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Production technology of chopped semi-finished products. Description of the technological scheme for the production of chopped semi-finished products Technological process for the production of chopped semi-finished products

Introduction

4. Estimated part

conclusions

Bibliographic list

Introduction

Meat chopped semi-finished products enjoy well-deserved recognition of the consumer and every year take an increasingly strong place in the diet of the population.

For businesses Catering these semi-finished products are of particular value, since without them it would be impossible to satisfy the demand of visitors for such widely popular and favorite dishes as steak, beef stroganoff, etc., even in the most limited quantities. cattle, which contains only two tenderloins (with a total weight of no more than 3 kg), it would be possible to cook at best 20-25 servings of steak, langet or beef stroganoff, i.e. quantity, in no way satisfying the needs of a large dining room and restaurant / 12 /.

The advantage of meat chopped semi-finished products is also the fact that, by facilitating and reducing the work of procurement shops, reducing the time required to prepare a hot meat dish or snack, they allow increasing the throughput of the enterprise. Meat processing plants produce semi-finished products under conditions that fully guarantee the freshness, good quality, purity and hygiene of products. Technological process and the recipe are built in such a way that for this type of semi-finished product only that part of the meat is used, which strictly corresponds to the product in terms of tissue structure, fatness, quality and culinary properties /9/.

Every year, chopped semi-finished meat products will be supplied to public catering establishments in a wider and more diverse assortment, every year these products will increase the range of dishes and snacks, reduce and facilitate the production processes of cooking while preserving all the taste and nutritional properties of the best gourmet and gourmet dishes /10/.

meat chopped semi-finished products

V last years the demand for semi-finished products that do not require a significant investment of time for cooking at home and in public catering establishments has increased significantly. Meat semi-finished products, as a rule, are produced in packed and packaged form, which also determines their high consumer qualities.

The range of meat chopped semi-finished products is constantly expanding as a result of the use of various combinations of meat raw materials with vegetables, cereals, flour and other protein components. Thanks to the use of flow-mechanized lines in the production of semi-finished meat products, their external design improves, packaging is improved /9/.

Minced meats of various recipes are becoming more common, from which you can cook a large number of variety of dishes.

1. Feature and theoretical basis production of meat chopped semi-finished products

Meat is one of the most important food products with excellent culinary qualities. It is easily combined with various products - vegetables, cereals, pasta, cooked as side dishes. Along with high-grade proteins, it contains fat and so-called extractive substances, which contribute to better digestion of food / 12 /.

For the preparation of semi-finished products, meat processing plants use the meat of cattle, sheep and pigs.

Depending on the structure of meat tissues, mechanical processing and culinary purpose, all semi-finished meat products are divided into natural, breaded, minced and culinary cutting meat. In addition, the industry puts on sale such semi-finished products as frozen dumplings / 9 /.

Meat chopped semi-finished products - a portioned product made from chopped meat raw materials with additives (minced meat). Meat chopped semi-finished products after manufacturing can be raw chilled or raw frozen. As an example, the following chopped raw semi-finished products can be given: cutlets, meatballs, hamburgers, schnitzels, steaks, rump steaks, kebabs, meatballs, meatballs, quenelles and croquettes.

Chopped semi-finished products. Cervical, femoral, scapular muscles, containing coarser and tougher connective tissue, are the main raw materials for the preparation of chopped semi-finished products.

Careful grinding of meat on special technically advanced machines and the addition of fat, eggs, spices to minced meat ensures good quality for these semi-finished products.

Moscow cutlets contain beef meat (any fatness category) - 25 g, raw bacon - 4.47 g, wheat bread - 7 g, as well as onion, pepper, salt and water. Prepared minced meat is given an oval-flattened shape. Cutlet weight 50 g.

Amateur cutlets are made from beef carcasses of fatty, above-average and medium fatness. After stripping, the pulp is crushed, mixed with spices, white bread and other ingredients, shaped into a large cutlet with a pointed end and breaded in ground breadcrumbs. Semi-finished product weight 75 g.

Pozharsky pork cutlets are made from semi-fat pork (45 g) with the addition of egg melange (2 g), wheat bread (South), pepper, salt and water. At the request of the customer, meat processing plants add onions to Pozharsky pork cutlets, as well as to amateur cutlets. Cutlet weight 75 g.

Kiev cutlets are made from pork containing up to 30% fat. The semi-finished product recipe contains approximately 30 g of pork, 7 g of wheat bread, onion, pepper, salt, water. The weight of one cutlet is 50 g.

Beef schnitzel is made from minced beef meat of the best quality, shaped like a flat oval cake. Schnitzel weight 100 g.

Pork schnitzel differs from pork pozharsky cutlets in weight and shape. The pork schnitzel is given a flat oval shape. This semi-finished product weighs 100 g.

Meatballs are ball-shaped. They are made according to the same recipe and from the same raw materials as Moscow cutlets.

Zrazy is made from ground beef stuffed with hard chopped eggs mixed with fried onions and ground breadcrumbs.

Beefsteak - a dish of fried beef, originally one of the types of steak, steak from the head of the tenderloin. Often there is such a subspecies of steak as chopped (often passed through a meat grinder) steak, which is the prototype of the cutlet. Beefsteaks are also classified into fried and "rare".

A rump steak is a lightly beaten piece of meat weighing 115 grams, cut from a thick edge or fillet, moistened with a beaten mixture of fresh eggs, water and salt.

Meatballs - small round cutlets made from minced meat (originally chops).

Meatballs - a dish that is balls of minced meat or fish, cooked with the addition of finely chopped onions, herbs and spices. Sometimes, to improve the consistency of meatballs, soaked loaf or bread is added to the minced meat. Usually meatballs are about the size of a walnut.

Kyufta is a kind of meatballs made mainly from lamb. A traditional dish from the Middle East and South Asia.

Quenelles are balls of meat, fish and chicken meat, with cream and egg /12/.

2. Technological scheme for the production of minced meat semi-finished products and features

meat chopped semi-finished products - a portioned product made from chopped meat raw materials with additives (minced meat). Meat chopped semi-finished products after manufacturing can be raw chilled or raw frozen. As an example, the following chopped raw semi-finished products can be given: cutlets, meatballs, hamburgers, schnitzels, steaks, rump steaks, kebabs, meatballs, meatballs, quenelles and croquettes.

To prepare minced meat for chopped semi-finished products, frozen meat raw materials (blocks) are crushed in a crusher. Also, for the preparation of minced meat, mechanically deboned meat obtained on a meat and bone separator can be used.

Then the minced meat is passed through the top. Pork bacon is added to minced meat, which is pre-crushed on a top or on a bacon cutting machine. Salt, water pre-chilled with ice, additives, spices are added to the minced meat and everything is mixed well in a meat mixer. A cutter can also be used for mixing.

Minced meat ready for molding semi-finished products is loaded into the bunker of the machine for molding semi-finished products, where the product of the required shape and weight is molded, for which, depending on the volume of production, a rotary or auger product molding system is used. In the molding machine, the patties are formed and dosed onto a belt, after which the product can be sent to the ice cream machine and / or breading machine for thin and dry breading, respectively.

Then the cutlets are sent on trolleys to the shock freezing chamber or automatically by conveyor to the spiral quick freezer in case of high line capacity. The duration of freezing meatballs ø75x20 mm weighing 85 g, in a shock freezing chamber is 2 hours, and in a spiral quick freezer - 40-45 minutes. After freezing, cutlets are packed and moved to a low-temperature refrigerator for storage /12/.

Beef, pork, lamb, horse meat, as well as meat of other types of slaughter animals are used as the main raw materials /4/.

Do not use double-frozen meat and pork with darkened bacon.

Along with meat raw materials, various protein preparations of plant and animal origin (soya, blood, milk proteins, etc.) are widely used, as well as melange, egg powder, vegetables and other components, depending on the direction of use of the meat product (Figure 2.1) / 4/.

Figure 2.1 Technological scheme for the production of chopped semi-finished products

3. Main process equipment

1.Crusher of frozen blocks - a machine for grinding deep-frozen meat (with a temperature of up to - 30 ° C) for further processing on a cutter or top. At the same time, preliminary defrosting of the product is not required, which allows preserving the taste of the product and preventing loss of nutrients.

The crushing of the block, depending on the subsequent destination of the raw materials obtained after the crusher (pieces the size of a fist or into slices), can be carried out on a machine with a rotating shaft with knives or rollers or on a guillotine type machine /2/.

.The grinder for meat is designed for industrial grinding of meat, meat products, fats in order to produce sausages and other food products.

The meat grinder is the main machine in the production lines for the production of sausages and semi-finished products. The quality of the products obtained directly depends on how finely and accurately the top cuts the lumpy meat.

The principle of grinding lumpy meat used in meat grinders has been unchanged for many years: the meat in the receiving hopper is captured by the auger or augers and fed through the body with internal ribs to the cutting tool, which is a set of fixed grates, usually consisting of three pieces, and movable knives, consisting of two pieces.

Different tops for meat, despite the same method of grinding and the apparent simplicity of design, have completely different quality of grinding. It is affected by even minor design features inherent in each of the structures, as well as the degree of wear as cutting tool, and housings with auger /7/.

.Meat mixer. The purpose of the meat mixers is to mix the crushed products with spices and other ingredients. Usually minced meat, cereals and other products are mixed in meat mixers.

The main components of the meat mixer are the bowl, the lid and the mixing mechanism.

Dezha is a mixing bowl connected to a kneading unit. Usually the meat mixer bowl is made of stainless steel with a smooth surface, which greatly facilitates its cleaning and operation in general. The meat mixer is designed in such a way that it contributes to uniform mixing of all minced meat ingredients. Mixing takes place by means of kneading screws.

The design features of the bowl (dezha) and the blades of the meat mixer ensure an even distribution of the ingredients over the minced meat.

Meat mixers are vacuum and open (non-vacuum). Mixing minced meat in a vacuum mixer ensures a dense, pore-free structure of minced meat, increases the color fastness of products.

All meat mixers have protective mechanisms. In particular, it is a mechanism for blocking one or more kneading augers when the bowl lid is opened. The process of loading and unloading raw materials is usually fully automated /3/.

.Meat-and-bone separators, or minced meat machines, are used to separate meat from bone in the production of edible minced meat, chicken or fish.

The minced meat obtained in this way can be used for the production of high-quality products, since it retains the structure of muscle tissue.

The principle of operation of the machine is that the incoming raw material is loaded into the separator hopper without prior grinding (with some exceptions). Pork or beef bones are recommended to be pre-shredded into fist-sized pieces, without the need for an additional grinder, which optimizes the use of production space.

All designs of mechanical separators are based on the use of the separation principle, taking into account physical characteristics processed raw materials.

Using various pressures, meat or other product is forced through the slotted or round holes of the separating head, and bones, cartilage and (or) veins are removed through the front of the machine. The product output is adjusted manually using the cones at the front of the separating auger and the restrictor.

Minimum temperature rise in case of incoming raw material temperature 0-2 º C (this temperature is optimal) - usually 1-2 º C on the chicken, 4-7 º C on a turkey, and about 10 º C on beef /6/.

.Cutter - turns meat into soft airy minced meat for cooking boiled sausages, sausages, sausages. The cutter grinds products in a vacuum. Fast rotating knives (up to 4500 rpm) instantly turn meat into minced meat, which retains its natural color, vitamins and nutrients in the absence of oxygen. Thanks to the processing without access to air, the quality of the final product and its shelf life are significantly increased.

.Ice maker. The meat processing industry requires a large amount of water ice. Flake ice produced on flake ice machines is optimal for use. It has a flat shape, thanks to which it has a large heat exchange surface, so it cools the minced meat better than other types of ice.

The temperature of the produced flake ice at the exit from the ice generator is up to minus 12°C, the thickness is from 0.8 to 2.8 mm. Machine productivity from 380 kg to 23 tons/day/7/.

.Lard cutter - allows you to cut into cubes, strips or circles fresh, boiled and frozen (up to - 5 ° C) meat, lard, as well as ready-made sausages, ham, vegetables. Products containing bones are not subject to cutting / 6 /.

8.Machine for molding semi-finished products. After grinding meat raw materials, adding other ingredients, mixing and cooling, the minced meat is ready for molding. With the help of forming equipment, it is possible to give products a variety of shapes /2/.

.Breading machine. The next stage after the molding of chopped meat products is the stage of breading (coating) of the product. The breading process consists of three operations - pre-sprinkling, liquid breading and coating with breadcrumbs. Various combinations of these operations or all three coatings may be used in the manufacturing process. However, there are standards for the amount of sprinkling used, the amount of which should not exceed 30% by weight of the finished product.

In fact, breading improves the product in many ways: it makes the product more juicy while retaining moisture and flavor. Breading makes products more attractive. In addition, breading increases the weight of products, increasing the cost.

Pre-sprinkling is often used in the manufacture of breaded products to improve the adhesion of the wet breading. This operation is very important for products with a wet or greasy surface. For this operation, flour or a dry protein mixture for breading is usually used.

There are many different types of dry breading used in the manufacture of meat products. They come in a variety of sizes, shapes, textures, colors and flavors. Finely ground breadings are very popular and traditional. They give the product an airy appearance and resemble a homemade product /7/.

.Laying machine. Liquid breading plays a very important role in the coating technology for semi-finished meat products. When preparing products, two types of breading can be used: yeast and unleavened. The choice of one type or another depends on the recipe of the product. Liquid breading is a mixture of various ingredients that may include flour, starches, eggs, milk, spices and herbs, leavening agents and stabilizers.

When applying a liquid breading in order to increase adhesion, it is used in combination with dry breadings. In this case, fresh breadings with different viscosities are more often used.

Equipment for laying minced semi-finished meat products from minced meat raw materials (minced meat) of beef, veal, pork, lamb without filling (cutlets, hamburgers, meatballs and other similar products) /6/.

.Shock freezer. Now the freezing of products occurs thanks to a special technology for removing heat from the product. At the same time, the temperature drops and at a certain point the water in the product begins to turn into ice crystals.

The product is considered frozen if its temperature is -6 degrees. In meat, 75 percent of the water freezes at minus 5°C; 80 percent - at minus 10°C; and 90 percent - at minus 20 degrees.

Freezing products is used primarily for their long-term storage.

Technologically, the freezing process can take a different amount of time. Best of all, product quality is preserved by quick (shock) freezing. As a result of this process, very small ice crystals are formed inside the product, which has a positive effect on the quality of the product, since there is minimal damage to the tissue of the product.

It was for these purposes that special devices were created - shock freezing chambers. They allow you to quickly freeze a product or dish, while maintaining its useful properties / 3 /.

.Packing machine. Filling and packaging machines, multiheads (electronic high-precision weighers), packaging systems for food or non-food small-piece, free-flowing, non-dusty products. The equipment uses the principle of weight dosing and is used for packaging /2/.

13.Refrigerated warehouses and storage chambers include: a heat-insulating circuit (chambers) with doors and a cold supply system.

As a heat-insulating circuit, chambers made of PPU sandwich panels with refrigerated doors produced by our own factory are used. The refrigeration system includes: a refrigeration compressor unit, a condenser, an oil cooler, a circulation receiver and a pumping station (in the case of a pump-circulation refrigerant supply scheme), an electrical control panel, refrigerant pipelines and electrical cable lines /6/.

. Settlement part

The calculation of the amount of raw materials and spices is carried out in accordance with the recipe for semi-finished products, the data are summarized in table 4.1

Table 4.1 Calculation of raw materials for the production of cutlets

Raw materials, spicesNorms, g (per piece) Requirements for raw materials according to the assignment "Homemade" "Moscow" "Piquant" Cutlet beef meat28.050.023.75085Fat trimmed pork29.7--1485 Cutlet pork meat--16.8840Fat raw beef or pork or unsalted bacon trimmings-8.94- 447 Frozen white cabbage--36.5 1825 Wheat flour bread13.014.0-1350 Wheat flour--10.8540 Breadcrumbs4.04.03.26563 Fresh peeled onions2.01.05.4420 Melange or eggs chicken 2.0-2.4220 Black or white ground pepper 0.10.060.0410 Edible table salt 1.21.21.1175 Drinking water 20.020.8-2040Total: 10010010015000

Based on the results of calculating the amount of raw materials and spices, it is carried out in accordance with the recipe for semi-finished products. According to an individual task, it was necessary to calculate the need for raw materials for 5 packages of each type of cutlets, in a package of 10 pieces of cutlets.

For the production of "Homemade", "Moscow" and "Piquant" cutlets, a total of 15000g (15kg) of raw materials is required.

5. Requirements for the quality of meat chopped semi-finished products

Semi-finished products must comply with the requirements of this standard, the document for semi-finished products of a specific name, in accordance with which they are manufactured, produced according to the technological instruction regulating the production process, in compliance with the rules of veterinary inspection of slaughter animals and veterinary and sanitary examination of meat and meat products, veterinary and sanitary regulations use and processing of imported meat and meat products at meat processing enterprises in Russia, sanitary rules for meat industry enterprises approved in the prescribed manner, and hygienic requirements for the safety and nutritional value of food products established by regulatory legal acts Russian Federation / 11 /.

On the cut, chopped semi-finished products should look like well-mixed minced meat. The taste and smell of chopped semi-finished products in raw form should be characteristic of good-quality raw materials, in fried form - characteristic of a fried product. The surface of breaded semi-finished products should be evenly sprinkled with breadcrumbs.

In chopped semi-finished products, they regulate the mass fraction of moisture, fat, salt, bread, as well as the mass of one serving / 8 /.

According to organoleptic indicators, semi-finished products must comply with the requirements specified in table 5.1/4/.

According to physical and chemical indicators, semi-finished products must comply with the requirements specified in tables 5.2 and 5.3 / 1, 5 /.

Table 5.1 Indicators of the organoleptic evaluation of meat

Name of indicatorCharacteristic Appearance and cut view Shape, surface condition on the cut, corresponding to this name of the semi-finished product, taking into account the prescription components used, including spices, sauces, marinades and breading, provided for by the recipe Taste and smell Peculiar to this name of the semi-finished product, taking into account the prescription components used, including spices, sauces, marinades and breading provided for by the recipe Color Peculiar to the color of the semi-finished product of lumpy or chopped meat raw materials used in this item, taking into account the used prescription components, including spices, sauces, marinades and breading provided for by the recipe

Table 5.2 Physical and chemical parameters of semi-finished meat products

Name of indicator Norm for semi-finished meat products Categories ABVGDMass fraction of protein, %, not less than 16121086 Mass fraction of fat, %, not more than 183550 Regulated in the document in accordance with which semi-finished products are made Mass fraction of starch, %, not more than 234 Mass fraction of sodium chloride, %, not more than 1.8 Mass fraction of total phosphorus ( R 205Mass fraction of bread, % Regulated in the document according to which semi-finished products are made Mass fraction of filling or coating, % Regulated in the document according to which semi-finished products are made Temperature in the thickness of the semi-finished product, °

Table 5.3 Physical and chemical parameters of meat-containing semi-finished products

Name of the indicator Norm for meat-containing semi-finished products Categories High-pressure milk mass fraction of protein, %, not less than 975 Mass fraction of fat. %, not more than 35Regulated in the document in accordance with which semi-finished products are manufactured Mass fraction of starch, %, not more than 6 Mass fraction of sodium chloride, %, not more than 1.8 Mass fraction of total phosphorus (P 205), % Regulated in the document in accordance with which the semi-finished products are manufactured Mass fraction of bread, % Regulated in the document in accordance with which semi-finished products are made Mass fraction of filling or coating, % Regulated in the document in accordance with which semi-finished products are made Temperature in the thickness of the semi-finished product, ° Regulated in the document in accordance with which the semi-finished products are manufactured

6. Packaging, labeling, storage conditions, transportation and terms of sale of minced meat semi-finished products

Each type of chopped semi-finished products must meet the relevant organoleptic and physico-chemical parameters. For cutlets, rump steak and meatballs, a rounded flattened shape is characteristic, for schnitzels - oblong, for minced meat and steaks - rectangular (in the form of briquettes), for meatballs - spherical or elongated-spherical.

The classification of semi-finished minced meat, dumplings, minced meat for baby food is presented in clause 3 of GOST R 51187-98 "Semi-finished minced meat, dumplings, minced meat for baby food. General technical conditions".

Meat chopped semi-finished products, dumplings, minced meat for rational, preventive and therapeutic nutrition of children must comply with the requirements of GOST R 51187-98 "Semi-finished chopped meat products, dumplings, minced meat for baby food. General specifications" / 8 /.

Marking. In accordance with clause 4.3 of GOST R 51187-98, the marking of consumer packaging for meat, chopped semi-finished products, dumplings, minced meat is determined in accordance with clause 4.1 of GOST R 51074-2003 indicating additional information(clause 4.2.2.2 GOST R 51074-2003):

Thermal state (chilled, frozen);

Date of manufacture and date of packaging;

On the label of minced meat semi-finished products, dumplings, minced meat intended for preventive and therapeutic nutrition of children, the purpose is additionally indicated.

On packs or packages with dumplings, the method of preparation / 11 / must be indicated in a typographical way.

Transport marking - in accordance with GOST 14192-96, with an additional stamp "Baby food" and with the use of handling signs (Ch. 4 GOST 14192-96) "Perishable goods", "Temperature limitation".

It is allowed not to apply transport marking on reusable containers with products intended for local sale /1/.

Package. In accordance with clause 4.4 of GOST R 51187-98, chopped semi-finished meat products are packed in corrugated cardboard boxes in accordance with GOST 13513-86, polymer reusable boxes in accordance with GOST R 51289-99, aluminum, as well as specialized containers or equipment containers.

Reusable containers must have a lid. In the absence of a lid, it is allowed for local sale to cover the container with parchment, subparchment or wrapping paper /5/.

Acceptance rules. According to Chapter 5 of GOST R 51187-98, the acceptance rules and the amount of samples are determined in accordance with Chapter 6 of GOST R 52675-2006/1/.

Semi-finished minced meat products are accepted in batches.

A batch is considered to be semi-finished products from minced meat of the same mass and name, produced during one shift and issued with one quality document.

Transportation. According to clause 7.1 of GOST R 51187-98, chopped semi-finished meat products, dumplings, minced meat are transported in refrigerated trucks in accordance with the rules for the transportation of perishable goods in force in road transport (Rules for the transportation of perishable goods by road in intercity traffic (section 13 of the Rules for the transport of goods by road)) /eleven/.

Storage (clause 7.2 of GOST R 51187-98). Chopped meat products, minced meat should be stored refrigerated at a temperature of 0 to 4 ° C for no more than 12 hours. In a frozen state at a temperature not exceeding minus 18 ° C - no more than 30 days, in sealed packaging - no more than 3 months / 1 , 5/.

The shelf life of minced meat semi-finished products, dumplings, minced meat, guaranteeing the safety, quality and safety of products, should be standardized normative document for a specific type of product, taking into account the "Conditions, terms of storage of perishable products" (Appendix 1 to SanPiN 2.3.2.1324-03 "Hygienic requirements for shelf life and storage conditions of food products") /8/.

conclusions

Meat chopped semi-finished products - a portioned product made from chopped meat raw materials with additives (minced meat). Each type of chopped semi-finished products must meet the relevant organoleptic and physico-chemical parameters. On the cut, chopped semi-finished products should look like well-mixed minced meat. The taste and smell of chopped semi-finished products in raw form should be characteristic of good-quality raw materials, in fried - characteristic of a fried product / 11 /.

And it is precisely because of this that chopped semi-finished meat products enjoy a well-deserved recognition of the consumer and every year take an increasingly strong place in the diet of the population.

Bibliographic list

1.Antipova, L.V. Methods for the study of meat and meat products [Text]: textbook / L.V. Antipova, I.A. Glotova, I.A. Rogov. - M.: Kolos, 2001. - 376 p.

2.Bautin, V.N. Mechanization and electrification of agricultural production [Text] / V.N. Bautin, V.E. Berdyshev, D.S. Buklagin. - M.: Kolos, 2000. - 536s.

.Bredikhin, S.A. Technological equipment meat processing plants [Text] / S.A. Bredikhin, Yu.V. Kosmodemyansky, L.L. Nikiforov. - 2nd ed., corrected. - M.: Kolos, 2000. - 392s.

.Gizatullin, R.S. Laboratory workshop on milk and meat processing / R.S. Gizatullin, S.G. Kanareikina, L.A. Zubairova; BashGAU. - Ufa, 2011. - 210s.

.Zayas, Yu.F. The quality of meat and meat products [Text]: account. allowance / Yu.F. Zayas. - M.: Kolos, 1996. - 480s.

.Ivashov, V.I. Technological equipment of meat industry enterprises [Text]: textbook / V.I. Ivashov. - Part 1: Equipment for slaughter and primary processing. - M.: Kolos, 2001. - 552 p.

.Ivashov, V.I. Technological equipment of meat industry enterprises [Text]: textbook / V.I. Ivashov. - Part 2: Equipment for meat processing. - St. Petersburg: GIORD, 2007 - 464 p.

.Rogov, I.A. General technology of meat and meat products. Book 1 [Text]: textbook. allowance / I.A. Rogov, A.G. Zabashta, G.P. Kazyulin. - M.: - KolosS, 2009. - 568 p.

The production of frozen semi-finished products is promising direction attachments Money because there is always a demand for these products. Organization of the business does not require much time, the main task is to equip the workshop where it will be located automatic line– production of semi-finished products, hire skilled workers, find reliable suppliers of high-quality raw materials and establish a sales system. The easiest way to establish an enterprise of individual ownership, it is faster and cheaper. It is necessary to obtain a state permit for this type of activity, a sanitary and epidemiological permit.

Features of production areas

When choosing the premises where the production will be located, one should take into account the proximity to farms, which will supply raw materials, this will reduce transport costs. The optimal workshop area is 200 m 2, a warehouse for raw materials and finished products. The building must have all communications, household rooms, an administrative department.

Before starting work, you must obtain permission from the fire supervision and SES authorities. All elements of the line for the production of semi-finished products are powered by the mains, so it is necessary to provide an emergency power generation system, the capacity of which should be enough for at least two hours of work to complete manufacturing process. Since the finished product is produced in a frozen form, the warehouse for its storage should be either a large cold store or equipped with industrial refrigeration units. If the enterprise is located in a rented premises, then the rent will be 15 thousand rubles, another 15 thousand for utility bills per month.

Staff

The production of semi-finished products involves the production different types cutlets and pancakes. Each type of product has its own set of equipment. The cutlet production line is operated by two workers, the pancake line will also require two people per shift. One person will be enough to prepare the raw materials and one to prepare the pancake filling. It will require a loader, a technologist who controls the production process and the quality of finished semi-finished products, and a service engineer to maintain the line. The payroll fund will amount to 100 thousand rubles per month, when the enterprise operates in one shift.

Consumption of raw materials for the production of semi-finished products

The main ingredient for making frozen meatballs is meat. According to the original recipe, there should be 50% pork and 50% beef, the total share of meat in cutlets is 55%, the rest is: water (22%), raw fat (5%), bread (13%), onions (3% ), breadcrumbs (2%), pepper (0.1%), salt (1%).

Table for calculating the cost of manufacturing 100 kg of cutlets:

To make pancakes you will need:

pancakes

For the filling, you can use fruit jams, curd mass, minced meat or liver. In the production of frozen pancakes, a wide variety of fillings can be used, catering to the tastes of potential buyers.

Pancake production technology

The manufacturing process is carried out using an automated pancake production line. The first step is to prepare the dough. In the bowl of the beater, the necessary ingredients are mixed and mixed for several minutes. The finished mass is fed to the pancake machine, where the dough is rolled out and baked. Semi-finished products are cut according to the specified sizes and served on the table for stuffing. There are lines in which this process is manual, but still most of the devices are fully automated. The baking line is followed by a filling dispenser, then a mechanism that folds the pancake in half and wraps the edges. Finished products must be blast frozen. It is speed that plays an important role, since the dough can be soaked with filling and change the structure and color. After freezing, semi-finished products are ready for packaging and transportation to refrigerators.

Line for double-sided frying of pancakes

To organize the manufacture of this type of semi-finished products, you will need:

pancake production line;
refrigerators compartment;
low temperature monoblock.

The automated line performs dough kneading, baking blanks, stuffing, wrapping. Specifications:

The refrigerating chamber is intended for storage of finished goods. Specifications:

dimensions - 4040 * 6460 * 2200;
volume - 58 m 3;
cost - 177,500 rubles.

The low-temperature monoblock is used for shock freezing of semi-finished products:

chamber volume - 80 m 3;
power - 380 V;
temperature - up to -22 ° C;
cost - 160 thousand rubles.

Cutlet production technology

Cutlet production line

At the initial stage, it is necessary to prepare all the constituent ingredients. The meat is cleaned and deboned, veins, cartilage, small bones are removed. To create minced meat, a minced mixing plant is used, which is part of the cutlet production line. All other ingredients required by the recipe are gradually added to the bowl of this installation. At this stage, it is important to temperature regime- do not allow minced meat to be heated above 14 ° C, otherwise its bacterial characteristics may deteriorate. The resulting mass is sent to the molding unit, in which the dosage of semi-finished products takes place according to the specified parameters. Cutlets of different weight, size and shape are obtained through the use of various nozzles. The next step is the blast freezing process. Finished semi-finished products can be packaged and sent to the finished product warehouse.

Profitability of production

For the convenience of calculations, the profitability of the production of cutlets on the line for the production of semi-finished products will be given. The cost of the line itself from different manufacturers may differ, for example, let's take the KOPPENS VM model, its cost is 1,450,000 rubles. The cost of the finished product is made up of the cost of raw materials, wages employees, rent of premises, transportation costs. Monthly fixed costs will be:

salary - 100 thousand rubles;
rent - 15 thousand rubles;
utility bills - 15 thousand rubles;
packaging - 8 thousand rubles;
transportation costs - 10 thousand rubles;
other expenses - 10 thousand rubles;
total - 158 thousand rubles.

The cost of production is calculated on the assumption that 50 kg of cutlets will be produced in one shift, there will be 22 shifts in a month, and the cost of raw materials per 1 kg of finished products is 101 rubles. We multiply all the indicators - we get 111,100 rubles of the total cost. The retail price of 1 kg is 400 rubles, the monthly revenue will be 440 thousand rubles. Profit calculation: revenue (440,000) - cost (111,100) - fixed costs (158,000) = 170,900 rubles. With such a value net profit profitability of production will be 40% - this is high rate speaks of a quick payback of capital investments (within 18-24 months).

Video: Process for the production of semi-finished meat products

The centralized production of semi-finished meat products makes it possible to mechanize many labor-intensive tasks that are performed manually in small enterprises, to increase the efficiency of equipment use, to implement production flow, to apply progressive technology, and to significantly improve the organization of labor.

The technological scheme for the centralized production of large-sized, portioned, small-sized, chopped semi-finished products is practically the same as in public catering enterprises operating on raw materials, but additionally includes cooling of semi-finished products, their packaging and transportation.

Portioned (natural and breaded) and chopped semi-finished products are placed on liners of plank, plywood, aluminum, polymer reusable boxes without wrapping in cellophane, in one row, semi-obliquely, so that one semi-finished product is partially above the other. Each box should contain no more than three inserts.

Large-sized and small-sized semi-finished products are placed in the same boxes, but without liners.

A label is put into the container, and a label is stuck on the box, which indicates the name of the manufacturer, the name of the semi-finished products (type of meat), the number of semi-finished products (pieces, kg), the date and hour of their manufacture, the shelf life and sale.

Before sale, semi-finished products are cooled to a temperature of 6-8°C.

Shelf life and sale at a temperature not exceeding 8 ° C (in hours): large-sized semi-finished products - 48, portioned natural - 36, portioned breaded - 24, small-sized - 24, chopped (natural and from cutlet mass) - 14.

Each batch of semi-finished products must have a quality certificate (certificate).

Procurement enterprises produce the same assortment of large-sized, portioned and small-sized semi-finished products as enterprises operating on raw materials. However, during centralized production on the tenderloin, thick and thin edges, the tendon is not removed from the outside.

Such portioned semi-finished products, such as rump steak, schnitzel, chops, are allowed to be produced without beating, loosening and breading in order to avoid loss of juice and soaking of the breading during transportation and storage. Natural zrazy can be unstuffed. In these cases, beating, loosening, stuffing is carried out at pre-cooking enterprises. Portioned semi-finished products are produced: sliced - weighing 80 or 125 g, rump steaks, schnitzel, cutlets chops without breading - 70 and 110 g each.

With the centralized production of chopped semi-finished products, the cooking technology is somewhat different from that provided for in the Collections of Recipes. So, for chopped steaks, the bacon is crushed on a lard and sent to a meat mixer.

In the centralized production of products from cutlet mass, it is not necessary to squeeze the soaked bread before combining it with meat, since this reduces the acidity of the semi-finished product, increases its pH, and creates favorable conditions for the development of microorganisms. In this case, water is continuously fed into the neck of the meat grinder simultaneously with pieces of bread.

To mechanize the main stages of the production of minced meat products, procurement enterprises install a meat grinder or cutter, a meat mixer, a semi-automatic cutlet, a bath for soaking bread, and a grinding mechanism for making breading.

With the centralized production of products from cutlet mass, it is possible to replace bread with semolina and mold the mass in the form of sausage loaves in the shell.

The range of chopped products produced centrally is as follows: Moscow cutlets, home-made cutlets, Kiev cutlets, lamb cutlets, chopped steak, chopped schnitzel, natural chopped cutlets, lula-kebab.

All semi-finished products must meet the requirements of regulatory and technological documentation for their weight, shape, size, organoleptic characteristics. For some semi-finished products, humidity, fat content, bones, connective tissue are also regulated.

Beef goulash should contain no more than 10% fat, pork - no more than 20%, lamb stew should contain no more than 20% bones, fat - 15%. In meat for lamb skewers, fat should be no more than 16%, from pork - no more than 20%, in roasted pork - 20%, etc.

In cutlets, the moisture content should be no more (in%): in Moscow - 68, homemade - 66, lamb - 65; bread - no more than 18% in home-made and no more than 20% in Moscow cutlets (including breadcrumbs).

The surface of large pieces is even, without tendons. No signs of spoilage, sunburn, sliminess, etc. are allowed. Natural portioned semi-finished products should have a slightly moist, but not sticky surface. The edges of breaded semi-finished products are even; the thickness of the breading layer is not more than 2 mm. The smell is characteristic of this type of meat. The consistency of muscle tissue on the cut of chilled meat is dense, elastic; thawed - softer. The shape of the pieces of small-sized semi-finished products is correct, the release of juice is not allowed. The color and smell are natural, characteristic of this type of meat. The surface of semi-finished products from minced meat is evenly breaded, without cracks or broken edges.

Compliance with the mass should be monitored by piece weighing at least 10 products. Allowed weight deviation for individual semi-finished products within ± 3%.

Piglet handling

Piglets are delivered to catering establishments without bristles and gutted, I and II categories. In the presence of remnants of the bristles, the carcasses are singeed, previously rubbed with flour, and thoroughly washed in cold water. Carcasses weighing up to 4 kg can be used whole for heat treatment. To do this, the vertebral bone between the shoulder blades and the pelvic bone are cut from the inside of the piglet, the carcass is flattened (bend down the sides) so that it warms up evenly. Carcasses weighing over 4 kg are cut in half along the spine, and larger ones - into 4-6 parts.

Characteristics of the organization structure of the plant

The organizational structure of the Remit Meat Processing Plant LLC is linear. Management within the structure of the enterprise is decentralized. The division of rights and responsibilities is divided between different bodies that manage technical development, the purchase of raw materials and materials, production, marketing, etc. Also on the territory of the enterprise there are three workshops for the production of products:

sausage shop;

workshop for the production of semi-finished products;

raw-smoked products shop;

as well as a transport and raw material shop.

The organizational structure of the workshops is the same type in all workshops and is linear. In each workshop there is directly the head of the workshop, in his subordination are: a technologist, a chief mechanic, a shift foreman and workers.

All finished products are stored in the finished product warehouse.

The organizational structure of the Remit Meat Processing Plant LLC is shown in Fig. one:

Rice. one.

Description technological scheme production of chopped semi-finished products

Fig.2

Following the technological scheme presented in fig. 2 is the process of production of chopped semi-finished products. MPZ presents to the buyer 8 types of cutlets: Kiev, fire, homemade, kebab, chicken, peasant, steak, Moscow. Chopped semi-finished products are made from beef, pork, chicken.

Meat raw materials. Beef enters the workshop in the form of minced meat, minced on a top, the diameter of the grate is 25 mm. Pork enters the workshop in half-carcasses, after which it is cut, deboned, trimmed. Deboning is carried out by a differentiated method, when each worker debons a certain part of the carcass, this happens on stationary and conveyor tables. The defrosted meat is supplied to the deboning, with a temperature in the thickness of the muscles of 1 - + 4 ° С. The permissible content of meat on the bones after deboning is up to 8%. After that, the meat is ready for the trimming process: removal of fat, tendons, cartilage, connective tissue films, large blood vessels, as well as blood clots and small bones from deboned meat. The zhilovschik performs the operation of dividing the meat into grades depending on the content of adipose and connective tissues.

Meat raw materials after trimming are crushed on tops of various systems with a lattice hole diameter of 3-6 mm. In the body of the top there is a working chamber for processing the product, which is a fixed hollow cylinder, inside which there are ribs that prevent the product (meat) from turning relative to the screw. To advance the product in the working chamber, feed it to the knives and push it through the knife grates, a rotating auger with a pitch of turns decreasing towards unloading is used.

For the manufacture of chopped semi-finished products, it is allowed to use frozen meat blocks without prior defrosting with grinding, which is located in the adjacent shop for s / c products. After grinding meat blocks in the form of meal on a block cutter with a lattice hole diameter of 20-25 mm or pieces of 10 x 3 x 3 mm in size, they are sent directly to a top with a hole diameter of 3-6 mm.

When compiling minced semi-finished products, protein preparations, vegetable or cereal components, bread, water, salt and all spices are weighed, according to the recipe, in a separate room specially designated for this. Weighed raw materials and spices are loaded into intermittent meat mixers and mixing is carried out to produce minced meat for cutlets. In the mixer, all the components of minced meat are thoroughly mixed for 3 minutes.

The prepared minced meat is molded on the AK2M-40 machine, the weight of each cutlet is 100g.

Next, the finished product is packed into trays, if the recipe requires, then some cutlets and steaks are evenly sprinkled with breadcrumbs. Chilled semi-finished products on trays-liners are placed in wooden, metal or polymer boxes or in equipment containers (containers). Frozen chopped semi-finished products are packed in two pieces in bags of polymeric materials approved by the Russian health authorities for contact with food products. Packages with frozen semi-finished products are placed in corrugated cardboard boxes.

Chopped semi-finished products intended for sale in a chilled form, after molding and laying on trays-liners and packing in boxes or container-equipment, are sent to the cooling chamber. Cooling is carried out at a temperature from 0 to 4°С until the temperature inside the semi-finished product reaches no higher than 4±4 0С, inside the minced meat briquette - 2±2°С. Chopped semi-finished products such as cutlets (cutlets, meatballs, rump steak, beef steak), intended for sale in frozen form, are placed in one row on frames, shelves or mesh containers after molding and sent to a freezer or quick freezer. In the chambers, semi-finished products are frozen at an air temperature not higher than -18 ° C.

When the finished product leaves the workshop for sale, the labeler weighs it, labels the boxes and sends it to the logistics department.

Chopped semi-finished products with manufacturing defects (deformed, with deviations from weight) with non-expired sales periods without signs of spoilage are used in the manufacture of semi-finished products of the corresponding assortment in an amount of not more than 3% of the mass of cooked minced meat with the permission of the veterinary and sanitary supervision. In this case, in the manufacture of minced semi-finished products, the amount of bread and breading contained in the semi-finished products sent for processing should be taken into account.

The shelf life, transportation and sale of chilled chopped semi-finished products at a temperature of 2 to 6 ° C is no more than 12 hours from the end of the technological process, including at the manufacturing plant - no more than 6 hours. Frozen chopped semi-finished products are stored at a temperature not higher than - 10 °C, depending on the species, from 10 to 20 days.

An approximate layout of the semi-finished products workshop is shown in Fig. 3, where:

1. Premises for receiving raw materials
2. Cutting pork
3. Chicken deboning
4. Mixing minced meat with spices (Stirrer)
5. Grinding of raw materials on the top
6. Finished product packaging
7. Weighing and labeling
8. Office foreman
9. Room for washing boxes
10. Product storage room
11. Product freezing chamber
12. Room for the production of dumplings
13. Spice storage room

chopped semi-finished product food sanitation

Chopped semi-finished products include:

cutlets - homemade, Moscow, Kiev, peasant, Krasnodar, meat and cabbage, meat and potato in Belarusian, meat and vegetable, Yakut, Transbaikal, Buryat, spicy;
meatballs - low-calorie children's;
schnitzel - Moscow, special;
beefsteak - urban, beef, youth;
rump steak;
minced meat - beef, pork, homemade, lamb, special, offal, for steaks;
meatballs - Kiev, Ostankino, meat and vegetable, Leningrad, children's;
meat croquettes;
dietary dumplings;
kyufta in Moscow.

Chopped semi-finished products are produced in chilled and frozen form. Chopped semi-finished products are made from beef, pork, lamb and offal. For the manufacture of all types of chopped semi-finished products, meat is used in a cooled, chilled and thawed state, which in terms of quality must meet the requirements of the relevant regulatory and technical documentation. Depending on the type of chopped semi-finished products, cutlet meat (beef, pork, lamb), trimmed beef of I and II grades, semi-fat, fatty, single-grade pork, raw beef and pork fat, sausage unsalted bacon are used. Of the by-products, trimmed meat of beef and pork heads, light pork and beef, trimmed meat trimmings are used. In addition to meat and animal fats, soy and milk protein preparations, blood plasma, wheat bread, chicken eggs and melange, rice and semolina, bread flour, onions and vegetables (cabbage, potatoes, carrots), as well as milk, butter, drinking water and spices.

The technological process for the production of chopped semi-finished products and minced meat is shown in Figures 1 and 2.

Each type of chopped semi-finished products must meet the relevant organoleptic and physico-chemical parameters. For cutlets, rump steak, and meatballs, a rounded flattened shape is characteristic, for schnitzels - oblong, for minced meat and steaks - rectangular (in the form of briquettes), for meatballs - spherical or elongated-spherical.

On the cut, chopped semi-finished products should look like well-mixed minced meat.

Quality requirements for chilled chopped semi-finished products

All types of chopped semi-finished products produced chilled, except for natural minced meat, must have a smooth, well-shaped surface without cracks and breaks, with even edges and the same layer of breading flour over the entire surface of the semi-finished product. The consistency should be homogeneous, sufficiently viscous, without coarse inclusions (tendons, small bones, cartilage, poorly soaked and insufficiently crushed pieces of bread). From above and on the break, semi-finished products should have a characteristic smell of fresh meat raw materials. Deviations in the mass of the 1st semi-finished product ± 5% are allowed. The mass of 10 pieces should not have deviations to the smaller side. The temperature inside the semi-finished product when shipped from the enterprise should be no higher than +6 °C.

Equipment for the production of chopped semi-finished products

The device and operation of the top

All tops have a fundamentally the same device of the actuator. In the body of the top there is a working chamber for processing the product, which is a fixed hollow cylinder, inside which there are ribs that prevent the product (meat) from turning relative to the screw. The location of the ribs can be helical or longitudinal (parallel to the axis of the working cylinder). The direction of the helical ribs is opposite to the direction of the screw turns.

To advance the product in the working chamber, feed it to the knives and push it through the knife grates, a rotating auger with a pitch of turns decreasing towards unloading is used.

A feature of the auger is the creation of pressure sufficient to move the meat through the cutting mechanism without squeezing the liquid phase contained in the product.

The cutting tool of the top consists of a fixed scoring grid, rotating cross-shaped knives and fixed knife grids with different hole diameters and
clamping nut. The most widespread gratings with a diameter of 200 and 160 mm.

The degree of meat grinding depends on the size of the outlet grate openings. With a small degree of grinding (16-25 mm), one cutting plane is sufficient, the top is assembled with one knife and one grate; with thinner (2-3 mm) the number of cutting planes should be increased.

The top consists (Figure 1) of the working chamber (1); ribs (3) located on the inner surface of the working chamber; feeding device - auger (2); a cutting tool consisting of a scoring grid (4), knife grids (5, b), clamping nut (7); loading bowl, electric motor, bed.

The top works as follows: from the loading bowl, the raw material is fed using a screw (or a system of screws) to the cutting mechanism (grid and knife), fixed with a clamping nut. The auger rotates from its own motor through a gear train. During the rotation of the auger, the pressure is created in the chamber, which is necessary to push the meat through the cutting mechanism.

The quality of meat grinding can be judged by the nature of its outflow from the neck of the top. With good grinding quality, the minced meat comes out of all the holes in the grate and flows in even streams. And when it's bad, it flows out in zigzag streams and mainly along the edge of the grate. If the top does not work properly, its neck heats up. In this case, the top must be disassembled and troubleshooted: sharpen the knives, assemble the cutting mechanism correctly, monitor the continuous supply of meat and prevent the top from running idle.

The device and operation of the cutter

Cutters are meat mincers with fast-rotating sickle-shaped knives.

They are used for medium and fine grinding of meat. Cutters are periodic and continuous action. They differ in the ways of loading and unloading raw materials (manual or mechanical), the location of the knife shaft, the number of speeds of the knife shaft, the presence or absence of programming devices, a hermetic bowl lid and a vacuum system. In the cutter, not only the grinding of raw materials takes place, but also its mixing. The cutter (picture 2) consists of:

The cutting mechanism of the cutter consists of sickle-shaped knives rotating on a shaft, a steel comb that cleans the blade of the knives from meat. The sickle-shaped knives are installed in such a way that there is a minimum gap between the blade of the knives and the bowl of the cutter. The number of sickle-shaped knives depends on the size (capacity) of the bowl, usually 6 sickle-shaped knives are installed, but they can be from 3 to 12. They are mounted in bulk with an open or closed nest.

The raw material is fed into the bowl, which rotates slowly. The inner surface of the bowl has the shape of a semicircle. The bowl rotation shaft is located vertically, and the knife shaft is horizontal. The sickle-shaped knives, during rotation, pass against the surface of the bowl and, after each revolution, cut the incoming raw material. Knives are capped and crescent shaped to provide high cutting speed while sliding along the surface of the bowl. Ready chopped minced meat is unloaded from the bowl using the unloader mechanism, the working body of which is a plate (disk): when the latter rotates, the minced meat is ejected from the bowl.

The main technical indicator of the cutter is the capacity of the bowl in liters. Cutters are available with a capacity of 120, 200 and 300 liters.

Cutting technology

Cupping should provide not only the proper degree of meat mincing, but also the binding of such an amount of added water or ice that is necessary to obtain a high-quality product at a standard moisture content.

The duration of cuttering significantly affects the quality of minced meat. During the processing of meat on a cutter, mechanical destruction of tissues occurs during the first 2-3 minutes, the surface of meat pieces increases significantly, after which swelling and binding of water added to the cutter begins and a new viscous-plastic structure is formed.

The total duration of cutting is 8-12 minutes. It depends on design features cutters, the shape of the knives, the speed of their rotation. For the optimal duration of cuttering, the duration of the process is taken, in which all indicators of minced meat and finished products reach the highest values. These indicators include stickiness, water-binding ability of minced meat, consistency and yield. finished products. With excessive cuttering, the minced meat overheats. In order to prevent overheating of minced meat in the cutter, cold water or ice is added at the beginning of cuttering in such a way as to keep the minced meat temperature at the level of 12-15 °C. With an increase in the content of adipose tissue, the amount of water and ice decreases.

When processing different types of raw materials on a cutter, beef or lean pork is loaded first, and then semi-fat and fatty pork.

Water is added when processing beef and lean pork. An excess amount of moisture, as well as overcutting, leads to the formation of broth-fat edema in the process.
heat treatment.

The device and operation of the meat mixer

The L5-FMB batch mixer (Figure 3) consists of a frame (1), an electric motor (2) with a drive (3), a bowl (reservoir) (4), in which two kneading spirals (5) rotate towards each other, a lattice cover (6), and unloading hatches (7). The bed is a welded frame, closed on all sides with quick-release facing sheets. The kneading spirals are driven by V-belts and gears. Tank hatches are designed for unloading minced meat, they are tightly closed with lids. The lattice cover is interlocked with the electric motor, which ensures that the kneading spirals are turned off. The lid in the raised state can be fixed using a special device.

The crushed meat raw materials and other components are loaded into 2/3 of the volume of the container with the lid open. Mixing is carried out until all components are evenly distributed, the finished minced meat is unloaded using kneading spirals with open unloading hatches.

Cutlet production

Raw material preparation

Meat, bacon, raw fat, onion, garlic are crushed on a top with a grate opening diameter of 2-3 mm. For peasant cutlets, meat raw materials are preliminarily ground on a top with a lattice hole diameter of 12-16 mm. For chopped Moscow schnitzel, fatty pork is crushed on a top with a lattice diameter of 9-12 mm. The lard is crushed on a lard cutter, cutter or manually, before cutting it is frozen to -2 ° C.

Fresh onions are crushed on a top with a lattice diameter of 2-3 mm. If dried onion is used, it is pre-soaked for 2 hours in water at a temperature of 15-17 °C.

The bread is cut into pieces, soaked in water and crushed on a top with a grate opening diameter of 2-3 mm. You can grind bread without pre-soaking. At the same time, water is supplied to the neck of the top simultaneously with pieces of bread, the amount of which must be taken into account when compiling minced meat.

Melange is pre-thawed in baths with water at a water temperature not higher than 45 ° C. Thawed melange is not subject to storage. Egg powder is mixed with water in a ratio of 274 g of egg powder and 726 g of water.

Bread flour is sifted and passed through magnetic traps. Salt is used in dry form with preliminary screening.

In order to improve the quality of the semi-finished product and ensure the output in fried form, it is recommended to use pork cutlet meat with a fat content of up to 30%. For homemade cutlets and chopped steaks, beef cutlet meat should be selected with a fat and connective tissue content of not more than 15%.

Minced meat preparation

For its preparation, batch mixers or continuous mince preparation units are used. Raw materials are sequentially loaded into the mixer according to the recipe. Mixing is carried out for 6-8 minutes until a homogeneous mass is formed. To lower the mince temperature during mixing, it is recommended to add flake ice, instead of 20% of the consumed water, the mince temperature should not exceed 8-12 °C.

Forming cutlets

Cooked minced meat is molded on automatic machines AK2M-40, flow-mechanized lines K6-FLK-200, V2-FPA.

The device and principle of operation of the cutlet machine AK2M-40

Cutlet machine AK2M-40 is designed for dosing and molding cutlets.

The cutlet machine (figure 4) consists of a body (1), a loading hopper (2) with a bladed screw (11), a molding table (3) with sockets (4), a disk (5) with a scraper (14), a mass regulator (13 ), electric motor (9).

Figure 4 - Cutlet machine AK2M-40

Cooked minced meat is loaded into the bunker, from where the minced meat is fed by a bladed screw to the hole located at the bottom of the minced bunker. Under the hopper, a working table with nests rotates, and out of five forming nests, only one is fed to the hopper opening. At this point, the piston in the seat drops to the bottom position. With a paddle screw, the minced meat is squeezed into the nest of the table and fills its entire volume due to the pressure created by the rotating blades of the screw in the bunker. With further rotation of the table with nests, the rod, sliding along the copier, moves the piston upwards, while pushing the molded cutlets from the table surface, from where they are thrown onto a disk under the action of centrifugal force, from which they are manually placed in trays.

The mass of cutlets made on the machine can be adjusted by changing the position of the copier in height - this changes the volume of the cylinder filled with minced meat.

Cooling of semi-finished products

Cutlets intended for sale in a chilled form, after molding and placing on trays-liners, are sent to the cooling chamber.

Cooling is carried out at a temperature of 0 to 4 °C until the temperature inside the semi-finished product reaches no higher than 4 ± 4 °C.

Packaging, labeling and storage of cutlets

Chopped chilled semi-finished products placed in trays are packed in reusable wooden, metal or polymer boxes. Boxes are closed with lids or inserts. It is recommended to stack no more than four trays in one box.

The weight of one box should not exceed 20 kg. It is allowed to release chilled chopped semi-finished products wrapped in 5-10 pieces in parchment, sub-parchment, plastic film bags, which are then heat-sealed, clamped with aluminum staples or sealed with adhesive tape.

A semi-finished product of one name and one mass is placed in each box. A label is placed in the box indicating the name of the manufacturer, its subordination, the name of the semi-finished product, the number plate of the packer, the quantity of the product, the mass, price, number of pieces, as well as the date and time of the end of the technological process, shelf life and sale.

The shelf life and sale of chilled chopped semi-finished products at a temperature of 0 ° C to 6 ° C from the end of the technological process is not more than 12 hours, including
at the factory - no more than 6 hours.

Production of semi-finished minced meat natural

Natural minced meat is made from chilled beef, pork and lamb of I and II fatness categories. When trimming for the manufacture of natural minced meat, all cartilage, tendons, connective tissue must be removed, and when trimming pork, excess fat is also removed, leaving no more than 3 (> -50%. Trimmed beef, pork, lamb are crushed on a top with a diameter of holes in the output grid 2- 3 mm without adding water.

The minced meat is packaged in parchment, subparchment, cellophane and other transparent films, in portions weighing 250 and 500 g. Natural minced meat is prepared from one beef, pork or lamb or a mixture of beef and pork in various proportions. Packed manually or on special machines for packaging and packaging of minced meat.

The device and principle of operation of the automatic machine AP1M

Designed for filling and packaging minced meat in parchment or foil in the form of briquettes of 250 g. bunker.

The machine (figure 5) works as follows: the packaging material from the roll (1) enters the guide roller (3), then the adjustable sectors (4) guide the packaging material between the knives (5), which cut the reaming of a certain length. The levers (6) feed the reamer onto the forming die (5) under the punch (7). The presence of a scan on the matrix is controlled by a probe (9) and in case of its absence, the machine automatically stops. The punch pushes the reamer through the die, giving it the shape of a box, which is inserted into the socket of the carousel table (12). The dispenser (10) of the hopper with a screw feeder (11) fills the box with a certain portion of minced meat, and the package valve closing mechanism (13) wraps the package. The pre-pressing mechanism (14) gives the bag its final shape. The bag is automatically removed from the forming table slot and the forming table bag remover (17) feeds the bag to the package tipper (16) which turns the bag closed side down. In this form, the package enters the conveyor (15), from where it is removed manually and placed in a container.

Production of chopped frozen semi-finished products

For the manufacture of chopped frozen semi-finished products, trimmed meat from beef, pork, offal and fatty raw materials of all types of livestock is used in a cooled, chilled and thawed state; milk and dairy products, eggs and egg products; onions, garlic, cereals, salt, spices and other auxiliary materials. It is allowed to use egg powder instead of 1 kg of melange or 24 chicken eggs; dried onion at the rate of 225 g instead of 1 kg of fresh; whole milk powder at the rate of 1 kg instead of 8 liters of pasteurized whole milk.

It is not allowed to use meat and products frozen more than once, pork with signs of yellowing of the fat, meat of bulls and boars, meat with signs of putrefactive decomposition.

Raw materials are selected according to the recipe and prepared in accordance with the requirements of technological instructions.

Minced meat is prepared on the equipment of continuous or periodic action. First, beef is loaded into the mixer, then cold water is added in an amount of 18-20% to the mass of raw meat, milk, table salt, onions, spices, rice or semolina, and 2-3 minutes before the end of mixing, add pork or bacon. The crushed raw materials with all components are mixed for 4-5 minutes until a uniformly mixed mass is formed.

Cooked minced meat is molded on molding machines.

Meatballs are molded in the form of checkers (cylindrical shape) with a diameter of 20 mm and a height of 20 mm, the weight of one meatball is 7-9 g.

Meat croquettes, dietary quenelles, Moscow-style kufta are formed in the form of checkers with a diameter of 36 mm and a height of 30 mm, each weighing 30 g.

Forming meatballs on the FFP machine

The FFP machine is designed for dosing and molding meatballs.

It consists of a frame, an electric motor (1) with a gear (2), a minced meat hopper (7) with an auger (5) located in it, a forming drum with sockets (4) and a socket (3) located above it, an eccentric-vane pump (9), designed to force minced meat into the socket, a belt conveyor for feeding trays, a vibrating knife (6) for separating meatballs from the drum (Figure 6).

Minced meat from the hopper is fed by a screw to an eccentric-vane pump, which pumps it into the socket, which fits snugly against the cylindrical surface of the drum in its upper part, and fills the nests. When the drum is rotated 180°, the pistons push the meatballs out of their nests onto a tray in which they are transferred to the freezer.

In chambers, meatballs are frozen at an air temperature not higher than -18 ° C, in quick freezers - at a temperature of -30 ° C ... - 35 ° C until the temperature inside the semi-finished product reaches no higher than -10 ° C.

Ready frozen semi-finished products should not be sticky, deformed. The taste of the finished product is characteristic of this type of product with a pronounced aroma of spices and spices. The mince is juicy. Foreign smells and tastes are not allowed. Frozen semi-finished products are packaged in cardboard boxes weighing 350, 500 1000 g. They are stored at a temperature not exceeding -10 ° C for no more than 1 month.