Pasta has long become a familiar and popular type of garnish in our country. Main advantages pasta- quick preparation and affordability. In addition, not without the participation of the producers of these flour products, the "image" of pasta is gradually changing. If earlier they were considered not the most wholesome food and were not recommended for people who are on a diet, now they are gradually acquiring the status useful product, thanks to the fashion for Italian cuisine... The demand for pasta grows especially during economic crises, when consumers stock up on products with a long shelf life.

The pasta business was considered very profitable just a few years ago. For the organization " pasta shop»Several thousand dollars are required (a relatively small amount for a manufacturing enterprise). The technology for making pasta is relatively simple. The payback period for such a business is short, and the profitability is high (about 30% in normal times and up to 80% in "hard times"). Therefore, there is nothing surprising in the fact that every year the number of players in this market is increasing two to three times. It is all the more unsurprising that soon this led to a crisis of overproduction (about 30% of domestic production capacities quickly became excessive), which is due to the fact that the volume of pasta production exceeded the volume of consumption.

Experts identify the following price segments on the pasta market:

• economy class (lower price segment). This group includes pasta category "B". Their share is over a third of the market (about 350 thousand tons).
• mid-price segment. This group includes packaged group B pasta. The share of this product on the market is about 25% (200 thousand tons). Such pasta is packaged in packages weighing from 400 grams to one kilogram.
.
• "Average plus". This group includes category "A" pasta, which are made from hard varieties wheat. Products of this category occupy about 35% of the pasta market share (300 thousand tons). It is these pasta that, for the most part, are packaged in polypropylene bags weighing up to one kilogram and sold under various brands.
• premium segment. This includes pasta category "A", mainly Italian producers (or Russian, but "masquerading" as Western in the name and design of the package). The products of this group have a small market share - about 5% (45 thousand tons). The cost of a half-kilogram pack of premium pasta starts at 55 rubles.

In the pasta market, as well as in the food industry as a whole, the majority of consumers (from 70 to 80% according to various sources) prefer middle-class products. At the same time, consumers in this segment, as a rule, do not have pronounced brand preferences. On the other hand, if the price-quality ratio of a particular product suits customers, then they willingly show loyalty to this brand, continuing to buy its products in the future. During crises, it is mainly the mid-price and premium segments that suffer. However, it is the production of group A pasta, which is made from durum wheat using imported equipment and raw materials, that is considered the most promising direction among entrepreneurs. If the low- and middle-price segments have long been filled and the competition there is too high, then expensive domestically produced pasta (including a new brand) may well compete with Western products not only in quality, but, more importantly, in price. Until recently, this segment consisted mainly of imported pasta, but recently the volume of their deliveries has noticeably decreased. The second most attractive segment is low-quality pasta made from soft wheat. In just two years, their market share increased from 40 to 55%. True, since 2011, the pace of development of this segment has slightly decreased, but it still accounts for most of the sales. According to analysts, there are less than 200 players on the pasta market now, including small producers.

Let's consider in more detail the main trends in the development of the industry. An excessively large selection of various pasta products has led to the fact that manufacturers are gradually moving from price to non-price competition, creating their own brands at the federal level. This tendency is inherent in more civilized market relations. The assortment of manufacturers consists mainly of mid-price segment pasta (costing from 35 to 125 rubles per pack). The development of the pasta industry directly depends on the suppliers of raw materials. Since flour acts as the main component for the production of pasta, the cost finished products completely depends on the pricing policy of flour mills. This is especially critical for products in the mid-price segment. For this reason, large producers, hoping to receive guarantees of timely supplies of raw materials of appropriate quality, are beginning to create grain holdings. These mergers significantly increase production margins - up to 5% by optimizing logistics processes and reducing the likelihood of supply disruptions. On the other hand, it is obvious that these measures are not suitable for medium and, moreover, small industries, and it is in these segments that the competition is most intense. Under such conditions, analysts are sure that in a few years only about five of the largest manufacturers will remain in the industry. But so far, the pasta business has not lost its appeal for small companies. The average consumption of ordinary pasta in our country reaches over 7 kg per year per capita. At the same time, for noodles and vermicelli fast food this figure is almost 8 kg per person per year.

Pasta is dried unleavened dough from wheat flour of special grinding and water, which is formed in the form of tubes, ribbons, threads or other shapes, and dried to a residual moisture content of 13%. Some pasta, due to low humidity, can be stored under appropriate conditions for a year without losing most of its consumer properties. Pasta varieties depend on their composition, calorie content and nutritional value. Pasta of each grade, depending on the standard, can be of one of four types: tubular, curly, thread-like and ribbon-like. Moreover, each of these types has its own subtypes and types, depending on the length, width and diameter of the product. Instant pasta, which stand out in a separate group, have a porous structure and various enrichment additives in their composition, so they do not require cooking. The main flour raw materials used in pasta production are flour and water. The most suitable raw material for the production of pasta is durum wheat flour (durum) for pasta, flour top grade increased dispersion from durum wheat, soft glassy wheat flour, bakery wheat flour and premium flour (grains), selected during bakery grinding. In this case, the flour must be necessarily cleaned of metal impurities and in some cases can be additionally enriched with vitamins (for this, heat-resistant water-soluble vitamins B1, B2, PP are used). The moisture content of the flour used should not exceed 15.5%, and the gluten content in it should be at least 28%. Pasta made from premium bakery flour is usually light cream in color, while products made from first grade flour are dark cream in color with a gray tint. Drinking water, which is used to prepare the dough, must also meet certain requirements, be epidemic safe, harmless chemical composition and taste good.

In addition to the main raw materials - flour and water, in the production of pasta, various additional components are used to improve the taste and quality of products: chicken eggs, egg melange, egg powder, dairy products (whole dry or skimmed cow's milk), vegetable products (concentrated tomato juices and pastes, natural juices with carrot and beet pulp). In addition, food colors can be used in the production of pasta - certified synthetic (for example, tartazine) or natural (for example, beta-carotene). Both tartazine and beta-carotene impart a pleasant yellowish color to the products.

Surfactants are used as improvers, which help to improve the quality of pasta, preventing them from sticking together during drying and helping to better maintain their original shape during cooking. In the manufacture of pasta for dietary and baby food they may contain vegetable and fruit puree, iron glycerophosphate, etc. Group A pasta is made from durum wheat flour (durum) or high-dispersion flour from durum wheat, group B products are made from soft flour glassy wheat, group "B" - from bakery wheat flour.

Pasta of each grade is subdivided according to the standard into four main types, depending on their shape: tubular, curly, thread-like, ribbon-like. Moreover, each of the types is subdivided into subtypes, depending on the length, diameter and width (pasta, feathers, horns). Pasta are long, straight-cut tubes. Their length can vary from 15 cm to 30 cm (short pasta) and from 30 cm (long pasta). In this case, pasta of the latter type can be double bent or single. Depending on the diameter, pasta is divided into straws (4 mm), special (4.1-5.5 mm), ordinary (5.6-7 mm) and amateur (over 7 mm). The feathers are tube-shaped pasta with an oblique cut. The length of feathers from an acute angle to an obtuse one can range from 3 to 10 cm. The types of such pasta depend on their diameter (special, ordinary and amateur) and sectional shape (round, square, embossed, etc.). Horns are pasta in the form of short, curved tubes with a straight cut. Their length along the outer curve is from 1.5 to 10 cm. Depending on the diameter, there are straw horns, special, ordinary and amateur. Thread-like products include vermicelli, which can have a different sectional shape: round, square, ellipsoidal, etc. Vermicelli is divided into the following types depending on the size of the section: spider web (0.8 mm), thin (1.2 mm), ordinary (1.5 mm), amateur (3 mm). Ribbon pasta is also called noodles. Noodles can be smooth or corrugated with straight, paw-like or wavy edges of various lengths (long - from 20 cm and short - from 2 cm). Figured products are produced in the form of shells, letters, ribbons, stars, gears, etc.

The recipe for pasta dough depends on the quality of the flour used, the type of pasta, drying methods and other factors. When compiling a recipe, it indicates the amount and temperature of flour and water, humidity and temperature of the dough, dosage of additives, if any. The technology for the production of pasta has some nuances. For example, there are two ways of storing flour in the warehouses of industrial enterprises - container, in which flour is stored directly in bags, and bulk method, in which flour is poured into a bunker (silo). The bulk method of transportation and storage of flour raw materials is considered better, since when using it, the amount of manual labor and additional losses of flour associated with its spraying or residues in bags are minimized. In addition, the cost of packaging production (sewing bags) is reduced. Before the flour is sent to production, it is carefully sieved to separate metal-magnetic impurities from it, heated to 10 degrees Celsius, samples from different batches are mixed to improve quality indicators. Then a predetermined portion of flour is loaded into the bunker of the mixer, and then drinking water is gradually introduced into it (sometimes water is pre-mixed with additives), in accordance with the recipe. Then the dough is kneaded for 8-10 minutes, fed to the matrix with the help of an auger and pressed through its holes. Products emerging from the matrix are blown with air from a built-in fan. The products are automatically cut into predetermined lengths, laid out on a tray, which is placed on the rack of the press machine table for preliminary drying. Final drying is carried out in an oven with thirty trays. Each tray can hold up to two kilograms of pasta. Pasta is dried for 50-60 minutes (the exact time depends on the type of product) until its moisture content reaches 19%. Then the pasta is packaged in a cardboard container, where it is naturally dried at a temperature of 25 degrees in a ventilated room. When the moisture content of the products reaches 13% (this takes at least four hours), they can be sent for packaging. But before that, they undergo an examination, where they are examined. appearance, taste and smell. Inspectors check products for substandard (broken and deformed pasta), crumbs, assess the moisture content of the products, their acidity, digestibility, the absence of granary pests and metal impurities, and strength. Pasta from batches that have passed the examination are packed in polypropylene bags using special filling and packaging machines.

To organize the production of pasta, special lines will be required. You can purchase both a semi-automatic line with a capacity of about 100 kg of products per hour (about 500-700 thousand rubles), and a fully automatic equipment with a capacity of about 500 kg of products per hour and a cost of 375 thousand euros. Required set equipment includes a press, a flour sifter and a drying line. Large capacity lines are usually equipped with conveyors and a stabilizing hopper. Presses are supplied with special dies (the exact set depends on your assortment). One matrix for the production of one type of product will cost 3-5 thousand rubles. It is enough for 500-2000 working hours, depending on the line load. In addition, you will need equipment to pack the finished products. Depending on your budget, you can choose semi-automatic, automatic equipment or a whole line (the latter option is suitable for large production volumes). As mentioned above, before packing, finished products are kept for several hours in cardboard boxes. This stage can be significantly reduced by using special equipment operating according to the hydrothermal technology for the production of pasta. This equipment cools the pasta and allows you to go straight to their packaging. In addition to lines, you will need racks for storing dies and finished products, trolleys for transporting raw materials, a device for sharpening dies knives (optional, but desirable) and a sink.

The minimum start-up capital for organizing the production of pasta of low and medium price category is from 950 thousand rubles (calculation of manufacturers and equipment suppliers). This amount includes the purchase of a production line, registration of a legal entity, rental of production and storage facilities. The payback period for such expenses and the availability of sales channels for finished products does not exceed 1.5 years. But it is worth considering the fact that the pasta production and sale business is subject to the seasonality factor. Thus, the greatest demand for pasta is observed in the winter months, and in the summer - in the season of fresh fruits and vegetables - there is a rapid decline in sales.

Sysoeva Lilia
- portal of business plans and guides

Pasta is firmly entrenched in the diet of almost every family. This is due to the large selection and availability of products, as well as the lack of the need to have special culinary skills for their preparation.

Situation in the pasta market

Pasta today can be found on the shelves of any store or supermarket. However, it cannot be argued that at the moment the market for such products is going through a phase of oversaturation with goods. In light of this, even a medium-sized production of various pasta will be able to take its place in the market, ensuring the demand for the products produced.

Today, not only budget varieties of pasta are in demand, but also expensive types. Assessment of consumer demand allows us to identify the frequency of consumption of this product by the population. The analysis is presented in Table 1.

Table 1. Frequency of consumption of pasta

The trend in the popularity of pasta among buyers presented in the table opens up opportunities for obtaining a good financial return when starting your own business for the production of a product. As a rule, products of the middle class of quality will be especially in demand, which are purchased by about 60-65% of buyers, elite varieties are allocated about 30% of the total share of consumption.

Market segments:

• Economy, which offers B-category weight products. They account for more than one third of production and sales (approximately 350 thousand tons);
• The mid-price segment, which also contains B-category pasta, but already in the package. The volume is about 25 percent or 200 thousand tons. Package weight 400-900 grams and 1 kilo.;
• "Medium plus", which offers A-category pasta made from durum cereals (wheat). The volume is 35 percent or 300 thousand tons. It is such a product that is mainly packaged in polypropylene bags and offered in ordinary ones. You can buy such a product for 40-45 rubles;
• Premium, in which you can see A-category products, usually made in Italy. Or domestic, but "disguised" with the name and design of the packaging as such. The volume is about 5 percent or 45 tons. The market price of a 0.5 kilo package is from 60 rubles.

When opening your mini-business, you should take into account that about 70-80% of buyers prefer a product of the middle price category. It is also important that such consumers do not have clearly expressed preferences in relation to the manufacturer's brand. But if the price and quality of cereals seem appropriate to them, then buyers move into the category of "permanent", continuing to choose the product they like and further.

In a “difficult time”, buyers refuse from the products of the mid-price and premium segments. But nevertheless, the business for the production of A-category pasta, in the opinion of entrepreneurs, is the most promising. They need to use imported equipment. You can't do without high-quality cereals. Why is this happening? The fact is that the competition among enterprises in the middle and lower price segment is too great for a beginner's mini-business to be able to bring the desired profit. But in the field of manufacturing A-category goods, the competition is not great, mainly there is a Western manufacturer, which it is quite possible to “overtake” by offering high-quality products, but at a more favorable cost. When drawing up a business plan, be sure to take this point into account.

If we consider the entire domestic business selling pasta, and not just the features of mini-productions, it turns out that most of the goods are packaging at a price of 40-130 rubles. The development of the industry is significantly influenced by the market environment. After all, the main component in the manufacture of pasta is flour. In order to increase the profitability of production, large manufacturing companies often merge into holdings. But such a step is not available for medium and mini industries, and therefore the competition is the highest here. According to analysts, only 5-6 of the largest manufacturers will soon be present on the country's market. However, today the cereal business is flourishing in Russia. According to statistics, every Russian eats more than 7 kilos of pasta a year. And about 8 kilos of noodles / instant noodles. When drawing up a business plan, think about the production of which products will interest you the most.

Market assessment of finished products

The pasta business is focused on cooperation not with the end consumer of the product, but with retail and wholesale points. Therefore, the entrepreneur's potential clients will be grocery stores and supermarkets, as well as catering establishments, wholesalers, catering companies. Market analysis demonstrates the following situation with regard to the most demanded places of purchase of all types of pasta. Table 2 shows the statistics of purchasing activity in various retail outlets.

Table 2. Places of purchase

At the initial stage of business development, you should be prepared for the fact that the product under the new brand will be perceived by the consumer with a degree of caution. Participation in tenders for the provision of food will help to gain a foothold in the market, as well as earn a good reputation. government agencies, active interaction with potential large customers. Opening a sales point for pasta on the basis of a workshop is the idea of ​​selling goods under the slogan "from the manufacturer", which is considered a rather winning marketing strategy.

Types of pasta

• by the type of the main raw materials used (flour) - the first and the highest grade;
• in shape - tubular, filamentous, ribbon-like and curly;
• in length - from 1.5 cm to 50 cm.

Also, the division into varieties concerns the main groups, which are divided into smaller subgroups, based on the characteristics of the finished product. As a separate group of pasta, it is worth highlighting soup fillings, products that are produced when various dyes are included in the composition and food additives.

Tubular pasta, depending on the size of the cross-section, are divided into types: straws up to 4 mm in diameter; special diameters from 4.1 to 5.5 mm, ordinary diameters from 5.6 to 7 mm, amateur diameters over 7 mm. The thickness of the tubular walls should be no more than 1.5 mm (up to 2 mm is allowed in an amount of no more than 5% of the mass of pasta in a packaging unit).

To tubular include (Fig. 1): pasta - a tube with a straight cut at least 15 cm long; horns - a curved or straight tube with a straight cut from 1.5 to 10 cm in length; feathers - a tube with an oblique cut, length from 3 to 10 cm.

Figure 1: A - pasta, B - horns, C - feathers

Filamentary pasta (vermicelli) by size in section are divided into types (Fig. 2); cobweb (diameter no more than 0.8 mm); thin (diameter no more than 1.2 mm); ordinary (diameter no more than 1.5 mm); amateur (diameter no more than 3 mm).

Figure 2: Thread-like products. A - long, B - short-cut

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

Figure 3: Ribbon-like. A - long, B - short-cut

Figured pasta (Fig. 4) can be produced in any shape and size, but the maximum thickness of any part in the fracture should not exceed: for pressed 3 mm, for stamped - 1.5 mm.

Figure 4: Shaped products. A - shells, B - scallops; B - stamped, D - curls, D - soup fillings

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

Organization of production of pasta

To open a business, you will need to go through a number of mandatory steps regarding the design and equipment of the workshop.

registration

Suitable for this business,. In the application for registration, you will need to indicate the OKVED code 10.73.1 “Production of pasta”. At the stage of business registration, an entrepreneur may encounter a number of subtleties, so in some cases it will be correct to seek the help of a specialized lawyer.

Room selection

An important criterion for choosing a suitable building for arranging a pasta workshop will be its total area. Ideally, in one room it would be most convenient to place not only a work shop, but also a warehouse and an office.

There are certain requirements for a production facility - the ceiling height in it must be at least 3 meters. This need is due to the correct organization of the work process, which implies the placement of machines for the production of products in compliance with safety standards for hired personnel.

The storage room must be dry, ventilation deserves special attention to comply with all storage standards for finished products and raw materials for the manufacture of pasta. As a rule, the workshop and warehouse are additionally equipped with microclimate controllers. The optimal size for a warehouse will be a room with an area of ​​more than 100 m 2.

As far as the office part is concerned, in this case, a 3-meter ceiling height is optional. It is most convenient to organize an office on the ground floor for the convenience of interaction with suppliers and consumers.

The building for production can be purchased or rented. Before launching a production line, an entrepreneur will need to obtain a certificate from the Sanitary and Epidemiological Service. The task of this organization will be to check the premises for compliance with the requirements for food production.

In addition, the operation of the production will be possible after obtaining permission from the fire inspection and the environmental safety service. After visiting the facility by authorized employees, the entrepreneur will receive special permits for the further operation of the workshop.

Taking into account the peculiarities of the production part, warehouse and office, the optimal area for starting a business will be a room of 300 m 2, most of which will be allocated to workshops. The geography of the location of the premises should be thought out with regard to the convenience of delivering the necessary raw materials and transporting finished products to the place of their sale.

Staff recruitment

The choice of qualified personnel is a question on which the quality of the final product and the profit of the enterprise will depend in the future. A small or medium-sized business organization may require the following personnel:

• chemists-technologists;
• line adjusters;
• cooks;
• office staff.

The number of workers required will directly depend on the scale of work and the overall automation of the workshop. Priority will be given to personnel with experience in Food Industry at least 3-4 years.

For example, for a small business, you will need to hire:

• manager and technologist;
• warehouse manager;
• service technician;
• driver;
• 2-3 workers;
• sales manager.

Purchase of equipment for the production of pasta

The automated lines for the production of pasta consist of the following machines:

• vacuum dispenser;
• flour sifter;
• agitator;
• apparatus for pressing;
• stacking machines;
• apparatus for drying products;
• pneumatic conveyor;
• cooling device;
• drive;
• conveyor and loader;
• packing machines;

You can buy semi-automatic equipment with a capacity of approximately 100 kg of pasta per hour. The price of pleasure is about 500-700 thousand rubles. An automatic line produces about 500 kilos of pasta per hour, and costs from 375 thousand euros. You cannot do without a press, a drying line and a flour sifter in production.

A high-capacity line usually has a conveyor and a stabilizing hopper. Presses are offered complete with dies, the complete set is selected depending on the desired type of pasta. The cost of one matrix capable of producing one type of pasta is 3-5 thousand rubles. The service life is 700-2000 hours of work. Do not forget that finished products will need to be distributed into packages - and this also requires special equipment. You can purchase semi-automatic or automatic equipment. Or you can become the owner of a whole line if you are counting on large volumes of product manufacturing. Before you start packing finished products, they need to stand for a couple of hours in a cardboard container. You can significantly reduce the duration of this stage by purchasing special equipment that works according to the hydrothermal technology of pasta production. The technician can cool the product and immediately begin the packaging process. In addition to equipment, you will need to purchase racks in which you will store dies and finished products. It is necessary to purchase a washer, an apparatus for sharpening matrix knives and carts for the delivery of production products.

If you want to produce pasta of a medium or low price category, you will need at least 1000-1100 thousand rubles. In this figure, we included the cost of purchasing equipment, the cost of registering a business and renting premises for warehouse and production.

Pasta production technology

The technological process of manufacturing food products will consist of a number of mandatory stages.

1. Preparation of raw materials... The mass, from which the creation of pasta occurs in the future, consists of flour. Before use, the purchased raw material undergoes a special cleaning with the help of a magnet that pulls metal components out of the product. Further, the refined flour is subjected to heat treatment, after which, it combines with water, in a ratio of 2: 1.
2. Dough kneading... The second stage of work will be the preparation of the mass with the appropriate characteristics in the kneader. At this stage, additional ingredients may be included in the product - colors, eggs, flavor enhancers, etc.
3. Pressing and forming... Then the dough is given the desired density, as a result of which it acquires plasticity and uniformity. After that, depending on the classification of pasta, they are given the desired shape by passing the mass through the appropriate holes in the equipment. The resulting pasta strips are cut under the blowing of cold air streams, which will prevent the mass from sticking together.
4. Drying... Then the pasta is dried on the production line when exposed to high temperatures. Thanks to heat treatment, the products are not deformed in the future, in addition, additional disinfection of the products occurs. At the end of the process, the pasta is cooled.
5. Cooling of dried products... The process is designed to equalize the temperature of the products with the temperature of the packaging. If they are not cooled, fogging of the package will be observed and, as a result, a change in the mass of the product.
6. Control and packaging... At the final stage, the batch is sent to a check regarding the presence of defects, after which it is divided by weight, followed by packing into boxes or bags.

Even a person who is far from the production of cereals knows that pasta is essentially dried. unleavened dough which was obtained from water and wheat flour. The shape of the products is different - tubes, threads, ribbons, etc. The residual moisture content of the product is 13%. However, some pasta have a low moisture content, and therefore they can be stored for about a year without risking losing their high consumer properties. The grade of the product is determined by its nutritional value, calorie content and, of course, composition. There are incredibly many types and subspecies of pasta. A separate category is instant pasta. They have a porous structure and are enriched with various additives. It is because of this that they do not need cooking.

The optimal raw material for making pasta is durum, that is, durum wheat flour. Also perfect for:

• semolina - premium flour, which is selected during baking;
• wheat bakery flour;
• soft glassy wheat flour;
• flour of the highest grade of increased dispersion from durum wheat.

In the production of cereals, it is very important to ensure that the flour does not have mini metal impurities. In addition, it should be enriched with heat-resistant water-soluble vitamins PP, B1, B2. The maximum moisture content of flour is 15.5%. Pasta made with premium baking flour is usually light cream in color. Grade 1 is characterized by a gray tint and dark cream color. In the manufacture of cereals, great attention is paid to the quality of the drinking water used.

As additional components to flour and water are the most different products... We can talk about chicken eggs, egg melange, egg powder, dairy products (whole dry or fat-free cow's milk), vegetable products (concentrated tomato juice and pastes, natural juices with beet pulp). Certified natural and synthetic ingredients (for example, beta-carotene or tartazine, respectively) are used as food coloring agents. It is they who give the pasta a yellow tint. Surfactants are used at both large and mini pasta production facilities. They improve the quality of the product, preventing it from losing its shape during cooking.

There are 4 main types of pasta, depending on the shape:

• ribbon-like;
• tubular;
• curly;
• filamentous.

Each type has a subspecies - and here the pasta is divided according to width, diameter and length (horns, feathers, pasta). The latter can be both long and short (15-30 cm) - these are long tubes with a straight cut. In addition, pasta is divided into amateur, ordinary, special and straws, depending on the size of the diameter. If the pasta has an oblique cut, then these are feathers. Length - 3-10 cm. Horns have a straight cut and are produced in the form of short curved tubes, 1.5-10 cm long. Horns are divided into amateur, ordinary, special and straw. Thread-like products - vermicelli of various shapes sections (round, square, and so on), are divided into amateur, ordinary, thin and cobweb. Ribbon pasta - noodles, length 2-20 cm, corrugated or smooth. Curly products - gears, ribbons, stars, letters and so on. Before you approve your plan for mini cereals production, think about what kind of pasta you want to offer customers.

The composition of the pasta dough depends on what quality flour will be used and what type of products you want to get. The drying method and many other factors matter. When making a recipe plan, indicate the volume and temperature of water and flour, the presence / absence of additives, the temperature and moisture indicators of the dough.

The technology for making pasta has its own characteristics. For example, there are several options for how you can store flour in the warehouse of a manufacturing enterprise:

• tare when flour is stored in bags;
• in bulk when the flour is poured into the silo-bunker.

The latter method is preferred. It allows you to reduce labor costs and avoid additional losses of flour, which are associated with its remaining in the container and spraying. In addition, the bulk method allows you to reduce the cost of manufacturing the packaging bags.

Before sending flour to production, it must be sieved well, separating metal-magnetic mini impurities, and warmed up to 10 degrees. To improve consumer and gustatory characteristics, manufacturers mix samples from different batches. Next, a predetermined portion of flour enters the mixer, drinking water is carefully introduced (sometimes, additional components are added to it in advance).

Video how pasta is made:

The dough kneading takes about 10 minutes, the auger feeds the composition to the matrix and pushes it. The pasta coming out through the holes of the matrix is ​​blown by the air of the built-in fans. The products are automatically cut into certain sections, laid out on trays, which then goes to the table of the press apparatus and is pre-dried. Final drying is carried out in drying equipment with a capacity of 30 trays. The maximum loading of each tray is up to 2 kilos of pasta. The products are dried until a moisture content of 18 percent is reached for 55-60 minutes (accurately determined depending on the type of product). Then the goods are packaged in cardboard boxes and dried naturally in a well-ventilated room at a temperature of 25 degrees. After at least 4 hours, when the pasta reaches a moisture content of 13 percent, they are sent for packaging. However, the examination of the final product takes place earlier, its aroma, taste and appearance are examined. Experts-controllers study pasta for the absence / presence of metal impurities, granary pests and substandard (broken and deformed products), crumbs, strength, digestibility, acidity, moisture, etc. Products from batches that successfully pass an expert assessment are packaged in polypropylene bags using special filling and packaging machines.

Business plan: calculated part

To calculate the financial part of the pasta business, you should calculate the amount of investment for the following mandatory items:

• rental of premises and utility costs;
• purchase of equipment;
• employee salaries;
• the cost of purchasing raw materials;
• other variable costs.

The average values ​​for rent and utility bills will be about 100,000 rubles.

The cost of purchasing equipment for mini-production includes the following items for the purchase of a domestic production line:

• dough mixer - 30,000 rubles;
• sifter - 15,000 rubles;
• product formatter - 150,000 rubles;
• drying cabinet - 40,000 rubles;
• packing machine - 100,000 rubles.

The total cost of purchasing the equipment will amount to RUB 335,000.

Obligatory salary costs for employees:

• technologist - 20,000 rubles;
• driver - 15,000 rubles;
• marketer - 25,000 rubles;
• adjustment workers - 10,000 rubles;
• production line maintenance personnel - 15,000 rubles.

The total amount will be equal to 85,000 rubles.

The expenses for the purchase of the main raw materials for the production of 1 kilogram of the finished product - purified water and flour, are summed up from the total mass of 1 kilogram. On average, a small workshop is capable of producing 210 kilograms of finished products per day, based on 22 working days per month. Therefore, 210 x 22 = 4620 kilograms.

The wholesale cost of 1 kilogram of flour will be 15 rubles. In this case, the cost of purchasing raw materials is equal: 15 x 210 x 22 = 69,300 rubles.

The main costs must be added to the costs of packaging, delivery, payment of variable costs - 20,000 rubles.

Thus, the initial investment in the business is equal to 609,300 rubles.

Income and estimated payback periods

The average cost of one pack of pasta in a retail network will be 50 rubles. Calculation of total revenue 4620 x 50 = 231,000 rubles.

Taking into account the obtained calculations, we can conclude that even a small workshop for the production of pasta will become a profitable activity for an entrepreneur. The work of the enterprise at a given pace will allow to cover capital investments in the enterprise in 5-6 months, and the increase in capacities and the active sale of products guarantee the payback of the project within a calendar year.

All kinds of pasta can be seen on store shelves. They occupy a significant proportion of the use in the daily diet of a person. The business associated with the production of pasta is profitable in advance, without incurring difficulties with the process of its implementation.

This type of food industry requires compliance with sanitary conditions. This is due to the provision of sanitary books for the working personnel, as well as the availability of documentation on the sanitary and hygienic condition of the premises.

The production of pasta is presented in the form of a mini-plant, which includes flour sifters, stabilizer bins, conveyors, equipment designed for packaging finished pasta. Flour is used for production different varieties, as well as natural additives in the form of dyes and egg yolk.

Production technology

Let's consider in detail the technology for the production of pasta on all points.

Range of products

Depending on the shape of the pasta, they are divided into the following types: tubular, thread-like, ribbon-like and curly.

Tubular pasta, depending on the size of the cross-section, are divided into types: straws up to 4 mm in diameter; special diameters from 4.1 to 5.5 mm, ordinary diameters from 5.6 to 7 mm, amateur diameters over 7 mm. The thickness of the tubular walls should be no more than 1.5 mm (up to 2 mm is allowed in an amount of no more than 5% of the mass of pasta in a packaging unit).

To tubular include (Fig. 1): pasta - a tube with a straight cut at least 15 cm long; horns - a curved or straight tube with a straight cut from 1.5 to 10 cm in length; tube feathers with an oblique cut, length from 3 to 10 cm.

Figure 1: a - pasta, b - horns, c - feathers

Filamentary pasta (vermicelli) by size in section are divided into types (Fig. 2); cobweb (diameter no more than 0.8 mm); thin (diameter no more than 1.2 mm); ordinary (diameter no more than 1.5 mm); amateur (diameter no more than 3 mm).

Figure 2: Thread-like products. a - long, b - short-cut

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

Figure 3: Ribbon-like. a - long, b - short-cut

Figured pasta (Fig. 4) can be produced in any shape and size, but the maximum thickness of any part in the fracture should not exceed: for pressed 3 mm, for stamped - 1.5 mm.

Figure 4: Figured products - a - shells, b - scallops; c - stamped, d - curls, d - soup fillings

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

Main stages of production

The pasta production process consists of the following main operations:

• Preparation of raw materials... The flour is sieved, it is separated from the metal-magnetic impurity, heated (the temperature of the flour should be at least 10 ° C), different batches of flour are mixed based on the instructions of the factory laboratory.
• Making pasta dough... The water is heated to the desired temperature, the additives and flour are stirred. All this gets mixed up.
• Dough pressing and shaping... This item is used to compact the kneaded dough, i.e. it needs to be turned into a homogeneous plastic dough mass. Then, shaping is carried out by forcing the dough through holes in a metal matrix.
• Cutting up raw products... The raw pasta pressed from the matrix is ​​cut into pieces and prepared for drying. When cutting, they already begin to intensively blow air to obtain a dried crust on their surface. This is to prevent the pasta from sticking.
• Drying... The purpose of this stage is to consolidate the final shape and prevent the development of microorganisms. This process is carried out at "elevated" temperatures.
• Cooling of dried products... The process is designed to equalize the temperature of the products with the temperature of the packaging. If they are not cooled, fogging of the package will be observed and, as a result, a change in the mass of the product.
• Rejection and packaging... Usually, boxes, boxes, paper bags, boxes and bags with bags are used as packaging.

Equipment for the production of pasta

We will not publish beautiful photographs of equipment for the production of pasta here, but instead we will consider in detail an example of a line.

Mini-line for the production of macaroni "Makiz" / Photo www.teko-makiz.ru

1 - flour sifter, 2 - agitator, 3 - vacuum dispenser, 4 - automatic press, 5 - pneumatic conveyor-stacker, 6 - control panel, 7 - conveyor dryer, 8 - pneumatic conveyor-stacker, 9 - cooler, 10 - pneumatic conveyor, 11 - storage bin, 12 - conveyor, 13 - bunker - feeder, 14 - conveyor - loader, 15 - automatic packing machine.

Prices for lines for the production of pasta start at about 1,500,000 rubles. Usually the minimum performance indicators of the cheapest are 100-150 kg per hour.

A production that is quite within the power of a small business is the manufacture of pasta. There is always a demand for them in our country. When organizing, special attention should be paid to equipment for the production of pasta.

There are many types of production lines today. They are capable of solving a variety of problems. Among the manufacturers of such equipment, both domestic and foreign factories are known. There is plenty to choose from, the main thing is to decide on the required capacities, assortment and markets for finished products.

Pasta is dried unleavened dough. The ingredients for mixing it are drinking water and flour of different qualities.... The technology is so simple that domestic businessmen began to master it even more often than the market demanded. A few years ago, there was an oversupply. Many entrepreneurs were forced to close production. You can attract wholesale buyers with a variety of products and their quality. It depends on what kind of flour is used and the drying method. Sometimes additives are added to the pasta dough, but more on that later.

Pasta making technology

The mini-line consists of a pasta press of the PMI 02 type and an SHS 1 drying cabinet (see the description below in the text)

The production technology has its own characteristics. On the taste qualities even the way flour is stored affects. It can be packaged and unpacked. The latter method is more economical as it reduces waste of raw materials and minimizes manual labor.

Before entering the dough mixers, the flour is carefully sifted and warmed up at a temperature of ten degrees. In the mixer, water is gradually added to it. The dough is kneaded for about 10 minutes. Then, to shape, the dough is pushed with a screw through a die with shaped holes. A stream of air is supplied to the workpieces at the outlet. Then they are cut to size. After forming, the pasta is laid out on a tray, which is part of the press of the machine.

For the final removal of moisture, the products are placed in drying ovens. For this, special baking sheets are used that hold about 2 kg of products. They are in the cabinet for about an hour until their humidity is 19%. From the cabinet, the product is scattered into cardboard boxes. In a separate storage room at a temperature of 25 degrees, they still lose moisture up to 13%. Then the products are considered finished and can be packaged.

A separate type is instant food. They have a completely different structure, and the technology of their manufacture is different. The most valuable pasta is made from durum wheat (durum). They are assigned category "A". Categories "B" and "C" are pasta made from flour, the quality of which is lower. Chicken eggs, egg powder or dairy products, vegetable concentrates are used as additives to the main ingredients. Sometimes for mass production it is allowed to use food colors... To keep the pasta in shape during cooking, surfactants are added to them. Diet foods and children's pasta is saturated with iron glycerophosphate. Often even fruit or vegetable puree is added to them for children.

What equipment to choose for the production of pasta?

For novice entrepreneurs, we can recommend a small production line of the type PMI 02. It is equipped with two drying ovens. Double-hopper press PMI 02 is able to knead, shape, cut and pre-dry the product. There are no special requirements for raw materials. This equipment is ready to work with soft and coarse flour.

The apparatus produces almost all stages technological process from kneading to shaping and drying. The press can be used independently or complete with drying. It comes with a set of interchangeable dies. The shape of the product can be customized according to market needs or national preferences. The press quickly manufactures products, and their quality meets the requirements of the consumer.

Technical characteristics of the press Type PMI 02:

Drying cabinet ШС-1 is used to bring products to a moisture content of 19%. Drying in it occurs due to forced blowing with hot air. The temperature in it is maintained in automatic mode. Below are the technical characteristics of the SSh-1 drying cabinet:

For restaurants and cafes, you can buy a very simple model. It's called a pasta machine. Sometimes they even use it at home. The machine comes in two models: with and without a kneader. A professional machine that only forms the dough costs from $ 30. If there is a function for kneading dough, then a pasta machine will cost about $ 300. Experts say that with such equipment you can not only please your home delicious meals and even start a small home based business. The main thing is to stock up large quantity nozzles and recipes for making delicious dough.

How much can you earn making pasta?

As for the large scale, the producers of domestic pasta initially invest about 500 thousand rubles in a small workshop. With a production volume of 4500 kg of products per month and an average price per kilogram of 39 rubles, the income will be 175.5 thousand rubles. At the same time, the net profit will amount to about 150 thousand rubles. In general, the industry has a profitability level of 20%. With such indicators, the investment will pay off within 12 - 24 months.

How much can you earn in the production of pasta

The profit from the production of pasta depends on the capacity of the enterprise. The profitability of this business is 10 - 25%, with an established production and sales market, the investment will pay off in 12 - 16 months. After that, the business will begin to generate income of 100 - 150 thousand rubles a month, subject to the manufacture and sale of 3-4 thousand kilograms of pasta.

How to choose equipment for the production of pasta

For the production of pasta, you must purchase the following machines:
- flour sifter;
- press apparatus for pasta products;
- apparatus for drying;
- an automatic machine for filling and packaging finished products.
High-quality specialized equipment is supplied by Italian manufacturers. Their machines and units are distinguished by high reliability, high-quality service and long-term warranty service. Due to the modularity of the devices, their readjustment makes it possible to produce a wide range of products on one conveyor.

Pasta production technology

The technological process for the production of pasta includes several stages:
1. Flour is weighed, cleaned and mixed, which makes it possible to achieve quality indicators of the initial product and prevent malfunctions of the vacuum press;
2. Preparation of pasta dough takes place in dough mixers. The composition of the dough usually contains only water and flour, other ingredients (eggs, dyes) increase the cost of production, which lowers the profitability of the enterprise; To begin

Holders of the patent RU 2430516:

The invention relates to the food industry. The composition for the production of pasta contains durum wheat flour, baking soft wheat flour and chickpea flour in the following ratio of components, wt%: durum wheat flour 5, baking soft wheat flour 85, chickpea flour 10. The invention makes it possible to obtain a product with increased biological value, with improved organoleptic and structural-mechanical quality indicators. 2 tab.

The invention relates to the food industry and can be used in the production of pasta with increased biological value.

Known dough composition for the production of pasta, including durum wheat flour or bread wheat flour of the highest grade and water. In addition, in the form of additives in the pasta dough, flour of other crops is used, for example, peas (Medvedev GM Technology of pasta production. - M .: Kolos, 1999, p. 7, p. 50-52).

The disadvantage of using only wheat flour in the pasta dough is the high starch content, which leads to the calorie content of the finished product and a low protein content. Also, when added to wheat flour flour of legumes, such as peas, there is also an insufficient amount of protein.

The composition of the dough for the production of pasta is known (prototype - RF patent for invention No. 2289952), including wheat flour, water and protein-containing additives - flour of legumes, namely, or pea flour in an amount of 10% by weight of wheat flour, or lentil flour in an amount 10% of the mass of wheat flour, or a complex additive consisting of bean flour in the amount of 2.5% of the mass of wheat flour and mountain ash puree in the amount of 7.5% of the mass of wheat flour, while the content of raw gluten in the wheat flour should not be below 28%.

The disadvantage of the prototype is that when a protein-containing additive in the form of pea and lentil flour is added to the wheat flour, the pasta dough contains an insufficient amount of amino acids and minerals.

The technical task is to create a composition for the production of pasta with increased biological value, with improved organoleptic and structural-mechanical quality indicators.

The technical problem is achieved by the fact that the composition for the production of pasta contains durum wheat flour, bread wheat flour and chickpea flour in the following ratio of components, wt%:

chickpea flour - 10

The difference between the proposed invention and the prototype is that chickpea flour is used in the composition for the production of pasta, with the following ratio of components, wt%:

durum wheat flour - 5

baking flour soft wheat - 85

chickpea flour - 10

The composition for the production of pasta is prepared as follows. Durum wheat flour in the amount of 5% is mixed with baking soft wheat flour in the amount of 85% and with chickpea flour in the amount of 10%. The amount of water for kneading is determined by calculation, taking into account the moisture content of soft baking wheat flour, durum wheat flour and chickpea flour. The prepared mixture of these three types of flour and water are fed into the first trough of the dough mixer, after which the finely lumpy dough, homogeneous in humidity, enters the second trough of the dough mixer, connected to the auger chamber. Pasta presses are used to make pasta. The pressed pasta is dried in cabinet dryers.

Table 1 shows the comparative data of indicators of the content of protein, essential amino acids and minerals in pasta prepared according to the prototype and the proposed composition.

Table 1
Indicators	Pasta
Composition according to the prototype (with lentil flour)	Composition according to the prototype (with pea flour)	Proposed composition
Protein content,% Content of essential amino acids, g per 100 g	13,02	12,44	14,26
squirrel, including	28,83	28,80	29,26
Lysine	2,97	2,85	3,26
Threonine	2,68	2,64	2,86
Valine	4,69	4,65	4,88
Leucine	7,03	6,76	6,99
Isoleiin	3,66	3,64	3,74
Meteonin	1,65	2,13	2,87
Tryptophan	1,52	1,32	0,87
Phenylalanine	4,63	4,81	5,99
Mineral composition, mg
Potassium	382,2	388,1	410,5
Calcium	59,6	60,2	70,7
Magnesium	101,6	102,4	106,7
Phosphorus	406,5	399,7	419,1
Iron	5,2	5,8	5,9

As can be seen from table 1, the content of essential amino acids in products with the addition of chickpea flour increased by 12%. The content of minerals in comparison with the prototype has increased by 9%.

The introduction of chickpea flour into the formulation of pasta is explained by the need to enrich it with balanced essential amino acids and minerals, which are higher in chickpea flour than in pea and bean flour. The use of a protein-containing additive in the form of chickpea flour in an amount of less than 10% leads to a deterioration organoleptic indicators quality and biological value reduction. The use of the specified additive in an amount of more than 10% worsens the structural and mechanical indicators of quality.

Introduction to the recipe of pasta dough wheat flour in combination with its different types- flour of durum wheat and soft varieties, and bakery flour of soft varieties in the largest quantitative ratio (85%) is explained by the fact that this type of flour is the most widespread and available in the food industry. In the recipe of the present invention, the flour quality improver is a natural additive in the form of durum wheat flour. When using durum flour less than 5%, the structural and mechanical indicators of pasta deteriorate, and the use of more than 5% is impractical, because the addition of this flour in an amount of 5% is sufficient to achieve optimal structural and mechanical properties.

Table 2 shows the quality indicators of the cooking properties of pasta, the composition of which is prepared according to the prototype and the invention.

As can be seen from table 2, the pasta prepared according to the invention has good cooking properties: the main indicator of cooking properties - the loss of dry substances into the cooking medium - is 7.8% lower compared to the composition made according to the prototype.

Example. To obtain a dough for the production of pasta, soft wheat flour in the amount of 8.5 kg, durum wheat flour in the amount of 0.5 kg and chickpea flour in the amount of 1 kg are pre-mixed and the mixture is sieved. The following actions are carried out according to the above method for preparing the dough.

The resulting pasta with a protein-containing additive in the form of chickpea flour has a high content of protein, essential amino acids and minerals. Cooked pasta with a protein-containing additive in the form of chickpea has a regular shape, elastic consistency and an attractive yellow tint.

Thus, the proposed composition for the production of pasta makes it possible to obtain products of increased biological value with improved organoleptic and structural-mechanical quality indicators.

A composition for the production of pasta, containing durum wheat flour, bread wheat flour and chickpea flour in the following ratio of components, wt%.