Economic indicators of the work of the condensed milk production facility located on 50 sq. m. and, subject to registration of the premises for rent and equipment with three main automatic installations

Condensed milk is perhaps the favorite delicacy of most children and adults, so this product is in constant demand. This allows us to judge the prospects of the business associated with its production. But in order to profit from the activity of condensed milk production, it is important to produce only a high-quality product that meets the state standard.

To do this, it is necessary to conduct a competent analysis of this market segment, as well as develop a thorough organizational plan and make preliminary calculations of the economic efficiency of a potential business.

Market analysis

The modern market for the production of canned food with milk content in Russia is developing rapidly, which leads to an increase in the volume of sales of these products, especially ready-made condensed milk. Positive changes in this market segment are explained by an increase in consumer demand for this product from organizations involved in the manufacture of confectionery products.

In fact, condensed milk is a concentrated milk with added sugar. Modern technologies have made it possible to expand the range of these products, so you can find specimens with various additives on store shelves:

• cocoa;
• coffee;
• fruits;
• berries and other ingredients.

In addition, if previously condensed milk was only a canned product packed in a special tin can, today manufacturers use the following containers as containers:

• glass and plastic bottles;
• tubes;
• plastic packaging and more.

But when analyzing this market segment, one must also remember the main nuance of condensed milk production, which is that the sales volumes of a quality product are strongly influenced by the abundance of similar but low-grade products on the windows of retail outlets. In other words, a product that does not comply with GOST, but is manufactured according to TU, but has a lower cost price.

The fact is that manufacturers seek to save money and therefore instead of natural raw materials, they use surrogate products, such as:

1. Stabilizers.
2. Emulsifiers.
3. Vegetable fats.

This circumstance opens up prospects for start-up entrepreneurs who have decided to start producing high-quality condensed milk.

Business registration and organization

To open your own business for the production of condensed milk, it is important to carefully think over all the nuances of its organization in advance. In addition, any business must exist legally, and therefore, first of all, an entrepreneur must register his business with the Federal Tax Service. An individual entrepreneur or LLC is suitable for opening such an activity.

Required Documentation

To conduct a business, you will need the following list of required documentation:

• certificate of registration with the Federal Tax Service as an individual entrepreneur or legal entity;
• Rospotrebnadzor permitting documents: product quality certificates;
• GOST, TU and collection of sanitary and epidemiological standards.

Premises and equipment

When choosing a room for organizing the production of condensed milk, it is important to take into account that it must comply with all sanitary and hygienic standards enshrined in current legislation. In addition, when choosing it, it is worth considering the following nuances:

As for the required equipment, its type will depend on the chosen production method:

1. If it is planned to organize a small workshop that will produce condensed milk made from whole milk, then several (2-3) USM-4 units will be required. She is capable of:

• produce up to 11 kg of finished products in one four-hour cycle;
• has low power and weight, which does not require large territorial areas.
• one employee is enough to work on the unit.

1. As an alternative or additional option, an entrepreneur in the production of condensed milk can use powdered milk. In this case, he will have to purchase a special line VSM-100. Of course, its cost is almost 10 times more expensive than USM-4, and the mass is much larger, but the device itself does not require a significant area (1.2 sq. M.) Either.

In addition to the above installations, for the organization of uninterrupted production, an apparatus for cooling the finished consistency and a special filling line for packing finished products into containers are required.

Raw materials

The main raw material for condensed milk is whole milk, in addition, according to the technology, sugar is also needed for its production. So, for the production of 1 kg of finished products, you need:

• 2.5 liters of whole milk with a fat content of 3.5%;
• 0.5 kg of sugar.

But even at the initial stages of starting a business, it is worth considering a number of difficulties that arise with whole raw materials:

1. The need for stable and constant suppliers.
2. Ensuring that the product is delivered to the processing site and stored correctly.
3. Seasonality. In the autumn-winter period, milk is a scarce product, the prices of which increase significantly.

Due to the absence of whole milk on the raw materials market during the cold season or its high cost, which increases the cost of production, powdered milk can act as its substitute. There will be no problems with its delivery at all, since there is an abundance of it on the modern market.

In terms of the composition of 3.5%, powdered milk is no different from a whole product, but condensed milk prepared on its basis will have a characteristic taste.

Production technology

The entire technological process for the production of a condensed product from a whole one consists in the passage of raw materials through a certain sequence of stages:

If the production operates on the basis of milk powder, then, first of all, the stage of liquid evaporation is excluded from the technological process. In this case, to obtain the finished product, the raw material is diluted with warm (40 degrees) drinking water, and the resulting mixture is passed through a filter and cooled.

The resulting product is kept for several hours to swell the proteins, after which a similar sequence of actions is carried out with it as in the case of whole milk.

Staff

As for the technological process, only a professional should lead it. To work on each automatic installation, one specialist is required. In any case, the list and number of production personnel directly depends on the selected equipment and the amount of manual work. In addition, warehouse workers may be required for medium production:

• accountant;
• raw material procurement manager;
• finished product sales manager;
• cleaners.

Advertising and sales market

Well-established production can bring an entrepreneur a stable volume of finished products, but in order to start making a profit from your business, you need to competently organize its implementation.

As a rule, for condensed milk, the optimal distribution channels are:

To establish sales links with buyers, it is also important to take care of advertising of your own production. Therefore, as part of the marketing policy, it is worth considering the following activities:

• placement of information about the company and the benefits of its products in the media and print media;
• creation of an official website;
• placement of banners and advertising posters in busy areas of the city.

You can also prepare brochures and business cards so that you can visually familiarize customers with the benefits of condensed milk from a particular company.

The financial component of the business

In addition to the organizational plan for future production, the entrepreneur must also make the necessary calculations of its economic efficiency. In other words, calculate the estimated amount of initial investment, current production costs and future income.

Opening and maintaining costs

Suppose a decision has been made to open a condensed milk production facility equipped with three units for processing whole raw materials and one unit for working with the original product in dry form. For this, a suitable room with an area of ​​50 sq. m., which will be issued for a long-term lease. Then the amount of the initial capital will be about 1.2 million rubles.

Subsequently, the enterprise will be forced to incur current expenses for payment:

• rent;
• utility bills;
• salaries of employees and deductions from it;
• purchase of raw materials;
• maintaining advertising.

On average, the amount of monthly costs will be 150 thousand rubles.

Amount of future income

To calculate the size of the future income of production, first you need to decide on the schedule of its work. If it is planned that the workshop will work 30 shifts per month, and the production day will be 8 hours, then taking into account the daily productivity of one installation (2 cycles - 22 kg), the volume of products produced will be 1980 kg per month.

Today, the wholesale price of 1 kg of condensed milk is 100 rubles, therefore, the amount of potential earnings per month will be equal to 200 thousand rubles.

Payback period

From the previous paragraph it follows that the approximate amount of monthly profit is 50 thousand rubles. This allows us to determine that the initial investment will pay off in at least two years of uninterrupted production.

Starting a condensed milk business is a promising idea for aspiring entrepreneurs. It does not require huge financial investments, in addition, the finished products of such production are in constant demand. But in order to get a stable profit and have a good reputation in this market segment, it is worth producing the highest quality product.

Who among us in childhood did not dream of secretly eating a jar of condensed milk, or even more than one? Of course, many of us wondered what and how such a coveted delicacy is made of. The employees of the Glubokoye Milk Canning Plant in the Vitebsk region have kindly agreed to open the veil of secrecy over the production process of the world-famous condensed milk in cans with a traditional white and blue label. The sanitary rules at this enterprise in the city of Glubokoe are akin to those in a surgical operating room. Complete sterility! I had to put on special clothes, sign in the appropriate magazine about the absence of infectious diseases and undergo sanitization. It is a very interesting procedure in itself. Hands must be thoroughly washed before visiting OJSC MKK - and not only with liquid soap, but also with a special antiseptic. Water from the washbasin taps is supplied automatically - there are infrared sensors here. This is done so that workers and visitors do not touch the taps with their hands, because if one person touches it with dirty hands, and the other with clean hands, then the effect of washing can be nullified. But that's not all! When entering the workshop, you must place both hands in a special automatic turnstile, which will pour a little disinfectant into the palm of your hand to wipe them. At the same time, the soles of shoes are treated with a special disinfectant solution. Only after the device is triggered, the green light will light up at the checkpoint, and the turnstile will allow you to go inside. Of course, all employees of the company regularly undergo the necessary medical examinations. They do not have to touch their hands directly with milk and dairy products, the entire technological process is automated, but the peculiarities of food production require full guarantees. “We have implemented a safety system for the production of canned condensed milk products ISO 22000 and the HACCP system, the requirements of which we must strictly observe,” says Lyudmila Duk, Deputy Director for Production. - First of all, incoming milk is checked for the presence of antibiotics, because they can seriously affect human health. For this, a special device is used - the HEAT sensor. If traces of, for example, tetracycline or other drugs sometimes used by veterinarians to treat cows are found in milk, this batch will not be accepted by us under any circumstances. If there are no antibiotics in milk, it undergoes a number of other laboratory tests, which should determine the group of raw materials purity, the percentage of fat mass fraction and, of course, organoleptic indicators - in other words, the taste, color and smell of the product. According to the approved methods, milk is first heated to exactly 35 degrees to determine the smell and to the boiling point, followed by cooling to determine the taste. And suppliers are obliged to bring it to the plant only cooled to 10 degrees, because the bactericidal phase of milk lasts only for two hours after its production. A veterinary certificate stating that it was obtained from healthy cows is also required. According to Lyudmila Georgievna, the raw material base of OJSC "Glubokoye Milk Canning Plant" is represented not only by the Glubokoye region, which is native to the enterprise, but also by two more - Sharkovshchinsky and Braslavsky. And, although the suppliers for many years of cooperation with the MCC are more than proven, and the regions themselves are environmentally friendly, each batch of milk supplied to the enterprise is subject to the strictest input control, because the safety of people depends on it. Irina Vaskovich, conducted an excursion along the same route that takes place when each batch of raw materials arrives at the enterprise: from "arrival" from the farm in a milk tanker to dispatch to consumers in the form of packaged jars with appetizing condensed milk. - Here, unloading is carried out, or, as we say, "rolling" of milk trucks, - says Irina Konstantinovna. - What you see now is the washing of the tanks after their unloading. This means that the arrived milk consignment passed laboratory tests, turned out to be of high quality and was accepted. We also looked into the reception laboratory, which, for the convenience of the process, is located next to the reception area. In it, the IWC specialists with might and main conjured with cunning devices capable of revealing even an insignificant percentage of antibiotics and other substances potentially dangerous to the consumer in milk. Other devices determined the degree of purity of the product, its fat content and grade, and the organoleptic qualities were checked by the laboratory technicians very simply: the milk was carefully examined, smelled and, of course, tasted. Today's raw materials had an excellent taste and smelled, as it should, of natural fresh milk, and very appetizing. In the meantime, the freshly arrived milk was pumped into the storage compartment - of course, through the counter. One could even observe this process through a special window. Tanks for storing newly received raw materials are also located near the receiving area, only slightly lower, and, of course, milk enters them only after cooling. The interior of the store is somewhat reminiscent of a submarine: the same set of pipes (albeit exclusively made of shining food-grade stainless steel) and round sealed hatches. It is impossible to keep milk here for a long time, because the sooner the raw materials are sent for pasteurization, the better. This process, discovered by the great biologist of the past, Louis Pasteur, is the heating of milk to a temperature at which disease-causing and lactic acid bacteria die, but the raw material itself is not yet boiling, which allows it to preserve all its taste, useful microelements, enzymes and vitamins. Pasteurization is carried out in a special area. Of course, all flows of "milk rivers" at the enterprise need to be managed somehow. This is successfully done by a fully computerized system, the operator of which can direct the process directly from his workplace - opening and closing valves manually, as several decades ago, is no longer required. However, back to pasteurization. After its passage, milk can be stored for much longer than untreated milk using this technology. It is stored in special containers, but also for a very short time, because the raw materials are already waiting at the thickening section. True, the "fate" of different batches of milk may be different depending on its purpose: for example, future concentrated milk without sugar will be immediately directed to evaporation, and sugar syrup must be added to condensed milk with sugar. And now - the most important thing. This syrup is the only addition! Absolutely no preservatives, sweeteners, enhancers of taste and aroma, as well as other food additives frightening the consumer, starting with the "E" index, are not used in Glubokoye. This is not necessary: ​​the guaranteed and thoroughly checked quality of the raw materials, coupled with modern processing technology, allow us to produce a product not with the taste of a flavoring agent, but with the taste of natural milk, from which it is actually made. Evaporation, like pasteurization, is carried out without bringing milk to a temperature of 100 degrees Celsius, which allows it to preserve the entire spectrum of useful qualities of a fresh product in it. However, boiling with the removal of "extra" water molecules in the form of steam does not necessarily occur at this temperature: every student knows that for this it is necessary to lower the pressure. Therefore, milk is condensed in special apparatus by evaporation under vacuum. The whole process is carefully monitored - both by instruments and visually. And when the condensed milk reaches the parameters set by GOST, it is placed in a special tank. In the meantime, tin cans (still empty) and lids for them come from a neighboring workshop. A special machine fills the cans with condensed milk with an accuracy of the gram, after which the container is immediately rolled up. Filled cans fly out of the car almost like a machine gun at a speed of 300 cans per minute! According to the assurances of the MKK employees, the modern production line of the Italian company Zilli & Bellini is capable of delivering 450 cans of condensed milk per minute, just such a speed is not used at the moment. Next, the filled, but still "unnamed" cans of condensed milk are sent to a conveyor that delivers them straight to the labeling machine. Like all processes at the Glubokoe MKK, this one is fully automated: smart equipment will stick the label on its own, and crimp it, and scroll the can during this process. The further path of cans of condensed milk, already decorated with the traditional white and blue label, runs to the machine, which collects them in the required quantity and puts them in boxes. The cardboard boxes themselves are made here by another machine. The filled and sealed boxes go to the conveyor, which takes them to the finished goods warehouse, and from there they go directly to the stores. True, the goods do not sit in this warehouse for a long time - condensed milk, like other products of Glubokoye milk canning, judging by the branded trucks scurrying back and forth, is in great demand among consumers. And this is a kind of "Hall of Fame" of the Glubokoye Milk Canning House, marked, however, by the relatively modest signboard "Our Achievements". The awards for product quality are already hard to fit on the wall! Moreover, there are among them not only Belarusian diplomas of winners of various exhibitions and competitions, quality certificates and various prizes, but also international ones. Which, however, is not surprising: after all, the products of Glubokoye milk canning are supplied to many countries of the world. This is clearly shown by the map located here. The states "conquered" by Glubokaya condensed milk are marked on it with special badges, while the markets of other Glubokaya milk producers have yet to conquer. Click on the button to subscribe to "How It's Done"! If you have a production or service that you want to tell our readers about, write to Aslan ( [email protected] ) and we will make the best report that will be seen not only by the readers of the community, but also by the site How is it done Subscribe also to our groups in facebook, vkontakte,classmates and in google + plus where the most interesting from the community will be posted, plus materials that are not here and videos about how things work in our world. Click on the icon and subscribe!

Canned milk Are products made from natural milk with the use of condensation (followed by sterilization or the addition of sugar) and drying. They have a high energy value due to the concentration of milk constituents in them. In addition, canned milk is characterized by good transportability and significant storage stability.

Canned milk is produced according to traditional technology in accordance with GOST 2903-78 and various technical specifications.

The production of canned milk is characterized by a number of general methods of preparation and processing of raw materials, such as receiving, cleaning, cooling and backing up, normalizing, heat treatment, homogenization, thickening.

Acceptance and preparation. Acceptance is carried out in accordance with GOST R -52054-2003. Then milk is passed through purifiers and plate coolers OOP-25, with a capacity of 25,000 l / h. From the coolers, the milk flows into the milk tanks. The plant has 24 tanks, each with a capacity of 6 tons.

Normalization of the original mixture. It is carried out to obtain the required ratio between the constituent parts of dry matter in canned milk. If the fat content is high, then skim milk is added to it, if the fat content is lower than normal, cream is poured in 20% fat. Further, milk is fed from the tanks by centrifugal pumps 50-ЗЦ 7,1-20 (with a capacity of 7100 l / h) into the pasteurizer.

Pasteurization. Before thickening, the normalized mixture is pasteurized at a temperature of 90 ± 2 ° C or 107 ± 2 ° C without holding. Immediately after pasteurization, milk is cooled to 70 ... 75 ° C to prevent denaturation of whey proteins and other undesirable physicochemical changes.

Thickening. After cooling, the milk is sent for thickening to mixing tanks, and from them to vacuum apparatus (Wiegand 8000). Food fillers such as sugar syrup, etc. are also served there. During evaporation, the main parameters of the process are temperature, exposure duration and concentration ratio. The evaporation temperature takes place at a temperature of 45 to 82 ° C. The milk is condensed to a dry matter content of 70%. The readiness of the product is determined by the dry matter content with a refractometer.

Cooling. Then the milk is sent to a vacuum - crystallizers (Vigant 4000), where it is cooled down to 20-25 degrees Celsius in a deep vacuum. Here, the dry matter content increases by 4%. Samples are taken from chilled condensed milk to determine physical, mechanical and biochemical parameters. If these indicators correspond to the regulatory documentation, then the product is sent for packing and rolling. If the product does not meet the requirements of GOST and technical specifications in terms of water and fat content, it is normalized after thickening with water, skim milk or cream. The water must be boiled and purified. If condensed milk with sugar contains more water than is provided for by regulatory documents, then it is allowed to mix it with a product of lower moisture content of another cooking.

To establish the readiness of the product, take a sample of it, cool it to 18-20 ° C and determine the density, mass fraction of dry matter and organoleptic characteristics. The density of condensed whole milk with sugar at 50 ° C is 1280-1320 kg / m3. Mass fraction of dry substances in the finished product according to a refractometer at 20 ° C is 73.8-74%.

The consistency of the product sample at 50 ° C should be slightly viscous. The product should drain easily from the spatula or hydrometer when removed from the cylinder in which the density of the sample was determined. The thickened product from the vacuum evaporator is sent for cooling. For this purpose, crystallizer coolers and vacuum coolers are used. The product is cooled to a temperature of 18-20 ° C for 40-60 minutes.

When condensed milk with sugar is cooled, crystallization of lactose begins. This process is uncontrollable, and the result is the formation of large crystals. To obtain a high quality product, it is necessary that the size of lactose crystals does not exceed 10 microns. If larger crystals are formed, then the consistency of the thickened product becomes powdery and even sandy. To intensify crystallization and the formation of small crystals of lactose, a seed is introduced into the condensed product - dry fine-crystalline lactose with a crystal size of 2-3 microns.

The amount of seed corresponds to 0.2% by weight of the product. Before adding lactose is heated at 105 ± 2 ° C for at least 1 hour. After adding lactose to condensed milk, the number of crystallization nuclei increases, which contribute to the formation of small crystals. As a seed, you can use condensed milk of the previous production. Its amount should be at least 10%. The crystallization temperature of lactose is 25-35 ° C.

Packing and packaging. Samples are also taken from chilled condensed milk to determine physical, mechanical and biochemical parameters... If these indicators correspond to the regulatory documentation, then the product is sent for filling and rolling, where the filling machine (B4-KRP-1, capacity 160 ± 10 bpm) fills metal cans with condensed milk, the seaming machine closes them. For packing condensed milk with sugar, consumer containers are used (metal cans No. 7, No. 7a, No. 4, No. 14, polyethylene barrel, cardboard drums, plastic bags, Pure-Pak bags, Doy-Pak bags, p / e buckets). The cans are delivered along the line to the packaging workshop, where labels are glued, all the necessary inscriptions are put on the body of the cans (the legend is stamped on the lid or applied with indelible paint in two rows). In the top row, data is applied according to GOST-23651-79:

M (dairy industry index);

manufacturer's number;

assortment number of canned food;

shift number.

The bottom row contains data

the number of manufacture of products - in two digits (up to the ninth digit inclusive, zero is put in front);

month of manufacture - in two digits (up to the ninth digit inclusive, zero is put in front);

the year of manufacture indicated by the last two digits of that year.

The outer surface of metal cans with products to be placed in the shipping container must be clean, smooth, without cracks, sharp deformations, teeth, notches, "birds" (deformation of the bottoms and lids of cans in the form of corners at the sides of the can), tongues, scratches and rust. In metal cans with products to be placed in shipping containers, the following are allowed:

on the outer surface of the cans there is a slight tarnishing, dullness, light prints from rolls, surface dots up to 1 mm in diameter;

minor teeth and notches - no more than two along the circumference of each fold;

slight beads of solder along the seam of the can;

slight bruising of the can body without sharp edges;

minor scratches and scuffs on lithographed and varnished cans on no more than 5-7% of the surface;

slight folds and swellings along the seam and body of the can (when packed in combined cans).

Canned food is not allowed in cans:

bombers with swollen bottoms and lids; not taking a normal position after pressing them with fingers;

with "clapping" ends (the bulge of the bottom or lid of the can does not disappear when pressed, disappears at one end of the can and simultaneously appears at the other end, accompanied by a characteristic clapping sound);

punched, with through cracks, with birds, black spots (in places not covered with half-day), having sharp bends of the tin, bruised folds, violation of the integrity of the half-fold on the folds and longitudinal seams;

having rust on the outer surface, after removal of which shells remain;

with smudges - traces of leaked product;

with an incorrectly formed seam (tabs, open teeth, undercut, fake seam, rolled seam).

The question of the use of canned milk in cans with "flapping" ends, with "birds", rusty, heavily dented and bombed, as well as products in tubes that have a swollen shape (bomb), punctured, leaky, with a strongly dented surface is decided by the sanitary epidemiological service.

Storage. The guaranteed shelf life of condensed milk with sugar in cans No. 7 at a temperature from 0 to 10 ° C is 12 months, in a transport container - 8 months. Condensed milk canned food with sugar and fillers is stored at temperatures from 0 to 1 ° C and relative humidity of 75% for 12 months. The guaranteed shelf life of coffee and cocoa with condensed cream and sugar at temperatures from 11 to 20 ° C is no more than 3 months.

The assortment of canned milk sold by Promkonservy LLC includes:

Condensed whole milk with sugar (380g., 400g., 4kg, 40l., 60l.)

"Condensed milk and cream" (360g.),

Whole milk var. thickened. s / s (4kg 3.75kg.),

"Boiled condensed milk" (4kg., 3.75kg.),

"Condensed milk" (380g.),

"Condensed milk with coffee" (380g.),

"Condensed milk with cocoa" (380g.),

Milk n / f condensed "Slavyanskoe" (40l.),

"Condensed milk Dairy country" (tank car, 40 l.)

Defects of canned milk. Depending on the nature of the physicochemical changes in the constituent parts of milk during the manufacturing and storage process, certain defects may appear in the products.

Thickening refers to the main vices of condensed milk with sugar. It appears during storage of the product. As a result of spontaneous thickening, the product acquires an excessively viscous consistency and becomes non-standard (a product that has been stored for 2 to 12 months should have a viscosity of no more than 12 Pa * s).

Lumpy and flaky consistency Condensed milk with sugar is characterized by the presence of small flakes and lumps of casein, formed during the partial coagulation of protein. Appears in a product made from milk with high acidity (for example, from milk mixed with colostrum, etc.).

Mealy and sandy consistency Condensed milk canned food is caused by a violation of the crystallization of lactose in condensed milk with sugar. The permissible size of lactose crystals in the product is no more than 15 microns. Slow uncontrolled cooling of the product can lead to the formation of crystals with a size of 16 ... 20 microns or more and, as a consequence, to the appearance of a defect. It is necessary to strictly observe the cooling regimes for condensed milk with sugar.

Rancid taste due to the hydrolysis of fat under the influence of lipase remaining after pasteurization. In condensed milk with sugar, the enzyme acts on the settled fat layer. To prevent the defect, milk should be pasteurized at a temperature above 95 ° C and condensed milk with sugar with a viscosity of at least 3.0 Pa * s should be produced.

Bombage- swelling of cans, formed during the life of gassing bacteria, which are formed as a result of insufficient sterilization or a low sugar content.

The plant minimized product rejection due to condensed milk defects, since the production laboratory is engaged in product control (chemical engineers, laboratory assistants of tank chemical analysis, microbiologists).

Like any other technological process, the production of condensed milk provides for a certain sequence, starting with the supply of raw materials, in particular fresh milk to the manufacturing enterprise. In most cases, huge sixteen-ton tank trucks are used to transport fresh milk, taking into account the fact that no more than 1 hour should pass from the moment the milk enters production until the start of its processing. This is explained by the fact that milk is a perishable product that, at best, can lose all its taste and useful substances as a result of a delay in the processing process, and thus cannot provide the manufactured product with a unique creamy taste.

The milk supplied to the plant undergoes a mandatory quality assessment, after which it is cooled and, by means of a special pump, is fed from the tanks to a special gauze filter, which ensures its filtering. Then the strained milk is normalized according to the fat content, where, depending on the need to reduce the fat content, skim milk is added to the raw material, or milk fat or cream is added to the raw material to increase the fat content. Upon completion of this procedure, milk is fed through special pipes into large vats, which provide the procedure for pasteurization of raw materials at a temperature of +90 to +95 0 C. Then the pasteurized milk is cooled to a temperature of 70–75 0 C and can be used directly for the production of condensed milk.

How is condensed milk made?

For the production of condensed milk, sugar is added to the feedstock, which can be both in solid form and as a thick syrup with a mandatory sugar content of at least 70%. To prepare sugar syrup, sugar is sieved beforehand, after which it is dissolved in warm water at a temperature of +60 0 С and heated to a temperature of 90–95 0 С, as a result of which it thickens and acquires a pronounced brown color. The sugar syrup obtained in this way is filtered and added to milk, taking into account the fact that the technology for the production of condensed milk provides for the possibility of introducing the syrup both before and after the thickening of pasteurized milk.

To carry out the procedure for thickening pasteurized milk, special vacuum evaporators are used, which provide intensive boiling of the feedstock in order to evaporate excess moisture and, accordingly, thicken the liquid. The readiness of condensed milk is determined by measuring the density level or by means of a refractometer for the dry matter content. Then the condensed milk is fed into special crystallizers designed for cooling condensed milk in vacuum with constant stirring for 20-25 minutes to the product temperature level of +20 0 C.

The main purpose of this procedure is to ensure a uniform consistency of the product without extraneous grains of sand and clots, as provided by the traditional recipe for condensed milk. In addition, the technology for the production of condensed milk categorically prohibits violating the tightness of the production process, providing tracking of the readiness of the product through special windows in the equipment. Upon completion of the cooling process, the finished condensed milk is served for packaging either in classic cans, or in their modern counterparts in the form of plastic bottles or tubes with mandatory sealing.

On an industrial scale, the production of boiled condensed milk began relatively recently, while the very appearance of this product was "overgrown" with several colorful legends. One of which says that for the first time boiled condensed milk was invented by soldiers, who cooked it in between battles in soldiers' bowlers as "a delicacy that brightens up the harsh soldier's everyday life." From another legend, we can conclude that boiled condensed milk appeared as a result of the unsuccessful experiments of Mikoyan's son, who set out to boil a can of condensed milk, as a result of which the latter burst and covered the ceiling and walls of the kitchen of the "gifted" toli chemist, toli "cook" with a new kind of delicacy - boiled condensed milk.

Be that as it may, boiled condensed milk is currently produced on an industrial scale using this product as a filler in confectionery, as well as some types of ice cream and glazed curd cheeses. Milk is accepted for production in accordance with GOST 13246-88, followed by cooling of raw materials to prevent the development of microorganisms, carried out in a special plate cooler in a closed flow by means of a refrigerant - ice water. The procedure for backing up raw materials is necessary to ensure the rhythmic and uninterrupted operation of production.

Heating of the feedstock to a temperature of 35–45 ° C is carried out in a special plate heater. To reduce the fat content in the feedstock, skim milk is added to its composition, while milk fat or cream is used to increase this value. In addition, if necessary, special stabilizing salts are added to the whole milk. Milk pasteurization is carried out at a temperature of 90–95 0 С in order to destroy pathogenic microflora and stabilize its physicochemical properties, which serve to avoid thickening of milk during subsequent storage. The milk pasteurization procedure is carried out by means of a special tubular pasteurizer, followed by cooling to a temperature of 70-75 0 С.

Intermediate storage before thickening

Sugar can be introduced into milk both in solid form and in the form of a thick syrup with a mandatory sugar content of at least 70%, the preparation of which is carried out as follows: sugar is sieved through a sieve, then dissolved in warm water at a temperature of 60 0 C and then heated to temperature 90–95 0 С, as a result of which the syrup thickens with giving it a pronounced brown color. Then the finished syrup is filtered and added to milk before the thickening process by mixing or in a stream.

The equipment for the production of condensed milk is quite diverse. Milk is thickened in a special vacuum-evaporating unit, where, when hot milk is injected, its instant and violent boiling is formed with intensive mixing of particles and moisture evaporation. Upon completion of the thickening procedure, hot milk is fed into a special vacuum crystallizer, where the product is cooled under pressure and stirring to a temperature of 20 ° C for 20-25 minutes, excluding the formation of large crystals of lactose and other clots in the product.

Condensed milk production equipment includes:

Condensed milk production line, video

Composition according to GOST

Technology

• First, the milk is received and its quality is assessed, and then it is cooled, backed up and cleaned.
• Normalization for dry matter and fat. In a normalized mixture, the fat content is calculated according to the following formula: W cm = W pr * SNF cm / SNF pr (where F cm and F PR is the percentage of fat content of the mixture and product; SNF cm and SNF pr is the percentage of nonfat dry milk residue in the mixture and product ).
• In order to increase the percentage of fat content of whole milk, it is normalized by adding milk fat or cream. In order to reduce the amount of fat in whole milk, skim milk is added to it. Salt stabilizers are added if necessary
• Pasteurization. The high-temperature pasteurization process, which takes place at a temperature of 90-95 ° C, leads to the destruction of pathogenic microorganisms and allows you to stabilize the physicochemical properties, preventing milk thickening during long-term storage.
• Cooling to 70-75 ° C.
• Intermediate storage until thickening begins.
• Adding sugar. Sugar is added to milk in solid form or in the form of 60-70% syrup. Technology for preparing sugar syrup: sifted sugar is added to water heated to 60 ° C, dissolve it, then the prepared syrup is heated to 95-99 ° C without using an extract. Sugar syrup is filtered before adding to milk. It is added to milk before the thickening process, mixing or in flow.
• Thickening. The resulting mixture of milk and sugar syrup is sent to a vacuum evaporator for thickening, where moisture evaporates during boiling. The degree of product readiness is determined by the content of dry substances, by density or by a refractometer
• Cooling. Hot products are transferred to crystallizers, in which in a vacuum environment, under constant mechanical action, it is cooled to 20 ° (20-25 min). This prevents the formation of large crystals and prevents the appearance of sandiness.
• Seeding. In the role of a seed, lactose, ground to a dusty state, is used, leading to the creation of many crystallization centers. This prevents the formation of larger crystals.
• Packing, storage. Usually condensed milk with sugar is packaged in cans. The permissible shelf life in such a container is 1 year. In recent years, much more often for this purpose, polystyrene or polypropylene cups and other small containers approved for use have been used. The shelf life in such a package is 3 months.

For boiling and evaporation of liquid at a pressure below atmospheric pressure, vacuum evaporators are used. In such equipment, products are boiled at a temperature significantly less than 100 °, which reduces the loss of nutrients in the feedstock. The evaporation process in a vacuum unit is much faster than the same volume of moisture at atmospheric pressure.

Vacuum evaporators are used in the food industry for the production of jams, condensed milk, sauces, confitures, vegetables, fruit purees, preserves, baby food, as well as in the chemical and cosmetic industries.

The process of preparing condensed milk lasts 2-2.5 hours.