• Project description
• Description of products and services
• marketing plan
• Production plan
• Recruitment
• Financial plan
• What equipment to choose

We bring to your attention a typical business plan (feasibility study) for opening an enterprise for the production of semi-finished products. This business plan can serve as an example for obtaining a bank loan, government support or attracting private investment. On the example of an enterprise in the Ulyanovsk region.

A typical business plan for opening an enterprise for the production of semi-finished products in a small village. On the example of an enterprise in the Ulyanovsk region.

Project description

The aim of the project is to open a workshop for the production of semi-finished products in the village of Mullovka Melekessky district of the Ulyanovsk region. The production of semi-finished products is a promising line of business. This statement is explained by the fact that the demand for semi-finished products is steadily growing. There are more and more busy people in society who do not have time to cook homemade food. Semi-finished products allow you to cook your favorite dish in a matter of minutes, while saving a significant part of precious time.

Despite the large number of enterprises that have opened today, there is still a shortage of high-quality semi-finished products at affordable prices. This niche is planned to be occupied by our enterprise.

Opening a workshop for the production of semi-finished products is also beneficial from an economic point of view. The main indicators of the economic efficiency of the project implementation are as follows:

• Net profit per year = 1,535,277 rubles;
• Farm profitability = 17%;
• Payback of the project = 8 months.

How to start opening a workshop for the production of semi-finished products

To implement the project, it is planned to receive subsidies in the amount of 300 thousand rubles within the framework of the state program to support small and medium-sized businesses in the Melekessky district - grants to start-up entrepreneurs. Also, own funds in the amount of 700 thousand rubles will be allocated for the implementation of the project. The total investment in the project will be 1 million rubles.

The opening of a workshop for the production of semi-finished products also has its own social indicators:

1. Registration of a new business entity in the Melekessky district;
2. Creation of 12 jobs in the district;
3. Receipt of additional tax payments to the budget of the Melekessky district.

How much money is needed to open a workshop for the production of semi-finished products

All funds received under the state small business support program will be used to purchase fixed assets. The cost estimate for the implementation of the project is presented in the form of a table:

What taxation system to choose for the enterprise

The organizational and legal form of our enterprise will be a limited liability company - Simbirsk Pelmeni LLC. The director of the enterprise is Ivanov Ivan Ivanovich, she is also the initiator of the project. The system of taxation of the workshop for the production of semi-finished products will be the simplified taxation system (STS).

The actual location of Simbirsk Pelmeni LLC is located at the address: Ulyanovsk Region, Melekessky District, r.p. Mullovka.

What documents are needed to open a workshop for the production of semi-finished products

Currently, practical activities have begun to implement the project:

1. LLC "Simbirskie Pelmeni" was registered at the local branch of the INFS;
2. A building was purchased to house the production. The area of ​​the premises is 1168 m2. Currently, the building is being renovated in order to comply with all the requirements of the SES and the fire safety of the production facility;
3. There is a preliminary agreement with the company LLC "Elves" for the purchase of equipment for the workshop for the production of semi-finished products;
4. Preliminary agreements were concluded for the supply of semi-finished products to stores in Dimitrovgrad and Samara.

Description of products and services

The initial range of products manufactured by the workshop will include:

• Homemade dumplings, wholesale price 130 rubles/kg;
• Amateur dumplings, wholesale price 110 rubles/kg;
• Pelmeni in Russian, wholesale price 90 rubles/kg;
• Homemade cutlets, wholesale price 110 rubles/kg;
• Amateur cutlets, wholesale price 90 rubles/kg.

With the development of the enterprise and the establishment of new sales channels, the range of products will increase.

About 150 kg of finished products will be shipped daily. The average wholesale selling price will be 106 rubles/kg.

Technology of production of semi-finished products

The technology for the production of semi-finished products includes such stages as: acceptance of meat, primary processing of carcasses, culinary cutting, sorting of meat, preparation of semi-finished products, packaging of finished products.

Our company will use only high-quality raw materials. This includes: cooled or chilled beef of the first and second categories (GOST 779-55), meat pork (GOST 7724-77), veal, baking flour (GOST 26574-85). Raw materials will come from local wholesale suppliers, large agricultural producers and farms. All incoming raw materials will undergo strict veterinary control.

marketing plan

The main competitors of our company will be similar manufacturers located in the Melekessky district and the city of Dimitrovgrad, as well as manufacturers from other regions. The line of goods produced by competitors is very wide, while the price range is also very significant. However, as studies show, there is a shortage of high-quality “home-made” semi-finished products in retail outlets. The demand for such products is always high, and the supply is often absent.

The competitiveness of our products will be achieved primarily through a competent ratio of price and quality of goods. It is planned to sell the manufactured products through the following distribution channels:

1. Sales through retail outlets, shops and pavilions;
2. Implementation through wholesale organizations;
3. Conclusion of supply contracts to local chain stores.

The main sales markets for products are the city of Dimitrovgrad and the Melekessky district, as well as the cities of Ulyanovsk and Samara. At present, there is an agreement for the supply of products to LLC Network of Supermarkets (Dimitrovgrad), LLC Saturn (Dimitrovgrad) and LLC New Product (Samara).

Advertising of manufactured products is planned to be carried out by placing information on bulletin boards, in the media, on the Internet, as well as during personal visits to trade enterprises.

How much can you earn on the sale of semi-finished products

The total monthly revenue of the enterprise will be 1,030 thousand rubles.

However, this indicator of revenue will be achieved only after 6 months of operation of the shop. Since before reaching large volumes of production, it will be necessary to establish distribution channels for products and win the trust of consumers.

Thus, the annual revenue of the enterprise will be 10,815,000 rubles.

Production plan

The production of semi-finished products will be carried out in a room with a total area of ​​1168.88 m2. In this case, the workshop itself will be divided into the corresponding sections:

• Area for receiving and cutting animal carcasses;
• A section for the production of semi-finished products, which has sub-sections for the production of minced meat and dough;
• Packaging and labeling area;
• Area for storage and warehousing of raw materials and finished products;
• Room for working staff;
• Shower and toilet rooms;
• Office of accounting and administration of production.

The enterprise will comply with all norms and sanitary rules imposed on such objects by the regulatory authorities. The workshop room will have good lighting, ventilation and air exchange with an influx of clean outside air. Walls, floors and ceilings adjacent to the cold store will be thermally insulated. All workplaces where personnel come into contact with unpackaged products will be equipped with sinks with hot and cold water supply.

What equipment to choose for the production of semi-finished products

The main equipment necessary for the production of semi-finished products includes: a dumpling machine, a dough mixing machine, a flour sifter, a meat grinder, a shock freezer, a split system, a freezer, a refrigerator, a chest.

When choosing equipment, the main emphasis is on reliability, ease of operation, availability of spare parts, low cost and, accordingly, high payback rates.

Recruitment

The planned staffing of the workshop for the production of semi-finished products will include 12 people.

Financial plan

The cost of raw materials for the production of semi-finished products, based on 1 kg of manufactured products, is as follows:

Taking into account the planned volume of production of semi-finished products, the annual cost of raw materials and ingredients will amount to 6,011,250 rubles.

The monthly expenses of the enterprise will amount to 750,737 rubles, and the annual expenses will amount to 9,008,850 rubles.

The main costs of the enterprise are the costs of purchasing raw materials for the manufacture of semi-finished products - 67% of the total costs per year. In second place are the costs of paying wages to shop workers - 19% of the total costs.

Net profit based on the results of annual sales of semi-finished products will amount to 1,535,277 rubles. The profitability of the workshop for the production of semi-finished products is 17.0%. With such indicators, the project will pay off in 8 months.

The enterprise will make tax deductions to various levels of the budget of the Ulyanovsk region up to 498,682 rubles a year.

How to start the production of semi-finished products

At the initial stage, we will need to register a new subject of production activity. After that, you need to rent or acquire ownership, build your own production facility.

How much money do you need to start a business

When opening the production of semi-finished products, the amount will be taken into account based on the final product. For example, when setting up the production of semi-finished meat products (dumplings, meatballs, etc.), 1 million rubles are needed. This is without taking into account the construction of the structure or the cost of rent, without remuneration of personnel.

How much can you earn in the production of semi-finished products

The full payback for the production of semi-finished products is eight months. After this time, we can talk about making a net profit. The net annual profit from the production of semi-finished products will amount to 1.5 million rubles. Taking into account the expansion of production areas, access to additional markets for finished products, net income from the production of semi-finished products increases significantly.

What equipment to choose

To establish the production of semi-finished meat, you will need to purchase:

• dumpling machine and freezer;
• shock freezing cabinet and vibrating meat sifter;
• kneading machine and refrigerator.

What documents are needed to open

registration documents as a subject of production activity;

• documents for the production facility (lease agreement, documents on ownership);
• permission of the sanitation station;
• permission from the fire inspectorate;
• contract for the purchase and supply of equipment for the production of semi-finished products;
• contracts for the supply of semi-finished products;
• an agreement with a company for the removal and disposal of production waste;
• contracts with employees and collective agreements;
• job descriptions, etc.

What taxation system to choose for registration of production of semi-finished products

A simplified taxation system for the production of semi-finished products is the best option.

Manufacturing technology of semi-finished products

• GOST 779-55 - for cooled and chilled beef of categories 1 and 2;
• GOST 7724-77 - meat pork;
• GOST 26574-85 - baking flour and veal.

A positive aspect and an indisputable advantage of the business for the production of semi-finished products is the ability to change the range, depending on the needs of the market. There are many types of meat dishes, and even cutlets and meatballs can be produced during the shift. At the same time, equipment for the production of pancakes or semi-finished meat products does not even need to be reconfigured.

Frozen products are a product subject to certification. To obtain permission to sell products to the distribution network, you need to register the workshop as an enterprise. When choosing a form of ownership, it should be taken into account that large retail chains prefer to work with LLCs. Permits for activities must also be obtained from the sanitary and epidemiological station. A declaration of conformity is issued for the products.

Production technology

The quality of raw materials affects the taste of semi-finished meat products. It must be fresh, and usually accompanies each batch of goods with a veterinary certificate. When entering the meat products workshop, the raw materials are additionally controlled.

The technology consists of several operations:

• preparation of raw materials;
• minced meat preparation;
• product formation;
• packaging, warehousing and sale.

If the meat is purchased in carcasses, then you need to cut it. This process is called deboning. From raw materials, all bones and veins must be isolated. Next, it is ground into minced meat. If the product is prepared from a pork-beef mixture, then the raw materials are taken in a 50/50 ratio. Spices and other ingredients are added to the already crushed main raw materials. It can be onions, bread, water, salt. The temperature of the mixture ready for shaping should not exceed 14 degrees, otherwise not only the taste of the product is violated, but also its bacterial characteristics. Often in modern industries, natural raw materials are partially replaced with vegetable ones. Soy is added to minced meat, eggs are replaced with egg powder and so on. You need to be careful with them, as they affect the taste of the final product.

Products are formed on a molding machine. Then meat semi-finished products are subjected to shock freezing.

What equipment is needed?

The workshop for the production of frozen semi-finished meat products is equipped with the following equipment:

Semi-finished products include products made from natural and minced meat without heat treatment. These are products that are maximally prepared for culinary processing.

Meat semi-finished products are divided into: natural (large-sized, small-sized, portioned, portioned breaded); chopped; semi-finished products in the test; chopped meat.

Natural semi-finished products. These are pieces of meat pulp of various weights, cleaned of tendons and coarse surface films. Natural small-sized semi-finished products also include meat-and-bone pieces of meat with a certain bone content. Semi-finished products are released chilled or frozen. The raw material is meat in chilled or frozen states. Meat of bulls, boars, rams, meat frozen more than once, and lean meat is not used.

Large-sized semi-finished products. Depending on the type of meat, large-piece semi-finished products are divided into four groups:

• - the first group: from beef - the longest muscle of the back (dorsal part, lumbar part), tenderloin (lumboiliac muscle, located under the bodies of the last thoracic and all lumbar vertebrae), hip part (upper, inner, lateral and outer pieces); from pork - loin, tenderloin; from lamb - the hip part;
• - the second group: from beef - the scapular part (shoulder and shoulder parts), the subscapular part, the chest part, as well as the hem (supracostal muscles removed from the 4th to the 13th rib, remaining after the separation of the subscapular part, brisket and longissimus muscle back) from beef of the 1st category of fatness: from pork - hip, scapular, cervical-subscapular parts; from lamb - scapular part, loin;
• - the third group: from beef - cutlet meat and beef trimmings of the 2nd category; from pork - brisket; from lamb - brisket, cutlet meat;
• - the fourth group: from pork - cutlet meat. Cutlet meat (for example, beef) - pieces of meat pulp from the neck, flank, intercostal meat, pulp from the tibia, radius and ulna, trimmings obtained by stripping large-sized semi-finished products and bones.

Portion semi-finished products. They are made from large-sized semi-finished products, cut manually or on special devices across the muscle fibers obliquely or perpendicularly. Assortment of portioned semi-finished products: from beef - natural beefsteak (from tenderloin), langet (two thinner pieces from tenderloin than beefsteak), entrecote (from the longest back muscle), rump steak (from the longest back muscle or the most tender pieces of the hip part - upper and internal), natural zrazy (from the same pieces of the hip part), beef wind (from the side and outer pieces of the hip part).

The range of portioned semi-finished products from pork includes: natural cutlet (from the loin), escalope (from the longest muscle of the back), wind pork (from the neck and shoulder part), tenderloin, schnitzel - from the hip part.

Portion breaded semi-finished products: rump steak (from beef), natural cutlet and schnitzel (from pork and lamb). For portioned breaded semi-finished products, pieces of meat are lightly beaten to loosen the tissues and rolled in finely crushed white bread crumbs to preserve the meat juice.

Small-sized semi-finished products. From beef they get: beef stroganoff (from the tenderloin, the longest muscle of the back and the upper and inner piece of the hip part), azu (from the side and outer pieces of the hip part), goulash (from the scapular and subscapular parts, as well as the hem), soup set (meat and bone pieces weighing 100-200 g with the presence of pulp at least 50% by weight of a serving), beef for stewing (pieces of ribs with pulp at least 75% by weight of a serving), brisket on kharcho (with a pulp content of at least 85% by weight of a serving) .

Small-sized semi-finished products from pork are represented by the following names: roast (from the hip part and loin with a fat content of not more than 10%), goulash (the same as beef goulash), meat for barbecue (from the hip part), stew (pulp content not less than 50% of the serving weight), home-style stew (the content of bones is not more than 10% and adipose tissue is not more than 15% of the serving weight).

Large-sized semi-finished products are sold mainly by weight, portioned - packaged, the mass of the product is 125 g (tenderloin 250 and 500 g), small-sized - portions of 250, 500 and 1000 g (meat and bone).

In the production of natural semi-finished products, salting and massaging can be used. The composition of the brine includes salt, phosphates, granulated sugar; for some items, a sprinkling of spices and decorative spices is used.

Semi-finished products in the test. The technical conditions developed by VNIIMP present the traditional and new assortment of dumplings, as well as other semi-finished products in dough: meat sticks, manti, khinkali. According to other specifications, several dozen types of dumplings are produced, designed for buyers with both high and low incomes. The composition of minced dumplings includes trimmed beef and pork, onions, black or white ground pepper. To prepare the dough, use flour of the highest grade (sometimes the 1st grade) with a normalized quantity and quality of gluten, egg products.

Meat sticks are cylindrical or rectangular in shape up to 10 cm long. Manty is a dish of Uzbek cuisine. They are larger than dumplings. They are not boiled in water, but steamed in a special dish - manti-kaskan. Khinkali is a dish of Transcaucasian cuisine such as dumplings in the form of a rhombus, a square. Meat for manti and khinkali is chopped larger than for dumplings and sticks, minced meat for these products contains an increased amount of onion.

Ravioli in minced meat also contain mushrooms and rennet cheese, they have the shape of a semicircle, rectangle, square.

Chopped semi-finished products. They are prepared from minced meat with the addition of other ingredients according to the recipe. The traditional assortment of chopped semi-finished products includes: Moscow, homemade, Kyiv cutlets, rump steak, beef steak. The main raw materials in their production are beef and pork cutlet meat, trimmed beef of the 2nd grade, trimmed fatty pork. During the years of the economic crisis, the range of chopped semi-finished products expanded due to the use of cheaper raw materials - mechanically deboned poultry meat, soy protein preparations, mainly textured soy flour, vegetables, cereals.

The recipe for cutlets consists of cutlet meat: Moscow - beef, Kyiv - pork, domestic - beef cutlet and fatty pork in half. The composition of all items includes (%): wheat flour bread - 13-14, onion - 1-3, water - 20, breadcrumbs - 4, salt, pepper, in Kyiv - egg melange. The rump steak uses hydrated soy protein instead of bread; in a steak - beef cutlet meat - 80%, sausage bacon - 12%, water - 7.4%, pepper, salt, no breading. It is allowed to replace 10% of raw meat in cutlets with soy concentrate or texturate and in all items 20% of raw meat with mechanically deboned poultry meat. Chopped semi-finished products are produced chilled (0-6 °С) and frozen (not higher than -10 °С).

Chopped meat. Minced meat is obtained from meat by grinding it on a top with a lattice hole diameter of 2-3 mm. The traditional range of minced meat: beef, pork, homemade, lamb, special meat and vegetable. For the production of minced meat, meat frozen more than once, boars, bulls, lean, pork with signs of yellowing is not allowed. The main raw material for minced meat: beef cutlet meat or trimmed beef of the 2nd grade (minced beef), semi-fat pork or pork cutlet meat (minced pork). The composition of homemade minced meat includes (%): beef (50) and pork (50) meat; special minced meat - beef (20), pork (50), soy concentrate (30).

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 molded 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 cutlets w75x20 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 cold store for storage.

Main raw material.

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

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.

Auxiliary materials.

Auxiliary materials for all products are salt (1.2% by weight of minced meat), black pepper (0.04-0.08%) and water (6.7-20.8%) added to minced cutlets to increase its juiciness. The introduction of isolated soy protein, high-protein milk concentrate in minced meat in the amount of 10-20% allows replacing up to 10% of meat, improving their organoleptic qualities, increasing nutritional and biological value, increasing water-binding capacity, and reducing losses during frying. When preparing auxiliary raw materials, onions and vegetables are washed and chopped. Bread is soaked and also crushed. Melange is thawed in advance in baths with water, the temperature of which is not higher than 45C.

Basic technological equipment.

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 of 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.

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 not changed for many years: the meat in the receiving hopper is captured by a screw or screws and fed through a housing with internal ribs to a 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 designs, as well as the degree of wear of both the cutting tool and the housing with the screw.

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 (bowl) 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.

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 principle of separation, taking into account the physical characteristics of the 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.

The minimum temperature rise in the case of an input temperature of 0-2ºC (this temperature is optimal) is usually 1-2ºC for chicken, 4-7ºC for turkey, and approximately 10ºC for beef.

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) turn meat into minced meat with lightning speed, 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.

Cuttering is the process of fine grinding of meat raw materials. The duration of cuttering significantly affects the quality of minced meat. Cuttering lasts an average of 5-12 minutes, depending on the minced meat being prepared, the design features of the cutter, the shape of the knives, and the speed of their rotation. Cuttering not only ensures the proper degree of meat grinding, but also the binding of the added ice. And it is the cutting process that largely determines the quality of the final product.

Ice maker. In the meat processing industry, a large amount of water ice is required for the production of various products. 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. The productivity of the machines is from 380 kg to 23 tons / day.

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 should not be cut.

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, you can give products a variety of shapes.

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 look and feel like a homemade product.

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

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 beneficial properties.

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.

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.

The demand for fresh meat products is constantly growing. The main competition is developing between the segments of chilled and frozen products. There is still a place in this niche for everyone, because different types of semi-finished products are clearly separated by purpose, distribution channels.

The volume of meat consumption in Russia has been constantly increasing over the past 10 years. Even according to the results of the depressive 2020, there is an increase (3%) compared to the previous period. At the same time, the production of semi-finished products is growing most actively, as well as their consumption. This is due to the employment of the population, the accelerated dynamics of modern life. To understand whether this direction is promising for small businesses, we briefly characterize:

• features of the Russian market of meat products;
• types of products, preferences, distribution network;
• technologies and equipment for meat processing;
• regulation of this type of business.

Supply and demand for semi-finished products

About 50% of the total volume of meat (Russian and imported) is sold raw. Approximately 30% - goes to sausage products, 5% - canned food, about 15% - the production of semi-finished meat products and supplemented with other ingredients. In recent years, their consumption has increased by 10-15% annually, while sausages - by only 5% (Fig. 1).

Figure 1. Dynamics of growth in the production of semi-finished meat products according to Rosstat.

Almost a tenfold increase is a response to ever-increasing demand. But production is distributed unevenly across regions (Fig. 2). Traditionally, over 60% falls on the Central and North-Western districts, where large meat processing plants are concentrated. According to experts' forecasts, consumption of these products will grow in the next 3 years, the highest rates are expected in the periphery.

Figure 2. Distribution structure of meat processing enterprises by districts in 2013.

Increased demand has changed the strategy of large meat holdings (Fig. 3). If earlier they focused on the production of sausages, sausages, and other delicacies, then in the last two years they have been actively re-profiled into raw semi-finished products. This, of course, will lead to increased competition. The developed capacities of giant enterprises, their own raw material base, the possibility of acquiring imported equipment and new technologies put small business in obviously unfavorable conditions.

Figure 3. Zones of influence of Russian agribusinesses for the production and processing of meat in the European part of Russia. According to Kommersant.

Most large meat processing plants produce frozen products. The transition from sausage production to products for cooking, the purchase of new technologies - increases its cost. Standard packages are also inconvenient: small ones are expensive for the manufacturer, large ones do not suit the buyer. Goods by weight are now in high demand.

Small businesses find a place in this niche for several reasons. Proximity to sales outlets saves transport costs. And the price in times of crisis is the main regulator of consumer demand. In addition, more and more buyers are choosing chilled meat over freezing; even if its cost is 10-15% higher. Since the shelf life of such products is up to 7 days, retailers take them from local producers. However, they often complain about the poor assortment, low quality of goods.

Varieties of products, sales directions

Meat semi-finished products are produced from all types of meat: beef, pork, poultry, including offal. Currently, their range includes about 40 units. Products are usually divided into two broad categories: chilled and frozen. According to the manufacturing technology, they are:

1. natural. Large, small-sized products, mainly from chilled meat: brass beef and pork, steaks, natural cutlets, shish kebab, stew, soup sets.
2. Breaded. Ready-to-cook dishes from fresh and thawed meat in liquid (with egg) crumb crumbs: offal, chops, rump steaks.
3. Chopped. Products from low-grade raw materials, often with the addition of bread, spices: cutlets, steaks, meatballs. This group also includes packaged and loose minced meat.

Mixed semi-finished products with the addition of dough and, to a lesser extent, vegetables are widespread on the Russian market (Fig. 4). The undisputed leader is dumplings, they even came up with a special vending machine for them.

Figure 4. Consumption rates of fast foods by type (2014).

Sales channels for products:

1. Retail chains- their share is about 50%. Dumplings, cutlets sell well in outlets of all kinds. Sliced ​​​​(shish kebab, goulash), minced meat, pancakes, pasties, manti - prevail in the markets, supermarkets. Both frozen and chilled products are sold.
2. Specialized Culinary occupy approximately 10%. These are ordinary stores selling goods from the counter. Own culinary workshops allow us to prepare a diverse range of ready-made dishes, quickly respond to seasonal changes, changing tastes and needs. They sell finely chopped meat in marinades, kebabs, goulash, khinkali, cabbage rolls.
3. HoReCa segment- about 14% of semi-finished meat products are sold through it. It is developing faster than anyone, thanks to the spread of fast food. Buyers - restaurants, bars, canteens, fast food cafes. Frozen products are supplied to public catering establishments more often, large-scale high-tech production wins here.

Main trends for 2020 - 2020:

1. Increasing demand for chilled products; increase in the proportion of poultry meat: chicken and turkey.
2. Expansion of the range of dishes in sauces, marinades of the original recipe; with vegetable ingredients.
3. Displacing traditional products with new, original dishes of the national cuisine of the peoples of the world.
4. Growth in the consumption of expensive semi-finished products, ready-to-eat meals.

How to open a workshop for the production of semi-finished products

If an entrepreneur decides to open a meat business, first you need:

• determine in which market segment to work, select an assortment;
• find, master, develop recipes taking into account modern technologies;
• purchase professional equipment, transport for delivery.

The technological process, for example, for natural semi-finished products includes:

• defrosting carcasses, half carcasses (defrosting) in the amount of daily processing - if necessary, if the workshop is located separately from the place of slaughter;
• washing, drying, cutting into large cuts, trimming, stripping;
• preparation of portioned, small-sized, chopped products on special machines;
• packing of goods in functional containers, sealed bags, labeling;
• cooling (freezing), storage, transportation to a warehouse.

As for the recipe, buyers prefer semi-finished meat products with a minimum degree of processing. For example, if these are chickens, then they are simply cut into half carcasses, breasts, wings, etc. However, there is a growing demand for "convenient" products, balanced in composition, with different ingredients, allowing you to prepare a dish in quick culinary ways. For this, modern packaging such as "protective atmosphere", "gaseous environment" is used. Experts believe that owning them will soon become a pass to the natural chilled food segment.

Inexpensive equipment for all types of processing is produced by Russian factories. It can be selected separately, or you can purchase a ready-made modular workshop for the production of semi-finished products. The set depends on the future assortment. As a rule, the equipment of the workshop is formed by: band saws, cutting presses, meat grinders of various capacities, machines for applying breadcrumbs, cutlet or dumpling machines. If there is no work experience, it is advisable to find a supplier providing comprehensive services, including training, information support. Often such equipment is purchased on lease. The main selection criteria: an integrated approach (multifunctional lines) and rationality - the ability to ensure the sale of the entire volume of products.

Organizational and legal issues

Production of meat, other food products with it (semi-finished products, canned food, sausages); rules for storage, transportation, packaging, labeling - are regulated by the Technical Regulations of the Customs Union "On the safety of meat and meat products" (TR TS 034/2013). This document contains all the requirements, manufacturing conditions and classification of products with different meat content, for example:

• meat - (> 60%) with the addition of other ingredients;
• meat-containing - (5 - 60%), with the inclusion of flour, eggs, cereals, water;
• meat and vegetable - (30 - 60%) using herbal ingredients.

Only the main groups are listed, in fact there are many more. After the development of the relevant GOSTs, their name will be indicated when marking. In accordance with the Regulation, manufacturers are required to issue one of three documents:

• veterinary certificate- fresh unprocessed meat (veterinary organization of the Ministry of Agriculture);
• state registration certificate- meat products for baby food (Rospotrebnadzor);
• declaration of conformity(DoS) - processed meat, including semi-finished products (certification body).

Declaration is carried out according to three schemes: for the period of storage, 3 and 5 years (Fig. 5). The accredited laboratory of the Customs Union has the right to conduct tests, draw up and register DoS.

Figure 5. List of actions for obtaining a declaration of conformity for 3 years.

Each manufacturer must have a package of documents, including technical documentation, laboratory test reports and DoS. As for the sale of meat products, it does not have any special differences, and is regulated by the general rules for retail trade.

Summing up. For small enterprises, it is unprofitable to manufacture finished products, since it is difficult for them to compete in terms of quality with sausages, sausages from large meat processing plants. It is more practical to produce fresh products that do not require deep processing of meat and do not duplicate common well-known brands. It is cheaper, does not require the development of complex processes, the involvement of qualified specialists.

The ultra-fast pace of life does not leave us a chance to enjoy the comfort of home, and even more so - home-cooked food. This is where a variety of products come to our aid, which have already passed all the stages of the technological process, except for the last one - preparation. The production of semi-finished products as a business, based on this need, is a rather profitable direction, although it requires certain investments of funds and efforts.

Varieties of semi-finished products

In general, these products can be divided into food and industrial. We, as consumers, of course, are more interested in the former, since they are the ones that get to our stove from store shelves.

From the name, we can conclude that this product has already passed the production process by half and requires only final processing - frying, boiling, stewing.

Semi-finished products can be vegetable, meat, fish, dairy, cereals, combined.

In more detail, the classification looks like this:

• natural meat;
• breaded meat in pieces - chops, rump steak, schnitzel, beef steak, chops;
• pieces of meat, cut into pieces and packaged in bags - langets, entrecote, escalopes, cutlets, schnitzels;
• kebab;
• meat sets of small pieces - azu, goulash, beef stroganoff, stew;
• meat by-products;
• chopped semi-finished products - minced meat, cutlets from it;
• fish semi-finished products;
• dumplings;
• peeled potatoes;
• frozen vegetables;
• cutlets from vegetables;
• semolina, rice, millet cutlets;
• vegetable mixes;
• syrniki;
• vareniki.

This list, of course, cannot be complete. You can continue it indefinitely, because the conditions of modern life force technologists to come up with more and more new recipes.

The production of semi-finished products implies another classification, which is based on the principle of heat treatment. Here produce frozen and chilled products. Speaking specifically about semi-finished meat products, they are also divided into different types according to the type of meat used - pork, beef, chicken and others.

Registration and documents

At the initial stage, it is necessary to decide in what form your enterprise will be clothed. There are two options - individual entrepreneurship or LLC. In the first case, you have to go through a simple registration procedure, but the second one will open the doors for you to many supermarkets and large stores, since such enterprises are much more willing to work with legal entities.

As equipment you will need:

• rolling pin;
• meat grinder;
• home scales;
• bowls;
• packaging materials;
• freezer.

The only condition is that there should be enough space in your kitchen, especially when production starts to grow and additional hands are needed to manage to process all orders. In a home business, you can succeed if you strictly adhere to the issue of the quality of your products. It will cost an order of magnitude higher than store semi-finished products, but the client will also expect more from her. Minced meat should be tasty, most importantly - meat, and in a normal amount.

The sale of semi-finished products of own production should be planned at the initial stage. At first, acquaintances, neighbors, relatives, all those who do not have time to produce cutlets and dumplings themselves can become your customers. It is these people who will make you good advertising through word of mouth. You yourself will not have time to look back, as the number of orders will increase dramatically.

Don't forget about regular discounts for loyal customers. Next, try to make contact with nearby cafes and restaurants. From products prepared at home, and even with a soul, hardly anyone will refuse.

Production of semi-finished products: Video