Cookie production technology. How to start a homemade biscuits business Equipment for the production of small stuffed nuts

Oreshek is a sweet confection that is traditionally used as a dessert. The product is in demand among all categories of buyers, as it is considered one of the most delicious delicacies.

Perhaps the reason for this is the reputation that developed around this cookie during the Soviet years. During the time of total scarcity, it was a real delicacy. And although today there are many confectionery factories that produce these cookies, this type of business remains promising.

Required raw materials

The following ingredients are used as raw materials for making cookies:

flour;
butter;
sour cream;
sugar;
soda;
condensed milk;
walnuts.

Manufacturing steps

Regardless of the filling, the recipe can be divided into the following stages of making cookies:

preparation of ingredients (sifting flour, granulated sugar);
kneading dough and filling;
butchering the dough;
baking cookies;
removal of finished products;
product cooling;
packing and packaging.

The following basic equipment can be distinguished, without which it is not possible to open a production:

dough mixing machine;
confectionery oven;
a machine for mixing filling ingredients;
dough divider;
thermal packer;
filler syringe;
transporters.

Implementation channels

The methods of selling finished products are necessary even at the stage of the birth of an idea. Ideally, at the time of production launch, it is desirable to have an agreement with at least one small chain of stores.

The main sales channel is retail grocery stores.

There is no need for novice entrepreneurs to go to large chain stores: in order to get on the shelf of a federal store, they will have to pay for space, as well as reduce the purchase price to a minimum. This is especially true of hypermarkets - they have the lowest markups. Therefore, the best option is to sell products through small networks.

Economics of opening a shop for the production of cookies "Oreshek"

The minimum set of equipment is as follows:

Taking into account the purchase of raw materials, the cost of delivery and installation of equipment, preparation of premises for food production and other expenses, investments in the organization of production will amount to 1.5-1.8 million rubles.

Wholesale price one kilogram of Oreshki biscuits is approximately 50-70 rubles. per 1 kg, this is 3 times lower than the cost of its production. The payback period for a business in the production of Oreshek cookies is on average no more than 2 years.

To start your own confectionery business, the production of dense dough products (nuts with condensed milk, curly cookies with a filling, tartlets, Viennese cookies) is considered the best option. Monitoring Russian market confectionery products showed that nuts stuffed with boiled condensed milk are the most popular. These baked goods do not belong to the position of standard biscuits of professional production and occupy a special product niche in the market.

The inexpensive price of confectionery equipment, the availability and natural basis of raw materials, an uncomplicated manufacturing technology and consumer demand are indisputable factors that ensure the prospects for the production of sweet baked goods.

To organize production, a minimum set of confectionery equipment is required:, and.

Ingredients: flour, sugar, eggs (egg powder), butter (margarine), milk (milk powder), baking powder and condensed milk (thick butter cream) For filling.

The technological process consists of the following stages: preparing dough and filling, baking dough pieces, filling the halves with filling and forming finished products.

Nuts with condensed milk belong to shortbread baked goods; they differ from other cookies in their recognizable shape and the presence of an invariable filling. In the minds of the consumer, nuts with a tasty filling are associated with homemade sweets and are perceived as a piece goods.

And the nuts are not easy - all the shells are golden!

Taste characteristics are an important criterion for the quality of a confectionery product. However attractive appearance baking is a kind of prelude to the overall assessment of the product. The correct shape, even golden color and uniform baking of the nuts indicate the right technology production.

The dough for nuts is obtained by thoroughly mixing the prepared components: melted butter, beaten eggs with sugar and flour. Kneading machine and mixer with high technical characteristics(design, engine power, speed and amplitude of rotation of the blades) allow you to obtain a homogeneous dough mass and a creamy cream of delicate consistency.

A professional confectionery oven for baking nuts, as a rule, has small dimensions (it can even be a desktop one). The furnace design consists of two plates that can be heated autonomously. The operator can set the baking time on the timer depending on the production needs.

Option of simultaneous or autonomous heating with the possibility of regulation temperature regime provides taste and external aesthetics of the "shell" of nuts. When replacing aluminum molds, you can significantly expand the range of products (cones, hearts, mushrooms, animal figures, geometric shapes).

Kernels - pure emerald

When producing nuts with condensed milk, it is not recommended to replace the product indicated in the name with another creamy filling. Of course, the use of ready-made condensed milk for the filling is absolutely unprofitable. An experienced confectioner knows the recipe for making condensed milk that meets the standard requirements for this product.

Planetary mixer with helical blades rotating in different planes, and good quality raw materials will allow you to get a sweet confectionery mass of uniform consistency.

Nut production itself is very profitable business, so do not add flour to the filling or bake thick-walled products. The success of the confectionery business directly depends on the honesty of the manufacturer to the consumer. Full compliance of the filling with the declared parameters is a guarantee of stable demand and high sales of nuts with condensed milk.

Cookies are divided into two types: shortbread - removable and sandy - jigging.

Shortbread biscuits contain a large number of fat and sugar and is made from plastic dough. The dough is kneaded in universal kneading machines with Z-shaped blades. Raw materials are loaded into a kneading machine in a certain sequence and mixed for 10-15 minutes. Then add egg powder or melange, if necessary, condensed milk, and water and mix again for 5 - 8 minutes, after which flour, glucose syrup and starch are added and the whole mixture is mixed for another 2 - 4 minutes. With mechanized molding on rotary machines, the dough is kneaded a little differently, but given that the bulk of products in small enterprises are produced by hand, we will dwell on this option in more detail. When molding dough by hand ready dough pieces weighing 7 - 8 kg are rolled out with a rolling pin on the table by hand. The table and rolling pin are pre-dusted with flour, a piece of dough is kneaded on the table by hand, and then rolled in two directions until a uniform layer with a thickness of about 5 mm is obtained. Cookies are cut out with special shaped notches, which are then baked in ovens of various models. This is generally the technology for the production of shortbread cookies. The equipment required for the organization of such production is an ordinary Z-shaped dough mixer. Such machines are widespread and are used to knead not only dough for shortbread cookies, but also for yeast, non-yeast, steep donut dough, dough for dumplings, and even for kneading minced sausage. The kneading trough and lid are made of stainless steel, the blades are cast in Z-shaped. The machines are produced in two versions: with a jacket - for cooling (heating) the product, and without a jacket. Different speeds of rotation of the blades (front and rear) lead to a more even kneading of the dough, intensify the kneading process, and prevent the dough from sticking to the blades. For the molding (cutting) process, there are a variety of curly cuttings made of tinplate. A large selection of shapes ("chamomile", "butterfly", "fungus", "herringbone", "comet", "cloud", card theme: "crosses", "spades", etc.) allows you to create cookies of various shapes, which leads to an increase in the range of products. Biscuits can be molded using rotary molding machines from various manufacturers. Biscuits are baked in a variety of oven models, from small convection ovens to rotary ovens. They must have a fast warm-up time, a powerful turntable, chamber lighting and a sealed door with a heat-resistant seal. Well-adjusted gaps in the baking chamber ensure even baking of products. The same cookie looks very different depending on the surface finish. The most commonly used coating of the surface of the biscuits with chocolate or glaze glaze. To do this, the cookies are immersed in a glaze heated to + 40C, and then cooled until the chocolate completely solidifies in a refrigerator at a temperature of + 8 ... + 10C. Depending on the type of products, the entire surface, half of the surface, the upper or lower surface of the products are glazed. Selected varieties until the chocolate hardens, sprinkle with chopped nuts, or use a comb to apply a pattern, others are sandwiched with fruit (or cream) filling. To do this, the filling is deposited on the lower surface of the chilled biscuits with a syringe bag or other device and covered with non-smeared biscuits, slightly pressing it for better gluing. The biscuits are then completely covered with a layer of heated chocolate, and the middle of the surface is sprinkled with crushed nuts. Nowadays, many companies offer a wide range of confectionery ingredients for the production of cookies that allow you to turn ordinary cookies into a work of art.

Shortbread butter biscuits. Contains a significant amount of fat and sugar. It is made from dough, which is close to creamy in consistency. Beat butter or special confectionery margarine with powdered sugar first for 10-15 minutes, then add the rest of the raw materials and lastly the flour. The dough for shortbread cookies can be cooked in kneading machines various designs, as well as with the help of planetary multi-speed mixers. Confectionery mixers allow the process of kneading the dough with a significant saturation of the dough mass with air at certain stages of the dough preparation process, which ensures an increase in the specific volume and an improvement in the quality of products. Forming of blanks is carried out, as a rule, either manually using syringe bags with various attachments, or on jig machines, mainly imported, the so-called "multidrops". Despite the relatively high cost of the imported molder, its ability to produce different types cookies allow in a fairly short time (about 6 months with a properly organized sales policy) to achieve a return on investment. Baking shortbread cookies is carried out in ovens of the same models as shortbread cookies.

Cookies "Nut" (shortbread)

The volume of the kneading chamber is 250 l, the load at a dough density of 1.1 kg / l is 183.7 kg of dough.

Determine the consumption of raw materials for the preparation of 183.7 kg of cookies "Nut" and enter all the calculations in table 2.4.

Table 2.4 - Production recipe for "Nut" cookies

For the calculation, we will take the moisture content of the dough equal to 18%.

Cookies "For tea" (sand-otzadnoe).

The volume of the kneading chamber is 250 l, the load at a dough density of 1.1 kg / l is 183.7 kg of dough. Determine the consumption of raw materials for the preparation of 183.7 kg of cookies "For tea" and enter all the calculations in table 2.5.

Table 2.5 - Production recipe for cookies "For tea"

name of raw materials	The amount of raw materials used for cooking 183.7 kg of cookies, kg	The amount of dry matter in the raw material, kg
Wheat flour, premium
Powdered sugar
Invert syrup
Margarine
Pasteurized cow's milk

Vanilla powder

Drinking soda
Roasted hazelnut kernels
Ammonium salt
Essence

For the calculation, we will take the moisture content of the dough equal to 15%.

Then the amount of water will be equal to:

Table 2.6 - Selection of technological equipment

Stage name	The number of processed semi-finished products, kg / h	equipment identification	Productivity, kg / h
Quantity
Preparation of raw materials
Sifting sugar		Burat PB 1.5
Making powdered sugar		Hammer micromill 8M
Sifting flour		Burat PB 1.5
Milk preparation		Separator-milk cleaner A1-OCM-10
Peeling a nut		Cleaning line walnut MKD 3
Nut pick		Machine OD1 for splitting walnuts and hazelnuts
Sizing the nut		Calibration sieve MKD-3-2 with aspiration
Nut roasting		Brazier PEZHCH-180
Crushing nuts		Crusher for nuts brand BM-2250
Cookies "Nut"
Cooking nut sugar shortbread cookies
Stacking		Stacker SB-4
Package
Pasting boxes		Om gluing machine
Cookies "For tea"
Preparation of sugar shortbread cookies "For tea"		Line of sugar biscuits A2-SHL-1P
Stacking		Stacker SB-4
Package		Automatic machine for group packaging "FLOUPACK"
Pasting boxes		Om gluing machine
Cookies "Original"
Making "Original" shortbread cookies		Line of shortbread cookies A2-SHL-1P
Stacking		Stacker SB-4
Package		Automatic machine for group packaging "FLOUPACK"
Pasting boxes		Om gluing machine

Designed for mechanization of the process of whipping various confectionery mixtures (cream, protein and egg-sugar creams), as well as kneading yeast dough in confectionery shops.

Specifications

1.Capacity of a tank, l 100
2.Frequency of rotation of the working body, 1 / s around its own axis 1.4 / 4.1 / 5.3 around the axis of the tank 0.7 / 2
3.Voltage, V380
4.Rated power of the electric motor, kW drive of the beater 2.2 drive of lifting the tank 0.55
5. Overall dimensions, mm 1000х710х1350
6.Mass, kg325

2. Confectionery oven

Confectionery oven ─ industrial oven designed for baking:
. Shortbread, butter biscuits and biscuit dough products.

Industrial furnace characteristics

Technical performance:
Nuts with condensed milk, kg / hour (without condensed milk)
Vienna waffles, kg / hour (without filling)
Butter (vanilla) cookies, kg / hour
Wafer sheet, kg / hour

Installed power, kW
Power consumption, kW
Rated voltage, V
Variable current type
The number of units of products produced at the same time:
Nuts with condensed milk (half 42x32x16), pcs
Vienna waffles (79x42x13), pcs
Butter (vanilla) cookies hearts (91x84x10), pcs
Wafer sheet (470x290), pcs
Waffle cone (tube), pcs
Baking temperature, deg. WITH
Overall dimensions (L * W * H), mm
Wiring accessories	ABB (Germany)
Electronics	Delta Electronics (Japan)
Mold material	Aluminum
Covering forms
Furnace weight, kg
Warranty, month

Possible block forms

Name	LxWxH, mm	Thickness, mm	Quantity, pcs
Walnut "Home"
Walnut "Kremlin"

Mushroom
Heart "Valentine"
Tartlet "Chamomile"
Heart from butter dough(pyramid)
Viennese biscuit waffle
Biscuit dough figurine - "Squirrel"
Waffle sheet		by order

Attention: We can make a form of any complexity according to your sketches.

Distinctive features of the pastry oven:

Heating inside the baking tins, even when the tins are open they do not lose temperature;
.temperature on the upper and lower plate is regulated separately;
.precision of keeping the temperature on the mold of only 3 degrees;
. the hinges of the molds are made of steel and are removed from the heating zone;
. bump stop on the bottom mold (silicone rubber, Germany);
.locks on the form open / close in a split second;
.high quality Teflon coating, which greatly simplifies the removal of cookies from molds and improves their taste;
. electrical installation products ABB (Germany);
. Electronics Delta Electronics (Japan);
.high-precision temperature sensors (USA);
. Timer with LCD screen. Automatic on / off when lowering / raising the form. The electronics are built in such a way that during operation you can not press any buttons (everything works automatically);
.quality powder painting;
. for shortbread and butter (vanilla) cookies, the oven has no analogues in terms of performance.

3. Thermo packer

The shrink wrapper is designed for packing boxes in shrink film. Its main advantage is its versatility, since the smooth temperature control used in this device makes it possible not only to pack a wide range of products, but also to use a film for this. different types and thickness.

Technical details

Overall dimensions are 2700 x 610 x 700mm.
Mains voltage 220 V / 50 Hz
Power consumption 4.5 kW
Weight up to 100 kg.
The maximum dimensions of the package are 450 x 350 x 220 mm.
Type of film used - PVC, PE, PP
The width of the used film is up to 500 mm.
Productivity up to 300 pack / hour

Business plan: Production of Oreshek cookies.

Start-up capital - 950 thousand rubles.
Profit per month - 120 thousand rubles.
The payback period is 9 months.

Oreshek is a sweet confection that is traditionally used as a dessert. The product is in demand among all categories of buyers, as it is considered one of the most delicious delicacies.

Required raw materials

The following ingredients are used as raw materials for making cookies:

- flour;
- butter;
- sour cream;
- sugar;
- soda;
- condensed milk;
- walnuts.

Manufacturing steps

Regardless of the filling, the recipe can be divided into the following stages of making cookies:

- preparation of ingredients (sifting flour, granulated sugar);
- kneading dough and filling;
- dough slicing;
- baking cookies;
- removal of finished products;
- product cooling;
- packing and packaging.

The following basic equipment can be distinguished, without which it is not possible to open a production:

- dough mixing machine;
- confectionery oven;
- machine for mixing filling ingredients;
- dough divider;
- thermal packer;
- filler syringe;
- conveyors.

Implementation channels

The main sales channel is retail grocery stores.

The minimum set of equipment is as follows:

1. Dough mixing machine TMM-03 74.5 thousand rubles.
2. Confectionery oven PEM-2U Profi, 3 pcs. 135 thousand rubles
3. Dough divider Jac DIV 20 301 thousand rubles.
4. Cream whipping machine MB-40 98 thousand rubles.
5.Dispenser (filler) automatic DF-200 102.5 thousand rubles.
6. Thermo-packing machine TM-2R M1 65 thousand rubles.
7. Weighing conveyor TV-L-30-60x40 174.5 thousand rubles.
Total RUB 950.5

Taking into account the purchase of raw materials, expenses for the delivery and installation of equipment, preparation of premises for food production and other expenses, investments in the organization of production will amount to 1.5-1.8 million rubles.

The wholesale price of one kilogram of Oreshki cookies is approximately 50-70 rubles. per 1 kg, this is 3 times lower than the cost of its production. The payback period for a business in the production of Oreshek cookies is on average no more than 1 year.

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