The traditional way of technology for the production of cottage cheese. Technological line for the production of cottage cheese

 

Products from cottage cheese are recommended for consumption by almost all categories of the population, since cottage cheese is an easily digestible product, it contains essential amino acids (methionine, choline) as well as a large amount of phosphorus and calcium.

Cottage cheese has a wide product line:

• sour-milk cottage cheese (fat-free, low-fat, classic, fatty);
• cottage cheese products - curds, creams, pastes, cakes. Curd products are presented on the market with various additives - fruit and vegetable, chocolate and dessert fillings.

Target audience and sales channels

The main buyers of cottage cheese products are consumers of retail stores (the main categories are children, pregnant women and housewives, the elderly, athletes), as well as establishments Catering and enterprises for the further processing of cottage cheese as a raw material (cooking, cafes).

The sale of ready-made cottage cheese can be carried out through the following distribution channels:

• retail network of shops and supermarkets;
• wholesale distributors engaged in the delivery of products
• enterprises for the processing of cottage cheese, using it as a raw material for curd products;
• HoReCa sector (, cafes, culinary).

The first two distribution channels occupy the main part products sold. At the same time, deliveries to the retail network make it possible to obtain higher profitability and sales regularity, and the sale of cottage cheese to wholesalers guarantees sufficient sales volumes at a lower price, but without the need to store and promote batches of manufactured products on their own.

Production process and required equipment

The production technology provides for the fermentation of pasteurized milk with the help of pure cultures of lactic acid bacteria, as well as with the possible use of rennet, calcium chloride and subsequent removal of a part of the serum from the clots.

The process of making cottage cheese consists of the following steps:

1. receiving milk and mechanical restoration(filtration);
2. Pasteurization (using an electropasteurizer);
3. Cooling and fermentation of milk with curd clot processing (curd baths are used);
4. Mechanical pressing of cottage cheese (using a press trolley)
5. Or Pressing in bags (using a drum-type machine for pressing and cooling the curd).
6. Packing (using a packing machine).

Thus, to build a complete technological process for the production of cottage cheese, it is necessary to use the following equipment (open type process):

• Milk receiving and filtering station
• Electropasteurizer
• curd bath
• Press trolley (economical option) or UPT drum type installation (more practical option)
• Filling machine

As the main line for the production of cottage cheese, we consider the equipment of the Ekomash plant, Noginsk, Moscow Region. This manufacturer offers various options lines, we will focus on two "Economy" and "Standard".

Option No. 1 "Economy", line capacity 130 kg. in hour.

Consists of the following units:

	Bath pasteurization OZU-0.35 Working volume: 50 l	230000 rub.
	Bath curd VT-1.25 Capacity: 1.25 m3.	135000 rub.
	Press carts for cottage cheese of the PTT-200 series Capacity (geometr.) 200 l	98000 rub.
	Station of acceptance and accounting of milk of the SPUM EM-CM-5 series	348000 rub.
		100000 rub.
Total:		911000 rubles

Option No. 2 "Standard", line capacity 130 kg. in hour.

This kit includes the following units:

	Station of acceptance and accounting of milk of the SPUM EM-SM-5 series Nominal productivity: 5 000 l/h	348000 rub.
	Installation of pressing and cooling of cottage cheese of the UPT series Productivity: 130 kg/hour. Tubular drum volume: 950l	249000 rub.
	Electric pasteurizer of the A1-OPE series Heating: infrared. Volume: 1000 liters.	605000 rub.
	Connecting units, pumps, pipes, sinks and other additional equipment - approximately 100,000 rubles.	100000 rub.
Total:		1302000 rubles

In addition to the main equipment in the workshop, you need to purchase the following items:

• (briquettes of 100-125g and 200-250g), productivity - 40-72 briquettes/min. - 885 000 rub
• (working temperature +5 C), price 117,800 rubles.

Thus, the cost of completing the workshop for the production of cottage cheese with the Economy line, taking into account additional equipment, will be 1.9 million rubles, and with the Standard line, 2.3 million rubles.

Let us carry out a comparative analysis of these lines.

As can be seen from the presented table, with a similar productivity, the labor intensity of production on the "Standard" line is much less due to a higher degree of automation of the production process. The cost of products produced on this line will be lower than on the Economy line, therefore, the manufacturer can reduce selling prices without compromising profitability, which in turn will have a positive effect on the company's financial results. In connection with starting a business, it is optimal to choose the Standard line.

Feasibility study of the project

Capital investments

• Purchase of equipment: 2.3 million rubles.
• Transportation costs, installation supervision, commissioning: 0.3 million rubles.
• Purchase of raw materials 1 million rubles.
• Preparation of the premises (repair, bringing to compliance with SanPina, electrical wiring) - 0.5 million rubles.
• Registration in INFS, account opening, other expenses: 0.1 million rubles.
• Total 4.2 million rubles

Calculation of revenue and profitability

* Profit according to industry average profitability data for this type of activity

* Calculations use average data for Russia

Cottage cheese is a healthy fermented milk product that is obtained by fermenting fresh milk with subsequent removal of whey from it and which contains valuable, easily digestible proteins, carbohydrates, fats, nutrients, vitamins and microelements necessary for a person.

Cottage cheese prepared in the traditional way is classified according to its fat content. According to GOST R, cottage cheese can be fat-free, low-fat (1.8%), classic (4-18%) and fatty (19-23%). Accordingly, cottage cheese differs in calorie content. One hundred grams of fatty cottage cheese contains over 200 kilocalories, in bold cottage cheese - 160 Kcal, and in low-fat - about 80-85 Kcal. The greatest demand, as studies show, is fatty and semi-fat types of cottage cheese. Fat-free and low-fat cottage cheese is somewhat inferior to them in taste, however, these types are used for the production of various curd products, including creams, curds, curd masses with various additives and fillers, curd desserts, etc.

Depending on the method of coagulation of milk proteins, cottage cheese is divided into acid and acid-rennet. Acid curd is prepared from skimmed milk by fermenting raw materials with special starter cultures. Under the influence of lactic acid, which is released during lactic acid fermentation when ferments are added to milk, the protein coagulates. Unlike acid curd, in the production of acid-rennet curd, both rennet (or pepsin) and lactic acid bacteria starter cultures are used to coagulate milk proteins.

So, cottage cheese is a nutritious and healthy delicious product suitable for both children and diet food. Its production is cost-effective and fast payback.

The "documentary" issue of organizing the production of cottage cheese

To open curd production you must first choose the legal form of your business and obtain the necessary permits. You can register as a sole trader or open an LLC. In both cases, there are advantages and disadvantages. The main difference between an LLC and an individual entrepreneur is the level of responsibility to creditors. If the LLC is declared bankrupt, and the company's property is not enough to pay off its debts, the founder will be obliged to pay creditors an amount not exceeding the authorized capital. An individual entrepreneur will repay the debts of his company at the expense of all his property. At the same time, the administrative responsibility of an individual entrepreneur is lower than that of an LLC. Another significant difference is in the taxation system. When choosing a traditional taxation system, an LLC will spend more on paying taxes than an individual entrepreneur. In addition, the company will have to keep accounting records, for which it will be necessary to hire an accountant. On the other hand, if you ever want to sell your share in the business, it will be easier to do it in the LLC format.

There is also an "image" nuance. As a rule, trust on the part of partners is higher for an LLC, and not for an individual entrepreneur. Although the first time you work, you are unlikely to notice the difference. If you do not plan to work on a large scale from the very beginning, then experts advise giving preference to an individual entrepreneur, since it is easier and cheaper to register it.

When registering, you will need to select an OKVED code. In our case, this is 15.51.14 "Production of cottage cheese and cheese-curd products." Once you have found the right production room, it will be necessary to obtain permits from the state sanitary and epidemiological service (SES) and the fire inspectorate. To do this, you must submit a copy of the certificate of state registration of the enterprise, a copy of the taxpayer's certificate, a lease agreement with the owner of the premises or territory, a technological map of production, a list of equipment used at the facility, indicate the capacity of the facility, the number of employees and data on medical examinations, a plan of the leased premises where the equipment is installed, a project for the reconstruction of the premises (if its original functions are changed) and the conclusion of the SES on the approval of this project, a passport for the ventilation system, an agreement for disinfection, a certificate of statistics with a seal.

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To carry out production activities, you also need to obtain a license. To do this, a package of documents is submitted to the licensing organization, which includes applications of the established form, copies of constituent documents and a receipt for payment of the state duty. Once your shop has been inspected, a permit is issued that is valid for at least five years.

Since cottage cheese is a product of the dairy industry, its certification is also required immediately after the launch of your production. For cottage cheese of domestic production, a declaration of conformity OKP 922290 Curd (922291 Cottage cheese from 0.1% to 9.0% fat content, 922292 Cottage cheese from 10.0% to 17.0% fat content, 922293 Cottage cheese from 18.0% or more fat content, 922294 Cottage cheese grained, 922295 Cottage cheese for baby food). This document confirms the quality and safety of your cottage cheese and is issued either for mass-produced products (for a period not exceeding three years) or for a batch of cottage cheese (for the shelf life of the products included in this batch). If you have no experience in issuing certificates and you are not well versed in these matters, then it is best to seek help from a specialized intermediary firm. This will save you a lot of time and effort. To obtain a certificate, you will need to prepare the following documents: application for certification, contract, constituent documentation, label layouts, phytosanitary registration certificate, veterinary certificate.

The cottage cheese you produce must comply with the established state standards: GOST R 52096-2003 “Cottage cheese. Specifications” (note that this standard does not apply to a product enriched with vitamins, micro- and macroelements, probiotic cultures and prebiotic substances), GOST 31534-2012 “Grained cottage cheese. Specifications".

If you care about the quality of your products, then from the very beginning you should take care of creating your own production laboratory, equipped with all the necessary equipment to control the quality of the raw materials supplied to you. Requirements for the organization of industrial microbiological laboratories are given in the "Methodological recommendations for the organization of industrial microbiological control at enterprises of the dairy industry", approved on February 7, 2008. The production laboratory of enterprises of the dairy industry and the organization of its activities must comply with the requirements of sanitary rules SP 1.2.731-99 "Safety work with microorganisms of groups III-IV pathogenic™ and helminths”, SanPiN 2.3.4.551-96 “Production of milk and dairy products” and “ methodological recommendations on the organization of industrial microbiological control at milk processing enterprises” MP 2.3.2.2327-08.

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Of course, the organization of the laboratory will require additional and tangible costs, but they will quickly pay off if you care about the reputation of your company. In addition, it makes sense to think about the development and approval of their own technical specifications for products.

Workshop for the production of cottage cheese

SanPiN 2.3.4.551-96 "Production of milk and dairy products" (approved by the Decree of the State Committee for Sanitary and Epidemiological Supervision of the Russian Federation of October 4, 1996 N 23) details all the requirements for the territory for the construction of the workshop, production and auxiliary premises, water supply and sewerage, lighting, heating, ventilation, security environment, to technological equipment, inventory, utensils, their sanitization, as well as to all technological processes. First of all, the premises that you rent or purchase must have enough space (the area of ​​\u200b\u200bthe main workshop must be at least 30 square meters). Even if you do not plan to open your own laboratory from the very beginning, you need to

Must have running water, sewerage, electricity and ventilation system. The water used for the workshop may be artesian, but must comply with the requirements of drinking water in accordance with GOST 2874-82. The walls in the workshop must be tiled to a height of more than two meters, the floors must be non-slippery, waterproof and resistant to acids. The walls of household, auxiliary and storage rooms are painted in light colors.

The cost of project development during the construction of a mini-factory from scratch will be from 70 thousand rubles. Such a project, as a rule, includes a general explanatory note, architectural and construction solutions, a master plan and transport, engineering equipment, networks and systems, technological solutions, environmental protection provisions.

Curd production technology

There are two main ways to produce curd, depending on how the clot is formed: acid and rennet. The first method is used to prepare fat-free and low-fat cottage cheese of a delicate texture. In this case, acid coagulation of proteins is carried out by fermentation of milk by bacteria. Accordingly, the second method, in which the clot is formed due to the direct influence of rennet and, accordingly, the waste of fat in the whey decreases, curds of medium and high fat content are obtained.

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Technological process cottage cheese production in the traditional way includes the following steps: receiving milk, normalizing milk to the required state, cleaning and pasteurizing milk, cooling milk to the fermentation temperature, adding starter and rennet to milk, fermenting milk, cutting the clot, separating whey, cooling curd, packaging, packaging and storage finished products.

Milk is accepted by a trained and certified laboratory assistant using equipment and methods in accordance with GOST 26809-86 “Milk and dairy products. Acceptance rules, sampling methods and sample preparation for analysis”, GOST 28283-89 “Method of organoleptic evaluation of smell and taste”. As a raw material for the preparation of cottage cheese in the traditional way, fresh whole skimmed milk with an acidity of not more than 20°T is used, which is pasteurized at a temperature of 79-80°C with an exposure of 20-30 seconds. It is very important to keep this temperature regime, as this is the main condition for the high quality of the finished product. At low temperatures, the resulting clot is not dense enough, because whey proteins almost completely go into whey, and the yield of cottage cheese is significantly reduced. With an increase in temperature, the denaturation of whey proteins increases, as a result of which the intensity of whey separation decreases and the yield of cottage cheese increases. To increase the fat content of the product with a separate method, pasteurized cream is added to it.

Pasteurized milk is cooled to the fermentation temperature. This temperature directly depends on the time of year: in the spring-summer period, milk is cooled to 28-30°C, and in the cold season - to 30-32°C. Then the cooled milk is sent to the baths for making cottage cheese. Sourdough for the production of cottage cheese is made on pure cultures of mesophilic lactic streptococci. It is added to milk in an amount of 1-5%. The duration of fermentation is from 6 to 8 hours. To speed up this process, 2.5% of the starter prepared on cultures of mesophilic streptococcus and 2.5% of thermophilic lactic streptococcus are added to milk. In the warm season, fermentation with the accelerated method is carried out at a temperature of 35°C, and in the cold season - up to 38°C. In this case, you can reduce the duration of fermentation of milk by 2-3.5 hours.

To improve the quality of the product, experts advise using a direct method of preparing starter cultures on sterilized milk, which allows you to reduce the dose of starter application to 1%.

When using the acid-rennet method of producing cottage cheese in the traditional way, immediately after adding the starter to the milk, a 40% solution of calcium chloride (400 g of anhydrous salt per 1 ton of milk) prepared in boiled water at a temperature of 40-45 ° C is added there. Thanks to calcium chloride, pasteurized milk can again form a sufficiently dense clot that separates whey well under the action of rennet. At the next stage, rennet (or pepsin) is added to milk in the form of a 1% solution at the rate of 1 gram per 1 ton of milk. Previously, the enzyme is dissolved in boiled water at a temperature of 35°C. A solution of pepsin to increase its activity is prepared in advance (at least five hours before use) on acidic clarified whey. To speed up the process of making curd, milk is fermented to an acidity of 32-35°T in special tanks and only then pumped into curd baths. Enzyme and calcium chloride are added to the raw material prepared in this way.

The fermentation process when using the acid method takes about six hours, and when using the acid-rennet method - 4-6 hours. The use of an active acid-forming starter can reduce this time by 1.5-2 times - up to 3-4 hours. The degree of readiness of the clot can be determined by the level of its acidity. For low-fat cottage cheese, this figure should be 75-80°T, and for fatty and bold types - 58-60°T. In addition, the clot is evaluated visually. Normally, it should be quite dense and have even smooth edges at the break with the release of a transparent greenish serum. It is very important to determine the end of fermentation in time, otherwise you will get an acidic sticky smearing mass, and not a tasty grainy cottage cheese.

To speed up the release of whey, the finished clot is cut with special wire knives into cubes with a face size of 2 cm. When using the acid-rennet production method, the cut clot is left for about an hour for intensive whey release, then it is subjected to self-pressing and pressing. At this stage, the cut cubes are placed in calico or lavsan bags with a volume of 7-9 kg, more than half filled. The bags are then tied up and stacked in several rows on press trolleys. Under the influence of its own mass, serum is released from the clot. This process, which is called self-pressing, is carried out in the workshop at a temperature of no more than 16 ° C and takes about an hour. The readiness of the mass is determined by eye: the surface of the clot loses its luster and becomes matte. After that, it is pressed until ready. Periodically, bags with cottage cheese are shaken several times and shifted. Pressing should be carried out at an air temperature of 3-6°C. A higher temperature leads to an increase in acidity and deterioration of the finished product. After pressing, the cottage cheese is sent to coolers, then it is packed on automatic machines into containers of the required volume. Cottage cheese is packed in small packages in the form of bars weighing 0.25; 0.5 and 1 kg wrapped in parchment and / or cellophane, bags, glasses made of polymeric materials. The finished product, according to TU 9222-180-11419785-04, is stored in the sale for no more than 72 hours at a temperature of 2-8 ° C and air humidity of 80-85%.

Workshop equipment and workers

For the production of cottage cheese, a whole range of equipment is used for receiving, cooling, processing, storing and transporting raw materials. So, for example, received milk is stored in tanks - metal containers, pumped using pumps, received using milk meters (scales), processed by milk separators, pasteurizers, filters, etc.

The main part of the line includes curd makers with pressing baths, curd baths with water heating, installations for pressing and cooling curds. Among coolers, two-cylinder designs are considered the most successful.

In addition to this equipment, filling and packaging machines, equipment for storage and transportation of finished products will also be required.

The minimum cost of such equipment is 2,450,000 rubles, not counting the cost of transportation and commissioning.

To work at a mini-factory, a staff of 6-10 workers is required. All of them must undergo a medical examination, training and be certified in hygienic training, have valid medical books. The procedure for undergoing hygienic training and certification was approved by Order of the Ministry of Health of the Russian Federation of June 29, 2000 No. 229. The frequency of medical examinations, a list of medical specialists, laboratory and functional studies, as well as a list of contraindications for work are given in the Order of the Ministry of Health and Social Development of the Russian Federation No. 302n of 12 April 2011

In addition, you will need an accountant and a sales manager.

Outlook, expenses and income

In general, competition in the field of milk processing and, in particular, the production of fermented milk products is assessed as medium. According to experts, in many regions this direction is promising and deserves attention.

The total investment in the creation of a mini-factory for the production of cottage cheese and other curd products is estimated at 5,500,000 rubles. The payback period is at least two years with stable operation and the fulfillment of plans for the production and marketing of finished products. In general, the profitability of production in the curd industry is 7-10%.

Approximately the same amount (5.5-6 million rubles) will cost a ready-made business for the production of pasteurized milk and kefir drink, packaged in plastic bags, sour cream and cottage cheese, packaged in plastic containers, Adyghe cheese packed in a plastic container. The volume of such production is 3000 liters of milk (acceptance, cleaning, processing with the production and storage of the above products). On the one hand, a ready-made business seems to be a more profitable option, primarily because of the already established relationships with suppliers, retail chains, individual stores, a well-formed staff ... However, if you are going to purchase an already functioning business, it is advisable to first consult with a specialist who will be able to assess all the risks and prospects.

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In the manufacture of cottage cheese, both primary raw materials (cow's milk not lower than the second grade and acidity not more than 21%) and processed products (skimmed milk obtained by milk separation) are used, as well as special products (sourdough for cottage cheese on pure cultured lactic acid streptococci, calcium chloride or calcium chloride 2-aqueous). Used as an auxiliary product drinking water. The technological process is carried out by the fermented milk method.

The production technology of cottage cheese goes through the following stages:

1. Acceptance of raw materials and assessment of their quality.

2. Heating and separation of milk.

This stage takes place in a plate pasteurization-cooling unit, where the milk is heated to a temperature of 37-40°C, and then the cream separator is sent to the separator. All this happens according to the rules of separation.

3. Compilation of a mixture of normalized milk.

When producing cottage cheese with MJ 18.9% and 5%, milk is normalized in order to establish the correct ratio between MJ and protein in the normalized mixture, which provides a standard product in terms of MJ and moisture.

4. Pasteurization and cooling of normalized or skimmed milk.

Dairy raw materials intended for the production of cottage cheese are cleaned on milk purifiers or filtered through three layers of gauze or other filter cloth. Purified milk is heated to 37 ± 2 "C and separated on cream separators. In the manufacture of fat, semi-fat and peasant milk, fat is normalized, taking into account the mass fraction of protein in whole milk, in order to obtain a finished product with a given content of fat and moisture. Skimmed or normalized milk is pasteurized at a temperature of 78 ± 2 ° C with a holding time of 15-20 s in plate or tubular pasteurization-cooling units or containers. After pasteurization, milk is cooled to the fermentation temperature. If milk after pasteurization is not used immediately for processing, then it is cooled to 6±2°C and stored for no more than 6 hours. After storage, the milk is again heated to the fermentation temperature.

The starter is prepared on pure cultures of mesophilic lactic acid streptococci. For accelerated fermentation, a starter prepared on pure cultures of mesophilic and thermophilic streptococci is used. The temperature of milk during fermentation is 30 ± 2 "C in the cold and 2 ± 2 ° C in the warm season, with the accelerated method - 32 ± 2 "C, when using the Darnitskaya starter - 26 ± 2 and the Kaunas starter -- 24±2°С. Before adding to milk, the surface layer of the starter culture is carefully removed with a clean, disinfected ladle and removed. Then the starter is mixed to a homogeneous consistency with a clean whorl (when cooked in starter tubs) or a stirrer and poured into the prepared milk in an amount of 1--5% of the total mass. With accelerated fermentation, 2.5% of the ferment prepared on cultures of mesophilic streptococci and 2.5% of the ferment on cultures of thermophilic streptococci are added to the milk. The duration of milk fermentation is 10 hours, and with the accelerated method - 6 hours.

There are two ways to produce cottage cheese - traditional (regular) and separate. The separate method of cottage cheese production allows to speed up the process of whey separation and significantly reduce losses. The essence of the separate method lies in the fact that the milk intended for the production of cottage cheese is pre-separated. From the resulting skimmed milk, low-fat cottage cheese is produced, to which is then added required amount cream, increasing the fat content of cottage cheese to 9 or 18%.

According to the method of clot formation, two methods of curd production are distinguished: acidic and rennet-acid. The first is based only on the acid coagulation of proteins by fermenting milk with lactic acid bacteria, followed by heating the clot to remove excess whey. In this way, low-fat and low-fat cottage cheese is produced.

With the rennet-acid method of coagulation of milk, a clot is formed by the combined action of rennet and lactic acid. The rennet-acid method is used to produce fatty and semi-fat cottage cheese, which reduces the waste of fat into whey.

The production of cottage cheese in the traditional way includes the following stages:

Acceptance of milk;

Normalization of milk to the required composition;

Cleaning and pasteurization of milk;

Cooling milk to fermentation temperature;

Introduction of sourdough and rennet into milk;

Fermentation of milk;

Clot cutting;

Serum separation;

Curd cooling;

Packing;

Packaging and storage of finished products.

Normalized and purified milk is sent for pasteurization at 78-80°C with a holding time of 20-30 s. The pasteurization temperature affects the physicochemical properties of the clot, which, in turn, affects the quality and yield of the finished product. By regulating the modes of pasteurization and clot processing, by selecting strains of starter cultures, it is possible to obtain clots with the desired rheological and water-retaining properties.

Pasteurized milk is cooled in the recovery section of the plate pasteurization-cooling unit 5 to the fermentation temperature (in the warm season up to 28-30°C, in the cold season - up to 30-32°C) and sent to special baths 6 for fermentation. Sourdough for the production of cottage cheese is made on pure cultures of mesophilic lactic acid streptococci and added to milk in an amount of 1 to 5%. The duration of fermentation after fermentation is 6-8 hours.

With the accelerated method of fermentation, 2.5% of the ferment prepared in a starter on cultures of mesophilic streptococcus and 2.5% of thermophilic lactic acid streptococcus are added to milk. The fermentation temperature with the accelerated method rises in the warm season up to 35°C, in the cold season - up to 38°C. The duration of milk fermentation with the accelerated method is 4.0-4.5 hours, i.e. is reduced by 2.0-3.5 hours, while the release of serum from the clot occurs more intensively.

To improve the quality of cottage cheese, it is desirable to use a non-transplanting method of preparing a starter culture on sterilized milk, which allows reducing the dose of starter application to 0.8-1.0% with its guaranteed purity.

With the rennet-acid method of producing cottage cheese, after adding the starter, a 40% solution of calcium chloride is added (at the rate of 400 g of anhydrous salt per 1 ton of milk), prepared in boiled and cooled to 40-45 ° C water. Calcium chloride restores the ability of pasteurized milk to form a dense, well-separating clot under the action of rennet. Immediately after that, rennet or pepsin is added to milk in the form of a 1% solution at the rate of 1 g per 1 ton of milk. Rennet is dissolved in boiled and cooled to 35°C water. A solution of pepsin in order to increase its activity is prepared on acidic clarified whey 5-8 hours before use. To speed up the turnover of curd baths 6, milk is fermented to an acidity of 32-35°T in tanks, and then pumped into curd baths and calcium chloride and an enzyme are added.

The end of fermentation and the readiness of the clot is determined by its acidity (for fatty and semi-fat cottage cheese it should be 58-60 ° T, for low-fat - 66-70 ° T) and visually - the clot should be dense, give even smooth edges at the break with the release of a transparent greenish serum. Fermentation with the acid method lasts 6-8 hours, with rennet - 4-6 hours, with the use of active acid-forming starter - 3-4 hours.

To speed up the release of whey, the finished clot is cut with special wire knives into cubes with a face size of 2 cm. In the acid method, the cut clot is heated to 36-38 ° C to intensify the release of whey and incubated for 15-20 minutes, after which it is removed. With rennet, the cut clot without heating is left alone for 40-60 minutes for intensive serum release.

For further separation of whey, the clot is subjected to self-pressing and pressing. To do this, it is poured into calico or lavsan bags of 7-9 kg (70% of the bag capacity), they are tied up and placed in several rows in a press trolley 7. Under the influence of its own mass, whey is released from the clot. Self-pressing takes place in the workshop at a temperature not exceeding 16°C and lasts at least 1 hour. The end of self-pressing is determined visually by the surface of the clot, which loses its luster and becomes matte. Then the curd is pressed under pressure until tender. In the process of pressing, the bags with cottage cheese are shaken several times and shifted. In order to avoid an increase in acidity, pressing should be carried out in rooms with an air temperature of 3-6 ° C, and after it is completed, immediately send the curd for cooling to a temperature not higher than 8 ° C using coolers of various designs. The finished product is packed on machines in small and large containers. Cottage cheese is packaged in cardboard boxes with liners made of parchment, polyethylene film. In small packages, cottage cheese is packed in the form of bars weighing 0.25; 0.5 and 1 kg, wrapped in parchment or cellophane, as well as in cardboard boxes, bags, glasses made of various polymeric materials. Cottage cheese is stored until sale no more than 36 hours at a chamber temperature not higher than 8 ° C and a humidity of 80-85%.

Curd makers with a pressing bath are used to produce all types of curd, while the laborious process of pressing curd in bags is eliminated. The cottage cheese maker consists of two double-walled bathtubs with a capacity of 2000 liters with a crane for draining whey and a hatch for unloading cottage cheese. Pressing baths with perforated walls are fixed above the baths, on which the filter cloth is stretched. The pressing vat can be hydraulically raised or lowered almost to the bottom of the fermentation vat. Ready cottage cheese is sent for packaging and then to the refrigerating chamber for additional cooling.

In order to reserve cottage cheese in the spring and summer periods of the year, it is frozen. The quality of thawed cottage cheese depends on the freezing method, which can be slow or fast. The cottage cheese is frozen in packaged form - in blocks of 7-10 kg and briquettes of 0.5 kg at a temperature of -25 to -30 ° C in thermally insulated continuous freezers to a temperature in the center of the block of -18 ° C and -25 ° C in for 1.5-3.0 hours. Frozen blocks are placed in cardboard boxes and stored at the same temperatures for 8 and 12 months, respectively. Defrosting of cottage cheese is carried out at a temperature not exceeding 20 ° C for 12 hours.

Table 4- Routing production of cottage cheese in VK-2.5 baths (on the example of the production of cottage cheese by the acid-rennet method at OJSC "Moloko Buryatiya")

	Name of the technological operation	Operation parameters and modes	Name of technological equipment, brand
	Reception and preparation of raw materials: Weighing Cooling Reservation	No more than 12 hours at t= 4?С Not more than 6 hours at t=6?С	SMI-500 scales gauze filter, etc. Reservoir cooler. OOL-25 Reservoir R2-OMG 6.3
	Heating Separation Reservation Normalization Pasteurization Cooling in the cold season Cooling in warm season Reservation Heating	(78±2)?С with a shutter speed of 15-20 sec. (28±2)?С or up to t=(4±2)?С (4±2)?С no more than 6 hours	Pasteurizer Plast.OPU10 Cream separator 5OS2N Reservoir R2-OMG 6.3 Reservoir R2-OMG 6.3 Pasteurizer Plast.OPU10 Tank Ya1-OSV-10 Bath for cottage cheese VK-2.5
fermentation Application of calcium chloride	1-3% starter cultures in milk 3-5% starter in sterile milk 400 g per 1000 kg of milk	Bath for cottage cheese VK-2.5 Bath for cottage cheese VK-2.5
Enzyme application Mixing	1 g per 1000 kg of milk
	Fermentation until the formation of a clot of sour. For cottage cheese low fat duration
	Clot cutting Clot exposure Heating of the clot to t: m.d.l 2-7% low fat	Cubes 2*2*2cm (38±2)?С, vyd 20-40m (36±2)?С, vyd 15-20m	Wire knives Bath for cottage cheese VK-2.5
	Whey drain Cluster cooling	Bath for cottage cheese VK-2.5
	Draining a clot on a sickle	Not less than 10%	Press trolley
	Self-pressing
	Pressing to the required moisture content in curd, %: low fat	No more than 73% No more than 76% No more than 80%
	Curd cooling		Cooler D5-OT5
Cottage cheese packaging	Filling machine М6-АР2Т
	Aftercooling		cooling chamber

The technological process must comply with these parameters throughout the entire production process, control must be carried out.

Delicious, fresh, puffed curd always in demand and residents of a large metropolis, and a small provincial town. Start a manufacturing business fermented milk product is not difficult, since the manufacturing technology does not require the use a large number ingredients and kitchen utensils. Nowadays, even a small subsidiary farm brings a good income, especially when making products with pleasure.

Features of opening a "curd" business

Before opening your own business, you must register with the Federal Tax Service or its regional representative office as an entrepreneur who wants to establish a business (IP). The newly minted IP will have to conclude agreements with Rospotrebnadzor, Sanitary and Epidemiological Station, and the Fiscal Tax Service. A number of reporting and daily documentation is subject to completion and maintenance, among which the logs of receipt and expenditure of funds and raw materials are of particular importance. Individual entrepreneurs must strictly comply with the clauses of contracts for the removal (disposal) of solid, household and medical waste, as well as in accordance with the instructions that determine the disinfection of a courier car.

For the manufacture of cottage cheese, a minimum set of kitchen utensils is required, which greatly simplifies the production process of the product and reduces its cost by eliminating additional expenses for the purchase of specialized tools. The cottage cheese maker's set is a set consisting of the following devices:

• 2 pans of various sizes;
• skimmers;
• 1 sieve.

At the same time, one should take into account the fact of cottage cheese production at home according to the simple recipe, requiring the presence of the 1st pan and gauze. Aluminum pans should be used as opposed to enameled ones for 1 simple reason: milk in enameled pans burns when heated and acquires an unpleasant burnt aftertaste, which negatively affects the taste of the finished product.

Choice of ingredients for making crumbly cheese

Milk is considered the main ingredient in homemade cottage cheese production. Some recipes for making crumbly cheese require the addition of additional ingredients - sour cream or kefir. It should be remembered that all the products that make up the cottage cheese must be natural: store-bought pasteurized milk is not suitable in this case. There are no special requirements for the equipment of the premises for the production of cottage cheese. The main thing is that the kitchen is spacious, clean, has enough space and working surfaces of tables and stoves for various technological operations.

Two employees (cooks) need to purchase a health book and undergo a medical examination. If an individual entrepreneur wants to produce not only ordinary, but also skim cheese also, he should purchase a special filtering apparatus - a milk separator. The principle of operation of the device is called the separation of milk into skimmed emulsion and cream. A production separator separates fermented milk into curd and whey, but such a device is unsuitable at home.

Curd mass preparation technology

As mentioned above, the technology for making homemade cottage cheese contains several recipes. We bring to your attention a couple of simple types, following step by step instructions which even an inexperienced cook can cook delicious cottage cheese.

Recipe "Minimum"

1. Milk is taken and poured into enamel pan in the required amount.
2. The pan is placed in a warm place for 30 hours. It is not recommended to interfere with milk during the fermentation process, since exposure to the product with a spoon worsens the quality of the formation of curd clots.
3. After the specified time has elapsed, the milk container is placed on a slow fire in order to avoid overheating of the liquid, which will adversely affect the separation process. curd mass from serum.
4. It is worthwhile to separate the cottage cheese from the whey using a water bath: a container of milk is placed in a larger saucepan filled with water, the level of which is set at the middle mark of the height of the inner saucepan of a smaller volume.
5. The temperature of the heated fermented milk is determined by touching the container with your hand. Separated liquids should not be mixed, because action impairs the quality of whey separation from the final cheese product. If the mixture is overheated, the curd will be dry and too crumbly. In the case of bringing the fermented milk emulsion to the optimum heating temperature, the curd product comes out sour taste quality and easily separable from the liquid part.
6. The heating process is carried out within half an hour.
7. The pan is removed from the fire, left alone in order to allow the 2-component product to cool until half cooked. The best indicator of separability from whey is dry cheese, cooled for 6-8 hours.
8. At the end of the cooling period, the clearly visible curd mass is laid out in a colander with a slotted spoon. The second method of separating cottage cheese and liquid is the method of pouring the contents into cheesecloth located above a jar or 2nd pan. One person drains the curd mixture, and the second one tightly holds a piece of gauze, stretching it in both directions.
9. The cottage cheese obtained in this way is allowed to drain for 1-1.5 hours. If the curd mass was placed in gauze, then the cloth is tied and hung over the sink or bathtub. If a cottage cheese turned out to be in a colander, then the device is placed on the opening of the pan so that the whey can finally flow out.
10. It is not worth keeping cottage cheese in gauze or a colander for more than 1.5 hours, because it loses its softness and tenderness of texture, becomes hard and dry.

Quick recipe

1. In a jar of milk, add a little sour cream or kefir, based on the calculation: 50 gr. to 1 litre.
2. We put in a warm place for 12-24 hours for ripening.
3. After the time necessary for the formation of curd clots, we take a jar of curd mass and put it in a larger saucepan (volume and diameter).
4. Pour water flush with the upper border of yogurt in a jar. We take out the product from the container with water.
5. Put the pot on the fire and bring the water to a boil.
6. We turn off the gas after the liquid boils.
7. We put a jar of fermented milk in hot water for half an hour.
8. Then we take out the bottle and let it cool for 40-45 minutes.
9. Pour the contents of the bottle into a colander or 2nd saucepan through cheesecloth.
10. We tie the gauze in a knot and hang it over the sink or bathtub.
11. We leave ready-made cottage cheese drain for 1.5 hours. The product is ready.

The IP will have to pay expenses on a monthly basis for the following items:

• the increased cost of paying for utilities: the use of gas, electricity;
• wages to hired employees: 2 cooks and a courier delivering goods to consumers' addresses;
• payment for the cost of a technical device for separating milk sections - a separator;
• payment of the cost of travel to the point of sale of finished products - the fair, including payment of the local market fee;
• expenses for attracting buyers: release of a commercial on the Internet, on television and radio;
• expenses for the purchase of high-quality feed for cows living in the subsidiary farm, especially in the cold season.

Promotion and business profitability

Distribution of finished products should be started by friends and acquaintances, who will make a good advertisement for individual entrepreneurs, the so-called, " word of mouth". Further, as you attract and accumulate capital, you should apply to create an advertisement in a web studio. It became possible to carry out a marketing campaign to promote goods independently, using the profiles of social networks Facebook, Twitter, Vkontakte, Instagram as an advertising platform.

Profitability home production cottage cheese is quite high. Based on the calculation of the production of 1 kg of curd mass from 3 liters of milk, then when receiving 10-20 liters of milk from cows, 6 kg of cottage cheese can be prepared daily. The cost of 1 kg of a fatty curd product on the market is about 260 rubles, and for a fat one - about 300. Thus, the monthly revenue will reach 45-50 thousand rubles. By-products of the curd craft are also in demand - whey and cream, produced using a separator. The production of homemade crumbly cheese does not create any particular difficulties, and the income is enormous.

This type of business is well suited for people who have their own subsidiary plots. The "curd" business, ideally, leads to an increase in net profit and an increase in one's own well-being.

Anna Goncharuk, [email protected]

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dream about own business each of us has. Someone has already implemented it, and someone else is lost in conjectures in which direction to move. Dairy industry - a good option. For example, you can engage in the production of cottage cheese. However, not all so simple. First of all, it is necessary to choose the right equipment for the production of cottage cheese, and this will be discussed in this article.

About the benefits of cottage cheese

This product is good in every way. It contains proteins that are very well absorbed. In addition, it contains a lot of calcium, which is necessary for the human body (especially young children). Cottage cheese, in fact, is a unique product, it is often included in various diets. In system proper nutrition he is always present. The recommended serving is 100 grams per day. To have healthy hair, nails and skin, it is enough to use this product three times a week.

Production features

This process goes according to the following scheme:

1) Acceptance of whole milk and its quality assessment.

2) Preheating and separation of raw materials.

3) Normalization of milk. This is necessary in order to obtain a product of a certain fat content. It should be noted that 5% and fat-free cottage cheese is most often produced (with mass fraction fat in the product 0.5-1%).

4) Pasteurization of the product and its cooling.

5) Adding sourdough to milk and fermenting it.

6) Cutting the formed clot and separating the whey.

7) Clot pressing.

8) Cooling of the finished product.

9) Packaging and labeling of cottage cheese.

Necessary equipment

Consider what equipment is required for the production of cottage cheese:

1) To receive milk, it is necessary to have large tanks in which the product will be stored until the next stage.

2) You will need a pasteurizer-cooler in which the milk is heated, and a separator for the production of cottage cheese, which separates the cream from the milk.

3) Tanks are needed for the normalization process.

4) At the stage of pasteurization and cooling, the same pasteurizer-cooler mentioned in the second paragraph is used.

5) Fermentation is carried out in the same tanks (another name for them is baths for the production of cottage cheese), into which milk enters after normalization.

6) To cut the clot, you need a special knife. After that, it is necessary to drain the resulting whey into another tank using a fitting or siphon.

7) To press the curd, you will need a press trolley covered with sickle. Here, the curd is self-pressed for about an hour.

8) Cooling of the finished product is carried out in refrigerators.

9) Packaging and labeling of cottage cheese is carried out by special machines that dose the product, pack it and apply special marks.

Automated installations

Today, the automated line for the production of cottage cheese is in great demand. Its significant advantage is that, due to the mechanization of the process, only two or three people of the service personnel are enough, and this is a significant savings in wages.

Such plants are capable of producing up to 3.5 tons of finished product (in terms of raw materials - 24 tons of milk). Do you want to increase production? Such equipment allows the organization of a wide line of several devices, while maintaining the flow of the process.

Thus, in order to start the production of such a valuable product, it is necessary to purchase a number of devices and place them correctly on the territory of the workshop. The easiest way is to purchase a line for the production of cottage cheese, which includes all the necessary machines.