"Well, I won't talk about halva - what fool does not like halva?" - said one of the characters in Denis's Tales. In the era of the USSR, halva was eaten by all citizens of a large country, especially since it was not uncommon on the shelves, like another tasty food... In eastern countries, halva still has few competitors - the reason is in the ability to observe traditions and appreciate ancient recipes. By the way, what is halva made of?

The appearance of a treat

Halva appeared presumably in Iran before our era, from there the recipe delicious treats spread throughout the East. If you look for the translation of the word "halva", then you will not find anything interesting, literally - "sweetness". Initially, it was made from ground nuts, sesame seeds and honey. Later, the inhabitants of eastern countries began to replace honey with sugar, and the recipe has undergone some changes from this. However, halva emerged victorious from all these troubles: a simpler and cheaper production allowed conquering the sweet tooth in other countries. Russia tasted this treat in the 19th century, and our nuts were replaced by sunflower seeds. As a result, we have become more accustomed to the version of seeds, and the nutty original is not considered classic in our country.

Halva types

Halva is known for its characteristic fibrous structure. The grated seeds, kernels or beans are mixed with the whipped caramel mass. The lamination of the dessert is given by a foaming agent made of proteins and licorice root. Modern technologies greatly simplify production, but in the East there are craftsmen who make halva by hand. By the way, nougat is considered one of the varieties of halva - syrup is added to the same composition of ingredients to obtain a dense, saturated structure.

The correct halva is divinely good in itself, but sometimes its taste is complemented by chocolate, pistachios or vanilla. There are several types of halva, and in different countries your preferences. So, in the Balkans, light sesame halva is respected, the inhabitants of the East prefer old recipe with honey. In Eastern Europe and Russia, they are faithful to sunflower halva. There are lovers of desserts made from peanuts, hazelnuts or cashews. In Iran, Turkey and Afghanistan, confectionery is made from corn, semolina and even carrots. Unusual halva is prepared in India - vegetables are mixed with ghee and condensed milk.

Tasty but harmful?

The question of the benefits or harms of halva remains open. On the one hand, the abundance of nuts and sugar cannot be a boon for the body - the dessert is very high in calories, and you should definitely not abuse it. On the other hand, strict Muslims would hardly have kept the recipe so reverently and sang a harmful delicacy for generations. It is known that halva is rich in proteins, fats and vitamins. The presence of sunflower seeds and nuts in the composition has a beneficial effect on bones, nails and hair. The sesame version contains a lot of calcium. Like any sweetness, halva cheers up. Finally, it is just very tasty, so sometimes it is very useful to indulge yourself with a piece of delicacy.

“No matter how much you say“ halva ”, your mouth will not become sweeter,” - is found in the diet of the Eastern sages. And if you ask them about the harm and benefits delicious halva, they, we dare to assume, will answer: everything is good in moderation.

Kaluga region, Borovsky district, Petrovo village

They are represented in the ethnographic park in a variety: there is a universal refectory, a Ukrainian tavern with dumplings and borscht, for Uzbek pilaf- to the teahouse, for pizza - in Italian restaurant, there are restaurants of Chinese, Indian cuisine, cafes for those who love solitude and grill - "Wilderness".

Hello to you lovers interesting facts and events. Do you like different kinds of sweets and snacks? Then, especially for you, we decided to tell you how sunflower halva is made in production. We hope you enjoy it.

Halva came to Russia from the Middle East at the beginning of the 20th century. It is produced at home and in factories. The manufacture of this product is a laborious process that consists of several stages. To make the delicacy tasty, only high-quality ingredients and special technology are used for its preparation.

Factory made sunflower seed sweetness

Everyone's favorite halva is prepared on an industrial scale at special factories. The composition of the factory sweets includes the following main components:

• protein base - seeds or nuts;
• caramel mass obtained from sugar or molasses;
• licorice or soap root - is a foaming agent and gives the product a stratification. Protein can sometimes be used;
• flavors and colorants are important ingredients of the halva from the plant.

The correct production technology is the main parameter that must be observed when making halva. The technologist responsible for this procedure monitors each stage. Before the sweetness acquires its required appearance and taste, it will be constantly mixed and stretched on special equipment.

Making sunflower halva

For 100 grams oriental sweetness you will need about 57 grams of sunflower seeds. The protein base of halva is sunflower seeds, which are ground on special equipment into a homogeneous mass.

Production scale

Halva is produced in large quantities in workshops with the required equipment. Professional machines prepare caramel, fry and grind the seed, mix all the ingredients many times, pack the finished product. Despite the fact that the whole process is automated, not a single step in the preparation of sweets should be overlooked.

In factories, sweets are prepared in hundreds and even thousands of kilograms. For the production of delicacies, the main component is sunflower seeds, bought in bulk from the manufacturer. If you count the time and money spent on making homemade halva, then it will be more expensive than the factory one. Technologists, during the manufacture of each batch of sweets, adhere to a strict recipe, which allows them to produce products with the same taste and appearance.

Equipment used

At the production site, halva is prepared using special equipment from foreign or domestic manufacturers. In the preparatory workshop there is a weaving and crumbling machine, a mill for grinding seeds and an apparatus for roasting them. In the production workshop there are vats for making caramel and kneading all the ingredients for the sweetness. In the filling department, there are packing machines that place specific pieces of product in branded or regular packaging.

Stages of making halva

In the production of halva, the following stages are present:

• preparation of protein mass from seeds;
• cooking caramel;
• obtaining a soap root extract;
• mixing the extract with caramel;
• thorough kneading of the resulting mass.

Basically everything. But let's take a closer look at this whole process. And at the end you will find a video where you will be shown everything in detail.

First stage

To prepare the protein mass, you first need to prepare the seed. For this, the grains are thoroughly cleaned and dried. After cleaning, the seeds will have a thin film (seed coat) from which they get rid of on the seedlings. Next, the kernels are washed and dried well. At the final stage, they are fried to a certain extent and crushed to obtain homogeneous mass... At the first stage of production, the basis for the future product is prepared.

Second stage

Properly prepared caramel is an important ingredient for making halva. It must be plastic and not crystallize. The high content of molasses in the caramel mass helps to ensure such qualities. The syrup is brewed by a special vacuum apparatus.

Third stage

At the third stage, a foaming agent (soap root decoction) is prepared. The root is boiled and boiled down to an extract with a density of 1.05. Next, the finished foaming agent is mixed with the caramel mass, which will make it possible to impart a porous structure to the halva.

In order to future product had a layered fibrous structure, it is necessary to knead all the ingredients several times. To begin with, a foaming agent and a caramel mass are placed in a vat and kneaded at low speeds. At the same time, prepared seeds and flavors are placed in the container. Further kneading takes place with a gradual increase in the speed of the apparatus. The whole kneading time does not exceed 5 minutes. The finished product after passing these stages will have a temperature of about 65-70 degrees.

Halva is a very tasty and original confectionery product. However, it is important to remember that this delicacy does not tolerate a long shelf life. When stored for a long time, the surface of the product is moistened and fat leaks. The quality of halva depends on the correct technology of production and storage of the product at a factory or store.

Well, to make it clearer for you, we suggest you watch a video fragment from the "Galileo" program about how the same halva is made from sunflower in production. Happy viewing.

We hope you liked it and you will definitely join our public on VK to always be aware of new interesting facts and events from the site. Also, be sure to read the article about. We are sure that you will also be interested to know about this.

For the organization of mechanized continuous production of halva from sunflower seeds, the following principle can be recommended technology system(fig. 77).

The seeds arriving in railway wagons go to the warehouse, from where they are fed by a hoisting-and-transport mechanism to the bunkers 1, installed in the ruffling-weaving department. The seeds weighed on the automatic batch scales D-100-3 2 by the noriya 3 are fed to the separator 4 for cleaning from dust, coarse debris.

After that, the partially cleaned seeds go to the bunker 5.

If the moisture content of the seeds is high, then from the hopper they are sent to the drum dryer 7, where they are dried to a moisture content of 8-9% and by the bucket elevator 8 are fed for cooling to the cooling column 9. From here, the seeds are sent to the hopper with elevator 10. If the moisture content of the seeds is 8-9% , then they are transferred to the hopper, bypassing the drum dryer.

For final cleaning, the seeds are fed to the POP-5 separator 12 and through the hopper 13 for dehulling into a crumbling MRN 14. After the crumbling, the seeds and husk are sent to the wake 15, on which the kernel is separated from the husk.

For a more complete removal of husk and remaining impurities, the kernel goes to the washing machine 19. The moisture content of the kernel after washing is 30-35%, therefore, to remove surface-bound water, the kernel is centrifuged, as a result of which the moisture is reduced by 5-10%.

The parched seeds are fed into the hopper 21, from which they are fed by the distributing auger 22 to the VIS-2 or VIS-42DK dryer, and then to the POP-25 separator to clean the sunflower kernel from a thin film, from which the kernel is sent to the hopper 26 and to the grinding plants ...

The crushed kernels, mixed with refined sunflower oil, enter the auger, where they are well mixed.

From the auger, the protein mass goes to the Finisher pullers (Fig. 78), on which the husk and other impurities are finally separated. The rubbed protein mass enters the collectors, from which the pump is pumped into the tanks equipped with mixers. Stirring the protein mass is necessary in order to prevent its delamination.

Caramel syrup made from sugar and molasses. The caramel mass is boiled down in coil vacuum apparatus.

The decoction of the soap root and the caramel mass are knocked down in a kettle with a stirrer equipped with steam heating. The knocked-down caramel mass is unloaded from the boiler through the lower nozzle into the receiving bowl of the kneading machine, where the prescription amount of the protein mass is located.

After mixing the mass, the bowl with halva is fed to a bowl lifter, with the help of which the mass is unloaded onto the inclined corrugated surface of the pulling mechanism and continuously enters the funnel of the dividing and filling machine.

Rice. 78. Cleaning machine "Finisher": 1 - stamped mesh; 2 - wooden whips; 3 - collecting tray; 4 - hole for removing husk residues.

Halva is a confectionery product of a layered fibrous structure, made from fried grated kernels of oil seeds and caramel mass, knocked down with a foaming agent. Halva - oriental delicacy, has long been produced in our country.

Halva production is widespread in many southern countries of Asia, on the Balkan Peninsula; there is no such production in Western countries.

Halva is a product with good taste properties and especially high, in comparison with many other confectionery products, nutritional value due to the high content, in addition to sugar (30-35%), also fat (30-35%) and high-grade protein substances (15-20%). The calorie content of halva reaches 510-520 kcal per 100 g. Halva can be used not only as a delicacy, but also as a complete food product. In terms of its high fat and caloric content, halva is close to such products as chocolate, surpassing it in terms of the content and value of protein substances.

Halva is produced in our country not only in large factories, but also in small enterprises of the confectionery, canning and other branches of the food industry.

Halva production scheme consists of the following stages:

• preparation of tahini (or other protein) mass;
• preparing a decoction of soap root;
• preparation of caramel mass;
• knocking down the caramel mass with a decoction of the soap root;
• kneading halva;
• packaging and packaging of halva.

Cooking tahini and protein sunflower and peanut mass

General properties of protein masses. Takhinny, as well as any other so-called protein mass is a homogeneous mass of partially dehydrated (fried or dried) ground seeds. Unlike pure vegetable oil, sleep contains, in addition to fat, all other parts of the seed, including protein substances. Proteins and carbohydrates of seeds have hydrophilic properties and form a gel phase in plant cells of seeds, i.e., having the character of a lyophilic jelly.

The gel and fat phases are in close (interaction. Fat is distributed in a continuous gel phase and is retained by capillary forces at the interface. Some role in this is probably played by lipoid substances (lecithin, etc.), which, along with lipophilic, also hydrophilic properties Being adsorbed on the surface of the fat phase, they are simultaneously associated with the hydrophilic gel phase, helping them to interact more closely in plant tissue.

In the process of obtaining protein (mass, the seeds are heated (roasting, drying). At the same time, along with the removal of moisture in the seeds, chemical and physicochemical changes occur. Protein substances undergo partial thermal denaturation when heated. This was shown for sunflower seeds in the works of Goldovsky. In the work of Misnik andGruner studied the change in the fractional composition of nitrogenous substances of sesame during [different heat treatment of it, as well as during long-term storage (Table 25).

Table 25

When heated, the amount / of the water-soluble fraction (such as albumin) decreases and the fraction soluble in a 10% solution NaCl fraction (such as globulins), the amount of the fraction soluble in a 0.2% NaOH solution and, especially, insoluble, increases. This heat denaturation process goes much deeper with more intense heat treatment (roasting). Similar, but less pronounced processes occur during long-term storage of the sesame kernel (crushed seeds).

Under the influence of heating, the bond between the oil and the gel phase in the tissues of the seeds is weakened. This is apparently due to the fact that with an increase in temperature, the viscosity of the oil decreases and the intermolecular forces that hold the oil on the surface of the gel phase decrease. Removal of moisture from the gel phase and thermal denaturation of the protein reduce the effect of the lipophilic-hydrophilic constituents of the seed. When grinding seeds, a significant development of the total surface of plant tissue particles occurs, which contributes to the binding of oil to the gel phase. In the resulting protein mass, the fat and non-fat parts are distributed quite evenly, forming a mass that is homogeneous in appearance. This system, however, is not very stable due to the indicated weakened bond of the oil with the gel phase. Over time, it gradually stratifies - the fat layer is separated from above, and a dense layer of larger parts of the seeds settles below.

In fried kernels and (the resulting protein / mass / appears under the influence of heating, a pleasant taste and aroma, nutty flavor. It is largely due to changes in protein substances. It is very likely that the reaction of melanoidinosis formation also occurs (see Chapter XII "Production of milk sweets") as a result of the interaction of carbohydrates (aldehyde groups) and amino acids,

Takhinny mass

Takhinny mass is produced from sesame seeds.

Sesame (Sesamum indicum L) is an annual plant, it is grown in a number of countries - in Asia, Africa, also in America, in southern Europe as an oil plant.

In the USSR, it is cultivated in Central Asia, the Transcaucasia, the North Caucasus, and southern Ukraine. Breeding work with sesame and work on sesame agrotechnics, carried out in the USSR since the end of the 1920s, contributed to the expansion of the area under this crop, its promotion to new regions (the North Caucasus, southern Ukraine), and the development of new, valuable varieties of sesame.

Sesame fruit is an elongated flat box divided into 4-8 nests. Seeds are similar in shape to flaxseeds, but significantly (2 times) smaller than them, they have a matte surface. Their color is white or light yellow, brown, gray, brown and black. Absolute weight (1000 seeds) from 2 to 3.9 2. Seeds have a shell, the content of which ranges from 7 to 15% of the weight of the seed.

Sesame kernels have a high nutritional value due to their high fat content (from 51.75 to 67.89%), nitrogenous substances (from 22.44 to 34.11%) and the presence of vitamins E and B 1

The work of the VKNII showed that various varieties of sesame grown in the USSR are suitable for the production of halva. Not only white-seeded, but also brown sesame varieties can be used if, after breaking them, white kernels are obtained, giving a light tahini mass. Takhinny mass and halva of good quality are produced by new breeding varieties of white sesame Kubanets 55, VNIIMK 81 and others, bred in the USSR by the All-Union Scientific Research Institute of Oilseeds and other breeding organizations. Industry experience and research by VKNII show that there are sesame varieties that have a bitter taste. The nature of the substances responsible for this bitter taste has not yet been studied. Sesame seeds with a bitter taste are not suitable for halva production.

The scheme for the production of takhin mass includes the following basic operations:

1) dehulling of seeds and separation of kernels from the shell;

2) frying (or drying) the kernels;
3) grinding.

Before crumbling, sesame seeds must be cleaned from weed and grain impurities on a separator. The collapse of sesame seeds (removal of the shell from them) has some peculiarities in comparison with the collapse of other seeds, which depends on the properties of the sesame shell and its connection with the kernel. The chemical composition of the sesame flower coat differs from that of, for example, oilseeds such as sunflowers or peanuts (Table 26).

Table 26

In terms of physical properties, the sesame shell is distinguished by the absence of fragility characteristic of the shell of sunflower, peanut, and significant elasticity. It is quite tight, without gaps (which are found in sunflower and peanuts), adjoins the core and between them there is, as it were, a layer gluing them together. It swells easily in water, in this state it easily moves. Moistened, also easily swellable, the casing becomes even more elastic and remains quite strong. It is easier to shift and go off the nucleus than it breaks. Therefore, in the case of a soaked seed, when the shell breaks (under mechanical stress), it is easily removed (shifted) from the kernel.

The applied sesame crumbling methods are based on the above properties of the sesame and its shell. They can be called wet caving methods, since they are carried out after preliminary soaking of the seeds. Some experiments have been carried out to dry sesame seeds, but this method has not yet received a sufficiently complete development.

The sesame hulling process used today begins with soaking the seeds. It should give an increase (due to swelling) of seeds in weight by 1.3-1.5 times.

The moisture content of the seeds after (swelling reaches 30-35% (with an initial moisture content of about 6-10%). The shell swells more, its moisture content is 10-15% higher than that of the kernel. The shell of swollen seeds stretches somewhat, peels off from the kernel and It breaks easily and separates under pressure and friction. The fullness and end of soaking are determined by touch, that is, they try with their fingers whether the shell comes off the kernels easily enough. seeds (for 1 weight part of seeds about 3-4 parts of water). Duration of soak 30-50 minutes in clean water, having a temperature of about 25 °. The use of warm (40-45 °) water speeds up the soaking. The same effect has the addition of soda (up to 1%) After soaking, the seeds are allowed to stand (40-50 min.).

The crushing of sesame seeds is carried out in various devices, the principle of which is mainly based on the fact that a moving part forcefully mixes the sesame seeds and causes mutual friction of the seeds; this leads first to rupture of the moist swollen shell, and then to the removal of the shell from the nuclei.

There are several designs of apparatus for dehulling seeds. The earlier ones include winch-breaking drums of the Vdovichenko system. In them, horizontal blades are fixed on a vertical shaft (in the Vdovichenko apparatus there are two mutually perpendicular stripes, one is located lower than the other). The shaft is mounted along the axis of a large drum (diameter about 2 m), into which the soaked sesame is loaded. When the blades rotate, sesame seeds are subjected to strong friction, their shell is torn and removed from the seeds; the required processing time is up to 20 minutes. with a load of about 200 kg and a rotation speed of the blades of about 120 rpm.

Good results are obtained by the use of a machine of the pastille-squeezing type for dehulling. It looks like an elongated box with a half-cylinder bottom made of stainless steel. On the horizontal axis, they rotate inside at a speed of about 200 rpm. beat in the form of shoulder blades. Loading of sesame seeds is about 70 / s, the duration of breaking up to 25 minutes. The machine gives good caving (under-shedding 3.5%), small losses (0.2:%); electricity consumption is about 4.5 kWh per 100 kg of dry sesame seeds. The car was proposed and installed at the Samoilova factory in Leningrad.

On the basis of the VKNII's work, the design of an apparatus for continuous sesame crushing is proposed. The apparatus is installed and (works at the Marat factory in Moscow. In the apparatus, sesame collapses while passing through a pipe, inside which on the horizontal axis there are beaters (in the form of blades inclined to the axis), (rotating at a speed of about 1000 rpm. Sesame ( after the lock is loaded continuously from one end of the apparatus and during the passage through it collapses and comes out from the other end.

After collapse, the removed shells are separated from the sesame kernels. For this, the difference in their specific gravity is used. The shell contains a lot of fiber and has a high specific gravity (about 1.5). There is a lot of fat in the kernel (the specific gravity of sesame oil is 0.92), therefore the specific gravity of the kernel is less (about 1.07). To separate the core from the shell, a liquid with an intermediate specific gravity between them is used - a salt solution (17-19%) with a specific gravity of 1.13-1.15 (at 13 °) - the so-called salt r.

The mixture of the core and the shell ("rushanka") obtained after the collapse is loaded with the said salt solution - Mix the rushanka with brine and incubate for several minutes in a vat; the seed shells sink and the kernels float to the surface. They are collected and washed (5-6 minutes) with clean cold water to remove salt. After washing, the kernels contain about 40-50% water and up to 0.05% salt (the tahini mass therefore has a slightly salty taste).

In order to remove surface-bound water, the nuclei are subjected to centrifugation (in mesh centrifuges with a speed of about 800 per minute). In this case, the moisture content of the kernel is reduced by 5-10%.

The separation of the shells from the sesame kernels and the washing of the kernels can be carried out in different installations. In the simplest cases, vats are used. Installations of continuous operation are being introduced more and more widely. The Leningrad factory named after Samoilova proposed and implemented a “ring strawing scheme”. Here, the rushanka enters the first vat with straw, then the floating core (with an admixture of the shell) is transferred over the edge of the vat (together with the salt solution) into the adjacent (lower) vat with straw and, finally, into the adjacent third vat with straw, from there to centrifuge, where it is washed with water. Solomur is continuously fed from the upper vat to the next ones, from which, after filtration, it returns back. In the apparatus of the VKNII and the Marat factory, rushanka is served from one side of the vat with straw, the separated core leaves on the other side (over the edge of the vat). The shell accumulating at the bottom is continuously removed by a rotating horizontal auger (Archimedean screw), which squeezes the saline solution out of it.

At the Samoilova factory, a new scheme of sesame crumbling without straw formation has been developed. In this case, the sesame seeds after the locks are slightly dried to a moisture content of 32-34%, then collapse, again dried, sieved. After roasting and cooling, the core is again sifted out on a vibrating sieve from the remnants of the shell (fig. 26).

The next operation - frying or drying the sesame kernel - reduces its moisture content, which is necessary for proper grinding. Heat treatment also leads to the formation of a specific pleasant taste and aroma.

Rice. 26. Scheme of sesame seed crushing without straw formation:

separator; 2-bucket elevators; 3- distribution augers; 4-lock vats; drying drums; 6-hauling machines; 7 - conveyor; 8-shaking screens; 9-farmers; 10- pump; 11 collection.

Frying the kernel is used more often. At the same time, the core temperature reaches 115-120 °, the humidity drops to 1-2%. Roasting should be regulated in such a way that overcooking and darkening of the kernel does not occur. The overcooked kernel takes on a bitter taste.

There are fryers ‘of various designs. A roaster-type apparatus is a low vertical cylinder (or cone) with a paddle-shaped stirrer mounted on a vertical axis. The roaster has double walls and is heated by steam. At the Samoilova Leningrad Factory, an installation was created from an apparatus for preliminary drying of sesame kernels, followed by frying them in a brazier. The dryer has the form of a horizontal rotating drum through which hot air is blown through according to the counterflow principle. The kernel is dried to a moisture content of 15-20%, and then fried.

At the Moscow factory named after Marat, for the heat treatment of sesame, a VIS-2 drying apparatus was used (previously proposed and used in pasta production (Fig. 27). This is a continuous dryer.

The material to be dried is periodically poured from top to bottom from shelf to shelf, and hot is supplied from below (air from

temperatures up to 130 °. The device is distinguished by its high productivity (up to 9 g per day), high efficiency and smooth operation, ensuring uniform, homogeneous drying.

Rice. 27. Dryer VIS-2. Air movement diagram.

After roasting or drying, the core should be immediately cooled to a temperature of 20-30 °. For this, the core is passed through a wake, or processed on trays with suction of air through a sieve bottom, or passed through a cooling horizontal rotating drum.

The fried (or dried) sesame kernels should be crushed to obtain a liquid mass with such a viscosity that in the future you can properly knead halva out of it. The normal viscosity of the takhin mass is about 20-25 poise at 40 °. The particle diameter should be no more than 0.1-0.3 mm.

The viscosity of the takhin mass depends not only on the degree of crushing of the sesame kernels, but also on their moisture content.

Normal humidity is not more than 1.2%. The increased moisture content of sesame kernels due to insufficient roasting (drying) makes grinding difficult and increases the viscosity of the protein mass. The finished takhin mass should contain 60-66% fat, no more than 1.5% water. The ash content should normally not be more than 3.5%, and ash insoluble in 10% HC1 should not be more than 0.1%. The acid number of fat is not more than 1.75, the peroxide number is up to 0.5.

To grind sesame kernels (and other kernels), millstones are often used, mills are farmers with vertically installed millstones. Roller mills are also suitable (see " Chocolate production"). Millstones (and other grinding devices) require correct installation and adjustment, provided that the millstones are well cut and milled under normal load of the apparatus (when the core is evenly fed for grinding in the required amount
ve). It is necessary to avoid too strong warming up of the emerging tahini mass (its normal temperature is 30-40 ° C).

The output of the takhin mass is about 70% of the weight of the sesame seed (according to the accepted standards, 1425 kg of sesame seed are consumed to obtain 1 ton of takhin mass). During processing, the shell is removed, the content of which fluctuates within 7-15%, the moisture content of the seed is reduced in comparison with the obtained takhin mass by 6-8%, there are losses of dry matter of the core (mechanical during washing, roasting, grinding and chemical during roasting) by 5- 10%. Large white-seed sesame varieties give a higher yield, as they contain less shell.

Sesame seeds and semi-finished products obtained from it should be stored under favorable conditions. These products contain antioxidants (mainly tocopherols, sesamole, etc.), so the oil in them is quite resistant to rancidity, however, high moisture content of seeds and semi-finished products, elevated temperature and the relative humidity of the air during storage adversely affect their storage capacity. Sesame seeds are stored for years without spoilage under favorable conditions (low moisture content of seeds, dry rooms with moderate relative humidity, low temperatures). Roasted sesame seeds can not stand long-term storage due to adverse changes in chemical composition fat and protein under the influence of heating. Tahini mass can be stored for several months at low temperatures. To do this, it is placed in iron barrels, which should be periodically turned over, at least twice a month. Short-term storage of the takhin mass can be carried out in tanks with a stirrer, stirring it daily. The mass is prone to delamination.

Sunflower and peanut protein masses

Protein masses and halva from them can be obtained from other oil seeds. Among them, the most important are as raw materials for the production of halva, sunflower and peanuts.

Highly oily sunflower seeds - oilseed sunflower and mezheumok are most suitable for processing into a protein mass.

The processes of hulling sunflower seeds and obtaining a pure sunflower kernel are well developed in the oil mill and can be carried out at enterprises producing low-skim cake. Seeds first, like sesame seeds, are cleaned from impurities on a separator. Then they are dried, since for better caving it is necessary that the moisture content of the seeds is no more than 12%, and preferably about 8-9%. Then the seeds are cleaned a second time from litter and small seeds (whole grain), in which the shell is poorly separated when it collapses. Oil is squeezed out of these seeds and added during grinding.

The sunflower is brought down on a whip roll - a drum with an inner corrugated surface, ‘With beats or whips fixed inside on a horizontal shaft. The seeds entering the drum from impacts on whips and the corrugated surface of the walls of the drum, as well as one against the other, are split and freed from the shells. After dehulling, the husk is winnowed (on rass * sowing wakes) for better husk removal - twice.

The cleaned kernel should be as free as possible from husks and unhulled seeds: it is assumed that their content should not be more than 5%, cut (crushed kernel) - not more than 3%. The cleaned kernel is recommended to be washed with water (in mesh tanks), which additionally removes the remaining impurities and improves the taste of the protein sunflower mass obtained in the future. Roasting, cooling of sunflower kernels, re-weaning of litter from them are carried out in the same way as when processing sesame seeds.

Grinding is carried out using mill hoops, farmers or rolling mills. The grinding method is the same as for sesame kernels, or with the addition of refined sunflower oil... Roasted sunflower kernels contain about 50% fat, and takhin mass contains 60-65%. Therefore, for the preparation of halva according to the usual recipe, the missing amount of oil is added to the mass from the sunflower kernel during grinding, about 20% to the weight of the kernel (for 843.8 kg of sunflower kernel 164.6 kg of refined sunflower oil).

Sunflower protein mass contains 1-2% water, 60-65% fat. The acid number of the fat is not more than 1.75. Husks no more than 0.3%.

To obtain 1 ton of sunflower protein mass, 1865.9 kg of sunflower seed, 164.6 kg of sunflower oil are consumed (according to approved recipes), i.e. the yield of fried grated kernel in relation to raw unbroken seed is about 39%.

Sunflower protein mass tastes different from tahini mass. It has a characteristic sunflower flavor. Sunflower halvah also has this taste, its color is grayish, and darkens during storage.

Were suggested different ways improving the quality of sunflower protein ("sub-protein") mass and halva from it. There is almost no unpleasant aftertaste if you take a fresh (not stale) kernel and do not fry it, but dry it at a temperature of 70-80 °. Therefore, one can think that the deterioration of the taste of grated fried sunflower kernels occurs due to strong heating of the kernel. The quality of the protein mass is somewhat improved if the core is treated with superheated steam. At the Samoilova Leningrad Factory, sunflower halva is prepared by subjecting the sunflower kernel to rinsing in water, then drying and frying and obtaining a proteinaceous mass from it. This method is used in other factories as well. Other methods of processing sunflower kernels were proposed (by individual inventors and VKNII) in order to improve the taste of halva:

Rice. 28. Scheme of in-line processing of peanuts:

1, 9 - bucket elevators; 2-fryer; 3, 6, 8, I, 13-bunkers: 4-receiver;

5 - cooling conveyor; 7-wheel maiina; 10-winnower; 12- distribution auger; 14-farmers for grinding; 15-conveyor; sixteen- collection.

re acetic acid (0.15%); biochemical treatment by adding liquid yeast to the sunflower kernel; processing of sunflower kernels with a weak 'solution of the enzyme pepsin with the addition of hydrochloric acid. Verification of the proposed methods does not give reason to believe that any of these methods allows obtaining quite high-quality sunflower halva, which is not inferior in taste to takhin halva.

Peanut protein mass is obtained according to a scheme slightly different from the scheme (production of tahini mass.

After cleaning from impurities on winners, the peanuts are brought down in peanuts or other similar dehumidifiers used in the oil industry. Next comes the roasting and grinding of peanut kernels. Confectionery factories often receive already husked peanut kernels, so the processing process does not include a hulling step.

At the Samoilova Leningrad Factory, a peanut mass production line was created (Fig. 28). Peanuts (shelled) come from the warehouse via a bucket elevator to be roasted in rotating fired roasting drums (such as cocoa roasting drums). The final temperature of roasted peanuts is 110-420 °. It is fed to a conveyor (25 meters long), where it is cooled by a counterflow of cold air to a temperature of 50-55 ° (at the exit). The chilled peanuts are fed into a crumbling machine (like a pastille used to crush sesame seeds). Here the skin is removed from the peanuts. Then, on a winnower, the peel is dislodged from the kernels. Further, the peeled kernels are transferred to the farmers for grinding with the help of an elevator and a distribution auger. From there, the peanut protein mass enters the receiving collector and then is pumped through pipes to the halvah shop for the production of halva.

Peanut protein mass usually has a bean and bitter flavor.

Various processing methods have been tested and proposed to improve the flavor of the peanut protein mass.

An improved method of obtaining peanut protein * mass should include, according to the work of VKNII, the following processes. First of all, it is necessary to separate the skin (film) and germ from the peanuts after roasting. Peanut skins contain tannins and other substances that impart an astringent and bitter taste to products. The peanut germ also tastes bitter. Removing the skin and germ before grinding significantly improves the flavor of the grated peanut mass. This separation is easily carried out on a crushing and sorting machine (for cocoa beans). Good results are also obtained by processing peanut kernels before frying with a solution of sodium chloride. It improves the roasting conditions, reduces the bean flavor even with moderate roasting (drying) of the peanut kernels, and delays the appearance of the bitter taste even with some overcooking of the peanuts. In addition, small amounts of table salt in peanut protein mass (as in other masses from grated roasted nuts) improve their taste.

The processing consists in the fact that peanut kernels are moistened with a solution containing 4-6% sodium chloride. The core completely absorbs the solution added in an amount of 6- ^ 8%. This is followed by roasting, separation of the skin and embryo, grinding the grains to obtain a peanut protein mass. It contains 0.2-0.4% salt and has an increased taste. Peanut protein mass with improved taste as a result of this processing can be used to make not only halva, but also candy masses, filling for caramel, etc.

Salt processing before frying can be carried out, for example, in pannets, wetting the peanuts with a salt solution gradually, while continuously rotating the pan and stirring the kernels. They immediately absorb the solution, slightly moistening.

At the Marat factory, short-term processing of peanut kernels in a salt solution (solomiration, like sesame seeds) is used, followed by washing in water, centrifugation, frying and winnowing the peel on a wake. Peanut protein mass contains 1-2% water, about 50% fat.

Soy protein mass. Soy can be successfully used for making halva. The Moscow Food Concentrates Plant has developed a method for producing soy halva of quite satisfactory quality, without a specific soy flavor. Soybeans are first deodorized by steaming it for 50-60 minutes. with a steam pressure of no more than 0.8 atm. After steaming, the soybeans are ventilated (shoveled on wooden tables), and then fried and crushed, adding 45-50% vegetable oil during grinding (to the weight of the kernel). For 55 weight parts of protein soybean mass take 45 weight parts of the knocked down caramel mass.

To obtain halva, hazelnuts are processed according to the method described above for sunflower and peanut kernels. Heat treatment is given in the form of a moderate frying.

Cashew nuts (chapter "Production of sweets with a nut base") are also suitable for halva, as shown by tests carried out at the factory named after Samoilova. They contain, like peanuts and sunflower kernels, about 50% fat, so vegetable oil should also be added to the protein mass (about 20% by weight of the kernel)

You can get a protein mass from a mixture of protein masses, for example; peanut-takhin mass and halva from it.

Preparation of a decoction of soap root or other foaming agent

A decoction of the soap root is used in the production of halva as a foaming agent.

Soap root is the root of the soapwort plant (Saponaria officinalis), which grows in Ukraine and Central Asia.

Other types of soap root are also used, for example Levantine (plants Gypsophila stratium).

Soap root contains glucoside saponin in an amount of 4-5%. General empirical formula of saponins С n Н 2n-8 О 10. Saponin of the Levantine soap root is credited with the formula C 17 H 26 O 10 + H 2 0. When hydrolyzed, saponins, like all glucosides, give aglucones (sapogenins) and several sugars - glucose, galactose, arabinose, and methylpentose. Saponins have a high surface activity, they greatly reduce the surface tension, their solutions give abundant and persistent foam. Saponin preparations (in the form of a decoction of a soap root) therefore find practical application as a foaming agent in fire extinguishers, as a detergent (for example, for silk fabrics). Saponins have a hemolytic effect, that is, they cause the dissolution of red blood cells. This action is largely paralyzed in the presence of fats and their accompanying lipoids (lecithins) and sterols. Therefore, when making halva, it is allowed to use the soap root decoction only in small quantities. The Scientific Medical Council allowed no more than 0.03% saponin in halva. For others confectionery the use of soap root is prohibited.

Soap root comes into production in the form of dried pieces 15-20 cm long. Its moisture content should not exceed 13%. The roots should not have mold or other signs of deterioration.

A decoction of the soap root is obtained on the basis of the diffusion of saponin (together with other water-soluble substances) from the tissues of the root into water heated to accelerate diffusion. The soap root is soaked in water at 60-70 ° for 10-15 minutes, then crushed into small pieces (3-4 cm long), washed in water and placed in a digester, poured with water and exposed for a long time, for 5-6 hour. digestion. When a sufficient amount of soluble substances passes into the broth and its specific gravity reaches 1.05, the digestion is completed. The broth is drained and filtered through a mesh to free it from root particles. The soap root is re-boiled (3-4 times). The specific gravity of the second and subsequent decoctions should be at least 1.01. All decoctions are collected together and boiled down to a specific gravity of 1.05. The finished broth should not contain particles of soap root, there should be no moldy smell or unpleasant foreign smell. The color of the broth is dark brown; with a specific gravity of 1.05, it contains about 10% of dry substances, at least half of which is saponin. The output of the broth is about 25% of the weight of the soap root.

The broth quickly (after a few days) deteriorates, becomes moldy; therefore it is received as needed, without storing it up for future use.

In addition to the decoction of the soap root, which is usually used as a foaming agent in the production of halva, other foaming agents have been tested and proposed.

Beet extract (VKNII) can be used as a foaming agent. You can knock down the caramel mass for halva on egg white and blood albumin.

Satisfactory results were obtained when testing (at the suggestion of VKNII) licorice extract (from licorice root), which has a large foaming ability due to the glycerrhizin (potassium-calcium salt of glycerrhizic acid) it contains. The taste of halva is quite satisfactory, but the halva is slightly darker in color. Licorice extract, which has a characteristic aroma and sweet taste, is used in foreign countries in the confectionery industry for the manufacture of sweets and caramel with a specific aroma and taste.

The protein preparation VNIRO, obtained from (fish (cod) and whale meat, has a significant foaming ability and makes it possible to obtain halva of satisfactory quality when used in an amount of about 0.1% by weight of halva, but it sometimes has a fishy smell.

Milk frothers (from skim milk) can also be used for churning caramel mass in the production of halva.

The decoction of the soap root, however, in comparison with the listed foaming agents, has the advantages of greater simplicity and reliability of production, and a low cost of the initial product - the soap root.

Cooking caramel mass

The caramel mass for making halva should have slightly different properties than the usual one. When kneading, it should retain plasticity for a long time, not harden and have increased resistance to crystallization, as it is exposed to prolonged mechanical stress - churning and kneading. Therefore, a lot of molasses is introduced into the recipe for the caramel mass: for 1 part of sugar, 1.5 and even 2 parts of molasses are taken (according to the approved recipe, 1.88 parts of molasses). The caramel mass is boiled down to a moisture content of 4-5%.

The caramel mass can be prepared with invert syrup added instead of all or part of the molasses. In this case, halva turns out to be worse - more hygroscopic and darker, with a less developed fibrous structure due to the lower viscosity and plasticity of the caramel mass on invert syrup. To increase the viscosity of such a mass, ‘use a stronger boiling it down to a moisture content of 3-4%. Invert syrup is introduced (In such an amount that the caramel mass contains 35-38% of reducing substances.

The quality of the caramel mass with invert syrup is significantly improved when using modifier salts with buffering properties - sodium salts of organic or weak mineral acids allowed in foodstuffs: sodium lactate, sodium citrate, etc. Adding these salts in small amounts (0.01-0.3%) to syrups containing sugars, invert sugar and molasses, increases pH, reduces the amount of reducing substances in the resulting caramel mass and its hygroscopicity , increases the viscosity of the syrup and mass, as can be seen from the table. 27 and 28.

Table 27

According to the increase (in%) of weight after two days of storage over a saturated solution of KCl at a relative humidity of 85%.

In the practice of the Leningrad confectionery factory named after Samoilova, the regular use of sodium lactate when cooking caramel mass for halva from sugar, invert sugar and molasses made it possible to produce caramel mass and halva of normal quality, with the content of reducing substances in the caramel mass within 25-27:%, while without sodium lactate the amount of reducing substances in these conditions increased to 40-45%.

Syrup composition: sugar 1000 kg, molasses 600 kg, invert syrup on lactic acid 800 kg

For cooking caramel mass, use / vacuum apparatus used in caramel production.

Knocking down the caramel mass with a decoction of the soap root

The caramel mass is knocked down in order to obtain a more porous, mobile mass, easily mixed with tahini or other protein mass and giving a better halva structure, with a more stable layered fibrous structure. When knocked down, the caramel mass is saturated with air, which is distributed in it in the form of small bubbles, and acquires a weakly pronounced foam-like structure. The specific gravity of the caramel mass is about 1.5, after churning - about 1.1; thus, the air in the knocked down caramel mass occupies approximately (105-1.1) / 1.5 * 100, i.e., about 26-28% of the volume, the specific weight of the drawn caramel mass used in caramel production is about 1.22 and , therefore, the volume of air in it is about 19-20%. To obtain the required porosity of the caramel mass in the production of halva, it is not enough to simply drag it; it is necessary to introduce a foaming agent in the form of a decoction of a soap root.

When knocking down the caramel mass, the introduction of surface-active saponin contained in the decoction of the soap root makes it possible to obtain a sufficiently porous and stable structure with evenly distributed small air bubbles. The role of saponin is to create an adsorption film on the surface of air bubbles, as a result of which it is easier to obtain a foamy structure and its destruction is hampered (foam stability is ensured). About 2% of the soap root decoction is added to the caramel mass.

Rice. 29. Cauldron for churning caramel mass

To churn the caramel mass / use a steam-heated cooker (Fig. 29). Inside, on a horizontal shaft, spade-shaped beaters are fixed, located at an angle of 120 ° to each other. The shaft rotates at a speed of 100-120 rpm, while the beater knocks down the caramel mass. The boiler is closed from above with a cap to prevent splashing of the whipped mass. Churning continues for about 15 minutes, while the caramel mass is heated. Its temperature during churning is 105-110 °. Readiness is determined by the organoleptic characteristics of a sample taken from the boiler: the mass should be white and drawn into a long and uniform thread. Insufficiently knocked down caramel mass has a yellow color, low splendor, the thread is drawn from it relatively short, uneven in thickness. From such a mass, halva turns out to be dark, non-fibrous.

More precisely, the readiness of the whipped caramel mass is determined by its specific gravity, which should be close to 1.10.

The knocked-down caramel mass is unloaded from the churning boilers through the fitting at the bottom and transferred further to kneading.

If the caramel mass is cooked not in a vacuum apparatus, but in an open kettle, then a decoction of the soap root is added during cooking. When the boiling point of the syrup reaches 118 °, they begin to knock down the mass, continuing further boiling.

Kneading halva, packaging, packaging

The task of the kneading process is to achieve a uniform distribution in halva of two components - tahini (or other protein) mass and caramel mass - and obtain a homogeneous layered fibrous structure. This is achieved by pulling the caramel mass to form fibers.
hence, between which the protein mass is placed (mass. Caramel mass (receives, when mixing, a highly developed surface on which the protein mass is distributed, retained in halva mainly due to the presence of a solid frame of caramel mass fibers. The protein mass is to a certain extent related to the surface forces.

With a large amount of takhin mass (60 parts per 40 parts of caramel mass), halva turns out to be soft and very fatty (fat is poorly retained in halva). If the takhin mass is small (40 parts per 60 parts of the caramel mass), then the halva turns out to be dry and very hard. The normal consistency of halva (it is well cut with a knife, almost does not crumble and is not too greasy) is obtained with a ratio of 53-55% of tahini mass to 47-45 parts of caramel mass. With a decrease in the fat content of the protein mass (for example, in the protein mass from sunflower and peanut kernels, prepared without adding vegetable oils), it is advisable to increase the amount of protein mass to 55-60 parts in parallel with a decrease in the caramel mass to 45-40 parts. With such dosages, halva will no longer be too oily and soft.

To obtain a good layered fibrous structure, halva is usually kneaded in several stages. At the beginning of kneading, the caramel mass has a high (about 80-100 °) temperature, it is easy to move and has little plasticity. The protein mass should have a temperature of 40-45 °. During the first kneading, mixing of the caramel and protein masses is achieved with the formation of a doughy mass with large caramel fibers without sufficient homogeneity.

With manual kneading after the first kneading ("mixing"), the mass is cooled to a temperature of 75-80 °. At the same time, the viscosity of the caramel mass increases and during the second kneading ("stirring") longer, non-torn threads are formed. They persist in the future in halva due to the increased plasticity of the caramel mass and the presence of fatty layers between the threads, which prevent them from sticking together. After the second batch, the mass is cooled to 60-70 °, its viscosity increases significantly. Then carry out the final kneading (or "pulling" the mass). Caramel threads even more stretched and halva gets the required fine-fibrous structure. Halva after the final kneading should have a temperature of 55-60 °. Its viscosity (plasticity) is so high that the formed structure is retained with further gradual cooling. The duration of the halva kneading is usually from 7 to 10 minutes. Use tin-plated metal bowls for mixing. At the same time, about 40 kg of tahini mass and knocked down caramel mass are loaded into the bowl.

In a warm form at a temperature of 55-57 °, halva in a plastic state is weighed out and placed in cans or boxes, which are lined with “parchment, parchment, glassine or cellophane. in parchment or cellophane, or other greaseproof casing with a label (net weight 100 to 500 g).

Rice. 30. Diagram of a kneading machine with a bowl.

Manual processes of kneading halva have been replaced by mechanized ones in large factories. At the Marat factory, devices such as concrete mixers are used to knead halva, where the knocked down caramel mass and protein mass are loaded. The stirrer rotates at a low speed (about 12 rpm), all mixing (the first two stages in one step) lasts no more than 5 minutes. The mixer is then overturned, without stopping the rotation, and the halvich mass is unloaded onto the table, where it is additionally thrown over and then (packaged. At the Leningrad factory named after Samoilova, it was carried out (based on the work of VKNII) mixing halva on the XMT kneading machine, adapted for this operation (Fig. 30) .The protein and caramel mass is loaded into the bowl of the machine and kneaded while the bowl rotates and the kneading lever works. The kneading time is 1 min., The mass temperature after kneading is about 75 °. the hopper of the pulling mechanism (Fig. 31). In it the mass goes down an inclined descent with a corrugated surface. In this case, tensile forces are created in the mass, as a result of which The general scheme of halva production is shown in Fig. 33.

Rice. 33. Scheme of production of takhin halva (before obtaining takhin mass):

1, 4, 10, 19, 23, 26, 28-bucket elevator; 2-separator; 3, 9, 18, 21, 22, 25-conveyors; 5, 7, 29 - distribution augers; 5-tanks for the lock; 8-hauling machines; I-A, B, V-straw installation; 12-seed separator; 13-auger: 14-seed distributor; 15- salt solvent; 16-centrifugal pump; / 7-centrifuge; 20-drying drum: 24 - fryer; 27 - cooling drum; 30 - farmer.

Features of the production of various varieties of halva

Takhinny (or sesame) halva can be prepared both without additions and with the addition of flavorings and other raw materials: vanillin (about 0.03%), cocoa powder (about 3%), nuts (about 10%). All additions, both in tahini and in other types of halva, are introduced into the protein mass before kneading.

Sunflower and peanut halva can be made without additions and with the addition of vanillin, as well as other flavors.

Hazelnut halva is produced with vanilla, (you can add other additions to it.

All of these types of halva can be made with the addition of vitamins, mainly fat-soluble, A and D , which are introduced into protein masses.

Kos-halva is prepared from knocked down caramel mass (horde), into which aromatic substances (essences), nuts (for example, pieces walnuts, which spread the surface of halva).

Halva usually does not withstand long-term storage. The most common defects that appear during storage are surface humidification, darkening of halva, fat leaking from it and its rancidity.

The presence of fat somewhat protects halva from moisture. However, the caramel mass in halva is highly hygroscopic due to the significant content of reducing substances in it. Therefore, the surface of halva in conditions of high relative humidity during storage in a raw container or during sharp temperature fluctuations is subject to soaking, the humidity of the surface layer reaches 10-12%. To avoid this, the humidity in the room should not exceed 75%, the container must be dry. Moistening the surface of halva usually causes it to darken, especially in sunflower halva. The reason for the darkening is, apparently, the formation of melanoidins due to the interaction, at high humidity, of amino acids and proteins contained in the protein mass with the sugars of the caramel mass.

Rancidity of fat in halva is relatively slow, especially in tahini halva. Sesame and sesame products contain antioxidants; in addition, rancidity appears to be inhibited due to the protective effect of sugar.

Losses from oil leakage in halva reach 3-3.5% per month of storage at 20 ° C. A slight decrease in temperature delays the flow of oil; at 10-12 losses per month do not exceed 2%. The use of greaseproof paper (parchment) or film (cellophane), as well as tinplate when packing halva helps to reduce fat loss during storage.

The rate of fat flowing out of halva depends on many reasons. The methods of making halva, especially the conditions for roasting kernels, grinding them, kneading halva, have a strong effect on the rate of fat flow. The composition of halva is also of great importance. So, adding powdered milk and milk proteins to halva delays the flow of fat from halva. New in the organization of halva production, ed. Technical management MG1PT USSR, Exchange of production and technical experience. M., 1956.

A. G. Terent'ev, Pstbchnaya line for processing peanuts, "Bakery and confectionery industry", 1958, No. 8, p. 37.

I.A. 3.1953.

VS Gruner, MI Soboleva, NA Gildebrandt et al, Obtaining a caramel mass using sodium lactate and other modifier salts, ed. NTO food industry, M., 1958

A. G. Terentyev, Flow mechanized line for packaging and wrapping halva, "Bakery and confectionery industry

Halva refers to various types of confectionery products that are made from roasted and crushed kernels of oil seeds or nuts, mixed with a caramel mass, knocked down with a foaming agent. It is thanks to the latter that halva has a characteristic layered fibrous structure. Halva is of several types, which differ depending on what kind of oil-containing seeds or kernels it consists of. In particular, you can find sunflower, peanut and soy halva on sale. Halva, which is made from sesame seeds, is called tahini. Halva based on oil seeds and nuts contains three main components: protein mass (paste from oil seeds and nuts), caramel mass (sugar and molasses), honey (this ingredient is not used in industrial halva) and a frother.

The last ingredient is licorice root, soap root (thistle root), marshmallow root and egg white... Sometimes other components are added to halva - flavors, dyes and flavorings. Basically, natural ingredients are used, such as vanilla, cocoa powder, chocolate, pistachios. The protein mass for tahini halva is made from ground sesame, and for sunflower - from ground sunflower seeds. Peanut halva is made from chopped peanuts. There are also combined types of halva - for example, tahini-peanut. Nut halva, made from almonds, cashews, walnut, peanuts, etc., is less common than other types of this confectionery product, which is due to a more complex and expensive production technology and, consequently, a higher production cost.

The halva production process includes several main stages that are common for confectionery products of this type: preparation of grated masses, obtaining caramel mass, preparation of soap root extract, churning of caramel mass with soap root extract, kneading halva, packaging and packaging of finished products. So, in the production of halva, grated masses are first prepared. They are based on finely ground oil-containing seeds of sesame, sunflower, peanut, etc. To prepare the grated mass, the seeds are first thoroughly cleaned of their peel and various impurities. Removing the seed coat in professional jargon is called caving. The peeled kernels are freed from the shell, heat treated (roasted) and crushed (ground to a homogeneous mass). The technology for obtaining grated masses may differ slightly, depending on which crops are used in this case. So, for example, when making takhin mass, one must take into account the fact that the shell of sesame seeds adheres to the core quite tightly. It is much more difficult to separate than, for example, sunflower seeds. Therefore, to facilitate this procedure, peeled sesame seeds are first soaked for 0.5-3 hours in containers with a capacity of 100-1500 liters, filled with water heated to a temperature of 50 ° C. Then the casing is separated (crushed) from the seeds on continuous machines. The separation occurs as a result of friction of the seeds against the walls of the tank body. The collapse process is based on the difference in the density of the shells and cores. A kernel that contains enough a large number of fat, has a density of 1070 kg / m3, and the shell, which consists mostly of fiber, has a much lower density - 1500 kg / m3. The seeds, including the kernels and the shell, are placed in a solution of table salt with a density of 1120-1150 kg / m3, which is called solomur. In straw, due to the difference in density, the kernels float, and the seed shell settles at the bottom. In order to separate them, machines of periodic or continuous action are used. Then the kernels are thoroughly washed from salt, and the water is removed from them using centrifugation. At the next stage, the kernels undergo thermal treatment - they are fried at a high temperature. This is necessary to reduce the moisture content of the kernels, as well as to give them a pleasant taste and aroma.

Roasting is carried out in braziers, in dryers (mine, wind), in airslides, in boilers with stirrers, etc. The temperature of the heat carrier depends on the design of the apparatus used for roasting and can range from 150 to 300 ° C. For roasting sesame seeds, experts recommend using soft modes - no more than 150 ° C.

The roasted seeds are cooled and ground at the same time using disc, roller or pin mills. The process of preparing protein mass from sunflower is somewhat simpler. First, sunflower seeds are peeled, then they are dried and crumbled. The shells of the seeds are winnowed off on the seedlings, the kernels are cleaned under water from the remnants of the shells. The peeled seeds are dried, roasted and crushed. To obtain a peanut mass, peanut kernels are fried, the film is removed from them (after heat treatment it is removed much faster and easier), and the nuts are crushed.

Simultaneously with the production of the protein mass, the caramel mass is prepared. The caramel mass is often used for the production of various confectionery products, but special requirements are imposed on the mass that is used to make halva. First of all, it should not solidify upon cooling, retain its plasticity, and be resistant to crystallization. In order for the syrup to have all these properties, more molasses is added to it. The ratio is 1.5-2 parts molasses to one part sugar. The syrup is boiled in special vacuum apparatus until the dry matter content in it is 94-95%. In this case, the mass will more easily go astray with foaming. In addition, the subsequent kneading of halva is greatly facilitated.

As mentioned above, the characteristic layered fibrous structure of halva is imparted by the foaming agent. As the latter, a decoction of a soap root (the root of a plant called soapwort) is most often used. This herbal component contains up to 5% saponin surfactant. First, the roots of the soapwort are washed in running water, and then cut into small pieces. They are boiled 3-4 times to obtain a decoction. Then the broth is filtered and boiled down to an extract with a relative density of 1.05. Soap root extract in the amount of 2% of the total mass of the product is introduced into the caramel mass in closed digesters. At the same time, the caramel mass is knocked down within 20 minutes at temperatures up to 110 ° C.

Finally, all components, including the protein mass and the whipped mass from the soap root extract and the caramel mass, are mixed together on kneading machines. The amount of protein mass is about 60%, and the amount of caramel mass is 40%. At this stage, flavors and flavorings are added to the mass. Stirring, carried out at a temperature of about 65 ° C, is necessary for the uniform distribution of the protein and caramel masses, as a result of which a layered fibrous structure of halva is formed. In some cases, the finished halva can be sent for additional processing (for example, cutting into small pieces, after which the small-piece halva is glazed with chocolate). Then halva in a plastic state is weighed and packed into boxes, which are covered with parchment or parchment, in cans, in packs of greaseproof paper or cellophane. Packaging is made using special equipment. First, the bowl with halva is installed in a lift, which then transports the halva to the dispenser of the packaging machine. Halva is often packed in 300 grams each in PVC film boxes, which are then covered with heat-sealable foil. These boxes are then placed in corrugated boxes and sent to the warehouse.

Special requirements are imposed on the storage conditions of the finished product. Halva cannot be stored for a long time, since during storage its surface is moistened and fat leaks (the higher the amount of reducing substances in the mass, the shorter the shelf life of the finished product). In warehouses, the relative humidity should not exceed 70-75%, and the air temperature should not exceed 18 ° C. The room must be clean, dry and well ventilated. Most of the halva species have a shelf life of up to 1.5 months, subject to all conditions.

Takhinny and glazed halva chocolates are stored a little longer - up to 2 months. The halva production shop consists of three sections: a seed preparation shop, a production section and a section for packaging and packing of finished products. Its area should be about 250 sq. meters. The main requirements are the availability of electricity, hot and cold water, sewerage and heat supply.

So, the main ingredients for the production of the most common type of halva - sunflower, are: molasses, sugar, sunflower seeds, soap root (licorice root extract), flavoring and aromatic substances (vanillin, cocoa powder, raisins, etc.). For the production of halva, you will need special equipment. On sale can be found as equipment Russian production and lines from Western manufacturing companies. The minimum cost of an automated line of European production is 4 million rubles. A semi-automatic line from Russian companies will cost at least 1.2 million rubles. The productivity of the line of the latter type is slightly less than 1000 kg of halva per 8-hour work shift.

It includes the following equipment: a crushing machine, a hobbing machine, a hammer mill, a calibrator, installations for roasting and cooling seeds and nuts, a caramelizer, baths for kneading halva. With the help of such equipment, it is possible to produce halva of several types: sunflower without or with various fillers (including raisins and peanuts), peanut halva, vanilla, glazed in chocolate, etc. You will also need to purchase a line for packaging finished products. In equipment of foreign production, this line is usually included in the set. The packaging line includes a packaging machine, a labeling machine and a thermal transfer printer. The average cost of such a line is 1 million rubles.

To work in a shop with such volumes of production, a staff of 5-6 people will be required: a technologist, a foreman and workers. Finished products is sold through regional retail chains, as well as through wholesale companies that supply their products to individual grocery stores.

The retail cost of halva is from 100 rubles per kilogram. Wholesale halva is sold at a price of 50 rubles per kilogram. The cost of making halva at average prices for raw materials in the regions is 25-30 rubles per kilogram.

Thus, with the sale of more than 20 thousand kg of halva per month, the proceeds of the manufacturing company will amount to more than 1 million rubles. With investments of about 3 million rubles. net profit the enterprise reaches 150 thousand rubles. per month. The payback period of the project with such initial data is 1.5-2 years.

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