of products belonging to the class of "healthy", the high content of viable microflora, even after thermization, allows us to characterize the product as probiotic. This yogurt contributes to the normalization of intestinal microbiocenosis and stimulation of the body's immune system.
The use of this yogurt in both mass and special nutrition is a means of mass prevention of polyhypovitaminosis, beriberi, iron deficiency anemia, calcium deficiency, as well as replenishing the insufficient intake of vitamins and minerals in almost any age and professional population groups.
The invention can be used both in mini-factories and in enterprises of large shift capacity.
The proposed method of yogurt was tested in laboratory conditions at the Faculty of Technology of Milk and Dairy Products of the Omsk State Agrarian University.
1. A method for the production of yogurt, including the introduction of hydrocolloids into a mixture of whole milk with skimmed milk powder, homogenization of the mixture, pasteurization, cooling to 32-43 ° C, introduction of a starter, fermentation to pH 4.0-4.55, cooling, introduction of fruit filler , packaging and additional cooling for 8-16 hours, characterized in that before formulating the mixture, milk is pasteurized at a temperature of 80-90 ° C for 3 seconds and cooled, a complex stabilizing system is used as hydrocolloids, a sweetening component is added simultaneously with hydrocolloids, pasteurization mixtures are carried out at a temperature of 94-98 ° C with an exposure of 2-10 minutes, combinations of cultures of direct introduction are used as a starter, fermentation is carried out for 4-7 hours, after cooling the mixture is reserved, the filler is added in a stream, vitamin or a mineral food additive, before packaging, the mixture is thermized at a temperature of 65-84°C with a holding time of 10-30 s and then cooled to a temperature of 18-22°C.
2. The method according to claim 1, characterized in that the complex stabilizing system "Hamulsion RABB 30" is used as hydrocolloids, including hydroxypropyl distarch phosphate, milk protein, gelatin, guar flour, or "Grinstead SB264", including amidated pectin normalized with sugar , gelatin, hydroxypropyl distarch phosphate.
3. The method according to claim 1, characterized in that as a vitamin nutritional supplement, ascorbic acid or vitamin premixes containing an antioxidant complex (β-carotene, vitamin E, vitamin C) or a multivitamin complex are used.
The technological process for the production of yogurt by the tank method (Fig. 1) consists of the following operations: acceptance and preparation of raw materials and materials, normalization for fat and solids, cleaning, homogenization of the mixture, pasteurization, cooling, fermentation, addition of fillers and dyes, fermentation, mixing, cooling, bottling, packaging, labeling and storage.
Rice. 1. Scheme of the technological line for the production of yogurt by the tank method: 1 - a container for raw milk; 2 - pumps; 3 - balancing tank: 4 - plate pasteurization and cooling unit; 5 - control panel; 6 - reverse valve; 7 - separator-normalizer; 8 - homogenizer; 9 - container for holding milk; 10 - container for yogurt; 11 - mixer; 12 - starter
Milk, selected for quality, is normalized by the mass fraction of fat and solids. For fat, milk is normalized either in-line, using a separator-normalizer, or by adding whole milk or cream to skimmed milk. In terms of dry matter, milk is normalized by adding milk powder, which is restored in accordance with the current regulatory documentation. In addition, normalization by dry matter is carried out by evaporating pasteurized and homogenized milk at a temperature of 55-60 °C.
In the production of sweet yogurt, normalized milk is heated to 43 ± 2°C, sugar is added, previously dissolved in part of the normalized milk at the same temperature in a ratio of 1:4. The mixture is cleaned on separators - milk cleaners, homogenized at a pressure of 15 ± 2.5 MPa and a temperature of 45-85 ° C. Homogenization is also allowed at pasteurization temperature. The prepared stabilizer is introduced into the mixture. The purified and homogenized mixture is pasteurized at 92±2°C with a holding time of 2-8 minutes or at 87±2°C with a holding time of 10-15 minutes and cooled to a fermentation temperature of 40±2°C. The mixture is fermented immediately after it has been cooled with selected starter cultures (for example, prepared on pure cultures of thermophilic streptococcus, Bulgarian bacillus and KD type in an approximate ratio of 7:1:7, followed by clarification of this ratio during microscopy of the preparation). The amount of starter introduced is 3-5% of the volume of the mixture to be fermented, and the starter prepared with sterilized milk is 1-3%. If a symbiotic starter is used, then it is added in the amount of 1-3%, and the bacterial concentrate is added in accordance with the Instructions for the use of dry bacterial concentrate. The starter is introduced into the milk into the tank for fermented milk products with the stirrer turned on. After filling the tank, the entire mixture is additionally stirred for 15 minutes. The starter can also be added before filling the tank with milk.
The end of fermentation is determined by the formation of a strong clot with an acidity of 95-100°T. The clot is cooled for 10-30 minutes and stirred in order to obtain a homogeneous consistency of the milk clot and to avoid whey separation. The clot, cooled to 16-20°C, is sent for bottling, packaging, labeling and post-cooling in refrigerators to a temperature of 4±2°C. After that, the technological process is considered complete, the product is ready for sale.
Thermostat way.
The technological process for the production of yogurt by the thermostatic method consists of the same technological operations as in the production of the tank method, carried out in the following sequence: preparation of raw materials, normalization, homogenization, cooling to the fermentation temperature, fermentation, packaging, fermentation in thermostatic chambers, curd cooling, maturation clot.
The scheme of the technological line for the production of fermented milk drinks by the thermostatic method is shown in Figure 2.
Figure 2. Scheme of the technological line for the production of yogurt by the thermostatic method: 1 - a container for raw milk; 2 - pump; 3 - balancing tank; 4 - pasteurization and cooling unit; 5 - control panel; 6 - return valve; 7 - separator-normalizer; 8 - homogenizer; 9 - container for holding milk; 10 - container for milk fermentation; 11 - milk packaging machine; 12 - thermostatic chamber; 13 - refrigerating chamber; 14 - storage room for finished products. Acceptance and preparation of raw materials, normalization, heat treatment, homogenization of the normalized mixture and its cooling to the fermentation temperature are performed in the same way as in the tank production method. Next, the normalized mixture is fermented in a container. After fermentation, the mixture is packaged in consumer containers and sent to a thermostatic chamber, where a temperature is maintained that is favorable for the development of the microflora of the starter. The end of fermentation is judged by the acidity and density of the clot. After fermentation, the product is sent to the refrigerator for cooling. The tank method for the production of fermented milk drinks has a number of advantages compared to the thermostatic method. Firstly, this method makes it possible to reduce production areas by eliminating bulky thermostatic chambers. This increases the removal of products from 1 m2 of production area and reduces the consumption of heat and cold. Secondly, it allows for more complete mechanization and automation of the technological process, reducing costs manual labor by 25% and increase labor productivity by 35%.
Currently, various types of yogurt are produced in Russia. Depending on the technology that determines the organoleptic characteristics of the finished product, including the consistency, there are yogurts prepared by a thermostatic method with an undisturbed clot and a dense consistency, yogurts produced by a reservoir method, with an impaired clot and drinking.
Drinkable yogurt is becoming an increasingly popular product. Its unique nutritional properties with a wide variety of flavors, practical and attractive packaging, lower cost compared to other types contribute to real success at the consumer.
Abroad, the technology of drinking yogurt differs in that the product after fermentation is mixed, homogenized, cooled to a storage temperature (5 ° C) and poured. In our country, when producing drinking-type yoghurt, the product after fermentation and mixing is partially cooled in a tank or in a stream to a storage temperature (4 ± 2 °C) and poured. In this case, the milk-protein clot, subjected to destruction during the cooling process, poorly restores the structure and is prone to syneresis, so the thixotropy (recoverability) and water-holding capacity of the system are of particular importance. There are several ways to improve these figures.
One of them is the choice of starter cultures. It is known that the microorganisms that make up the starter cultures for yogurt, depending on the physiological characteristics, form milk-protein clots with different types of consistency during fermentation of milk: prickly or viscous with varying degrees of viscosity. For drinking yogurt, viscous type starters with a reduced tendency to syneresis are used.
Clot-forming starters with good water-holding capacity, determined by centrifugation for 5 minutes at a separation factor F=1000, should not release more than 2.5 ml of whey per 10 ml of starter culture. The structural properties of the clot are also affected by the temperature of the cultivation of starter cultures. Optimal fermentation temperatures for starter cultures consisting of Str. Thermophilus and Lb. delbrueckii subsp. bulgaricus, - 40-45°C. A decrease in the fermentation temperature to 32 ° C causes excessive formation of exopolysaccharides and the production of a product characterized by a more pronounced consistency stability, but also by excessive ductility.
IN industrial production apply the following modes of fermentation of yogurt when using a starter consisting of Str. Thermophilus and Lb. delbrueckii subsp. bulgaricus: in Russia, fermentation temperature is 40-42°C, fermentation time is 3-4 hours, fermentation amount is 3-5%; in the EU countries, respectively, 37-46 ° C, 2-6 hours, 0.01-8% (usually 2-3%) or 30-32 ° C, 8-18 hours, 0.01-1%.
Culture Lb. delbrueckii subsp. bulgaricus, Str. subsp. Thermophilus are able to form extracellular polymers, which are carbohydrate-protein complexes. The amount of these polymers increases at lower fermentation temperatures or under the influence of unfavorable factors. Thickening capacity of polysaccharides produced by Str.thermophilus. differs from that produced by Lb. delbrueckii subsp. bulgaricus.
Mucous substances produced by different strains of Str. Thermophilus and Lb. delbrueckii subsp. bulgaricus may have a different chemical composition. In polysaccharides Lb. delbrueckii subsp. bulgaricus contains arabinose, mannose, glucose, galactose, which are connected by linear or branched bonds. Such polymers are chemically similar to ß-glkzhans, which are part of cell membranes. Some bacteria Str. Thermophilus produce tetrasaccharides consisting of galactose, glucose and N-acetyl-galactosamine with a molecular weight of 1 million, which have thickening properties. The presence of these mucous substances improves the uniformity and elasticity of the clot.
Based on comprehensive research chemical composition and rheological properties of the clot, it is assumed that the increase in its elasticity formed by viscous strains is associated with the inclusion of interlayers of exopolysaccharides in casein matrices, thus increasing the distance between casein micelles, which causes an increase in water-holding capacity and obtaining a soft texture of yogurt.
At the same time, it was noted that cultures of microorganisms producing exopolysaccharides in the same concentrations formed clots with different organoleptic and rheological properties. Thus, more mucilaginous cultures formed clots with lower viscosity than less mucilaginous cultures with the same amount of exopolysaccharides. Differences in the consistency of yogurt are explained not by the amount of exopolysaccharides, but by the nature of the formed spatial protein structure. The more extensive, branched the network of protein chains and polysaccharides produced by cultures of microorganisms, the higher the viscosity of the clot.
Considering that not all slimy strains have the ability to increase the viscosity of the clot, based on the evaluation of the flow curves obtained by viscometry methods, a distinction is made between slimy and thickening cultures. In the production of drinking-type yogurt, the milk-protein clot undergoes the most significant mechanical impact and therefore needs a special approach, namely: a sufficiently high viscosity of the clot after fermentation is required, the milk-protein clot must be sufficiently resistant to destruction, have the ability to maximize the restoration of the structure after destruction and retain whey throughout the shelf life.
Structured systems that appear in milk during fermentation with thickening starter cultures contain both irreversibly collapsing bonds of the condensation type, which have great strength, imparting elastic-brittle properties to the structure, and thixotropic-reversible bonds of the coagulation type, which have low strength and impart elasticity and plasticity. At the same time, judging by the degree of restoration of the destroyed structure, which ranges from 1.5 to 23% for various starter cultures, the proportion of thixotropic bonds in this case is still not high enough.
Another way to obtain a homogeneous, non-separating. viscous consistency of yogurt, which has increased thixotropy, water-holding capacity, storage stability, is the use of various additives.
The use of additives containing protein in certain concentrations (powdered milk, milk protein concentrates, soy protein, etc.) leads to an "increase in the solids content and (depending on the type of additive) an increase in density, viscosity, and a decrease in the tendency to syneresis. However, they do not allow to obtain a significant increase in the thixotropy of the bunch.
In the production of yoghurt, it is also possible to use consistency stabilizers. In this case, it is necessary to take into account a number of regularities.
It is known that macromolecular substances (HMW) - hydrocolloids, which are part of the stabilization systems used in the production of yogurt, form gels that exhibit different mechanical properties depending on the types of bonds that arise between polymer macromolecules in solution. HMW solutions, in which intermolecular bonds are extremely weak and the number of permanent bonds is small, are able to flow and do not form a strong structure in a wide range of concentrations and temperatures (starch, gums).
Solutions of macromolecular substances with a large number of bonds between macromolecules give a rigid spatial network with a slight increase in concentration, the structure of which strongly depends on temperature (gelatin, low methoxylated pectin, agar, carrageenan). Gelatin has the lowest gelation temperature. Its 10% solution turns into jelly at a temperature of about 22 ° C. Mixtures of the former and the latter are formulated in order to increase their functionality, i.e. manifestations in varying degrees of the properties of both groups.
It is known that a decrease in temperature causes the formation of bonds between polymer (hydrocolloid) molecules, leading to structuring. Permanent bonds between molecules in HMW solutions can be formed as a result of the interaction of polar groups carrying an electric charge of different signs, as well as due to chemical bonds. Structuring is the process of appearance and gradual strengthening of a spatial grid. At higher temperatures, due to the intensity of micro-Brownian motion, the number and duration of existence of bonds between macromolecules are small. The lower the temperature, the more the spectrum of contacts between macromolecules expands and shifts towards greater strength.
If the bonds formed (coagulation structure) are not too strong, then mechanical action (mixing) can destroy the structure. But when the external influence is removed, the solutions usually restore their structure again and become gelatinous. However, when the system is formed by stronger bonds (condensation structure) and is one continuous spatial grid, strong mechanical influences cause its irreversible destruction.
The thixotropic properties of clots and their ability to resist mechanical action are characterized by the magnitude of the change in relative viscosity, which corresponds to the degree of restoration of the destroyed structure.
The table shows the average changes in the relative viscosity (Bo5*/Bo40*) of yogurt with and without some stabilizers (control sample) at filling temperatures of 40 and 5 °C. Sample numbers are given in descending order of their thixotropic properties.
From the data given in the table. it follows that the use of stabilizers causes an increase in the degree of restoration of the destroyed structure (with the exception of modified phosphate starch) by 3.5-43.5% when bottling yogurt at a temperature of 5 °C, which is usually used in the production of a drinkable product (cooled in a stream to storage temperature).
The highest degree of clot structure recovery was observed in product samples produced with multicomponent mixtures containing gelling agents and thickeners, which ranged from 47 to 71%, which exceeded the same indicator for the control sample by 19.5-43.5%. Structures that are more reversible after mechanical destruction are obviously formed by coagulation bonds due to a significant proportion of thickeners in the composition of stabilization mixtures.
It follows from the data obtained that multicomponent stabilization systems containing gelling agents (gelatin, carrageenan, agar-agar) and thickeners (modified starch, guar gum), which, as a result, have more diverse physical and chemical properties and a wider range of compatible gelation mechanisms, create structures in yogurt that, accordingly, exhibit the properties of both groups to a greater extent, i.e. greater resistance to destruction and greater ability to restore compared to one-component stabilizers (gelatin, modified starch).
The water-holding capacity of yoghurt samples produced with stabilizing additives (with the exception of phosphate starch, samples No. 1-7) was characterized by the absence or separation of no more than 10% of whey when the product sample was centrifuged for 30 minutes at a separation factor of 1000.
The addition of hydrocolloids in sufficient quantities, which have the ability to stabilize CMC and increase the water-holding capacity of yogurt during storage, made it possible, provided that microbiological purity was ensured, to increase the shelf life up to 21 days, during which the consistency of the product was maintained without deteriorating the original quality. The exception was the control samples and product samples produced with phosphate starch, in which, after 2 weeks of storage, the presence of whey on the surface of the product and the liquefaction of the consistency were noted. Yogurt samples made with gelatin also received unsatisfactory consistency ratings at the end of storage, which were considered uncharacteristic of a drinking-type product.
Thus, the best organoleptic, structural-mechanical characteristics and water-holding capacity of drinking yogurt over a long period of storage were provided by multicomponent stabilizing additives with pronounced thickening properties. When choosing a stabilizing additive for drinking-type yogurt, one of the main criteria is thixotropy (the degree of restoration of the destroyed structure), which is characterized by the amount of effective viscosity loss during filling of a milk-protein clot cooled to the storage temperature of the finished product.
| Sample No. | Stabilizer (composition) | Average relative viscosity of the product (Bo5*/Bo40*) | average value loss of effective viscosity (Во *) when filling the product at 5 ° "С,% | |
| Bottling at 40°C | Bottling at 5°С | |||
| 1 | Hamulsion RABB (gelatin, guar gum E412, modified starch) | 0,94 | 0,71 | 29 |
| 2 | Turrizin RM (gelatin, modified starch E1422, carrageenan E407, agar-agar E406) | 0,92 | 0,54 | 46 |
| 3 | Palsgaard 5805 (gelatin, modified starch, mono-, diglycerides E471) | 0,88 | 0,47 | 53 |
| 4 | Grinstead SB 251 (gelatin, pectin E440, modified starch E1422, native starch) | 0,9 | 0,42 | 58 |
| 5 | Gelatin P-7 | 0,89 | 0,415 | 58,5 |
| 6 | Ligomm AYS 63 (gelatin, low methoxyl pectin E440) | 0,895 | 0,405 | 59,5 |
| 7 | Hamulsion SM (gelatin, guar gum E412) | 0,91 | 0,31 | 69 |
| 8 | Control (no stabilizer) | 0,85 | 0,275 | 72,5 |
| 9 | Phosphate starch | 0,86 | 0,21 | 79 |
Note: Bo5* - coefficient of effective viscosity, Pa s (at shear rate γ= 1 s-1) of the product cooled after fermentation and bottled at a storage temperature of 5 °C; Bo40 - coefficient of effective viscosity. Pa s (at a shear rate value γ= 1 s-1) of a product bottled at a fermentation temperature of 40 °C. Measurements in all samples were carried out at 18°C. The stabilizing additive was added in doses selected on the basis of an organoleptic evaluation of the finished product, manufacturers' recommendations, as well as the results of studies of the structural and mechanical characteristics (SMC) of the finished product.
LITERATURE
1. Bannikova L.A., Koroleva N.S., Semenikhina V.F. Microbiological bases of dairy production. -M.: Agropromizdat. 1987.
2. Voyutsky S.S. Course of colloidal chemistry-M-Chemistry, 1964.
3. Gorbatova K.K. Biochemistry of milk and dairy products.-M.. "Light and food industry. 1984.
4. Collection of instructions for the selection of lactic acid bacteria and the selection of starter cultures for fermented milk products - M.: VNIMI, 1985.
5. Dellaglio F. Starters for fermented milks. Sections 3//Bull. of IDF. 1988. No. 227. Ch.11.
6. Puhan Z. Overview of current availability and technology of fermented milks in IDF member countries//Bulletin of the IDF. 1992. No. 277.
7. Puhan Z. Results of the Questionnaire 1785B. "Fermented Milk"//Bulletin of the IDF. 1988. No. 227.
8. Salvadori Bruna Bianchi. Lactis acid bacteria, biochemical characteristics affecting the texture of fermented milks//IDF. Symposium on "Texture of fermented milk products and dairy desserts". Abstract book: Italy, Vicenza. 1997, May 5-6.
9. Sebastiani H., Gelsomino R., Walser H. Cultures for the improvement of texture in quarg//IDF. Symposium on "Texture of fermented milk products and dairy desserts". Abstract book: Italy, Vicenza. 1997, May 5-6.
10. Skriver A. Texture characterization of yoghurt fermented with different bacteria cultures/ZIDF. Symposium on "Texture of fermented milk products and dairy desserts". Abstract book: Italy, Vicenza. 1997. May 5-6
11. Speck M.L. Yoghurt qualities affected by starters and processings/Dairy Ind.lnt. 1979. V. 44, No. 3.
12. Zoon P.J.M.E. Van Marie, K.C. De Kruif. Relationship between the consistency of stirred yoghurt and the structure of the yoghurt gel// Symposium on "Texture of fermented milk products and dairy desserts". Abstract book: Italy, Vicenza. May 1997.5-6
Introduction
General characteristics of the enterprise
1 Characteristics of the organizational and economic activities of Tander CJSC
2 Characteristics of technological equipment and general production resources of the enterprise CJSC "Tander"
Analysis of the technological process of production
1 Characteristics of the main suppliers of raw materials and raw materials
2 Characteristics of the technological process of the enterprise for the production of yoghurts
Characteristics of the product range
1 Principles of planning and formation of the production range
2 The range of manufactured products and assessment of the assortment diversity of the enterprise's products
Product quality control
1 Quality requirements and quality control of products
2 Factors for maintaining product quality
Conclusion
List of sources used
Introduction
Milk is a complete food. Milk contains more than 120 different components, including 20 amino acids, 64 fatty acids, 40 minerals, 15 vitamins, dozens of enzymes. Milk production is a complex technological process that includes several stages. Milk production is one of the most important industries that provides the industry with raw materials, and the population with biologically valuable food products.
The decrease in the volume of dairy production today is caused, first of all, by the disinterest of commodity producers in the development of the industry, the growth of non-payments, the deterioration in the supply of feed and other material and technical resources. A long-term forecast for the development of the livestock industries outlines the stabilization of the number of livestock and some increase in its productivity. Based on the introduction of intensive technologies and state support industry involves significantly increasing the productivity of animals and increasing the production of marketable products. In the near future, it is planned to switch to the most efficient, resource-saving technologies for milk production, which will increase productivity. One of the important directions of stabilization and further development of the industry is the transition to high-commodity production based on differentiated state and regional financing of agricultural producers. In a competitive business environment, the need for an effective solution of organizational, economic, technical and technological issues of milk production and the identification of factors to reduce the cost of production, increase the economic efficiency of its production is obvious.
1. General characteristics of the enterprise
.1 Characteristics of the organizational and economic activities of Tander CJSC
CJSC "Tander" was founded in 1994 in the city of Krasnodar, as a company specializing exclusively in the sale of household chemicals. The founder of the company is Sergey Nikolaevich Galitsky, at the moment he is also the main owner of the Magnit chain of stores and has the largest share of shares (46.43%). Thunder is rapidly becoming one of the leading distributors of household chemicals and cosmetics in Russia, working with companies such as Johnson & Johnson
CJSC "Tander" is a commercial organization in the organizational and legal form of a closed joint stock company, created for the production and marketing of products, goods, works and services in order to meet public needs and make a profit.
The retail network of Magnit stores includes such formats of outlets as a convenience store, a hypermarket, Magnit Cosmetic, Magnit Family. As of September 30, 2014, the network included 9,020 stores, including: 7,891 convenience stores, 175 hypermarkets, 68 Magnit Family stores and 886 Magnit Cosmetic stores. The retail stores are currently located in 2019 settlements Russian Federation. The company has 64 branches, 1 representative office and 23 distribution centers. The company also has its own vehicle fleet, there are motor transport enterprises at each distribution center of the company. The staff of the company, according to the official website, currently has more than 230,000 people. The company has repeatedly been awarded the title of " Best Employer of the year". In addition to the opportunity to develop and improve their skills in special training centers, the company provides for its employees social guarantees and privileges - a full social package, including sick leave and vacation pay, own non-state pension fund, to which friends and relatives of the network employees can also be transferred, a sanatorium owned by the network in the Krasnodar Territory, vouchers to which are awarded to distinguished employees, gifts to employees' children for the New Year and so on.
The Stavropol Territory and the republics belong to the Pyatigorsk branch of CJSC Tander, whose head office is located in the city of Pyatigorsk. The branch structure consists of several departments that control production and sales activities: planning department, purchasing department, sales and control department, production assurance department, marketing department, quality control department. As well as accounting, human resources, legal and other departments. The branch is headed by a director who controls the entire process of production and marketing activities. In 2011, the distribution center of CJSC Tander in the city of Lermontov was fully launched; until 2011, food was supplied to the Magnit retail chain in the Stavropol Territory mainly from the distribution center in the city of Kropotkin in the Krasnodar Territory. Concerning logistics system, then Magnit is leading in the development of its own logistics system among grocery retailers: in fact, the company demonstrates one of the most justified business models in the current environment. Its main advantages are the ability to increase the share of direct purchases from suppliers through their own distribution centers, achieving more favorable conditions and, as a result, increasing gross profit margins. The distribution center is the key point of the logistics structure of the retail network. Of course, there are companies that, having a large number of stores, do without distribution centers, relying on direct supplies from manufacturers and suppliers. But in this case, they have to allocate large areas in each store for the storage of goods. CJSC "Tander" excludes such problems from the process of supplying goods. In search of a buyer, Magnit expands the range of products offered and has a sufficient quantity to carry out immediate delivery. The negative point of such a policy is the additional costs associated with the cost of storing large stocks. In general, the logistics system of Tander CJSC is a well-established mechanism.
Also in the city of Lermontov there is a workshop for the production of products. Finished goods are delivered to the stores of the network through the logistics system of the distribution center, and Tander CJSC has a contract for the supply of its products to other retail chains. CJSC Tander has a very flexible pricing policy. The very name "Magnet" is an abbreviation for the Low Tariff Shop.
Also, the network has a wide range of products of its own brand, which can only be found in Magnit stores. The store has a branded, recognizable logo.
As for the production of goods, this is an important, albeit "young" part of the company's activities, which is rapidly developing. Products are manufactured in accordance with sanitary regulations. Food additives comply with SanPin 2.3.2.1293-03 " Hygiene requirements on the use of food additives. Prohibited food additives are not used.
Engineering support includes centralized cold water supply, the company also has a boiler house, which produces heat energy for heating production facilities. The plant is lit with fluorescent lamps to save energy. An important component of production work is the observance of sanitary standards. Employees have medical books, production is not allowed without sterile clothing, caps and sterile gloves. During production, workers should not wear any jewelry or even watches. All equipment is meticulously crafted. A specialized team works in the workshop, on average, about 20 people work in a shift. The work schedule is flexible and all work safety rules are observed. The internal labor regulations are regulated by the local normative act CJSC Tander.
The company is actively developing, but currently production line less developed than marketing. Production volumes are steadily increasing every year. This is due to the fact that for Tander CJSC production is a relatively new direction of the enterprise's activity. But the company has firmly occupied its niche in sales activities, has its own recognizable style, this is also very helpful in sales activities, as the popularity of chain stores contributes to the growth in popularity of private label products.
1.2 Characteristics of technological equipment and common resources enterprises
The enterprise CJSC "Tander" today works in the direction of production and marketing activities. This company has been successfully operating for many years, it is fully equipped with production, financial and labor resources. The company's revenue for 2013 amounted to almost 560 million rubles. In connection with low prices and a wide range of products, the company serves a large number of customers, which directly affects the growth of revenue. Financial indicators are also growing in connection with the investment in the company's activities of funds also coming from foreign investors. All financial reporting on the performance of the enterprise is open and publicly available. Information can be seen on the main website of CJSC "Tander".
The total staff of the company is about 230,000 people. The enterprise has a developed infrastructure. Apart from production shops and stores, the enterprise has 25 distribution centers, which are the basis of the logistics system of Tander CJSC. Timely delivery of products to all stores of the retail network allows us to implement our own fleet of 5674 vehicles. Mainly used trucks MAN. The use of our own distribution center and a motor transport company allows servicing the entire Pyatigorsk branch of Tander CJSC (KMV and the republics) by monitoring and regulating commodity flows, which also has a positive effect on profitability indicators. The company both rents and owns retail and production areas.
Both the production and marketing sectors are equipped with good computers, powerful computers and office equipment. Work on the computer is ongoing, as with the help of technology, acts are formed on the balance of finished products, returns certificates, waybills. Production is also automated. The production line includes the following equipment: a two-layer food stainless steel tank with a frame-type agitator, a milk pump, a cream separator, a normalizer, a buffer tank for cream, a two-layer tank with an anchor-type agitator, a homogenizer, a flow cooler, an emulsifier with agitator device, starter, packing machine, shut-off and pipeline valves, control panel. At the enterprise, with the help of a computer, flow production lines are monitored, and the operation of computerized packaging machines is regulated. This avoids errors when loading lines in production and allows workers to use their working time more efficiently. The time worked with the help of electronic terminals for data collection is recorded both for workers in the manufacturing and marketing industries. This allows you to pay wages for the hours actually worked, which makes the wage system at the enterprise more fair.
Production activity CJSC "Tander" is highly specialized and is aimed at the production of dairy products, since production is a relatively young direction of the company's work. The production structure of the enterprise in the Pyatigorsk branch consists of production shops, a laboratory, warehouses for finished products and raw materials, as well as a sales department. The total area of production shops is 1100.2 square meters. m, as well as the area of the warehouse is about 500 sq. m. Workshops are divided into:
¾ workshop for the production of drinking milk;
¾ cream production shop;
¾ shop for the production of fermented milk products;
¾ sour cream production shop;
Each workshop is fully equipped with the necessary production equipment. CJSC Tander works with the following companies in terms of purchasing equipment: Elf 4M, PackLine LTD, CJSC Merpasa and others. Internship takes place in the dairy products workshop. The list of equipment for the production of yogurt includes:
¾ bath reception with a capacity of 1T;
¾ centrifugal pump IPKS-017;
¾ set of equipment for milk pasteurization IPKS-013;
¾ cream separator Zh5-OSB (for 1000l/h);
¾ separator-normalizer;
¾ long-term pasteurization bath VDP for 200 L IPKS-011;
¾ long-term pasteurization bath VDP (H) per 100 l;
¾ receiving capacity for 500 l;
¾ semi-automatic packaging in plastic cups PRS-2U;
¾ installation semi-automatic UD-2,1200 doses/h;
¾ installation for welding cups with lids made of aluminum foil USS-2,600 pcs/h;
¾ semi-automatic milk filling IPKS - 036, 300 pack/h;
Also for storage of finished products and raw materials on the territory of the enterprise there are capacious refrigerating chambers. The equipment is new, every quarter the company checks the equipment, new pieces of equipment are constantly purchased.
2. Analysis of the production process
.1 Characteristics of the main suppliers of raw materials and raw materials
At the enterprise CJSC "Tander", where my practice takes place, there is a dairy production of its own products. After the production of certain products, they go through the distribution center to the stores of the network, where they are further sold. In any production, raw materials are an important component. The raw material for the production of yogurt is milk. To produce high-quality yogurt, it is necessary to use milk of at least the second grade, with an acidity of not more than 19 T. The grade and characteristics of milk are indicated in Table 1 below.
Table 1
Requirements for milk depending on the variety
Index Grade Highest 12 Odor and taste Typical for milk, without foreign smells and tastes. A slight fodder smell and taste is allowed in the winter-spring period of the year Acidity, Т016-1816-1816-18 Degree of purity according to the standard, not lower than group 112
For skimmed yogurt, skimmed milk is used, with an acidity of not more than 20 tons. Also, beet sugar and fruit and berry syrups from natural fruits and berries are used as raw materials for production.
At the enterprise where the practice takes place, the commodity manager is engaged in acceptance. Milk is supplied to the plant from various dairy farms in the Stavropol region, but the main and largest supplier of raw materials is the dairy farm Agrofirma Selo Voroshilova, which is located in the village of Suvorovskaya, Stavropol Territory. This dairy farm was founded on October 1, 2003. The farm has 1,800 milking herds and produces up to 20,000 tons of milk per year. This firm was selected due to the following factors:
¾ the small distance of the dairy farm from the direct place of production of the company makes it possible to save on the cost of transporting milk, which makes its purchase price more optimal than that of competitors;
¾ the activity of the farm is carried out in a specially protected ecological region of the CMS, in connection with which special requirements for ecology and sanitation are imposed on production;
¾ a warmer climate, a longer growing season, cheaper and higher quality feed (compared to the Moscow region) also make the milk of this company better than other suppliers;
CJSC "Tander" accepts for its production only milk of the highest and first grade. When accepting milk, its quality is assessed by organoleptic indicators, fat content, acidity and temperature. They accept milk in accordance with GOST 13264-88 “Cow's milk. Purchasing requirements. The preliminary stage of acceptance is the inspection of containers with raw materials. Milk arrives at this enterprise only in transport containers. According to GOST, non-impregnated paper four- and five-layer bags, plywood-stamped barrels, cardboard winding drums can be used as containers. When packing the product in a transport container, polyethylene bags should be used. As for this enterprise, the milk comes here in barrels. The container in which the milk arrived must be hermetically sealed and sealed. An external inspection of the transport must also be carried out for compliance with the commodity neighborhood during delivery, as well as compliance with the temperature and sanitary conditions of delivery. After the container has been inspected, the milk is taken according to organoleptic indicators. Cow's milk should be natural, white or slightly creamy, without sediment and flakes, according to GOST. Freezing milk is not allowed. The smell should not be pronounced, or may be slightly pronounced, depending on the variety. Also, upon acceptance, the mass fraction of fat, density, acidity and purity of milk are determined.
.2 Characteristics of the technological process of the enterprise for the production of yoghurts
As mentioned above, the company operates in two directions - sales and production.
The practice takes place in the workshop for the production of fermented milk products. sour milk product is a dairy product or a dairy compound product that is produced by fermenting milk using starter bacteria. Fermented milk products include: liquid fermented milk products (yogurt, fermented baked milk, yogurt, varenets, kefir, koumiss, ayran), sour cream and products based on it, cottage cheese and curd products. This report examines the production of yoghurts in the fermented milk production workshop.
Having studied the production process at the enterprise, the following technological scheme for the production of yogurts can be deduced:
.Acceptance and preparation of raw materials;
2.Cleaning and separation;
.Normalization and dispersion;
.Pasteurization and cooling to fermentation temperature;
Mixing;
ripening;
.Introduction of fillers, final mixing and cooling;
.Bottling, packaging, labeling;
After passing through all the stages, the goods are delivered to retailers and, with the help of the sales department, are sold both through chain stores and through third-party trading enterprises. An important milestone is also the control and evaluation of the quality of finished products. Let's consider each of the stages of the scheme in more detail.
A laboratory operates at the enterprise to receive milk. It consists of two departments: microbiological and physico-chemical. The chemical department of the laboratory analyzes the physical and chemical parameters, the microbiological - respectively, microbiological. When assessing the quality, an average sample is taken from a batch of milk, which is a part of the product taken from each package in one container. Before taking an average sample, the milk is stirred until completely homogeneous. A label is glued onto the dishes with an average sample of milk, the deliverer and the date of receipt are indicated. The merchandiser receives the milk and prepares it for further stages of processing. Thus, the first stage of the technological chain is completed.
After acceptance, the milk is stored in metal tanks. They are made of stainless steel, which does not oxidize and does not affect the product. After conclusions are drawn about the quality indicators of milk, you can begin to clean it. Before carrying out this stage, the milk must be cooled. Purification refers to the purification of milk from mechanical impurities, such as blood, mucus, and so on. At this enterprise, milk is purified by pressure filtration on filters through filter cloths to remove impurities. In the production of fermented milk drinks, two methods are used: thermostatic and reservoir. With the thermostatic method for the production of fermented milk drinks, the fermentation of milk and the maturation of drinks is carried out in bottles in thermostatic and cold chambers. With the tank method of production, fermentation, fermentation of milk and maturation of drinks occur in one container (milk tanks).
The company uses a tank method. After cleaning, the milk is sent for temporary storage in tanks, and after that it is sent for separation. Separation of milk is carried out in special machines - separators available at the enterprise. Separators designed to separate milk into cream and skimmed milk are called cream separators, and for milk purification - milk purifiers. Cream separators with milk normalization devices are called normalizer separators. This company uses a separator-cream separator, as well as a separator-normalizer. In the sediment formed by the separators, mechanical impurities and bacteria accumulate, and, as a rule, they are destroyed. This concludes the second stage of the technological scheme.
3. Normalization and dispersion of milk. Normalization of milk is to reduce or increase the content of fat or dry fat-free substances in it. Milk with a fat content above 3.2% is normalized by passing through separators-normalizers. On the normalizers of this enterprise, the fat content of normalized milk is adjusted using a cream screw. Further, the mixture, by introducing certain components, is given a homogeneous structure. This process is called dispersion. The more finely and evenly dispersed one or another component milk, the less its content varies: for example, the content of fat is subject to greater changes than the content of protein substances. The most constant in terms of quantitative content of milk are lactose and salts. Before adding to the resulting mixture, granulated sugar is pre-weighed and sieved. Skimmed milk powder or other dry milk products (whole milk, cream) are pre-weighed and mixed with sugar. The stabilizers are weighed and mixed with skimmed milk powder (or other dairy products) and granulated sugar. The mixture obtained in this way is stirred until the dry components are completely dissolved, then mixed with the main mass of normalized milk heated to (30-40) ° C. This completes the third stage of the technological scheme.
4. To extend the shelf life of the resulting mixture, it is pasteurized. Depending on the equipment available in dairies, pasteurization can be instant, short-term or long-term. Instant pasteurization is carried out in a few seconds without exposure at a temperature of 85-90 degrees, short-term - at 74-76 degrees with an exposure of 15-20 seconds, long-term - at a temperature of 65 degrees with an exposure of 30 minutes. Despite the fact that short-term pasteurization is the most widespread, CJSC Tander uses the method of long-term pasteurization. Long-term pasteurization and high temperature (85-87°C with a holding time of 5-10 minutes and 92-95°C with a holding time of 2-3 minutes) lead to almost complete coagulation of whey proteins, and during the subsequent fermentation of milk, they completely aggregate together with casein. This pasteurization method is ideal for the production of yoghurts.
Mixing. In the case of pasteurization, cooling and fermentation normalized in the mixture in the same container, the leaven is added to the normalized mixture cooled to the fermentation temperature with the stirrer turned on. sourdough starter this production they are introduced through a special device (lock system) in a stream with a normalized mixture during the filling of the tank or through an open hole in the upper part of the tank (after filling it with a mixture of 1/3) with the mixer turned on. Stirring is completed 15 minutes after filling the tank. This completes the mixing step.
After exposure, the mixture is cooled to a fermentation temperature equal to (41±2)°C. Storage of unfermented mixture is not allowed. The mixture is fermented and fermented in tanks for fermented milk drinks with a cooled jacket, equipped with special agitators that ensure uniform and thorough mixing of the mixture with the ferment and the milk clot. With small production volumes, pasteurization, aging, cooling, fermentation and fermentation of the mixture can be carried out in VDP baths. It is these bathrooms for 100 and 200 liters that are used in Tander CJSC. The sourdough can also be added before the mixture is fed into the tank. The end of fermentation is determined by the formation of a sufficiently strong clot and acidity, which should be no more than 85°T. Upon completion of fermentation, ice water is supplied to the interwall space of the tank for 30 to 60 minutes. The curd is then stirred for 10 to 30 minutes. Upon reaching a clot of a homogeneous consistency, the stirrer is turned off. Further mixing is carried out periodically with a time interval of 40 to 60 minutes. Thus ends the fermentation stage.
Fruit and berry fillers (natural pastes) are introduced into consumer containers at the bottom of the package using a dosing device. Then the fermented milk base is served. Fruit and berry concentrates or flavoring additives and dyes are added to the mixed and partially cooled clot, mixed until they are evenly distributed, cooled and served for bottling.
According to GOST R 51331-99, yogurt is packaged in consumer containers of various capacities from packaging materials approved in the established manner for contact with dairy products, ensuring the quality, safety and preservation of yogurt during its production, transportation, storage and sale. Pouring is carried out in plastic cups of 200 and 500 ml. Before hitting the belt, the raw material for the plastic cup is disinfected, and then plastic cups are stamped out of it using a hot press, which are already filled with the product. With the help of an installation for welding cups with aluminum foil lids, they are closed with lids.
technological yoghurt assortment quality
3. Characteristics of the range of products
3.1 Principles of planning and formation of the production range
Yoghurt is a fermented milk product produced from milk normalized in terms of fat and solids content, fermented with sourdough, prepared on pure cultures of Bulgarian bacillus and thermophilic lactic streptococcus with or without the addition of fruit and berry syrups, flavorings, fillers and dyes. In other words, yogurt is a fermented form of milk, a product of its fermentation.
A commodity producer, namely CJSC Tander, must offer a certain set of goods, which, in turn, must fully satisfy certain needs of buyers. This set of offered goods is called the production assortment. When forming the assortment, the enterprise first of all faces the problem of establishing a pricing policy and requirements for the quality of goods. In this case, the company is not a leader in the yogurt production industry, therefore it is forced to form its production and pricing policy based on the experience of similar manufacturing companies. Therefore, planning and forming an assortment is an important component in competitive strategy firms. The assortment planning mechanism is based on general principles planning, which include:
the need to use the range - especially taking into account the requirements rational use resources. Yoghurt is a popular product in our country, the company has all the necessary resources for its production.
unity - provides for the development of a general plan for socio-economic development with the mutual coordination of elements.
continuity - the need for the continuity of all planning processes, the connectivity of tasks by time intervals. In the near future, the company plans to expand the production of fermented milk products, including yogurt, for this, negotiations are underway on the supply of milk in larger volumes and at a lower price. These tasks are included in the company's development strategy for the next year.
flexibility - involves the adaptability of the planning process, taking into account the changing market conditions. The company needs to adapt to changing market conditions, track new products from competitors in order to timely monitor their own products and expand the range. For this, various mechanisms are used: studying the formation of prices for different product groups at similar production and marketing enterprises, questioning buyers to identify their needs, using exclusively new ingredients in production.
accuracy is a principle inherent in short-term planning. All tasks in assortment planning have their own designated deadlines for solving in the near future, which are formed depending on the changing situation in the production and marketing market.
From this we can conclude that the planning and formation of the assortment largely depends on the situation on the market, which must be monitored and adjusted in a timely manner.
3.2 The range of manufactured products and assessment of the assortment diversity of the enterprise's products
The rate of consumption of yogurt in Russia is about 3-5 kilograms per person per year. Experts consider the yogurt market to be one of the most promising areas. The beneficial properties of yogurt meet the current consumer demand for a healthy diet. The classification of yogurts is given in GOST R 51331-99 “Yoghurts. Are common specifications". In accordance with it, depending on the raw materials used, yogurts are divided into the following groups:
¾ from natural milk
¾ from standardized milk or standardized cream
¾ from reconstituted milk
¾ from recombined milk
Depending on the use of flavoring additives, yogurts are divided into:
¾ fruit or vegetable
¾ flavored yogurt
Depending on the mass fraction of fat in the product, yogurts are divided into:
¾ dairy non-fat not more than 0.1%
¾ low-fat dairy 0.3-1.0%
¾ dairy bold 1.2-2.5%
¾ dairy classic 2.7-4.5%
¾ milky - creamy 4.7-7.0%
¾ creamy milk 7.5-9.5%
¾ creamy not less than 10%.
¾ fat free
CJSC Tander produces all types of yoghurts, except fat-free ones, as well as yoghurts with vegetable fillings. Vegetable yogurt is made by adding pieces of natural vegetables to the yogurt mass. This type of yogurt is not as widespread in our country as fruit yogurt. That is why an enterprise with an underdeveloped industry does not risk producing a product of this type. Although, in the conditions of modern competition, the production of a fundamentally new type of product would attract increased attention to the products of Tander CJSC. Also, the company does not produce skimmed yogurt, although the list of equipment includes a cream separator, which technically allows the production of skimmed milk. This is an omission in the formation of the assortment of the enterprise. Currently, the range of dairy products is so extensive that it is quite difficult to choose one, so it is important to make your products unique. Despite the fact that yoghurts produced by CJSC Tander are competitive in price (due to the absence of expensive delivery), as well as in quality (due to exceptionally high-quality raw materials), they cannot be sold on a par with such giants as, for example, Milkfest and Unimilk. To do this, it is necessary to take some measures regarding the production and marketing policy.
I made the following proposals to the management of the enterprise to improve production and marketing activities:
.Expansion of the assortment of the enterprise. Start production of vegetable and fat-free yoghurts. The global downward trend in milk consumption has necessitated the development of a new generation of dairy products that are in high demand among buyers. This primarily concerns dietary fermented milk products, the importance of which in nutrition is generally recognized.
2.Produce bottling of dairy products in containers of 120 milliliters. This will make the consumption of the product optimal for customers who have children, since the amount of food consumed by children is less than that of adults.
.Pour yogurt not only into plastic cups, but also into bottles. It is convenient to take yogurt in a bottle anywhere with you, it does not require a spoon for its use, which means that it can be consumed outside the home, which will undoubtedly increase its popularity.
With regard to marketing activities, I made the following suggestions:
.Design a separate showcase with goods of your own brand. This will allow yoghurts not to get lost on the shelves among similar products - competitors.
All my comments are taken into account by the management of ZAO Tander.
4. Quality control of products
.1 Quality requirements and implementation of product quality control
Yoghurt must be produced in accordance with the requirements of this standard in compliance with sanitary norms and rules for technical and technological documentation approved in the prescribed manner for a specific name of yogurt. According to organoleptic indicators, yogurt must meet the requirements specified in Table 2.
table 2
Organoleptic characteristics of yogurt
Indicator nameCharacteristic Appearance and consistency Taste and smell Color Homogeneous, moderately viscous. When adding a stabilizer - jelly-like or creamy. When using flavoring additives - with the presence of their inclusions. Sour-milk, without extraneous tastes and smells. When made with sugar or sweetener, moderately sweet. When produced with flavoring additives and flavoring agents with the appropriate taste and aroma of the added ingredient. Milky white uniform throughout the mass. When produced with flavoring additives and food colorings - due to the color of the added ingredient.
According to physical and chemical parameters, yogurt must comply with the standards specified in Table 3.
Table 3
Physical and chemical indicators of yogurt
Name of indicator NormMass fraction of fat*,%: Dairy low-fat Milk of high fat content Dairy semi-fat Dairy classic Milk-cream Cream-milk cream Mass fraction of protein,%, not less than: - For yogurt without fillers - For fruit (vegetable) yogurt Mass fraction of dry fat-free substances milk, %, not less than: - For yogurt without fillers - For fruit (vegetable) yogurt Mass fraction of sucrose and total sugar in terms of invert sugar Mass fraction of vitamins, % Acidity, T Phosphatase Temperature at the outlet from the enterprise, СН more than 0.1 From 0.3 to 1 From 1.2 to 2.5 From 2.7 to 4.5 From 4.7 to 7 From 7.5 to 9.5 At least 10 3.2 2.8 9.5 8, 5 It is set in the technical documentation for a specific name of yogurt produced with sugar and (or) fruit and berry fillings. It is set in the technical documentation for a specific name of fortified yogurt From 75 to 140 Not available 4+2
Also, the mass of yogurt in consumer packaging must be taken into account. It must comply with the standards specified in table 4.
Table 4
Mass of yogurt in consumer packaging according to GOST R 51331-99
Capacity of consumer packaging in cubic centimeters Nominal value of the net weight of yogurt in grams Permissible deviation of the net weight of yogurt in consumer packaging in grams 5.0150-200150-200+/ - 6.0200-250200-250+/ - 8.0250-500250-500+/ - 10.0500-1000500-1000+/ - 20.0
Yoghurt in consumer packaging is released from the enterprise in shipping containers from packaging materials approved by the State Sanitary and Epidemiological Supervision of the Ministry of Health of Russia for contact with dairy products. At the enterprise, yogurts are packaged in plastic cups with different volumes and closed with foil lids.
The basic requirements for yogurt fillers are as follows:
- strict observance of the current standards, sanitary rules and norms approved for the acceptance of fruit and berry fillers;
- observance of sanitary conditions for storage of fruit and berry fillers (dry, clean, well-ventilated storage facilities at a temperature not exceeding 20°C and relative humidity not exceeding 75%);
- strict observance of storage periods various kinds fillers from the date of manufacture: for example, fruit and berry syrups - 8 months, dessert syrups - 6-18 months. etc.;
- observance of the established thermal regimes for the processing of fillers before introducing them into containers;
- adding fillers to fermented milk drinks produced by thermostatic and reservoir methods after cooling to 20-25°C;
- natural food colorings are added to the container at a temperature of 20-25°C;
- to ensure production guaranteed in terms of product quality, each batch of filler is examined in terms of physicochemical, organoleptic and bacteriological indicators; according to microbiological indicators, they must comply with the current instructions;
- frozen fruits, berries and food colorings should not show signs of spoilage caused by the vital activity of microorganisms (mold, fermentation, etc.).
.2 Factors to maintain product quality
Before entering the warehouse of finished products, yoghurts are again sent to the laboratory. There, the products are again checked, including the taste. Research is carried out at all stages of the production cycle - from the receipt of raw milk to the output of finished products, and the state of the finished product in the storage cycle is analyzed (at various temperature conditions and for various durations - for absolute certainty in the stability of the product quality throughout the entire shelf life). This is also done in order to eliminate or reduce the possibility of defects. In case of incorrect technological process and storage of yoghurts in the factory, defects can occur.
Defects in yogurt arise as a result of the use of low-quality raw materials, the action of bacterial starter cultures in violation of the technological regimes of production or non-compliance with the conditions for cooling or storing finished products. Defects in yogurt include defects in the production process and defects in the storage process.
.Defects in the production process
Structural and mechanical changes. Yoghurt is produced by introducing a starter into milk, under the action of which the coagulation of proteins occurs and the formation of a spatial structure from milk proteins with inclusions of milk fat and moisture.
During the heat treatment of milk under certain conditions, complex formation occurs between casein and whey proteins. Characteristically, an increase in temperature accelerates the process of structure formation. Increasing the pasteurization temperature increases the viscosity of the clot. This is reflected in table 5.
Table 5
Effect of pasteurization temperature on curd viscosity 10^3 (in Pa)
Structure statePasteurization temperature, С63728090Undestroyed45754912341896Destroyed4,536,016,397.9 15 min after destruction6,326,328,2210.11
.Defects during storage:
If the storage regime is violated, undesirable processes can occur in fermented milk products that reduce the quality and even lead the product to complete spoilage. As a result, defects appear. Sour taste occurs at elevated storage temperatures due to ongoing lactic acid and other types of fermentation.
A greasy taste appears due to the oxidation of milk fat to the formation of dihydroxy acids. Activates this process sunlight, increased storage temperature, the presence of air in the package, catalyst metals.
A bitter taste is a consequence of the breakdown of protein substances under the action of proteolytic enzymes of microflora during long-term storage of products, especially if sanitary conditions are not observed during transportation and storage.
Rancidity appears as a result of the hydrolysis of milk fat under the influence of molds.
A putrid taste is a consequence of protein decomposition by putrefactive bacteria, indicating long-term storage in unfavorable sanitary conditions.
A yeasty, fermented taste is found in products that have been stored for a long time, its appearance is accompanied by gas formation, swelling of the product. This defect appears at elevated storage temperatures. After the quality assessment, standard products are sold through the trade and retail network.
Proper storage of products is an important factor in production. For quick placement and selection, ensuring the required storage modes, they develop schemes for the placement of goods, providing for permanent storage places, the possibility of monitoring their safety and caring for them. When developing schemes, the frequency and volumes of receipt and shipment of goods, the optimal methods of packing, the conditions for their shipments, and for some types of goods, the “right neighborhood” are taken into account.
The main conditions that ensure proper storage are: a certain temperature and relative humidity of the air, appropriate lighting and ventilation; observance of the commodity neighborhood; consolidation permanent seats for the goods; ensuring liability; implementation of sanitary and hygienic measures to prevent the loss and damage of goods. When storing goods, they are placed on pallets, racks, racks, in cabinets, hung on hangers, brackets. Storage of goods on the floor is unacceptable. The company complies with all storage conditions for products.
The sales department generates shipping documents, waybills, invoices. The database of the sales department receives information generated automatically from all stores in the network. The goods are delivered to stores with the help of their own transport companies. The conditions of transportation of finished products significantly affect its quality.
When transporting goods important role plays the choice of vehicles, type of packaging, method of laying. Each unit of consumer packaging must be marked with a non-washable, odorless ink approved by the Ministry of Health of the Russian Federation for contact with food products, marking indicating the following information:
- name of the type of product;
- information data on the mass fraction of fat, protein, carbohydrates, calories;
- date of the deadline for the implementation (applied with a composter or embossed or stamped).
- The shipping container must have a label or tag indicating:
- name or number of the manufacturer or trademark enterprises;
- name of the type of product;
- gross, net, container weight of goods;
- number of units and net weight of each packaging unit and each piece;
- date of the deadline for implementation;
- batch number and place number;
- designation of the corresponding standard.
After arriving at the stores, the goods are put on the shelves for final sale.
Conclusion
Yoghurt is a fermented milk drink produced from pasteurized milk, normalized by mass fraction of fat and solids, with or without added sugar, fruit and berry fillers, flavors, vitamin C, stabilizers, vegetable protein and fermented with sourdough prepared on pure cultures of lactic acid thermophilic streptococci. races and Bulgarian sticks. Depending on the flavoring and aromatic additives used, yogurt is produced the following types: yogurt, sweet yogurt, fruit and berry with vitamin C, fruit and berry diabetic.
To date, the production of yogurt in Russia is one of the most common types of food industry. Technical re-equipment and equipping of the enterprises of the dairy industry of the country with modern technological equipment, the latest technology is constantly taking place, production is being comprehensively mechanized and automated. Increasingly, computers are being used. A lot of work is being done to improve the quality, improve and enrich the range of dairy products, since quality is one of the most important criteria for the competitiveness of goods. However, such awareness has not yet come to all manufacturers, which has a negative impact on the image of Russian goods in general. Therefore, it is necessary to qualitatively improve and modernize the production of dairy products. Yoghurts have many beneficial substances, they have a beneficial effect on the digestive activity of the human body. Yogurt quickly relieves hunger, quenches thirst. With qualitative development, introduction of new developments in the technical and technological spheres of yogurt production, there are broad prospects for promoting products to foreign markets, where there is a high purchasing power of the population.
List of sources used
1.GOST 13264-88 “Cow's milk. Purchasing Requirements »
2.GOST R 51331-99 “Dairy products. Yoghurts»
.SanPin 2.3.2.1293-03 "Hygienic requirements for the use of food additives".
.Kastornykh M.S., Kuzmina V.A. et al. Commodity science and examination of edible fats, milk and dairy products - 2nd ed., corrected. / ed. Kastornykh M.S. - M.: Ed. Center "Academy", 2006.
.Krylova G.V., Sokolova M.I. Marketing: theory and practice. - M.: UNITI-DANA, 2004.
.Raikova E.Yu. The theory of commodity science and expertise: a textbook for bachelors. - M.: Publishing and Trade Corporation "Dashkov and K0 ". - 2012
.Commodity research of homogeneous groups of food products. Textbook / Ed. d.t.s. L.G. Eliseeva. - M.:ITK "Dashkov and Co"
Tutoring
Need help learning a topic?
Our experts will advise or provide tutoring services on topics of interest to you.
Submit an application indicating the topic right now to find out about the possibility of obtaining a consultation.
