The demand for pasta is constant, so it is quite profitable to produce this product. As in any business, production regulation is difficult. It is necessary to select the appropriate premises, purchase high-quality equipment and raw materials, think about hiring qualified workers.

For beginners, you can start by opening a small single production line by purchasing domestic or foreign equipment. But when choosing, take into account the power of the units, productivity per hour, cost. It is equally important to establish sales markets for finished products.

Necessary equipment for making pasta

The production of pasta is not complete without an automatic line. You can prefer inexpensive budget options for lines with an average capacity and production up to 150 kg / h. But even with the most simplified manufacturing process, it is impossible to organize the purchase and installation of technological equipment.

Main types:

• vacuum dispenser for dividing the initial pledged raw materials into doses;
• pneumatic conveyor loader for feeding products from a press machine to a conveyor dryer;
• conveyor dryer for drying finished products by supplying high temperatures and the required humidity;
• timer for monitoring the residence time of products in the unit;
• press machine for dough production, equipped with a vacuum hopper to remove air bubbles from the total mass;
• flour sifter for removing foreign particles and impurities from flour;
• storage bin for storing finished products;
• a bag holder with a filling mechanism for packing products into packages and unloading them into storage bins;
• matrices for giving the desired shapes to pasta, taking into account the varieties of products.

Special attention should be paid to the production room (workshop) for the placement of the line. The premises must be dry, heated and ventilated with all utilities connected. The approximate area is 150 m 2. Separate premises will be required for the storage of raw materials and finished products. For beginners, you can rent it with a monthly payment of 15,000 rubles. and making utility bills up to 10,000 rubles.

Rating of manufacturers of quality lines inexpensive

• Makiz Ural;
• Real Past.

Makiz Ural Soviet-made with the ability to produce any technological processes. This is a fully equipped mini-line with a capacity of up to 90 km / h, consisting of:

• express vending machine;
• pneumatic conveyor;
• cooler-stabilizer;
• storage hopper;
• bag holder;
• flour sifter.

BID from Russian manufacturers with the ability to process flour of any grind, but in addition, you will need to purchase a filling machine and a matrix.

Real Past from Italian manufacturers with a capacity of 500-600 km / h and the ability to manufacture non-standard types of pasta (lasagne, beshbarmak).

Characteristics of the production line PMI 02

To begin with, experts advise purchasing a production line of the PMI 02 type with the following equipment:

• drying cabinets (2 pcs.);
• bunker press for kneading, shaping, cutting and drying products.

The line is suitable for working with flour of coarse and soft grinding, as well as carrying out a step-by-step technological process: kneading, shaping, drying products. In addition to the unit, replaceable dies with the ability to produce different forms of pasta and taking into account national preferences will be required.

The work of the bunker press is carried out completely offline, which makes it possible to manufacture products in accordance with all the requirements of GOST. The main technical characteristics of the production line of the type PMI 02 include:

• electric motor power - 4 kW;
• operating voltage - 380 V;
• weight - 250-270 kg;
• eavesdropping fan power - 30 W;
• hopper capacity - 13 kg;
• productivity - 80 kg / hour;
• dimensions - 1100x 600x1700.

What to choose?

When purchasing equipment for the production of pasta, Russian entrepreneurs give more preference to Russian, Chinese and Italian manufacturers:

• Italian equipment with a line capacity of 250 kg / hour is expensive, but it is possible to produce elite varieties of pasta;
• Russian models with a capacity of 250 kg / hour are reliable, inexpensive and acceptable for purchase by newcomers in business;
• Chinese counterparts with a capacity of 200 kg / h are low in cost and have proven their effectiveness in work.

All equipment lines are fully automated. But with a lack of budget, it is possible as an option to purchase used equipment from Russian manufacturers, promising the availability of many spare parts and parts in the range in case of a breakdown of one or another unit.

Cost of equipment

In the opinion of entrepreneurs, it is enough to have a capital of 450-500 thousand rubles in order to achieve success in the pasta business by purchasing the original equipment in a complete set and starting production.

The production of pasta requires the purchase of exclusively special equipment. An inexpensive line with a capacity of up to 150 kg of products per hour will be appropriate for opening a small mini-workshop. The cost is $ 800,000.

If more powerful units are needed, they will cost more - up to $ 24,000. Separately, and taking into account the assortment of products, you need to purchase matrices - $ 50-70 per 1 piece. Taking into account the rapid wear and the need for replacement, it is enough to have 5–6 varieties of matrix shapes. It is advisable to keep the forms in stock and purchase 2–3 identical forms at once in addition.

When purchasing a whole line for the production of pasta in the form of a factory with the inclusion of almost all technological processes, the price will be approximately - $ 27-28 thousand.

• Matiz line - 300,000 rubles;
• Italian equipment with a production capacity of up to 250 kg / h - $ 80,100 thousand;
• second-hand units from Russian manufacturers - $ 83,000-120,000, from Chinese manufacturers - $ 180-200 thousand.

Cost of individual production units

Approximate prices for certain types of equipment:

• drying cabinet - 32,000 rubles;
• pasta press - 160-180 thousand rubles;
• flour sifter - 8000 rubles;
• dough kneading - 25,000 rubles;
• pasta press - 160,000 rubles;
• packing machine - 60-70 thousand rubles.

On average, the cost of a fully equipped line with a capacity of up to 100 kg / hour will be required in the amount of 300-500 thousand rubles. with the possibility of producing over 500 items (shells, spirals, spaghetti).

Today, domestic and foreign manufacturers offer equipment with the ability to perform almost any operations in a complex.

Unlike imported equipment, domestic analogues can be purchased 2-3 times cheaper. Moreover, the assortment provided assumes to choose units that are acceptable in price, performance and quality.

You can always pick up spare parts for Russian equipment and make repairs as soon as possible or buy a used line from Russian manufacturers.

Mini line price

If you want to open a small cafe or restaurant, you can purchase inexpensive models in the form of machines for making pasta at home. These are compact, inexpensive models complete with a dough mixer and are appropriate for starting a home business. It is enough to buy 1 professional apparatus for the formation of the test, which costs $ 30,000. To prepare delicious dough and use the best recipes in the production of pasta, it is imperative to have in stock nozzles of different shapes and sizes.

The production process requires a competent and organized approach. Having invested money once, the payback is 1 year. The profitability is quite high. But the minus of the production of pasta is a lot of competition, which will have to be overcome at the initial stage. It is important to decide on the sale of finished products at the stage of planning your business development and developing a business plan.

A production that is quite within the power of a small business is the manufacture of pasta. There is always a demand for them in our country. When organizing, special attention should be paid to equipment for the production of pasta.

There are many types of production lines today. They are capable of solving a variety of problems. Among the manufacturers of such equipment, both domestic and foreign factories are known. There is plenty to choose from, the main thing is to decide on the required capacities, assortment and markets for finished products.

Pasta is dried unleavened dough. The ingredients for mixing it are drinking water and flour of different qualities.... The technology is so simple that domestic businessmen began to master it even more often than the market demanded. A few years ago, there was an oversupply. Many entrepreneurs were forced to close production. You can attract wholesale buyers with a variety of products and their quality. It depends on what kind of flour is used and how it is dried. Sometimes additives are added to the pasta dough, but more on that later.

Pasta making technology

The mini-line consists of a pasta press of the PMI 02 type and an SHS 1 drying cabinet (see the description below in the text)

The production technology has its own characteristics. Even the way the flour is stored affects the taste. It can be packaged and unpacked. The latter method is more economical as it reduces waste of raw materials and minimizes manual labor.

Before entering the dough mixers, the flour is carefully sifted and warmed up at a temperature of ten degrees. In the mixer, water is gradually added to it. The dough is kneaded for about 10 minutes. Then, to shape the dough, it is forced through a die with shaped holes using a screw. A stream of air is supplied to the workpieces at the outlet. Then they are cut to size. After forming, the pasta is laid out on a tray, which is part of the machine press.

For the final removal of moisture, the products are placed in drying ovens. For this, special baking sheets are used that hold about 2 kg of products. They are in the cabinet for about an hour until their humidity is 19%. From the cabinet, the product is scattered into cardboard boxes. In a separate storage room at a temperature of 25 degrees, they still lose moisture up to 13%. Then the products are considered finished and can be packaged.

A separate type is instant food. They have a completely different structure, and the technology of their manufacture is different. The most valuable pasta is made from durum wheat (durum). They are assigned category "A". Categories "B" and "C" are pasta made from flour, the quality of which is lower. Chicken eggs, egg powder or dairy products, vegetable concentrates are used as additives to the main ingredients. Sometimes the use of food coloring is allowed for mass production. To keep the pasta in shape during cooking, surfactants are added to them. Diet foods and children's pasta are saturated with iron glycerophosphate. Often for children, even fruit or vegetable puree is added to them.

What equipment to choose for the production of pasta?

For novice entrepreneurs, we can recommend a small production line of the type PMI 02. It is equipped with two drying ovens. Double-hopper press PMI 02 is able to knead, shape, cut and pre-dry the product. There are no special requirements for raw materials. This equipment is ready to work with soft and coarse flour.

The device performs almost all stages of the technological process, from kneading to shaping and drying. The press can be used independently or complete with drying. It comes with a set of interchangeable dies. The shape of the product can be customized according to market needs or national preferences. The press quickly manufactures products, and their quality meets the requirements of the consumer.

Technical characteristics of the press Type PMI 02:

Drying cabinet ШС-1 is used to bring products to a moisture content of 19%. Drying in it occurs due to forced blowing with hot air. The temperature in it is maintained in automatic mode. Below are the technical characteristics of the SSh-1 drying cabinet:

For restaurants and cafes, you can buy a very simple model. It's called a pasta machine. Sometimes it is even used at home. The machine comes in two models: with and without a kneader. A professional machine that only forms the dough costs from $ 30. If there is a function for kneading dough, then a pasta machine will cost about $ 300. Experts say that with such equipment, you can not only delight homemade delicious dishes, but even start a small home business. The main thing is to stock up on a large number of attachments and recipes for making delicious dough.

How much can you earn making pasta?

As for the large scale, the producers of domestic pasta initially invest about 500 thousand rubles in a small workshop. With a production volume of 4500 kg of products per month and an average price per kilogram of 39 rubles, the income will be 175.5 thousand rubles. The net profit will be about 150 thousand rubles. In general, the industry has a profitability level of 20%. With such indicators, the investment will pay off within 12 - 24 months.

How much can you earn in the production of pasta

The profit from the production of pasta depends on the capacity of the enterprise. The profitability of this business is 10 - 25%, with an established production and sales market, the investment will pay off in 12 - 16 months. After that, the business will begin to generate income of 100 - 150 thousand rubles a month, subject to the manufacture and sale of 3-4 thousand kilograms of pasta.

How to choose equipment for the production of pasta

For the production of pasta, you need to purchase the following machines:
- flour sifter;
- press apparatus for pasta products;
- apparatus for drying;
- an automatic machine for filling and packaging finished products.
High-quality specialized equipment is supplied by Italian manufacturers. Their machines and units are distinguished by high reliability, high-quality service and long-term warranty service. Due to the modularity of the devices, their readjustment makes it possible to produce a wide range of products on one conveyor.

Pasta production technology

The technological process for the production of pasta includes several stages:
1. Flour is weighed, cleaned and mixed, which makes it possible to achieve quality indicators of the initial product and prevent malfunctions of the vacuum press;
2. Preparation of pasta dough takes place in dough mixers. The composition of the dough usually includes only water and flour, other ingredients (eggs, dyes) increase the cost of production, which reduces the profitability of the enterprise; Begin

Holders of the patent RU 2430516:

The invention relates to the food industry. The composition for the production of pasta contains durum wheat flour, baking soft wheat flour and chickpea flour in the following ratio of components, wt.%: Durum wheat flour 5, baking soft wheat flour 85, chickpea flour 10. The invention makes it possible to obtain a product with increased biological value, with improved organoleptic and structural-mechanical quality indicators. 2 tab.

The invention relates to the food industry and can be used in the production of pasta with increased biological value.

Known dough composition for the production of pasta, including durum wheat flour or bread wheat flour of the highest grade and water. In addition, in the form of additives in the pasta dough, flour of other crops, such as peas, is used (Medvedev GM Technology of pasta production. - M .: Kolos, 1999, p. 7, p. 50-52).

The disadvantage of using only wheat flour in the pasta dough is the high starch content, which leads to the calorie content of the finished product and a low protein content. In addition, when bean flours such as peas are added to wheat flour, there is also an insufficient amount of protein.

Known composition of the dough for the production of pasta (prototype - RF patent for invention No. 2289952), including wheat flour, water and protein-containing additives - bean flour, namely, pea flour in the amount of 10% by weight of wheat flour, or lentil flour in the amount 10% of the mass of wheat flour, or a complex additive consisting of bean flour in the amount of 2.5% of the mass of wheat flour and mountain ash puree in the amount of 7.5% of the mass of wheat flour, while the content of raw gluten in the wheat flour should not be below 28%.

The disadvantage of the prototype is that when a protein-containing additive in the form of pea and lentil flour is added to the wheat flour, the pasta dough contains an insufficient amount of amino acids and minerals.

The technical task is to create a composition for the production of pasta with increased biological value, with improved organoleptic and structural-mechanical quality indicators.

The technical problem is achieved by the fact that the composition for the production of pasta contains durum wheat flour, bread wheat flour and chickpea flour with the following ratio of components, wt%:

chickpea flour - 10

The difference between the proposed invention and the prototype is that chickpea flour is used in the composition for the production of pasta, with the following ratio of components, wt%:

durum wheat flour - 5

baking flour soft wheat - 85

chickpea flour - 10

The composition for the production of pasta is prepared as follows. Durum wheat flour in the amount of 5% is mixed with baking soft wheat flour in the amount of 85% and with chickpea flour in the amount of 10%. The amount of water for kneading is determined by calculation taking into account the moisture content of soft baking wheat flour, durum wheat flour and chickpea flour. The prepared mixture of these three types of flour and water are fed into the first trough of the dough mixer, after which the finely lumpy dough, homogeneous in humidity, enters the second trough of the dough mixer, connected to the auger chamber. Pasta presses are used to make pasta. The pressed pasta is dried in cabinet dryers.

Table 1 shows the comparative data of indicators of the content of protein, essential amino acids and minerals in pasta prepared according to the prototype and the proposed composition.

As can be seen from Table 1, the content of essential amino acids in products with the addition of chickpea flour increased by 12%. The content of minerals in comparison with the prototype has increased by 9%.

The introduction of chickpea flour into the formulation of pasta is explained by the need to enrich it with balanced essential amino acids and minerals, which are more abundant in chickpea flour than in pea and bean flour. The use of a protein-containing additive in the form of chickpea flour in an amount of less than 10% leads to a deterioration in organoleptic quality indicators and a decrease in biological value. The use of the specified additive in an amount of more than 10% worsens the structural and mechanical indicators of quality.

The introduction of wheat flour in the formulation of pasta dough in a combination of its different types - wheat flour of hard grades and soft grades, and bakery flour of soft grades in the largest quantitative ratio (85%) is explained by the fact that this type of flour is the most common and available in food industry. In the recipe of the present invention, the flour quality improver is a natural additive in the form of durum wheat flour. When using durum flour less than 5%, the structural and mechanical indicators of pasta deteriorate, and the use of more than 5% is impractical, because the addition of this flour in an amount of 5% is sufficient to achieve optimal structural and mechanical properties.

Table 2 shows the quality indicators of the cooking properties of pasta, the composition of which is prepared according to the prototype and the invention.

As can be seen from table 2, the pasta prepared according to the invention has good cooking properties: the main indicator of cooking properties - the loss of dry substances into the cooking medium - is 7.8% lower compared to the composition made according to the prototype.

Example. To obtain a dough for the production of pasta, soft wheat flour in the amount of 8.5 kg, durum wheat flour in the amount of 0.5 kg and chickpea flour in the amount of 1 kg are pre-mixed and the mixture is sieved. The following actions are carried out according to the above method for preparing the dough.

The resulting pasta with a protein-containing additive in the form of chickpea flour has an increased content of protein, essential amino acids and minerals. Cooked pasta with a protein-containing additive in the form of chickpeas has a regular shape, elastic consistency and an attractive yellow tint.

Thus, the proposed composition for the production of pasta makes it possible to obtain products of increased biological value with improved organoleptic and structural-mechanical quality indicators.

A composition for the production of pasta containing durum wheat flour, bread wheat flour and chickpea flour in the following ratio of components, wt%.

The process of production of pasta consists of the following main operations: preparation of raw materials, preparation of pasta dough, pressing of the dough, cutting of raw products, drying, cooling of dried products, rejection and packaging of finished products.

Preparation of raw materials... It consists in sifting the flour, separating the metal-magnetic impurity from it, heating it (the temperature of the flour must be at least 10 ° C), mixing different batches of flour in accordance with the instructions of the factory laboratory. The water intended for kneading the dough is heated in heat exchangers and then mixed with cold tap water to the temperature specified in the recipe.

Preparation of supplements consists in stirring them in water intended for kneading the dough. When using chicken eggs, they are pre-washed, and if melange is used, then it is pre-defrosted.

Making pasta dough... It consists of dosing ingredients (flour, water and additives) and kneading dough.

Dosing is carried out using dispensers that supply flour and water with additives dissolved in it in a continuous flow into the kneading trough in a ratio of about 1: 3. In the kneading trough there is intensive mixing of flour and water, moistening and swelling of flour particles — the dough is kneaded. However, unlike bread or biscuit dough, pasta dough by the end of the kneading is not a solid connected mass, but a lot of moistened scattered lumps and crumbs.

Pressing testa... The goal is to compact the kneaded dough, turn it into a homogeneous, knitted plastic dough mass. and then give it a certain shape, shape it. Shaping is carried out by forcing the dough through holes made in a metal matrix. The shape of the holes in the matrix determines the shape of the extruded raw products (semi-finished product). For example, circular holes will produce noodles, rectangular holes will produce noodles, etc.

Cutting up raw products... Consists of cutting the raw products extruded from the matrix into pieces of the required length and preparing them for drying. This preparation, depending on the type of manufactured products and the drying equipment used, consists either in laying out raw products on mesh conveyors, frames or in tray cassettes, or in weighing long strands of raw products on special drying poles - bastuns. Before cutting, or during cutting, the pressed products are intensively blown with air to obtain a dried crust on their surface. This prevents raw products from sticking to drying surfaces and from sticking together during drying.

Drying of products... The goal is to fix their shape and prevent the possibility of the development of microorganisms in them. This is the longest and most important stage of the technological process, on the correctness of which the strength of the products depends first of all. Very intensive drying will lead to cracks in dry products, and very slow drying can lead to acidification of products. At pasta enterprises, convective drying of pasta is used - blowing of the dried product with heated air.

Cooling of dried products... This process is necessary in order to equalize the heat of the products with the temperature of the air in the packaging compartment. If pasta is packaged without refrigeration, then moisture evaporation will continue already in the package, which will lead to a decrease in the weight of the packaged products. Most preferably, slow cooling of the dried products in special bins and chambers called storage stabilizers. Chilled products are subjected to rejection, during which products that do not meet the requirements for their quality are removed, and then packed.

Package... It is produced either in small containers (boxes, bags) manually or by filling machines, or in bulk "in large containers (boxes, boxes, paper bags)

Pasta is firmly entrenched in the diet of almost every family. This is due to the large selection and availability of products, as well as the lack of the need to have special culinary skills for their preparation.

Situation in the pasta market

Pasta today can be found on the shelves of any store or supermarket. However, it is impossible to argue that at the moment the market for such products is going through a phase of oversaturation with goods. In light of this, even a medium-sized production of various pasta will be able to take its place in the market, ensuring the demand for the products produced.

Today, not only budget varieties of pasta are in demand, but also expensive types. Assessment of consumer demand allows us to identify the frequency of consumption of this product by the population. The analysis is presented in Table 1.

Table 1. Frequency of consumption of pasta

The trend in the popularity of pasta among buyers presented in the table opens up opportunities for obtaining a good financial return when starting your own business for the production of a product. As a rule, products of the middle class of quality will be especially in demand, which are purchased by about 60-65% of buyers, elite varieties are allocated about 30% of the total share of consumption.

Market segments:

• Economy, which offers B-category weight products. They account for more than one third of production and sales (approximately 350 thousand tons);
• The mid-price segment, which also contains B-category pasta, but already in the package. The volume is about 25 percent or 200 thousand tons. Package weight 400-900 grams and 1 kilo.;
• "Medium Plus", which offers A-category pasta made from durum cereals (wheat). The volume is 35 percent or 300 thousand tons. It is such a product that is mainly packaged in polypropylene bags and offered in ordinary ones. You can buy such a product for 40-45 rubles;
• Premium, in which you can see A-category products, usually made in Italy. Or domestic, but "disguised" with the name and design of the packaging as such. The volume is about 5 percent or 45 tons. The market price of a 0.5 kilo package is from 60 rubles.

When opening your mini-business, you should take into account that about 70-80% of buyers prefer a product of the middle price category. It is also important that such consumers do not have clearly expressed preferences in relation to the manufacturer's brand. But if the price and quality of cereals seem appropriate to them, then buyers move into the category of “permanent”, continuing to choose the product they like and further.

In the “hard times”, buyers refuse from the products of the mid-price and premium segments. But nevertheless, the business for the production of A-category pasta, in the opinion of entrepreneurs, is the most promising. They need to use imported equipment. You can't do without high-quality cereals. Why it happens? The fact is that the competition among enterprises of the medium and below the price segment is too great for the beginner's mini-business to be able to bring the desired profit. But in the field of manufacturing A-category goods, there is little competition, mainly there is a Western manufacturer, which it is quite possible to “overtake” by offering high-quality products, but at a more favorable cost. When drawing up a business plan, be sure to take this point into account.

If we consider the entire domestic business selling pasta, and not just the features of mini-productions, it turns out that most of the goods are packaging at a price of 40-130 rubles. The development of the industry is significantly influenced by the market environment. After all, the main component in the manufacture of pasta is flour. In order to increase the profitability of production, large manufacturing companies often merge into holdings. But such a step is not available for medium and mini industries, and therefore the competition is the highest here. According to analysts, only 5-6 of the largest manufacturers will soon be present on the country's market. However, today the cereal business is flourishing in Russia. According to statistics, every Russian eats more than 7 kilos of pasta a year. And about 8 kilos of noodles / instant noodles. When drawing up a business plan, think about the production of which products will interest you the most.

Market assessment of finished products

The pasta business is focused on cooperation not with the end consumer of the product, but with retail and wholesale points. Therefore, the entrepreneur's potential clients will be grocery stores and supermarkets, as well as catering establishments, wholesalers, catering companies. Market analysis demonstrates the following situation with regard to the most demanded places of purchase of all types of pasta. Table 2 shows the statistics of purchasing activity in various retail outlets.

Table 2. Places of purchase

At the initial stage of business development, one should be prepared for the fact that the product under the new brand will be perceived by the consumer with a degree of caution. Participation in tenders for the provision of food products to government agencies, active interaction with potential large customers will help to gain a foothold in the market, as well as to earn a good reputation. The opening of a sales point for pasta on the basis of a workshop is the idea of ​​selling goods under the slogan "from the manufacturer", which is considered a rather winning marketing strategy.

Types of pasta

• by the type of the main raw materials used (flour) - the first and the highest grade;
• in shape - tubular, threadlike, ribbon-like and curly;
• in length - from 1.5 cm to 50 cm.

Also, the division into varieties concerns the main groups, which are divided into smaller subgroups, based on the characteristics of the finished product. As a separate group of pasta, it is worth highlighting soup fillings, products that are produced when various dyes and food additives are included in the composition.

Tubular pasta, depending on the size of the cross-section, are divided into types: straws up to 4 mm in diameter; special diameters from 4.1 to 5.5 mm, ordinary diameters from 5.6 to 7 mm, amateur diameters over 7 mm. The thickness of the tubular walls should be no more than 1.5 mm (up to 2 mm is allowed in an amount of no more than 5% of the mass of pasta in a packaging unit).

To tubular include (Fig. 1): pasta - a tube with a straight cut at least 15 cm long; horns - a curved or straight tube with a straight cut from 1.5 to 10 cm in length; feathers - a tube with an oblique cut, length from 3 to 10 cm.

Filamentary pasta (vermicelli) by size in section are divided into types (Fig. 2); cobweb (diameter no more than 0.8 mm); thin (diameter no more than 1.2 mm); ordinary (diameter no more than 1.5 mm); amateur (diameter no more than 3 mm).

Ribbon-shaped pasta (noodles) are produced in various names (Fig. 3): smooth or corrugated, with straight, wavy or sawtooth edges, etc. Any width of noodles is allowed, but not less than 3 mm, its thickness should be no more than 2 mm ...

Figured pasta (Fig. 4) can be produced in any shape and size, but the maximum thickness of any part in the break should not exceed: for pressed 3 mm, for stamped - 1.5 mm.

Figure 4: Shaped products. A - shells, B - scallops; B - stamped, D - curls, D - soup fillings

Depending on the length, pasta is divided into long (from 15 to 50 cm) and short (from 1.5 to 15 cm). Pasta is made only long; vermicelli and noodles, both long and short; horns, feathers, curly products - only short ones; according to the method of molding, short pasta is divided into short-cut and stamped ones.

Organization of production of pasta

To open a business, you will need to go through a number of mandatory steps regarding the design and equipment of the workshop.

registration

Suitable for this business,. In the application for registration, you will need to indicate the OKVED code 10.73.1 “Production of pasta”. At the stage of business registration, an entrepreneur may encounter a number of subtleties, so in some cases it will be correct to seek the help of a specialized lawyer.

Room selection

An important criterion for choosing a suitable building for arranging a pasta workshop will be its total area. Ideally, it would be most convenient to place not only a work shop, but also a warehouse and an office in one room.

There are certain requirements for a production facility - the ceiling height in it must be at least 3 meters. Such a need is due to the correct organization of the work process, involving the placement of machines for the production of products in compliance with safety standards for hired personnel.

The storage room must be dry, ventilation deserves special attention to comply with all storage standards for finished products and raw materials for the manufacture of pasta. As a rule, the workshop and warehouse are additionally equipped with microclimate controllers. The optimal size for a warehouse will be a room with an area of ​​more than 100 m 2.

As far as the office part is concerned, in this case a 3-meter ceiling height is optional. It is most convenient to organize an office on the ground floor for the convenience of interaction with suppliers and consumers.

The building for production can be purchased or rented. Before launching a production line, an entrepreneur will need to obtain a certificate from the Sanitary and Epidemiological Service. The task of this organization will be to check the premises for compliance with the requirements for food production.

In addition, the operation of the production will be possible after obtaining permission from the fire inspection and the environmental safety service. After visiting the facility by authorized employees, the entrepreneur will receive special permits for the further operation of the workshop.

Taking into account the peculiarities of the production part, warehouse and office, the optimal area for starting a business will be a room of 300 m 2, most of which will be allocated to workshops. The geography of the location of the premises should be thought out with regard to the convenience of delivering the necessary raw materials and transporting finished products to the place of their sale.

Staff recruitment

The choice of qualified personnel is a question on which the quality of the final product and the profit of the enterprise will depend in the future. A small or medium-sized business organization may require the following personnel:

• chemists-technologists;
• line adjusters;
• cooks;
• office staff.

The number of workers required will directly depend on the scale of work and the overall automation of the workshop. The priority will be personnel with at least 3-4 years of experience in the food industry.

For example, for a small business, you will need to hire:

• manager and technologist;
• warehouse manager;
• service technician;
• driver;
• 2-3 workers;
• sales manager.

Purchase of equipment for the production of pasta

The automated lines for the production of pasta consist of the following machines:

• vacuum dispenser;
• flour sifter;
• agitator;
• apparatus for pressing;
• stacking machines;
• apparatus for drying products;
• pneumatic conveyor;
• cooling device;
• drive;
• conveyor and loader;
• packing machines;

You can buy semi-automatic equipment with a capacity of approximately 100 kg of pasta per hour. The price of pleasure is about 500-700 thousand rubles. An automatic line produces about 500 kilos of pasta per hour, and costs from 375 thousand euros. You cannot do without a press, a drying line and a flour sifter in production.

A high-capacity line usually has a conveyor and a stabilizing hopper. Presses are offered complete with dies, the complete set is selected depending on the desired type of pasta. The cost of one matrix capable of producing one type of pasta is 3-5 thousand rubles. The service life is 700-2000 hours of work. Do not forget that finished products will need to be distributed into packages - and this also requires special equipment. You can purchase semi-automatic or automatic equipment. Or you can become the owner of a whole line if you are counting on large volumes of product manufacturing. Before you start packing finished products, they need to stand for a couple of hours in a cardboard container. You can significantly reduce the duration of this stage by purchasing special equipment that works according to the hydrothermal technology of pasta production. The technician can cool the product and immediately begin the packaging process. In addition to equipment, you will need to purchase racks in which you will store dies and finished products. It is necessary to purchase a washer, an apparatus for sharpening matrix knives and carts for delivering production products.

If you want to produce pasta of a medium or low price category, you will need at least 1000-1100 thousand rubles. In this figure, we included the cost of purchasing equipment, the cost of registering a business and renting premises for a warehouse and production.

Pasta production technology

The technological process of manufacturing food products will consist of a number of mandatory stages.

1. Preparation of raw materials... The mass, from which the creation of pasta occurs in the future, consists of flour. Before use, the purchased raw material undergoes a special cleaning with the help of a magnet that pulls metal components out of the product. Further, the refined flour is subjected to heat treatment, after which it is combined with water, in a 2: 1 ratio.
2. Dough kneading... The second stage of work will be the preparation of the mass with the appropriate characteristics in the kneader. At this stage, additional ingredients can be included in the product - dyes, eggs, flavor enhancers, etc.
3. Pressing and forming... Then the dough is given the desired density, as a result of which it acquires plasticity and uniformity. After that, depending on the classification of pasta, they are given the desired shape by passing the mass through the appropriate holes in the equipment. The resulting pasta strips are cut under the blowing of cold air streams, which will prevent the mass from sticking together.
4. Drying... Then the pasta is dried on the production line when exposed to high temperatures. Due to heat treatment, the products are not deformed in the future, in addition, additional disinfection of the products occurs. At the end of the process, the pasta is cooled.
5. Cooling of dried products... The process is designed to equalize the temperature of the products with the temperature of the packaging. If they are not cooled, fogging of the package will be observed and, as a result, a change in the mass of the product.
6. Control and packaging... At the final stage, the batch is sent to a check regarding the presence of defects, after which it is divided by weight, followed by packing into boxes or bags.

Even a person who is far from producing cereals knows that pasta is essentially a dried unleavened dough that was obtained from water and wheat flour. The shape of the products is different - tubes, threads, ribbons, etc. The residual moisture content of the product is 13%. However, some pasta have a low moisture content, and therefore they can be stored for about a year without risking losing their high consumer properties. The variety of products is determined by its nutritional value, calorie content and, of course, composition. There are incredibly many types and subspecies of pasta. A separate category is instant pasta. They have a porous structure and are enriched with various additives. It is because of this that they do not need cooking.

The optimal raw material for making pasta is durum, that is, durum wheat flour. Also perfect for:

• semolina - premium flour, which is selected during baking;
• wheat bakery flour;
• soft glassy wheat flour;
• flour of the highest grade of increased dispersion from durum wheat.

In the production of cereals, it is very important to ensure that the flour does not have mini metal impurities. In addition, it should be enriched with heat-resistant water-soluble vitamins PP, B1, B2. The maximum moisture content of flour is 15.5%. Pasta made with premium baking flour is usually light cream in color. Grade 1 is characterized by a gray tint and dark cream color. In the manufacture of cereals, great attention is paid to the quality of the drinking water used.

A variety of products act as additional components to flour and water. We can talk about chicken eggs, egg melange, egg powder, dairy products (whole dry or skimmed cow's milk), vegetable products (concentrated tomato juices and pastes, natural juices with beet pulp). Certified natural and synthetic ingredients (for example, beta-carotene or tartazine, respectively) are used as food coloring agents. It is they who give the pasta a yellow tint. Surfactants are used at both large and mini pasta factories. They improve the quality of the product, preventing it from losing its shape during cooking.

There are 4 main types of pasta, depending on the shape:

• ribbon-like;
• tubular;
• curly;
• filamentous.

In each type there is also a subspecies - and here pasta is divided according to width, diameter and length (horns, feathers, pasta). The latter can be both long and short (15-30 cm) - these are long tubes with a straight cut. In addition, pasta is divided into amateur, ordinary, special and straws, depending on the size of the diameter. If pasta has an oblique cut, then these are feathers. Length - 3-10 cm. Horns have a straight cut and are produced in the form of short curved tubes, 1.5-10 cm long. Horns are divided into amateur, ordinary, special and straw. Thread-like products - vermicelli of various cross-sectional shapes (round, square, and so on), is divided into amateur, ordinary, thin and cobweb. Ribbon pasta - noodles, length 2-20 cm, corrugated or smooth. Curly products - gears, ribbons, stars, letters and so on. Before you approve your plan for mini cereals production, think about what kind of pasta you want to offer customers.

The composition of the pasta dough depends on what quality flour will be used and what type of products you want to get. The drying method and many other factors matter. When making a recipe plan, indicate the volume and temperature of water and flour, the presence / absence of additives, the temperature and moisture indicators of the dough.

The technology for making pasta has its own characteristics. For example, there are several options for how you can store flour in the warehouse of a manufacturing enterprise:

• tare when flour is stored in bags;
• bulk when the flour is poured into the silo-bunker.

The latter method is preferred. It allows you to reduce labor costs and avoid additional losses of flour, which are associated with the remainder of it in the container and spraying. In addition, the bulk method allows you to reduce the cost of manufacturing the packaging bags.

Before sending flour to production, it must be sieved well, separating metal-magnetic mini impurities, and warmed up to 10 degrees. To improve consumer and gustatory characteristics, manufacturers mix samples from different batches. Next, a predetermined portion of flour enters the dough mixer, drinking water is carefully introduced (sometimes, additional components are added to it in advance).

Video how pasta is made:

The dough kneading takes about 10 minutes, the auger feeds the composition to the matrix and pushes it. The pasta coming out through the holes of the matrix is ​​blown by the air of the built-in fans. The products are automatically cut into certain sections, laid out on trays, which then goes to the table of the press apparatus and is pre-dried. Final drying is carried out in drying equipment with a capacity of 30 trays. The maximum load of each tray is up to 2 kilos of pasta. The products are dried until a moisture content of 18 percent is reached for 55-60 minutes (accurately determined depending on the type of product). Then the goods are packaged in cardboard boxes and dried naturally in a well-ventilated room at a temperature of 25 degrees. After at least 4 hours, when the pasta reaches a moisture content of 13 percent, they are sent for packaging. However, the examination of the final product takes place earlier, its aroma, taste and appearance are examined. Experts-controllers study pasta for the absence / presence of metal impurities, granary pests and substandard (broken and deformed products), crumbs, assess the strength, digestibility, acidity, moisture, etc. Products from batches that successfully pass expert evaluation are packaged in polypropylene bags using special filling and packaging machines.

Business plan: calculated part

To calculate the financial part of the pasta business, you should calculate the investment amount for the following mandatory items:

• rental of premises and utility costs;
• purchase of equipment;
• employee salaries;
• the cost of purchasing raw materials;
• other variable costs.

The average values ​​for rent and utility bills will be about 100,000 rubles.

The costs of purchasing equipment for mini-production include the following items for the purchase of a domestic production line:

• dough mixer - 30,000 rubles;
• sifter - 15,000 rubles;
• product formatter - 150,000 rubles;
• drying cabinet - 40,000 rubles;
• packing machine - 100,000 rubles.

The total cost of purchasing the equipment will amount to RUB 335,000.

Obligatory salary expenses for employees:

• technologist - 20,000 rubles;
• driver - 15,000 rubles;
• marketer - 25,000 rubles;
• adjustment workers - 10,000 rubles;
• production line maintenance personnel - 15,000 rubles.

The total amount will be equal to 85,000 rubles.

The expenses for the purchase of the main raw materials for the production of 1 kilogram of the finished product - purified water and flour, are summed up from the total mass of 1 kilogram. On average, a small workshop is capable of producing 210 kilograms of finished products per day, based on 22 working days per month. Therefore, 210 x 22 = 4620 kilograms.

The wholesale cost of 1 kilogram of flour will be 15 rubles. At the same time, the costs of purchasing raw materials are equal: 15 x 210 x 22 = 69,300 rubles.

The main costs must be added to the costs of packaging, delivery, payment of variable costs - 20,000 rubles.

Thus, the initial investment in the business is equal to 609,300 rubles.

Income and estimated payback periods

The average cost of one pack of pasta in a retail network will be 50 rubles. Calculation of total revenue 4620 x 50 = 231,000 rubles.

Taking into account the obtained calculations, we can conclude that even a small workshop for the production of pasta will become a profitable activity for an entrepreneur. The work of the enterprise at a given pace will allow to cover capital investments in the enterprise in 5-6 months, and the increase in capacities and the active sale of products guarantee the payback of the project within a calendar year.