What preservatives are used in the production of margarine. Contains polyunsaturated fats

03.05.2019 Fish dishes

Margarine, despite the fact that it is far from the most natural product is in demand among consumers. It is usually used for baking bakery and confectionery products. Fat and oil products of different price categories are presented on the shelves of stores - customers have plenty to choose from. But the competition among margarine producers is not as high as it might seem at first glance - budding entrepreneurs have room to grow. The margarine production technology is simple and involves the use of available raw materials, it is possible to equip the workshop with inexpensive equipment - the idea of organizing a business in this niche is quite feasible.

Our business valuation:

Starting investment -6,000,000 rubles.

Market saturation is medium.

The complexity of starting a business is 8/10.

Organizational issues when opening a plant

To open a margarine factory in Russia, you will need to collect a package of documents, obtain permission from supervisory authorities (SES and fire inspection). The process is quite lengthy - to check it is necessary to prepare the premises for work, install a production line, develop a product range.

It is better to register a business activity in the form of an LLC. Then you will have the opportunity to cooperate in the future with large customers. You will need to select the OKVED code. In this case, this one is suitable - 15.43.1 Production of margarine.

An important step in registering a business is the procedure for certifying the product produced. The Inspection Commission will check whether the goods produced comply with established standards quality. Everything is checked - starting with the packaging of margarine and ending with its taste.

Product range

Start margarine production only after the development of a specific product range. Many modern lines allow you to get several types of margarine on the same equipment at once - the difference is only in raw materials.

Margarines are:

Solid (39-84% fat). Retain their consistency at a temperature of 18-22 °C. The product is actively used in home and industrial cooking.
Soft (39-82% fat). Melting point - 8-12°C. Such a product can not only be used for baking bakery products but also eaten directly.
Liquid (60-95% fat). It melts at a temperature of 17-38°C. Used for baking and frying.

The production of fats and margarine can be started with the release of only a few products. A large assortment will require significant costs, and therefore, it will be easier to stop at 2-5 positions.

In addition to table margarines, it is profitable to sell chocolate margarines. The product is much cheaper chocolate butter which increases the demand for it among consumers.

What raw materials do you need

Raw materials for the production of margarine, which will have to be purchased in the future, are divided into main and auxiliary.

The main components include the fatty base - vegetable and animal fats. The quality of the finished product will also depend on their quality, so cooperate only with trusted suppliers who offer raw materials that have passed all checks.

It is difficult to determine the exact list of auxiliary raw materials - everything will depend on the recipe that the technologist develops. As a rule, in production, to give the product the necessary taste properties milk, water, natural or synthetic preservatives, emulsifiers, flavors, dyes, salt, sugar are used.

On average, about 82% of fats are spent on the production of 1 ton of margarine, and the rest is made up of additional components.

In addition to the products that are needed directly for the manufacture of margarine, you will need a container in which it will be packaged. You should agree in advance with companies that will make containers according to your layouts.

Margarine production technology

The process of manufacturing oil and fat products, if the workshop is equipped with modern automatic equipment, will require a minimum amount of manual labor. And yet, each of the stages will require mandatory control - it is important to monitor the quality of raw materials and the finished product!

Generally, technology system margarine production looks like this:

Preparation of components. Fat components are thawed at natural temperature for a day, emulsifiers are dissolved in refined vegetable oil, milk is pasteurized and fermented, butter is placed in melting containers.
Preparation of margarine emulsion. All ingredients for the production of margarine are mixed with each other in a tank with a cylindrical agitator. The output should be a homogeneous, well-mixed mass.
Preparation of margarine. The semi-finished product passes through a subcooler, which consists of several heat exchangers. Here the emulsion is cooled to 12-13 °C. Then the mass enters the crystallizer - margarine acquires its commercial properties.
Packaging. Margarine enters the filling and packaging machine, where it is packaged in a specific container. It can be foil, plastic boxes, cardboard boxes, glasses, parchment.

Before implementation finished product should be stored in refrigerators at -20…+15 °C.

What equipment is installed in the workshop

A margarine plant, even if it is a small enterprise, must be equipped with high-quality equipment. All machines and automatic machines for compliance with sanitary standards will be checked by supervisory authorities.

The "medium" line for the production of margarine consists of the following machines and apparatuses:

The minimum cost of the entire set of equipment is 2,500,000 rubles. And this is far from the limit - more powerful automated lines are much more expensive. You can buy equipment for the production of margarine, both new and already used. In the second case, you will save up to 50% of the original cost of the line.

Equipment must be thoroughly rinsed after each production run, either manually or automatically. A special washing station greatly simplifies the task - such stations are installed in almost all oil and fat enterprises. The system consists of tanks for mixing alkaline and acid solutions, pumps for supplying liquids, and a control panel. Automatic CIP-washers are quite expensive (at least 1,500,000 rubles), but they allow production to be carried out almost continuously. In addition, there will be no problems with the quality of margarine, since the uncleaned pipelines production line can cause contamination of the finished product with microorganisms and an increase in the proportion of fats in it. This means that the cost of purchasing a CIP car wash should also be included in the capital costs.

There are lines of domestic and foreign brands on the market. As practice shows, European lines are much more reliable, but they are much more expensive than domestic counterparts. Compare Before Buying specifications equipment and choose the best option.

What room to look for a workshop

Production creamy margarine should be carried out in a prepared room. We are talking about a food industry enterprise, so the requirements here are quite strict!

Rent price production premises will be lower if you look for free buildings in the industrial part of the city. A plant with a capacity of up to 500 kg of product per hour will require at least 200 m 2 of free space. The workshop, offices, warehouses for raw materials and finished products, a boiler room, utility rooms will be located here.

Electricity, water, sewerage, heating - you need to prepare the room for work. The refurbishment of the shop can take impressive amounts of money.

Marketing Campaign and Potential Business Profit

Considering how high the price of equipment for making margarine is, when organizing a business, you should prepare for large financial investments. To launch a small plant with a capacity of up to 500 kg / h, you will need at least 6,000,000 rubles. Capital costs include not only the purchase of a production line, but also the preparation of premises, the cost of branding and preparation of documentation, the cost of raw materials.

Profit will directly depend on how well the distribution channels will be debugged. And start searching for interested customers already at the stage of developing a business plan! It is possible to organize private sales grocery stores and wholesale warehouses, bakeries and confectionery, food companies that use margarine as a raw material. It is too early to think about cooperation with large federal hypermarket chains - a "young" enterprise with its products rarely manages to get on their shelves in the first years of operation on the market. The greatest return in terms of profit, of course, will be given by wholesale customers.

On average, margarine is sold to wholesale buyers at a price of 50-70 rubles/kg. If the plant will work seven days a week for 12 hours, it is possible to produce up to 180 tons of finished product monthly - with a capacity of 500 kg / h. Then the average monthly proceeds from sales of margarine can be about 10,000,000 rubles. Reach high performance sales to newly opened plants in the first years of operation will be difficult - for sure, the enterprise will sometimes be idle. But according to forecasts, it is quite realistic to recoup all the costs of launching the enterprise in 2-3 years.

Note that sales levels will fluctuate throughout the year. Seasonality has a negative effect - in summer margarine is not in high consumer demand.

Definition and types of goods

Margarine is a product consisting mainly of fat, similar in texture and smell to butter. Its calorie content per 100 grams is 752 kcal (3123 kJ). Digestibility - 97.5%.

By appointment, there are margarines:

canteens (Russian, Amateur, Dairy);
sandwiches (Extra, Special, Slavic);
margarine intended for industrial processing.

There are also margarines with flavorings(Chocolate milk, Chocolate cream, Chocolate New).

According to the consistency there are margarines:

solid - have a high density, retain their shape at a temperature of 18-22 ° C. Fat content - 39-84%, moisture - no more than 60%. Used in cooking and household for the manufacture of confectionery products (breads, creams, soufflés).
soft - retain their consistency at a temperature of 8-12 ° C. Contain trans-isomers of oleic acid in fat (no more than 8%). Fat - 39-82%, moisture - no more than 60%. It is used directly in food.
liquid. Fat - 60-95%, moisture - no more than 40%. Melting point - 17-38°C. They are mainly used for frying and baking in cooking.

Recipe

For the production of margarine, the main and auxiliary raw materials are used. The main one is fat base(82%), which is used as refined vegetable oils (sunflower, soy, palm) and animal fats. This component determines such qualities of margarine as melting point, hardness, solids content. Auxiliary raw materials are:

water;
milk;
butter;
vitamins (A, D2, D3, C);
preservatives (benzoic and sorbic acids in combination with citric);
emulsifiers (0.6%) - stabilize the consistency of the product, ensure storage stability. In Russia, MHD (distilled monoglycerides) and MFM (soft myoglycerides) are used;
flavors - flavors are used by Naarden (Netherlands) and domestic VNIIZh;
dyes (carotene, annatto);
citric and lactic acids;
antioxidants - butylhydroxytoluene and butylhydroxyanisole (0.02%);
salt (from 0.15 to 2.0%);
sugar.

Components without oil and emulsifiers make up the water-milk phase of margarine. Its content: in dairy and sandwich - 17.75%, in chocolate - up to 37.8%. Dairy-free margarine is also produced.

The production of 1 ton of margarine 82% takes about 833 kg of fat (taking into account losses and waste). An approximate recipe for the amount of fat that makes up margarine is as follows: hydrogenated vegetable fats- 75% (625 kg), liquid vegetable oil - 15% (125 kg), coconut or palm kernel oil - 10% (83 kg). The cost of raw materials for one ton of product is 35-40 thousand rubles.

Production technology

The production of margarine includes several stages.

1. First prepare the raw materials. Refined and deodorized fats are stored in separate tanks for no more than 24 hours at a temperature of 5-10 °C above the melting point. Butter is placed in melting containers. Emulsifiers are dissolved in refined deodorized vegetable oil in a ratio of 1:10 at a temperature of 80-85 °C. Dyes are added in the form of oil solutions. Milk is pasteurized, cooled and fermented.

2. Preparation of the emulsion. All components are sent to a cylindrical mixer, the discs of which rotate at a speed of 1450 rpm.

3. Preparation of margarine. The finished emulsion through the surge tank enters the subcooler, which consists of several heat exchangers. The emulsion is gradually cooled to 12-13°C, after which it enters the mold, in which it acquires the qualities necessary for margarine (hardness, uniformity and plasticity). The crystallizer consists of a filter-homogenizer and three cylinders. The temperature of the product rises to 16-20°C.

3. Packaging. The finished product enters the filling and packaging unit, where it is dosed and packaged in packages from 150 to 500 grams. Parchment, laminated foil, polymer cups and boxes are used as packaging.

Margarines are stored in refrigerators away from substances with a pungent odor at temperatures from minus 20 ° C to plus 15 ° C - 60 days, 0-4 ° C - 45 days. General technical requirements to the product are described in GOST R 52178-2003.

Equipment and raw materials (prices)

The margarine production line includes the following set of equipment:

a tank for storing fats and oils (50-100 thousand rubles);
a chamber with a melting cone (120-400 thousand rubles);
container for tempering and pasteurization of prescription components (120-500 thousand rubles);
emulsifier preparation tank (60 thousand rubles);
vertical cylindrical mixer, capacity from 100 kg to 3 tons (100-700 thousand rubles);
centrifugal type emulsifier (80-200 thousand rubles);
surge tank (about 100 thousand rubles);
pumps (20-70 thousand rubles);
subcooler (200 thousand - 1 million rubles);
crystallizer (from 50 thousand rubles);
dosing apparatus (250 thousand rubles);
packaging unit (300-800 thousand rubles);
cold rooms(from 100 thousand rubles);
a set of measuring instruments and PU (about 80 thousand rubles);
collector (30 thousand rubles);
flow-through water heater (20 thousand rubles);
a set of product pipelines and fittings (130-200 thousand rubles);

In total, the total cost of equipment will be about 3 million rubles.

The cost of the main raw material for margarine:

lard (fat) - about 40-50 rubles / kg
sunflower oil– 35-40 rub/kg
Coconut oil– 45-54 rub/kg
milk - 12-13 rubles / l

Premises and staff

The number of personnel and the production area depend on the productivity of the line:

Performance	Area, m2	Staff

For the production of medium volumes (150 tons per month), you will need a room with an area of about 600 square meters. m. and a staff of 10 people.

Investments

The total cost of starting a business, when renting a room and producing 150 tons per month, will be about 10 million rubles. Monthly expenses about 6-7 million. The average wholesale price is about 56 rubles / kg. The average income is 8-8.5 million rubles.

Marketing

The greatest demand is for table margarines used for the preparation of confectionery. Therefore, it is possible to arrange the sale of goods to local bakeries. Do not forget about outlets: shops, hypermarkets. There are also prospects for export trade, many firms sell large quantities of margarine to the CIS countries. Sales are affected by seasonality: since margarine perishable product, it is little bought in the summer.

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Modern technologies for the production of margarine make it possible to obtain low-calorie product with moderate cholesterol. Thanks to this, he gained a wide market, using stable demand representatives of wholesale and retail trade. It is used in cooking by catering and pastry shops.

Technological process

Margarine is a homogeneous mass consisting of two main components: suspended microdrops of water in an oily dispersion medium. In other words, it is a mixture of the smallest particles of water and oil. In the production of margarine, the following components are used: milk, fat, salt, sugar, vitamin complex, dyes, emulsifiers, etc. The fat base of margarine is combined from deodorized and refined vegetable oils, edible lard, animal fats, interesterified fats. For making margarine palatability, inherent in butter, are introduced into its composition natural milk and related flavors. Emulsifiers are used to maintain a stable emulsion structure.

With the help of food coloring, a natural color is achieved. butter. The fullness of taste is provided by moderate additions of salt and sugar. The presence of salt in the composition of margarine also contributes to an increase in the allowable shelf life under appropriate conditions.

Stages of the technological process for the production of margarine

Preparation of raw materials for the fat base. Preliminary heat treatment process dietary fat vegetable and natural origin.
Milk preparation. Dilution of a mixture of powdered milk, normalization of the concentration of its components. Accompanied by preliminary cleaning and heat treatment of milk. The use of fermented milk implies the addition of lactic acid bacteria during its processing. The stage of milk harvesting is completed by its cooling.
Preparation of emulsifiers. Assumes mandatory water filtration for the subsequent dissolution of emulsifiers and flavors in it.
Direct preparation of the emulsion by thoroughly mixing the appropriate proportions of all components, incl. proportional introduction of vitamins, dyes, preservatives, citric acid, sugar.
Receipt of the finished product. On the last step supercooling (crystallization) of the resulting emulsion occurs with its subsequent mechanical processing.

Let us consider in more detail the stages of the technological process of obtaining margarine

The introduction of components into the protein base occurs in a special mixer of a vertical cylindrical type. At the initial stage, preliminary emulsification is achieved. The main element of the mixer is a screw mixer, the rotation cycle of which is carried out at a frequency of 1 rpm. The bumpers fixed on the body prevent the mixture from twisting, ensuring uniform mixing of the mass. This is facilitated by the presence of a water mixer jacket. Submission of components is carried out through the fitting. As a result of mixing, the finished product is removed through the drain pipe.

On a production scale, as a rule, a system of two alternately activated devices is used. After the formation of a coarse emulsion in a cylindrical vertical mixer, it enters the centrifugal emulsifier. Its main working elements are 2 rotating discs and 2 fixed ones. Activation of this device when a coarse emulsion enters it, processes it into a homogeneous mixture of particles, the size of which is about 6 microns. Intensive dispersion is achieved by rotating the discs at 24 rpm.

The resulting composition of the margarine emulsion enters the surge tank. Then, under the influence of high pressure, provided by the action of a specialized pump, it enters the subcooler. It is one of the most important aggregates for obtaining high-quality margarine products. During this treatment, the final process of fine emulsification, cooling, as well as mechanical processing of the mixture takes place. This is achieved by successively passing the mixture through a system of several identical cylindrical heat exchangers.

Each of them is a construction on the principle of "pipe in pipe", separated by a heat-insulating layer. The working chamber is an inner tube with a hollow shaft. Hot water is continuously supplied to it in order to prevent the margarine mixture from sticking to its walls. The rotation of the shaft with a frequency of about 0.8 rpm drives 12 knives. With the help of a specialized pipeline system, a cooling agent (ammonia) is supplied to the space between the 1st and 2nd pipes, thus forming. evaporation chamber. As a result of cooling, the margarine emulsion crystallizes on the surface of the inner tube, from where it is cut off with knives. At the end of the cycle of the 3rd cylinder, an emulsion is obtained at the outlet, the temperature of which is up to 13°C.

As a result of the emulsion entering the mold, it acquires the necessary crystalline structure. The hardness, plasticity and homogeneity achieved at the same time make it possible to package margarine. The active elements of the mold include: filter-homogenizer, 1 conical and 2 cylindrical sections. Under the influence of the processes taking place in them, the mass of margarine is slowly fed into the filling machine. The packaging process is optimized by intermittent supply of mass, which is achieved by introducing a compensating device into the installation.

By raising the temperature during the crystallization process to 20° C., the recrystallization process begins to take place. The alternating change of opposite processes stimulates the acquisition of the most important quality indicators of the finished product: plasticity, consistency, melting temperature, etc.

As a result of the completion of a multi-stage technological process of production, high-quality margarine is obtained. Now it is ready for dosing and packaging in containers made of polymeric materials, which are hermetically sealed with lids. Standard portion size range: 150-500g.

According to established physical and chemical indicators the finished product must contain 82% fat. Produced and separate view of this product with a reduced fat content (about 70%, 60%). The remaining share is accounted for by the content of moisture, as well as volatile substances. Depending on the intended purpose of the product, the melting point of margarine fats ranges from 27 to 36°C.

The production of bar and soft margarines is carried out in a continuous or batch process, which includes the following main stages:

* preparation of fatty raw materials. Storage and tempering of refined deodorized oils and fats;

* preparation of milk;

* preparation of emulsifiers and other non-fat components;

* preparation of an emulsion;

* obtaining margarine, hypothermia, crystallization of margarine emulsion. Mechanical (plastic) processing of margarine;

* packaging, packaging, stacking finished products.

The process of obtaining soft margarines is carried out on the lines of the company "Johnson", "Alfa Laval", "Schroeder" or "Koruma".

Preparation of vegetable oils, fats and butter. Refined deodorized fats and oils are stored in fat storage tanks separately by type for no more than 24 hours. The storage temperature of solid fats and oils should be 5-10 °C higher than their melting point. To prevent oxidation of refined deodorized oils and fats, it is recommended to store them in an atmosphere of inert gas - nitrogen or carbon dioxide.

Butter is freed from containers and loaded into a chamber with a melting cone. The temperature of the melted butter should be between 40-45 °C. The homogeneity of the consistency of the molten butter is maintained by means of an agitator or a pump by means of recirculation.

Preparation of emulsifiers. To evenly distribute and increase the effectiveness of emulsifiers, distilled monoglycerides are dissolved in refined deodorized vegetable oil in a ratio of 1:10 at a temperature of 80-85 °C. Soft monoglycerides are added to the same solution at a temperature of 55-60 °C, after which, if necessary, a phosphatide concentrate is added in the amount specified in the recipes. A complex emulsifier used instead of a monoglyceride composition is dissolved in refined deodorized oil in a ratio of 1:15 at a temperature of 65-75 °C. If an imported emulsifier is used, then it is dissolved in refined deodorized oil in a ratio of 1: 10 at a temperature of 48-55 °C.

Preparation of dyes, vitamins, flavors. To give color to soft margarines, oil solutions of natural beta-carotene isolated from carrots, pumpkins, palm oil, microbiological beta-carotene, turmeric colors and annatto seeds. Dyes and vitamins are diluted in deodorized vegetable oil. Flavorings are injected directly into the fat or water-milk phase of margarine.

Preparation of milk and secondary dairy products. Whole cow's milk is pasteurized and then cooled to a temperature of 23-25 °C.

Fermentation of milk is carried out biologically or by acid coagulation.

When using powdered milk, it is diluted with water to obtain at least 8.5% fat-free solids in the finished solution.

When using secondary dairy products, they are dissolved with stirring in water in a ratio of 1:3 - for whey powder; 1:6 - for whey protein concentrates (WPC). The resulting solutions are heated to a temperature of 85-90 °C and 60-65 °C, respectively, kept for 30 minutes, cooled and fed into supply tanks for production.

Preparation of citric acid and water-soluble flavors. citric acid used in the form of a 1-10% aqueous solution, which is simultaneously injected with water-soluble flavors.

Preparation of salt, sugar, preservatives and starch. Salt is used in the form of a saturated solution of 24-26% concentration.

Sugar or sweeteners are used in the production of dessert soft margarines in the form of an aqueous solution of 30% concentration.

preservatives (benzoic, sorbic acid, sodium benzoate) is used in low-fat soft margarines when introducing milk, especially in the summer and when elevated temperatures storage. Preservatives are dissolved in water in a ratio of 1: 2.

The starch is first dissolved in cold water in a ratio of 1: 2, then brewed hot water to a ratio of 1: 20, incubated for 30 minutes, cooled and transferred to a storage tank.

Emulsion preparation. The margarine components are mixed according to the recipe in a vertical cylindrical mixer, in which pre-emulsification also takes place. Inside the mixer is a screw mixer with a rotation speed of 59.5 rpm. Baffles are attached to the mixer body, which do not allow the mixture to twist in the direction of rotation. The mixer is equipped with a water jacket. The product enters through the fitting and exits through the outlet. The coarse emulsion from the mixer then enters the centrifugal type emulsifier, the working body of which is two rotating and two fixed disks, the space between which the emulsion enters. The disks rotate at a speed of 1450 rpm, providing intensive dispersion of the emulsion to a particle size of 6-15 microns in diameter.

After the emulsifier, the margarine emulsion, passing through the surge tank with a high-pressure pump, is fed into the supercooler, which is one of the main devices for producing margarine products and provides emulsification, cooling and mechanical processing of the emulsion. The subcooler consists of several identical cylinders - heat exchangers operating in series.

The block of cylinders of the three-section subcooler is installed in the upper part of the apparatus, each of the cylinders is a heat exchanger of the "pipe in pipe" type with thermal insulation. The first inner tube is a working chamber, in which a hollow shaft is located, where hot water to prevent sticking of margarine emulsion. Twelve knives are fixed on the shaft, the shaft rotates at a frequency of 500 rpm. The space between the second and the first pipe is occupied by the evaporation chamber for the cooling agent - ammonia, which is supplied by a piping system. Margarine emulsion, cooling, crystallizes on the surface of the inner tube and is removed with knives. The temperature of the emulsion at the outlet of the third cylinder is 12-13 °C.

Then the emulsion enters the crystallizer, where it is given the necessary crystalline structure, the required hardness, uniformity and plasticity necessary for margarine packaging. The main components of the crystallizer are a homogenizer filter and three sections - conical and two cylindrical, in which margarine slowly moves to the conical nozzle and then to the filling machine. The compensating device provides intermittent supply of margarine for packaging. The temperature in this case rises to 16-20 °C due to the heat of crystallization.

When margarine emulsion is cooled, a complex process of crystallization and recrystallization of triglycerides of the fat base of margarines occurs, which determines the most important quality indicators of the finished product - consistency, plasticity and melting point.

At sufficiently high temperatures, the content of the solid phase in the fat bases of soft margarines is small, and they are a suspension of solid triglycerides in liquid ones. As the temperature decreases, the least soluble high-melting triglycerides begin to separate from the melt in the form of crystals and the solids content increases. When the margarine emulsion is cooled, a complex crystallization process occurs, which is based on the phenomena of polymorphism associated with the transition of less stable (metastable) low-melting crystalline a-forms through intermediate rhombic P-forms to stable (stable) high-melting crystalline modifications. In soft margarines, fat crystals are usually present in the P-form. The transition to the P-form negatively affects the structural and rheological properties of soft margarines due to the formation of large crystals with a denser packing of molecules, with high temperatures melting and density. To ensure a homogeneous plastic structure of soft margarines, the emulsion after deep cooling is subjected to intensive mixing and prolonged machining. Crystallization of the margarine emulsion in combination with mechanical processing leads to the formation of finely dispersed crystals of the solid phase, which form coagulation structures in the liquid phase. At the same time, the solid and liquid fractions of the fat base of soft margarines are distributed evenly, and the finished product does not lose fluidity when poured into boxes made of polymeric materials, acquires a plastic consistency that remains long time at temperatures of 5-7 °C. Violation of the modes of crystallization and cooling leads to margarine defects that cannot be eliminated by mechanical processing.

The margarine obtained in this way is fed into the balance tank of the filling and packaging unit, which doses (150-500 g) and packs the margarine into cups made of polymeric materials (polystyrene, polypropylene), sealed with metallized caps.

For the production of low-fat margarines, stronger emulsification is required, which is achieved by recirculating the emulsion. During recirculation, air should be avoided as far as possible in the emulsion. In the production of dairy low-fat margarines, special attention should be paid to the intensity of mixing. In the event of excessive emulsification, a phase reversal may occur and the emulsion will be destroyed. In addition, special attention is paid to the correct selection of the composition of the fat and water-milk phases, the amount and type of emulsifier, and strict adherence to the technological regime. The production technology before the packaging stage provides for a decrystallization stage, which is necessary for the low-fat product to have a semi-liquid paste-like consistency at the packaging stage during bottling. To do this, decrystallizers are used that destroy the crystalline structure of the product in order to form a fine crystalline structure and a shiny surface of the product.

One of the methods for the production of low-fat margarines widely used abroad is the following: part of the fat is emulsified with an aqueous phase, the remaining part is recrystallized during mechanical processing, cooled and mixed with the emulsion, and the margarine is packaged. The ratio of emulsified and non-emulsified fat is 65:35 or 35:65. The emulsion contains 50-65% fat. At a temperature of 17-23 ° C, an emulsion with a pH value of 4.4 is mixed with fat, beforehand 5-20% of non-emulsified fat is crystallized. To do this, the fat is cooled to 7-18 ° C in a thin layer on a subcooler. The product is homogenized before packaging.

Margarine production

1. Technology for the production of margarines

The production of bar and soft margarines is carried out in a continuous or batch process, which includes the following main stages:

* preparation of fatty raw materials. Storage and tempering of refined deodorized oils and fats;

* preparation of milk;

* preparation of emulsifiers and other non-fat components;

* preparation of an emulsion;

* obtaining margarine, hypothermia, crystallization of margarine emulsion. Mechanical (plastic) processing of margarine;

* packaging, packaging, stacking of finished products.

The process of obtaining soft margarines is carried out on the lines of the company "Johnson", "Alfa Laval", "Schroeder" or "Koruma".

Preparation of dyes, vitamins, flavors. To impart color to soft margarines, oil solutions of natural beta-carotene isolated from carrots, pumpkins, palm oil, microbiological beta-carotene, turmeric dyes and annatto seeds are used. Dyes and vitamins are diluted in deodorized vegetable oil. Flavorings are injected directly into the fat or water-milk phase of margarine.

Preparation of milk and secondary dairy products. Whole cow's milk is pasteurized and then cooled to a temperature of 23-25 °C.

Fermentation of milk is carried out biologically or by acid coagulation.

When using powdered milk, it is diluted with water to obtain at least 8.5% fat-free solids in the finished solution.

Preparation of citric acid and water-soluble flavors. Citric acid is used in the form of a 1-10% aqueous solution, into which water-soluble flavors are simultaneously added.

Preparation of salt, sugar, preservatives and starch. Salt is used in the form of a saturated solution of 24-26% concentration.

Sugar or sweeteners are used in the production of dessert soft margarines in the form of an aqueous solution of 30% concentration.

Preservatives (benzoic, sorbic acid, sodium benzoate) are used in low-fat soft margarines when introducing milk, especially in summer and at elevated storage temperatures. Preservatives are dissolved in water in a ratio of 1: 2.

Starch is first dissolved in cold water in a ratio of 1: 2, then brewed with hot water to a ratio of 1: 20, incubated for 30 minutes, cooled and transferred to a storage tank.

The block of cylinders of the three-section subcooler is installed in the upper part of the apparatus, each of the cylinders is a heat exchanger of the "pipe in pipe" type with thermal insulation. The first inner pipe is a working chamber in which a hollow shaft is located, where hot water is supplied to prevent sticking of the margarine emulsion. Twelve knives are fixed on the shaft, the shaft rotates at a frequency of 500 rpm. The space between the second and the first pipe is occupied by the evaporation chamber for the cooling agent - ammonia, which is supplied by a piping system. Margarine emulsion, cooling, crystallizes on the surface of the inner tube and is removed with knives. The temperature of the emulsion at the outlet of the third cylinder is 12-13 °C.

At sufficiently high temperatures, the content of the solid phase in the fat bases of soft margarines is small, and they are a suspension of solid triglycerides in liquid ones. As the temperature decreases, the least soluble high-melting triglycerides begin to separate from the melt in the form of crystals and the solids content increases. When the margarine emulsion is cooled, a complex crystallization process occurs, which is based on the phenomena of polymorphism associated with the transition of less stable (metastable) low-melting crystalline a-forms through intermediate rhombic P-forms to stable (stable) high-melting crystalline modifications. In soft margarines, fat crystals are usually present in the P-form. The transition to the P-form negatively affects the structural and rheological properties of soft margarines due to the formation of large crystals with a denser packing of molecules, with a high melting point and density. To ensure a homogeneous plastic structure of soft margarines, the emulsion after deep cooling is subjected to intensive mixing and prolonged mechanical processing. Crystallization of the margarine emulsion in combination with mechanical processing leads to the formation of finely dispersed crystals of the solid phase, which form coagulation structures in the liquid phase. At the same time, the solid and liquid fractions of the fat base of soft margarines are distributed evenly, and the finished product does not lose fluidity when poured into boxes made of polymeric materials, acquires a plastic consistency that persists for a long time at temperatures of 5-7 °C. Violation of the modes of crystallization and cooling leads to margarine defects that cannot be eliminated by mechanical processing.

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