In this article:

Purpose of the project: substantiation of financial and economic efficiency and technically possible implementation of the production of chocolate sweets in the territory of the Russian Federation. The main criterion is a conservative scenario for the development of events; the calculation of prices is given taking into account inflation. The project has significant economic potential based on an assessment of the current state of the market.

Chocolate candy production project concept

It is planned to build production and storage facilities or rent them, install equipment for the production of products. An initial assortment of glazed fondant candies and chocolate is planned:

• oval-shaped chocolate glazed sweets with a chocolate fondant filling of a different taste. The mass ratio is 60/40%. Candy weight up to 12 grams;
• oval-shaped chocolate glazed sweets with jelly filling. Mass ratio 70/30%, candy weight up to 11.5 grams;
• chocolate bar weighing 100 grams, with a pattern.

Analysis of the confectionery market

Market confectionery and chocolates (chocolate) is resistant to economic crisis. Gifts and purchases for children, gifts and personal preferences make this segment of products quite popular among the broad consumer masses.

At the moment, the Russian market, in particular the business of producing chocolate sweets, is represented by a wide range of products in the form of chocolate: milk, porous, black or ordinary with various fillings; chocolates of the most varied shapes and fillings. In value terms, the segment of sales of chocolates and bars accounts for 1/3 of the total sales of confectionery products.

It should be noted that production of chocolates depends on the season, at the time of the greatest surge (holidays and pre-holidays), production can increase by 300%. The rest of the time, the plant can be loaded only at 30-60% of the planned capacity.

The most popular product is loose sweets and chocolate bars; sales are represented by regional offices of large confectionery companies. This has its advantages: the cost of delivery and payment of office representations increase the cost of their products by 6-8%.

For example, Nestle sweets have a cost of $ 3 per 1 kg, their sale in the regions is $ 8 for the same kilogram. The production of sweets in your region makes it possible to reduce the price of your own product of high consumer demand.

Consumer behavior towards confectionery

Active buyers of chocolates and chocolate are 65% of buyers, regardless of the season, buying these products 3-4 times a week, and 20% are inactive, buying once a week. Thus, taking into account the size of the population in the region, it is possible to calculate in advance the volume of production of chocolates and chocolate bars.

Production plan of the project

1. Rent of premises: production workshop and warehouse. Mandatory drawing up of a contract according to the established regulations. Construction of additional structures (office and utility rooms), rental of transport for the delivery of products to retail outlets.

2. Installation and installation of the necessary equipment, commissioning, launch of the production line.

3. Manufacturing process for the production of sweets.

The candy production technology consists of several stages:

- mixing the individual ingredients of the fondant mass;

- brewing process;
- molding or casting the fondant mass into special oval shapes;
- passing the molds through the cooling systems;
- glazing of sweets with chocolate fondant;
- cooling;
- packaging of products in wrapping paper.

Chocolate bars production technology:

• mixing the ingredients of the chocolate mass;
• brewing process;
• casting into special molds;
• run through the cooling system;
• wrapping tiles in wrapping paper.

Equipment for the production of chocolates

It should be noted that the candy production line consists of four sections, each of which has its own range of equipment:

1. Section for the production of candy mass:

• universal cooker, used for cooking, mixing and emptying the mass, with automatic control;
• weighing device for dosing components of fondant or chocolate mass;
• loading pump for supplying the mass to the casting;
• dosing pump for flavors, acid, fondant and chocolate colors.

2. Installation of casting:

• One-shot casting unit with servo drive and electronic control;
• conveyor of molds for casting;
• cooling cabinet, including control cabinet and cold air preparation station;
• forms.

3. Line for the production of sweets (for enrobing the bodies):

• a table for feeding products to the glazing machine;
• enrobing machine;
• surplus return pump.

4. Automatic candy wrapping packing line:

• distribution conveyors for supplying sweets to warehouses.

The technological scheme for the production of chocolates and chocolate bars is rather complicated, requiring highly qualified personnel and serviceable equipment.

The cost of purchasing equipment, renting premises is about $ 50,000, which is the start-up capital. The estimated time of self-sufficiency and profitability of the enterprise is 5-8 years. The expected profit per year is 36% of the start-up capital.

Analysis of income and expenses

The cost of rent (construction) and raw materials make up 77% of the total start-up capital, the next item in the cost column is for electricity, water and gas - 7.5-8%. The salary fund is 8% of total expenses, 3-5% insurance premiums and taxes, 7% other expenses, which include expenses for advertising and product promotion.

The dynamics of reducing the burden of expenses on production costs is calculated for 5 years, after which the expenses will stabilize and the price may remain fixed.

Production plan

Considering the structure of variable costs, one can see that the highest expenditures (over 77%) are spent on the purchase of raw materials. Thus, the calculation of the cost of production is:

the amount of expenses for raw materials + the amount of the salary fund and expenses for communications, rent, taxes + 6% to increase profits.

According to a more simplified formula:

the amount of expenses + 37-38% of the amount of expenses = the cost of 1 kg of sweets.

Product demand risk

In order for the enterprise to be considered profitable, it is required to calculate the minimum critical level of production, taking into account seasonal sales.

Payroll costs (per year) + taxes (per year) + utility and rental costs (per year) / divided by total annual income = minimum production in kg per day.

Thus, the minimum (critical) cost of sweets (taking into account the risk) is $ 6 per kg - this is the threshold value of the selling price for the production of chocolate and sweets, the minimum production volume per day is from 5 tons.

The candy business is risky because of its quality and design requirements. The packaging material for sweets and chocolate bars must match the positive image of the company.

Packaging material will be considered the cheapest if you make it yourself. This will require:

• special wrapping paper and foil (for chocolate) and cardboard (for making candy boxes);
• inkjet printer for printing;
• a computer.

The production of boxes for chocolates has its own manufacturing characteristics:

• the cardboard has a corresponding certificate, which allows it to be used in Food Industry;
• made according to ready-made correction;
• can be used for automatic and manual packaging.

Business idea: production of sweets at home.

A profitable business is the production of sweets, you can start at home with minimal investment by purchasing only the necessary molds for making sweets and the actual ingredients.
You can sell them in local chocolate shops, small cozy cafes, negotiate with the organizers of the celebrations to promote sweets at events, and also create your own website or VKontakte group to sell goods. To draw attention to sweets, order beautiful shiny wrappers.

Only venerable candy factories supply sweets to the Russian market. There are no private producers in the candy market. It's surprising, because in every city there are many small bakeries in which cakes and pastries are prepared, but no one prepares homemade sweets, only mothers and grandmothers in the kitchens.
Huge profits are received by factories for the production of sweets of dubious taste and composition. But the production of homemade candy can be a profitable business.

Before starting the production of sweets, you must decide that you are interested in this business, that you, as a perfumer, are ready to invent new flavoring bouquets. You must have your own secret recipe.
If there is none, you definitely need to come up with, subtract, modernize, come up with a legend that you got this recipe from your great-great-grandmother, who made sweets according to this recipe even at the royal court. It is important to create a mystery and a fairy tale around sweets, because we all come from childhood.

You can start making candy in your kitchen. Over time, you will be able to open a small confectionery factory. You will not compete with large concerns, because the scale of your production will be several times smaller, because your sweets will be handmade.
But you will have to buy equipment for the production of sweets and kitchen utensils, you cannot do without molds and special devices. Packaging is a separate expense item. Each candy can be wrapped in a designer wrapper, if you do not have your own design abilities, you can order development for a fee. By the way, the appearance of sweets can be "copied" from foreign sites.

Be sure to have a variety of boxes for packing sweets in your arsenal. Gift wrapping is the key to the success of your business. After all, most people will buy products as a gift.

Learn the technology of candy production, chat with professional confectioners on the forums. You may not have a professional education, but you should be able to cook deliciously. Come up with some candy recipes, it can be chocolates, lean sweets from dried fruits and nuts, organic lollipops.

Your products can be delivered to pastry stalls cities, gift shops, just keep in mind that home-made sweets are quickly perishable, so most sweets will have to be made to order. This can be a chain of cafes and restaurants or a company that serves special events. Opening your own shop is too expensive, especially at the initial stage of business development. Create an "appetizing" site on the Internet, offer your work on it.

Make bouquets of sweets, focus on natural ingredients. During the holiday period, take orders in advance, take on part-time jobs for the New Year and on March 8 couriers and confectioners who will help you not to miss out on customers, please everyone, and not lose income.

The technological scheme for the manufacture of sweets includes several operations: preparation of candy masses, molding of candy bodies, surface treatment, wrapping and packaging.

The bulk of the sweets is produced in a flow-mechanized way. The flow-mechanized line includes a universal station for the preparation of candy masses, a casting machine with an installation of accelerated casing aging, an enrobing machine, mechanized wrapping and packing of sweets [p. 214, 18].

Cooking candy masses.

Fondant mass... The fondant mass consists of two phases - solid and liquid. The solid phase is sugar crystals, evenly distributed in a saturated sugar-sugar or sugar-inverted syrup, which is a liquid phase. In addition, the lipstick contains a very small amount of air that gets into the lipstick during the churning process.

Distinguish between sugar lipstick, milk and creme brulee. Sugar fondant is prepared on the basis of sugar syrup. Milk fondant and creme brulee are prepared on the basis of milk sugar syrup. Creme brulee lipstick differs from milk in its high milk content. Syrup for creme brulee is subjected to a special heat treatment, as a result of which it acquires a brown tint. Lipstick contains 9-12% water.

The process of making lipstick consists of two operations: preparing the fondant syrup and churning the lipstick. The proportion of molasses in the recipe should be 5-25% by weight of sugar, and the proportion of invert syrup - 3-12%. When making fondant syrup, condensed milk, fruit and berry semi-finished products, candied fruits, butter, grated nuts, cocoa products can be added to the recipe. All types of lipstick are flavored with essences, and in some varieties they are introduced food colorings... In the production of fondant syrup in a continuous way, the prescription mixture from the mixer is fed by a dosing pump to the coil of the cooking column, from where the mass to be boiled enters the steam separator. Mass fraction of solids in fondant syrup should be 86-90%. When using boiling under vacuum, the syrup is lighter. Syrup lipstick is produced in batch and continuous methods. The fondant syrup from the steam separator is drained through the pipe into the funnel of the machine and gets inside the receiving section and then for cooling and churning into the working sections. When the auger rotates, the syrup is intensively cooled and knocked down. The finished lipstick gets out of the car and goes into the collection.

With the periodic method of preparing the fondant mass, the syrup is cooled on metal tables to a temperature of 35-40 * C. After that, in a kneading machine with two Z-shaped blades, the fondant mass is churned. Sugar lipstick should have an outlet temperature of 55-60 * C, and milk fondant 70-75 * C. This temperature determines the required size of the sucrose crystals. The proportion of the liquid phase in lipstick should be 30-45%.

The fondant mass can be obtained using the “cold method”. In this method, fine powdered sugar is mixed with sugar syrup, molasses, invert syrup. The whole cooking process takes place in one stage without heating. The disadvantage of cold-prepared lipstick is its ability to dry quickly.

After the introduction of flavoring and aromatic components of the recipe, the fondant candy mass is tempered at a temperature of 65-72 * C. In this case, there is a process of partial dissolution of sugar crystals and, accordingly, changes in the ratio between liquid and solid phases [p. 220, 18].

Fruit jelly masses. Such masses can be divided into three groups: fruit, jelly-fruit and jelly. They differ in their gelatinous base and consistency. Fruit masses are prepared from fruit and berry raw materials and sugar. The gelling agent in them is pectin contained in fruit and berry raw materials. This mass is characterized by high viscosity and elastic consistency. Jelly-fruit masses are prepared from fruit and berry raw materials and sugar with the introduction of a gelling agent (agar, agaroid). These masses have an elastic consistency. Jelly masses are prepared without the introduction of fruit and berry raw materials from sugar, molasses and gelling agents (pectin, agar, agaroid, etc.). In the formulations of many fruit candy bodies, the introduction of 50% apple and 50% apricot, plum or blackcurrant puree is provided. Special instructions for recipes provide for the introduction of sodium lactate or other salts (citrates, phosphates, etc.) into fruit candy masses. These salts have the ability to reduce the viscosity and gelation temperature of the boiled fruit and berry masses.

The process of preparing fruit candy masses consists of the following operations: preparing a fruit and berry mixture, boiling the fruit mass, introducing prescription additives. The mass fraction of dry substances in the boiled mass during cooking without sodium lactate should be at least 81%, and when boiled with sodium lactate - at least 78%.

Jelly-fruit masses are prepared in different ways: depending on which gelling agent is introduced along with the fruit puree. If it is beet, apple or other pectin, then the difference between the preparation of these masses from fruit ones lies only in the fact that at the end of cooking, when the mass fraction of dry substances reaches 70-72%, the amount of pectin corresponding to the recipe is introduced into the mass in the form of 5% solution. And then it is additionally boiled down to a mass fraction of dry matter of 75%. If agar or agaroid is used as a gelling agent, then the process is carried out in several stages. At the same time, a mass based on fruit and berry puree and a part of sugar is prepared separately, and a mass based on agar or agaroid with the remaining part of sugar and molasses is prepared separately. Separate boiling is carried out because agar or agaroid, when heated together with the fruit mass, which always contains acid, loses its gelatinous properties. Both masses are mixed in a tempering machine at a temperature of 70 * C, mixed, acid and essence are added and immediately sent to molding.

In the manufacture of jelly masses, sugar-agar syrup is prepared, boiled down to a mass fraction of dry matter of 77-83% and cooled to a temperature of 80 * C.

From all fruit-jelly masses, the corresponding candy masses are prepared. To do this, during tempering, the flavoring and aromatic components provided for by the recipe are introduced into them. The duration of tempering is 5-10 min at a temperature of 70-75 * С [sec. 223, 18].

Whipped masses... Whipped candy masses have a foamy structure consisting of two phases: gas (air) and liquid. For whipped masses, the presence of small, evenly distributed air bubbles separated by thin layers of sugar-agar mass is characteristic. Foam formation occurs when churned. Obtaining a stable highly dispersed foam is due to the presence of a foam stabilizer (agar) and a foaming agent (egg white).

Depending on the recipe and technology, whipped candy masses can be divided into two main types: light and heavy, which can be milk-whipped or fruit-whipped. Whipped masses of light type include masses for sweets like Souffle, bird's milk; and the heavy type - Nougat, Zoological.

The process of preparing whipped masses of light type consists of the following operations: preparation of sugar-agar syrup; preparation of the mass knocked down on proteins; mixing these components in a whipping machine with the introduction of fruit mass or milk syrup and other flavoring and aromatic components. Churning is carried out until a homogeneous fine-pored structure is obtained. When making "Bird's milk" sweets, condensed milk mixed with butter is gradually introduced into the whipped mass.

The process of preparation of heavy-type whipped masses consists of three operations: preparation of sugar syrup; churning proteins with syrup; mixing with the rest of the recipe components. There is no agar in the formulations of heavy-type whipped masses, so the syrup is prepared only from sugar and molasses. Heavy churns contain significantly less air. Mass fraction of dry substances in whipped masses 80-89% [p. 230, 18].

Nut masses... Candy masses containing nuts are classified as masses highest quality... Candy masses prepared on the basis of nut kernels are subdivided into two groups: praline masses, in which roasted nuts are used; marzipan, in which the kernels are used raw.

The mass of praline is pounded roasted kernels of nuts or oil-containing seeds, mixed with powdered sugar with the addition of fat. Usually the composition of the praline mass contains 30-33% fat and 50-60% sugar. Mass fraction of dry substances 96-99%. The fat contained in nuts has a low melting point, therefore, after crushing, the nut mass has a semi-liquid consistency. The formulations provide for the introduction of various fats: cocoa butter, coconut oil, confectionery fat, etc. The main structure-forming agent of praline masses is fat. The process of fat crystallization is the most important process of the structure formation of praline masses. The more solid fats and, first of all, cocoa butter in the mass, the stronger it is.

The production process of praline masses consists of the following operations: cleaning of nut kernels; heat treatment cores; getting grated nut mass; mixing recipe components; crushing (rolling) of the mass; wiring; workout. The two-stage introduction of the prescription fat filling is caused by the fact that the praline mass with a full fat content is difficult to grind - rolling. The nut roasting temperature is 120-140 * С from 15 to 60 minutes. After roasting, the nuts are quickly cooled to a temperature of 30-40 * C and crushed in melangers. In the manufacture of some praline masses of the highest grades, roasting of nut kernels with sugar is used. Mixing of nut masses with powdered sugar, fat and other components of the recipe is carried out in kneading machines with heating at a temperature of 35-40 * C. Then the mass is crushed in five-roll mills, while the mass turns from a pasty consistency into a free-flowing one. Wiring and kneading is carried out in kneading machines. In this case, for distribution, the remainder of the solid vegetable fat provided by the recipe is introduced into the mass.

Marzipan masses are divided into two groups: raw marzipan and custard marzipan. Raw marzipan is a mixture of raw, crushed nut kernels with powdered sugar. Custard marzipan is obtained by “brewing” mashed raw nut kernels with hot sugar-sugar or sugar-milk syrup. From the masses of custard marzipan, candy shells are prepared, which are then glazed with chocolate.

The process of preparing dry marzipan consists of the following operations: scalding almonds; peeling almonds; drying; preparation of grated mass; mixing crushed almonds with prescription ingredients; grinding the resulting mass. For scalding almonds, water is heated to a temperature of 70-80 * C and kept for 5-10 minutes. The wet kernel is passed through an almond peeling machine. The core separated from the shell is dried in a dryer at 45-60 * C. Grinding the dried kernel is carried out on a three-roll mill. Powdered sugar is mixed in kneading machines for 10-15 minutes. Usually the ratio of grated nut mass to sugar is 1: 1. The resulting mixture is additionally crushed on roller machines. After that, the mass is placed in a tempering machine and flavoring and aromatic components are introduced. Raw marzipan contains about 90% dry matter.

To prepare custard marzipan, instead of powdered sugar, sugar is introduced in the form of hot syrup. Syrup formulation may include molasses, milk, etc. Mixing is carried out for 10-15 minutes, and then the remaining components of the recipe are introduced. The mass of custard marzipan is much more stable in storage than raw [p. 231, 18].

Liqueur masses... This is a syrupy mass consisting of a saturated solution of sugar with the addition of milk, fruit semi-finished products, alcoholic beverages etc. In the candy body, the liqueur mass is in a shell (sugar crust) formed during the aging process and consisting of sucrose crystallized from the mass itself. Depending on the additives introduced, liqueur masses are divided into three groups: wine, fruit and dairy. To obtain a wine liqueur mass, sugar syrup is prepared. Water for syrup is taken in the ratio of water to sugar 1: 2. This will produce a syrup that is completely free of sugar crystals. Boiling is carried out to a mass fraction of dry substances of 76-81% at a temperature of 108-112 * C. The finished syrup is filtered and quickly cooled to 85 * C. Alcohol or alcoholic beverages and other components of the recipe are carefully introduced into the chilled syrup. Then the resulting candy mass is poured into cells molded in starch.

Fruit liqueur masses are prepared in the same way as wine. However, sugar syrup is boiled down at a temperature of 116-120 * C to a mass fraction of dry matter of 90%. This is done in order to reduce the duration of subsequent boiling in the presence of acidic fruit and berry puree and to slow down the hydrolysis of sucrose. The proportion of puree should not exceed 30% of the finished mass. Agar syrup is added to some masses to increase viscosity and slow down crystallization. The finished mass is cooled to 90 * C, prescription components are introduced and poured into starch forms.

Milk-liqueur masses are prepared in two stages. Pre-milk sugar syrup, and then it is mixed with prescription ingredients. The syrup is boiled down to 77-83% of the mass fraction of dry substances. At the end of boiling, a small amount of molasses and, if provided by the recipe, butter are introduced. The finished syrup is filtered, cooled to 90 * C and the components provided for by the recipe are introduced. Milk liqueur candy mass is immediately sent for molding by casting into starch molds.

Trays with liqueur mass poured into starch forms are sprinkled with starch on top and placed in drying chambers with a temperature of 50-60 * C. The holding time of the shell of the candy body is 6-7 hours. Crust thickness 0.5-1mm. Inside there is a saturated sugar-alcohol, sugar-fruit or sugar-milk syrup. The mass fraction of dry substances formed inside the sugar crust of a saturated solution is 70-75%. mass fraction of dry matter of the crust itself is 94-96% [p. 233, 18].

Cream masses... They are an oily mass based on sugar and fat with the introduction of chocolate, grated walnut, milk and other flavoring and aromatic components, obtained by mixing with the introduction of air when processing on whipping machines. When knocked down, small air bubbles are evenly distributed throughout the mass. This makes the mass lighter and gives it delicate taste... A typical representative of creamy candy masses is the Truffle mass for sweets.

The mass is prepared as follows. Carefully rolled chocolate mass is mixed at a temperature of 40-45 * C with cocoa butter and butter or coconut oil for 1-1.5 hours. 10-15 minutes before the end, the essence is introduced and the mass is filtered through a filter with cells with a diameter of 2 mm. The resulting mass is tempered at 28-30 * C and knocked down in churning machines. Mass fraction of dry substances of this mass is 89.5%. The main property of cream masses is their viscoplastic consistency, which will allow them to be given and maintained in a different shape.

Milk masses... Milk candy masses are a partially or completely crystallized mass consisting of sugar, milk and molasses, to which butter, grated nuts, fruit and berry semi-finished products, etc. can be added. Some dairy masses, for example "Lady" and "Creamy toffee", may have an amorphous structure. All milk candy masses are made by boiling milk sugar syrup. First, a recipe mixture is prepared from sugar, molasses, milk and butter in special mixers with heating and boiled at a temperature of 110-115 * C. Mass fraction of dry substances 89-90%. The boiled mass passes through a steam separator and goes to the casting without cooling. If you want to get such masses of light colors, they are boiled under vacuum at low temperatures[with. 236, 18].

Roasted masses... The recipes provide for three types of roasted candy masses: hard roasted nuts (chocolate roasted candies), soft roasted nuts (Kievsky roasted candies) and fruit roasted nuts (Serenada candies).

Hard roasted nuts is a solid amorphous mass of sugar, including crushed, roasted kernels of nuts, almonds. It is obtained by melting sugar and then introducing it into the melt of nut kernels. Mass fraction of dry substances of this mass is 97.7-99.3%. The share of the nut is over 30%.

Soft roasted nuts are obtained by preliminary preparation of sugar-honey syrup, followed by the introduction of fried crushed kernels. Mass fraction of dry substances of this mass is 95.5-96.5%. The proportion of walnut kernels is about 30%. This type of roasted nuts can be prepared by replacing honey with molasses.

Fruit roasted nuts is a hard-boiled fruit-sugar mass with roasted crushed walnut kernels. Mass fraction of dry substances 88-92%. Share of nuts for different varieties ranges from 18 to 40%. The finished candy mass is sent for molding at a temperature: for hard roasted nuts 125-130 * С, for soft - 105-110 * С, for fruit roasted nuts 90-95 * С.

Forming candy masses.

Molding is understood to mean the division of plastic or liquid candy masses into separate portions of a certain volume, giving each portion a certain desired configuration. There are five ways to mold sweets: casting; smearing; rolling; extrusion; jigging.

Casting. Casting is the most common molding method. Casting is mainly used to form masses with low viscosity (good fluidity). Molding in this way makes it possible to obtain products of various shapes, including those consisting of several different layers of candy masses. Casting is carried out mainly into molds made of starch, less often - from granulated sugar. Casting into starch molds is used to produce cases of fondant, milk-fondant, fruit-jelly, liqueur, whipped and other candy masses. The candy mass is cast into cells specially stamped in starch and having the desired shape. In starch, the mass acquires the appropriate shape and hardens or becomes covered with a sufficiently strong crust. Starch as a forming material must absorb moisture well from the cast mass. For casting various candy masses, technological instructions regulate a certain temperature. Optimum temperature for casting, C: fondant (sugar and milk) 65-72, fondant with nuts 70-75, fruit-fondant 80-85, fruit 96-106, jelly 70-75, milk 100-110, liqueur 90- 95. Each type of candy mass requires a different retention regime: fondant mass 32-40 min at 4-10 * C, fruit mass 40-50 min at 4-10 * C, milk mass 60-90 min at 25-28 * C (at the beginning of retention) and 8-10 * C (at the end of the stand).

Smudging. Many types of candy masses are formed by smearing followed by cutting: fondant, fruit, nut, whipped and even cream. In this way, it is possible to obtain multilayer candy bodies, which are rarely made of more than three layers, different masses can be included, belonging to the same or different types.

The smear molding process consists of several separate operations: preparation of the candy mass; smearing; posture; cutting. Preparation of the candy mass consists in tempering it before molding. Fondant masses are smeared at a temperature of 60-65 * C, fruit masses - 80-85, whipped "Bird's milk" - 55-60, cream - 28-30 * C.

On a spreading conveyor, one-layer and multi-layer candy bodies and unglazed candies can be obtained from shapeless plastic candy masses. Initially, a layer is produced on a conveyor, which is then cut in two directions, usually at right angles. As a result, individual housings of a regular shape are obtained. The second and, if necessary, subsequent layers are smeared onto the cooled previous layer. Duration of vystoyka depends on the type of mass, its properties and temperature conditions.

The surface of the layer of fondant and some other masses is sprinkled with powdered sugar or a mixture of powdered sugar and cocoa powder and served for cutting. Layers of whipped masses after vystoyka from above are coated with a thin layer chocolate glaze temperature 28-30 * C.

The seams are cut in two mutually perpendicular directions into separate bodies of predominantly rectangular shape. This operation is carried out on machines of two types: with circular knives or with strings. In both methods, the layer is cut alternately, first into strips, and then into individual products. The knives are placed so that in one mechanism they are located at a distance equal to the width of the candy, and in the other - at a distance equal to its length. The resulting bodies go for glazing, and unglazed candies for wrapping and packaging.

Rolling. This method is more advanced than smearing. The formation of a candy layer occurs when the mass passes between the rollers, the thickness of the layer depends on the gap between the rollers. By the rolling method, bodies are formed from custard nut masses, fondant mass, roasted roasted masses. In multi-layer candy bodies, each layer is formed on a separate roller mechanism.

Forming of candy masses on a wafer basis is carried out on a machine with three working rolls, one of which is corrugated and two are smooth. The corrugated roll forces the crop into the space between two smooth rolls. Before entering the cooling chamber, the layer with wafers passes under the pressure roll, after which the layer is cut by wire cutting machines.

Pressing out. The method is based on extrusion of the candy mass through the holes of the dies into the bundles of the corresponding profile (round, oval, rectangular, etc.). This method forms plastic masses, which include mainly fat-containing (nut masses) and some fondant masses.

The praline mass is prepared for molding by kneading for 30 minutes at a temperature 2-8 * C higher than the melting temperature of the mixture of fats included in its composition. In this case, a complete destruction of the structure occurs and the mass acquires a liquid-like consistency. Then this mass is cooled to the optimum molding temperature (see table. 1.2).

Table 1.2

Optimum mixing and forming temperatures

Depending on the design of the forming machine, extrusion of the candy mass is carried out through 6, 18, and 22 holes of the forming matrix. The extrusion of the mass during molding is carried out by a screw blower, into which the mass is supplied from the hopper. From the forming mechanism, the mass comes out in the form of endless belts or ropes, which are cooled on a conveyor in cabinets. The ropes acquire significant strength, the fat contained in the mass crystallizes. Cooling time 7-8 minutes.

Jigging. When molding by jigging, piece products of complex configuration are obtained from candy masses by extrusion through profiling nozzles onto a receiving conveyor or sheets. In this way, mainly cream and whipped masses are molded. When deposited, the products are dome-shaped, therefore, when using this method, subsequent cutting is not required. Molded products can be given a different configuration by changing the shaped nozzles [p. 258, 18].

Surface treatment of sweets.

Surface treatment of sweets consists in their glazing. Glaze gives sweets a more attractive appearance and greater shelf life, improves taste. Glazing is carried out with various types of glaze:

a) couverture - natural chocolate coating. It contains powdered sugar, cocoa mass, cocoa butter, vanilla essence; in some varieties, it is allowed to introduce confectionery fat up to 3-5%, soy phosphatide concentrate - 4%;

b) chocolate glaze is a semi-finished product, which is a finely ground mass consisting of processed products of cocoa beans, as well as fat equivalents of cocoa butter with or without the addition of various flavors and aromatic additives;

c) fat glaze is a semi-finished product, which is a fat mass made on the basis of confectionery fat, powdered sugar and other flavoring and aromatic substances;

d) fondant glaze - is a fondant mass with the addition of wine, essences; rarely used;

e) caramel glaze - melted caramel mass with which nut kernels are glazed.

In addition, the surface of glazed and unglazed sweets can be sprinkled with sugar, cocoa powder, nut or waffle crumbs, chocolate grits, and also decorated with nuts and fruits.

The process of glazing candy bodies can be carried out in different ways: ordinary single glazing; double glazing; first coating the bottom with chocolate glaze, and then the entire body. Waffle-based casings are glazed twice. In accordance with the recipes, the amount of glaze on sweets with solid-structure bodies should be 22-25%, of a weaker structure (liqueur, whipped) - 30-45%, with wafer-based bodies - 30-40%. The chocolate enrobing process must be preceded by an important tempering process. Glazed sweets pass through the refrigerator at a temperature of 6-10 * C for 5-6 minutes. During this time, the cocoa butter completely crystallizes and the glaze solidifies. In some designs of enrobing machines, a device is provided for applying various patterns to sweets.

The bodies are glazed with fatty glaze on the same machines on which the bodies of sweets are coated with chocolate glaze. Fat glaze does not require tempering. It is heated to a temperature of 37-40 * C.

Fondant glaze is most often glazed by hand. For this, sugar or milk lipstick is heated to a temperature of 50-55 * C and flavoring and aromatic components are introduced. Prepared bodies of sweets are covered with heated lipstick and placed on metal sheets. After standing in the workshop for 3-4 hours, they are transferred for filling and packaging. Fondant glaze dries quickly (white spots are formed), therefore, lipstick glazing is used most often only for sweets included in sets that have a short shelf life [p. 260, 18].

Sweets are one of the most common and favorite sugar-based confectionery products for children and adults. They can have a different composition, taste, shape and design; they are made from one or several candy masses at once. The assortment of candies comprises several hundred items. Experts count about 500 types of these delicacies.

The production of sweets is carried out in specialized and universal confectionery factories, in large and small confectionery shops... There are several classifications of sweets: according to the design and the presence of packaging (wrapped, not wrapped, in plastic and other materials, in fillets, in capsules, in foil, etc.), according to consistency (soft and hard), depending on methods of preparation and finishing (unglazed, glazed, chocolate with fillings and relief patterns on the surface, in powdered sugar, in waffle crumbs, with colored powder, etc.).

The main part of the candy that is under the glaze is called the body by experts. Candy bodies are made from a variety of candy masses. Chocolate finely ground mass is made from sugar and cocoa products with the addition of milk, fat, nut crumbs, vanillin and other flavoring and aromatic additives. The roasted base is a solid amorphous mass, which is made from sugar, various semi-finished products (berries, fruits, nuts) and other flavoring and aromatic components. The liquor mass, as a rule, has a liquid or syrupy partially crystallized consistency. It is prepared on the basis of sugar with the addition of alcoholic beverages or without them (when it comes to sweets for children), fruit and berry semi-finished products and other additives.

Plastic and viscous marzipan mass is made from sugar and unroasted nuts with the addition of various aromatic components. The fondant mass has a fine-crystalline structure and is made from sugar and molasses. For improvement taste various components are added to it (semi-finished products from berries and fruits, nuts, milk, etc.).

The milk mass can be partially or completely crystallized. It is made on the basis of milk, as the name implies, and sugar with the addition of butter, fruit and berry fillers and other additives.

The fruit mass is viscous in consistency and similar to jelly. It is made from sugar and fruit and berry semi-finished products. The creamy mass, oily and knocked down in consistency, is made from sugar, fat, chocolate with various additives. Finely ground praline mass is made from roasted nuts, sugar and fat with the addition of cocoa products, milk powder and other components. Whipped foamy mass is prepared from a frother, sugar, gelling agent and various additives (milk, cocoa powder, berry puree etc.).

The jelly-fruit mass is similar in consistency to jelly and is made from sugar, gelling agent, molasses and fruit and berry semi-finished products. The jelly mass has the same composition, with the exception of fruit and berry additives.

Candy bodies can be made from one or several candy masses. If there are several layers, then they are usually separated by waffles. They also cover the body of the product. In addition, nuts, berries and fruits, cookie crumbs, etc. are often used as fillers.

Confectionery production, in general, refers to a highly mechanized and automated food industry. Most of the sweets are produced in a flow-mechanized way, except for expensive hand-made chocolates. A wide selection of equipment is on sale for the manufacture of all types of confectionery - from caramel to chocolate. The flow-mechanized line allows the production and packaging of glazed cast sweets with fondant, fondant-milk, jelly, milk and other cases. The maximum productivity of such a line is up to 10,000 items per minute.

Let's consider the process of making sweets using the example of products made from fondant and fondant-candy masses. The procedure for making this type of sweets consists of several main stages: preparation, boiling sugar-syrup and milk syrup, filtering it, churning the fondant mass, dosing and mixing semi-finished products, tempering the candy mass, molding the candies and packing them.

The fondant mass, depending on the components, is ordinary, milk and creme brulee. The basis of any such mass is sugar, molasses and water. Only in milk lipstick, most of the water is replaced with milk, and baked milk is part of the crème brulee mass. In addition to the main ingredients, the recipe also includes cocoa powder, red color and vanillin.

There are several technologies for preparing fondant mass. For example, according to one of them, pre-sifted and purified from impurities sugar is loaded with the help of a dispenser into a mixer, where molasses flows from a tank through a plunger dispenser, and water through another dispenser. All these components, getting into the mixer, form a mixture of granulated sugar and sugar solution in water-treacle solvent. With the help of a plunger pump, the flow of which can be regulated, this mixture enters the apparatus, which is heated by steam. Along the way, the mixture gradually heats up, the sugar dissolves and forms a concentrated solution, which, in turn, is filtered and collected in a collector. The resulting semi-finished product is still too liquid, therefore, for further work with it, it is fed into the cooker.

All released steam is separated in a steam separator, where the boiled solution enters. Then the syrup is filtered again and drains into the funnel of the fondant machine. It is fed gradually, which helps to cool the liquid. The cooled solution is mixed in a fondant machine, which leads to the crystallization of sugar. The resulting lipstick is transferred to a heated collection container equipped with a special stirrer. Heating is needed so that the fondant does not freeze ahead of time. At this stage, flavoring and flavoring agents, as well as dyes are added to it. The resulting mass is brought to the desired temperature, molded and wrapped in a wrapper.

Molding refers to the process of shaping and shaping a candy. appearance including various finishes. Molding, depending on the type of sweets, is carried out in two main ways: with obtaining a candy layer or a bundle, followed by cutting it into separate portions or by producing separate products at once. The candy layer is formed in two ways - by smearing and rolling. In the second case, molding is carried out by casting or jigging.

Casting is carried out into molds that are stamped in rice or corn starch. The first method is somewhat more complicated and consists of several procedures: preparation of the candy mass, molding the mass into a layer, holding the layers and cutting them into separate products or bodies, if we are talking about the production of whipped and cream candy masses.

When using the extrusion method, the mass is squeezed out in the form of a rope through a hole in the dies. Then the strands are cooled and cut into separate pieces. This method is usually used in the production of sweets from fondant and praline masses. One of the varieties of this method is jigging. In this case, the mass is squeezed out in a vertical plane. In this way, cream, whipped, nut and fondant masses are formed.

After molding, according to the recipe, the candies can be glazed. This is done to protect the inside of the product from the effects of the external environment, increase nutritional value, giving it a more attractive appearance and better taste. The sweet mass, which is used to cover the candy shells, is called the glaze. The icing can be chocolate (it costs more and tastes better) or fatty.

The procedure for coating the candy body with glaze is carried out using special equipment. The tempered glaze is fed into a container, from which it flows onto the candy. And the underside of the product, where the glaze does not fall from above, is glazed with rollers. Then the candy is blown with air, which removes excess glaze, and cooled in a cooling cabinet at a temperature of 6-10 degrees Celsius for five minutes.

The finished candy is wrapped in a wrapper, packed in cardboard boxes or stacked in boxes. Most of the products are wrapped or plastic wrapped. With the help of packaging equipment, sweets are wrapped on machines in a label or foil and in a label with a roll of waxed paper and foil. Ready-made candies are poured into packs or boxes of corrugated cardboard or plywood boxes, in which they go to stores.

There are other technologies for the production of fondant sweets with the addition of molasses (at least 3% by weight of sugar), which acts as an anti-crystallizer. When the mixture enters the lipstick machine, it cools down, which allows you to maintain any crystallization mode. The degree of readiness of the syrup is determined by its moisture content. To obtain a fondant mass, flavors, flavors and dyes are introduced into it.

Thus, the line required for the production of candies from fondant mass includes the following equipment: a cooker, a filter, an installation for preparing fondant masses, a tempering and jigging machine and a steam generator. Equipment in this configuration will cost 900 thousand rubles. Its payback period, according to suppliers, is less than six months. To service such a line, four workers are enough per shift.

Production caramel products, which account for over 20% of the total production of confectionery products in our country, has some differences. As raw materials for their production, molasses, sugar and various fruit and berry semi-finished products are used, as well as all kinds of confectionery masses (dairy, whipped, walnut-chocolate, etc.).

Technological processes include the preparation of caramel mass, its cooling, tempering, dosing, mixing with additives, rolling and molding of caramel, cooling, separation of the layer into separate products, supply of products to packaging.

First, sugar-treacle is made caramel syrup with a moisture content of about 15%, which is boiled down into a caramel mass with a moisture content of 1.5-2.5%. The resulting mass is molded and cooled to a temperature of 45 degrees Celsius, wrapped in a wrapper, packed in bundles and packed in boxes. For the production of caramel, you need a cooker with a stirrer, an intermediate tank, a temperature table, forming rollers, a conveyor-type cooling machine, a vibrating tray, tables for packing ready-made sweets. Such a line with a productivity of 150 kg of products per hour is also served by 3-4 workers. Its cost is about 1.2 million rubles.

The equipment for the production of truffle sweets, which includes cocoa in various forms (grated, powder, butter), toffee essence, coconut oil, will also cost the same amount. Truffles are made in several stages, which include the preparation of the candy mass, tempering (one of the important stages in the production of, first of all, chocolates), body molding, cooling, sprinkling with cocoa powder, finishing and packaging of sweets.

The production line includes a digester, tempering machines, whipping, jigging, cooling and conveyor equipment, machines for applying glaze, a steam generator, a conveyor belt for feeding sweets for stacking. A line with a capacity of 150 kg of sweets per hour will cost 1-1.5 million rubles. The payback period is, according to manufacturers, more than six months.

The cheapest line is for the production of dragees - small round-shaped candies in a glossy shell or in a sugar polished shell. The dragee consists of a body and an outer coating, which is rolled onto the body in special rotating boilers installed at an angle. First, the base of the dragee is prepared, then this mass is coated and glossy. The finished candies are packed and packed in boxes. Perhaps this is one of the easiest confectionery products to make.

A line with a capacity of 100 kg of dragees per hour, consisting of a micro-mill, a digester, a dragee drum, a sugar sifter and a packaging machine, will cost 200-250 thousand rubles. To install this equipment, an area of ​​30 square meters is sufficient. m, and three people will be enough to service it.

Regardless of what kind of sweets you are going to produce, for their storage you will also need a specially equipped warehouse with a constant temperature of about 18-20 degrees Celsius and a relative humidity of no more than 75%.

Experts advise entrepreneurs who do not have a large start-up capital to choose one direction to start. For example, it is possible to produce only caramels and dragees, or chocolates and truffles. Then, as the company develops and its profits grow, you can gradually expand the range of products.

Large factories use lines with a capacity of over 1000 kg of products per hour, and small enterprises purchase equipment that allows them to produce about 150-200 kg of sweets per hour. Mini-lines of domestic and foreign production are especially popular among entrepreneurs. A small area (about 100 square meters) is sufficient for their placement. Compactness and affordable price allow buying these lines in the future, as soon as the company has an opportunity to expand the range of its confectionery products.

So, to open your own confectionery factory, you will need a suitable premises, brought in accordance with all sanitary standards, equipment, qualified workers, including a pastry chef and a technologist. The quality of your products and, consequently, the success of your business directly depends on the qualifications of the last two specialists.

Often small confectionery are located in the regions, since the average level of wages there is much lower than in large cities. Competition in the candy market is quite high both among domestic producers and among Western companies. Small businesses working for the region sell their products through retail chains, individual grocery stores and private business outlets. Some of them open their own points of sale - from individual trade stalls to shops.

If you plan to work with other regions, you will need a wholesaler finder. In addition, it is worth considering creating your own website with company contacts and assortment data.

Sales of confectionery products are directly dependent on the season. The peak of sales of sweets in sets falls on the period of various holidays (September 1, March 8, New Year, etc.), sweets by weight sell well from autumn to mid-late spring. In summer, there is a significant decline in the market for chocolates, sweets, soufflés, but at the same time it almost does not affect the segment of caramel and dragees.

Lilia Sysoeva
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One of the main brands of the Saratov region is the confectionery factory "Saratovskaya", its abbreviated name is JSC "KONSAR". It is better known as Confashion. Let's talk a little about the factory today, and at the same time see how sweets are made.

The factory has existed for many years - its history dates back to 1930, when in the form of an artel named after. Rosa Luxemburg was located in the city center (at the corner of Radishchev and Kutyakov Streets). Now the factory has a different address, and its assortment is wider.

Why is the factory one of the main brands of the region? So, after all, its products are sold in most regions of Russia (more than 60 constituent entities of the country), as well as abroad (export is made to 12 countries the former USSR, except for the Baltic countries, as well as in China and the USA). And in 2015, the factory became the best exporter of the region. But despite this, the factory is more of a regional manufacturer.

Photo taken from Denis djhooligantk

Let's take a look at the production of the factory's main commodity, candy. Confectioners call this type of production sugar. So, all the important sugary confectionery products are produced at Konsar: chocolates, caramel, toffee and gummy candies. They also sort gift sets. The products are constantly being updated.

Information stand for workers

The factory produces 18.5 thousand tons of sugar products per year on 14 production lines. By the way, the equipment at the factory is both domestic and foreign (Italian, German and Swiss). Equipment of different years, there is already old one. But it does its job well and there is no need to change it. In addition, all equipment undergoes periodic maintenance.

Although it should be said that the factory is constantly working to improve the quality of the assortment and the variety of the assortment. Therefore, new equipment is also bought - to open new lines. So, recently a line of sweets "One Shot" was opened with the most modern equipment of Italian origin. The peculiarity of this line is that the filling and the body are formed simultaneously.

And now let's get acquainted with the process of candy production itself. We will start the excursion from workshop No. 6 (there are 7 workshops in total in the factory, in which there are 40 lines for the production and packaging of confectionery products). This is a workshop for the production of the most expensive products - assorted chocolates, which are also used for gift sets (see the title photo). By the way, the factory produces about 1.5 million of these sets per year. For such sweets, by the way, real cocoa butter is used.

The beginning of the line - a machine with empty molds for sweets embedded in it

The workshop has 2 production lines (both German) - Knobel and Yubitek .
Yubitek is a line for the production of sweets with assorted fillings. It produces chocolates with a variety of fillings. Moreover, the forms of sweets are very diverse. Examples of candies of this line are candies and sets of candies "Confessional de Luxe", "Overture", "Miracle nut", "Cherry in chocolate".
And on the line Knobel make jigging sweets - sweets based on marzipan, truffle and praline.

As mentioned above, sweets have different shapes: a basket, a bottle, a hemisphere, etc. It depends on the terms of reference received on the line. Each form has its own dose of chocolate glaze. Glaze, by the way, is also different. The factory uses bitter, milk and white chocolate for the glaze.

This is what a press looks like for giving the future candy different shapes. Now the simplest forms are being made - hemispherical.

The process of creating a candy is as follows: first, the machine forms the body of the candy (just the photo above), then the body comes in a cooling tunnel (10-14 degrees Celsius), then the filling is poured into the body. The filling and glaze are prepared ahead of time - in another workshop.

Top photo - a machine for shaping (on the right you can see already finished products- then the conveyor line). Bottom right photo - the body of the candy after cooling.

There are 2 filling machines installed on the line (photo below) - to quickly switch from one to another when the raw material runs out. It also allows you to make sweets with two fillings at the same time.

And now the body of the candy is filled with filling.

And this is what marriage looks like. Such candies do not go on sale - they are processed for subsequent production (for example, they are used for filling waffles).

After filling with the filling, the bottom of the candy is made. For this, the candies are slightly warmed up (to melt the top a little), and then poured with chocolate and level.

End view

And at the very end of the line, the candies are “shaken out” of the mold and put on pallets for further sorting.
Some of the products go to the packaging line, and some go to warehouses.
Let's take a look at the packaging line first. Here, first, the sweets enter the wrapping machine. There are several such machines, each with its own wrapping.

General view of the machine

Sweets wrapping process

Finished sweets at the exit from the machine

Then the already wrapped candies go to packing and packaging.

Here we see the weight packaging of truffles.

Video of this line and the packaging of sweets

The kingdom of various sweets

Sweets are numbered here: each type is in a special tray under its own number.

And already according to these numbers, the process of assembling the kit is going on.

This is where various gift sets are formed: seasonal, festive and thematic. These are - in the form of assorted

Or such

The residents of the region can buy the products of the factory both in federal chain stores and in their own branded outlets (for example, in the well-known Chudesnitsa stores). Also, the factory has created an online store, which distinguishes the factory from others. This store is little known to the people of Saratov, and in vain - all ordered products will be delivered to your home free of charge. True, there are limitations there (for example, the minimum order value is 700 rubles), but a bonus system is provided.

By the way, the work clothes of the employees are strictly monitored here: white robes are strictly over all clothes and mandatory hats.

But not only candy is made at the factory. Here is also presented flour production of confectionery, which we will talk about next time.