Technological schemes for the production of gingerbread (custard and raw)

Gingerbread - flour confectionery products of various shapes with a convex surface, high sugar content and various flavors.

Gingerbreads are layered, most often with fruit filling or jam, baked semi-finished product from gingerbread dough, which has a rectangular flat shape.

Depending on the technology for preparing the dough, gingerbread cookies are divided into custard and raw. Each of these products can be produced with or without filling, glazed and unglazed.

The technological process of making gingerbread (Fig. 1.2.) Consists of the following operations:

preparation of raw materials for production;

dough preparation;

molding;

cooling;

glazing (for glazed gingerbread);

packaging, labeling, transportation and storage.

Preparation of raw materials for production

Preparation of raw materials for production is carried out in accordance with the current documents: "Instruction on the prevention of foreign objects in products at the enterprises of the confectionery industry and in cooperatives" (Appendix 1), "Sanitary rules and regulations SanPiN 2.3.4.545-96.

Figure: 1.2. Technological scheme for the production of gingerbread

Production of bread, bakery and confectionery products (Appendix 2), issued instead of the "Sanitary rules for the enterprises of the confectionery industry (except for enterprises producing cream confectionery products)" and "Sanitary rules for enterprises and workshops producing confectionery products with cream".

Melange. Frozen melange, before being fed into production, is pre-thawed in baths with water or special chambers at a temperature not exceeding 450C and filtered through a sieve with a mesh size of not more than 3 mm. For products in which whole milk or water is used when kneading the dough, the melange can be mixed in a 1: 1 ratio before straining. Thawed egg products should be used within 1 to 4 hours.

Egg powder is recommended for use in production as a premixed mixture with water. The moisture content of this mixture should be 25 - 30%, the water temperature should not exceed 500C. The mixture must be filtered through a sieve with a mesh size of no more than 3 mm.

Milk. It is recommended to store whole milk in a specially equipped refrigerator. The milk cooling temperature is set depending on the duration of its storage. When stored for 6 - 12 hours, milk is cooled to a temperature of 8 - 100C, and when stored for 24 - 36 hours - up to 4 - 50C. During the storage of milk, the laboratory must control its acidity.

Increased acidity (up to 400T) can be reduced to 180T by methods approved by the sanitary inspection authorities.

To reduce acidity, an aqueous 8.5% solution of baking soda (sodium bicarbonate) is used. Powdered whole or skim milk, if necessary, is preliminarily dissolved in a small amount of water used to prepare the dough.

Water for dissolving milk powder obtained on a spray dryer should have a temperature of 20 - 350C, on a drum dryer - 80 - 850C. In the case of consumption of powdered milk for the preparation of sugar-milk syrups, it is mixed with water in such a way that the mixture contains 60% water.

Before being fed for production, milk is filtered through a sieve with cells of no more than 2 mm in size.

High-viscosity condensed milk is heated to a temperature of 30 - 400C.

Nuts are used as a whole, crushed and chopped, both when kneading dough and when finishing the surface of products. To improve the aroma and taste of nuts, they are fried at a temperature of 120 - 1400C to a moisture content of 2 - 3%. The casings are removed as follows: hazelnut and peanut kernels are placed in a hot oven for a few minutes; almond kernels are placed in boiling water for 1 min, then washed with cold water and immediately dried at a temperature of 50-700C; pistachio kernels are placed in boiling water for 30 s, then they are also washed and dried.

When processing the kernels with hot water at a temperature of 70-800C, they are kept in water for 10-15 minutes.

Before grinding, spices are freed from foreign impurities, and some of them are freed from shells. After grinding, the spices are sieved through a sieve with cells with a diameter of not more than 2.5 mm.

Baking powder and salt. Sodium bicarbonate, ammonium carbonate and edible salt are sieved through a sieve with cells of no more than 2 mm in diameter before being fed to production in a free-flowing state, and in dissolved form, filtered through a sieve with a diameter of 0.5 mm.

To dissolve the specified raw materials, the following ratio is taken: for 100 parts of water, 35 parts of edible salt, 25 parts of ammonium carbonate, 10 parts of sodium bicarbonate.

The compressed yeast is freed from paper before use, the frozen yeast is slowly thawed at a temperature of 40C.

Fat from the refrigerating chamber is fed into the defrostation chamber and tempered to a temperature of about 200C.

The tempered and emptied blocks of fat are loaded into a plant where the fat is plasticized. The molten fat is pumped into an intermediate tank, where it is stored at a temperature of 45-500C.

The fat preparation system must be continuously circulated.

The malt extract is tempered to a temperature of 40C.

Citric acid, sodium pyrosulfite. Solutions of citric acid in a ratio of acid and water 1: 3 and sodium pyrosulfite (sodium metabisulfite) in a ratio of 1: 10 are prepared one or two times per shift in special containers. The water temperature for dissolving sodium pyrosulfite should be 15 - 200C, and for citric acid - no higher than 250C.

Water. The amount of water for mixing is calculated according to the following formula (1.1):

X \u003d (100 * C / 100 - A) - B (1.1)

where A is the desired moisture content of the dough;

B - all raw materials (without water) loaded into the kneader;

С - weight of dry substances of this raw material, kg;

X is the required amount of water, l.

The above calculation sets the approximate amount of water. The final dosage of water is determined by a trial batch.

Gingerbread production.

The production of this type of flour confectionery is especially widely developed in our country. Products like gingerbread with honey were produced in our country even when sugar was not used or had very limited use. And nowadays honey is widely used as one of the raw materials in the production of gingerbread. In many cities of our country, they specialized in the development of branded, local varieties of gingerbread. This was the basis for the name of some of their species: "Tula". "Vyazemskie", etc.

Gingerbread comes from the adjective spicy (Old Russian пъпърянъ), which, in turn, is formed from the word pepper (Old Russian пъпъръ), meaning spices, seasonings. The names of the gingerbread have the same meaning in other languages: fr. pain d "épice, Spanish pan pepato (lit. pepperbread), German Pfefferkuchen, Dutch peperkoek, Norwegian pepperkake, Swedish pepparkaka, Finn piparkakku (peppercake).

Gingerbreads are flour confectionery products of various shapes, mostly round with a convex surface, containing a significant amount of sugar substances, molasses, honey and various flavors, including various spices. The group of gingerbreads also includes gingerbreads, which are a baked semi-finished product made of gingerbread dough, sandwiched with fruit filling or jam, having a rectangular shape. Depending on the production method, two types of gingerbread are distinguished: custard and raw. In addition, all types of gingerbread can be produced with or without filling. Gingerbread cookies are produced with various external finishes: glazed with sugar syrup with and without additives, chocolate glaze. sprinkling with sugar, poppy seeds, kernels of nuts.

Gingerbread production schemes

Gingerbread production consists of the following stages:

• preparation of flour for production;
• preparation of sugar-treacle and circulation syrups, saline solution; melting fat;
• kneading dough;
• molding;
• baking;
• replication;
• cooling gingerbread;
• packing.

Large enterprises produce gingerbread with and without filling on production lines.

Mechanized production line for the production of gingerbread.

The line includes prescription-mixing complexes for the preparation of syrups and dough, a forming machine, an oven, a drawing drum, a cooler, a filling machine. Flour and liquid components are dosed into the dough-mixing machine. After kneading, the dough is fed into the hopper of the roller forming machine, which deposits the dough pieces on baking sheets or on the conveyor belt of the tunnel oven. From the oven, the gingerbread cookies are unloaded onto a transverse one and are cooled on a conveyor from a temperature of 103-105 to 45-50 ° C and fed into a drawing drum, into which sugar syrup is fed. Sugar syrup is prepared in a mixer, where sifted granulated sugar from a sifter and water are loaded. Boiled to the required concentration, the syrup is dosed into the rotating drawing drum. The gingerbread cookies are covered with syrup and unloaded onto a conveyor for drying the gingerbread. Dried gingerbread cookies are cooled on cradles in a multi-tiered refrigerator, and then served for packaging.

A mechanized production line for the production of gingerbread with a filling.

The production of filled gingerbread consists of the following main operations: kneading dough, forming dough pieces with filling, baking, finishing, drying and packing into containers.

A portion of the sifted flour is poured into the kneading machine, and the dispenser / feeds a liquid mixture: sugar syrup, molasses, margarine, vegetable oil, ammonium carbonate and essence, measured in a certain amount and mixed in an emulsifier. After kneading, the dough is fed into a forming machine. The resulting dough pieces with filling from the machine are unloaded onto the oven conveyor or onto baking sheets. The baked gingerbread cookies are cooled, glazed in a drawing drum, and then dried and sent for packing and delivery to the expedition.

Mechanized production line for the production of Tula gingerbread.

The sifted flour is dosed into the kneading machine, where granulated sugar and honey are supplied in the form of a liquid mixture. fat and other components. The finished dough is directed by an inclined conveyor to the dough divider. Pieces of dough are transferred by a conveyor to the first rolling out into the machine The rolled dough on metal baking sheets goes to the tables, where the workers apply a layer of filling on one half of the layer of dough, and the other half of the filling is covered from above and transferred to the second rolling machine. The rolled double layer of dough with the filling inside is fed under the rotor of the forming machine, which also performs longitudinal cutting. Cross cutting of workpieces is done manually on tables. The molded gingerbread is laid out on stencils and sent for baking in an oven with a cooling device. The baked gingerbread is placed on tables and covered with sugar syrup. Chilled gingerbread cookies are removed from the nets and transferred to packaging.

Dough preparation

Gingerbread dough is a homogeneous mass of viscous consistency. When kneading, flour with medium quality gluten is used. Gingerbread dough contains a significant amount of sugar, which limits the swelling of the flour's gluten. Thanks to this, the dough acquires a loose and at the same time viscous consistency. For kneading the dough, machines of various designs are used: drum with U-shaped blades, universal with Z-shaped blades.

Kneading machine for tough dough HWH, HWJ

Kneading dough for raw gingerbread.

The raw materials provided by the recipe are weighed and loaded into the kneading machine in the following sequence: sugar (sugar syrup), water, honey. molasses, invert syrup, fat, melange, essence, dry perfume, leavening agents and last but not least flour. If sugar is introduced in the form of a sugar syrup prepared in advance, then the kneading process is carried out in two stages. First, all raw materials without flour and baking powder are mixed for 1-2 minutes, and then, after the introduction of baking powder and flour, they are mixed for another 5-I2 minutes. The duration of the kneading is regulated depending on the air temperature in the workshop, the water temperature, the rotation speed and the capacity of the kneading machine. At elevated air temperature in the workshop and water temperature, as well as the speed of the kneading units, the kneading time is reduced. With an increase in the capacity of the kneading machine and, accordingly, the mass of the load, the duration of the batch increases. Kneading is stopped when the mass in the kneading machine becomes homogeneous with a uniform distribution of all raw materials. The disintegrants are introduced in the form of an aqueous solution, which is prepared in advance. Semi-finished products, the preparation of which is associated with heating (sugar and invert syrup, scorch), before being introduced into the kneading machine, are cooled to a temperature not higher than 20 ° C. The water should also not have a temperature higher than 20 ° C. The temperature of the finished dough in all cases should not exceed 20-22 ° C, and the humidity should be in the range of 23.5-25.5%. The increased temperature of the dough leads to its tightening - a process in which the flour gluten, interacting with water, gives the dough elastic properties. As a result, the shape of the products is disturbed. When making dough for gingerbread "Tulskie" and "Vyazemskie", sugar-honey syrup is prepared, it is cooled to 30-35 ° C and all raw materials, including flour, are kneaded for 30-40 minutes. The final dough temperature should be 27-28 ° C, and the humidity should be only 18-20%. In order to lengthen the shelf life of raw gingerbread, when kneading, invert syrup or artificial honey is used instead of sugar, and 50% of wheat flour is replaced with rye. When kneading, in this case, invert syrup or artificial honey is heated to a temperature of 90-92 ° C and introduced into a kneading machine, where it is stirred until the temperature drops to 30-35 ° C. After that, wheat and rye flour are introduced and mixed 25 min., and then the dough is kneaded with the rest of the raw materials. The total kneading time is more than 60 minutes. and the moisture content of the dough is only 15-16%.

Kneading dough for custard gingerbread.

Kneading is carried out in three phases: flour brewing, brewing cooling and brewing kneading with all components of the recipe. The brew is prepared as follows. First, prepare the syrup. For this, the components of the recipe containing sugar (sugar, molasses, honey) are loaded into the digester. Water is introduced in an amount necessary to obtain a brew with a humidity of 19-20 ° / u, and everything is heated to a temperature of "70-75 o C. In this case, all the sugar should go into solution. The resulting hot syrup is loaded into a kneading machine with a water jacket, cooled somewhat, at not lower than 68 ° C and gradually, with stirring, introduce flour intended for making the infusion. After 10-15 minutes the infusion is ready. It should not contain lumps and traces of impurities. It is better to cool the infusion directly in the kneading machine. But for this, the kneading machine must to have a water jacket, and the workshop has a sufficient number of kneading machines. Cooling is carried out without unloading the tea leaves from the machine. The water jacket is connected to cold air. In low-mechanized workshops, the tea leaves are unloaded from the kneading machine into special chests. Each layer is poured with crumbs or each layer is lubricated with vegetable oil and cooled to a temperature of 25-27 C. Correct and sufficient cooling of the tea leaves provides high quality products. If the tea leaves are not sufficiently cooled, the gingerbread will be dense and irregular in shape. When the tea leaves are cooled in a kneading machine, already at a temperature of 28-30 ° C, the rest of the raw material is introduced into the tea leaves and kneaded for only 10 minutes. The tea leaves, which are not cooled in a kneader, are mixed with the rest of the raw materials for a longer time (30-60 minutes). The temperature of poi and unloading from the machine should be 29-30 ° C. and humidity 20-22%.

Shaping, baking and finishing gingerbread

When molding, in addition to giving the dough a certain shape, in some types of gingerbread, a drawing or inscription is applied to the surface. The bulk of the gingerbread is formed on the FPL machine. Most of the forming machines can be purchased from the equipment supplier LLC "Trading House Borodinsky". The dough to be formed enters the hopper. In the lower suit of the funnel, two injection rolls, rotating one towards the other, push the dough through the dies. The dies have holes of various shapes. The dough in the form of bundles is cut into separate pieces by a moving string. The formed blanks are transferred to the stencils moving along a special conveyor. When baking not on stencils, but on a steel belt, a similar machine is used, which deposits the molded dough pieces directly onto the steel belt of the oven. For mechanized production of molded dough pieces of gingerbread with filling, a special machine is used. This machine can also shape dough pieces for gingerbread without filling. This increases the productivity of the machine.

Some types of gingerbread are molded using various shapes (metal and wood). Gingerbread cookies molded into wooden forms are called printed ones. Such gingerbread cookies are mainly intended for children, so the shapes have the outlines of birds, fish and various animals. When forming such gingerbread cookies, the dough is pressed manually or with the help of special wooden blocks into a wooden mold, which is a board with an engraved pattern or inscription. The resulting dough piece is removed from the mold, placed on a metal sheet and sent to baking. When making a gingerbread with a filling, wooden molds are used, consisting of two parts. One part of the form, on which a drawing or inscription is engraved, forms the upper part of the gingerbread, and the other part of the form, without a drawing or inscription, forms the lower part of the gingerbread.

The molding process is carried out as follows. On the molded dough without a pattern and inscription, put the filling and cover with the molded dough with a pattern and inscription, and then the edges of the two halves of the gingerbread are squeezed like this. so that the filling does not leak out. When making gingerbread with a filling of the "Tulskie" type, molding with wooden stencils is used. The rolled dough with a thickness of 5-6 mm should be twice the size of the stencil. Half of the layer is smeared with an even layer of filling and covered with the other half of the layer, then the edges are squeezed with fingers so that they stick together. A stencil is a wooden board of a certain size, along the edges of which various designs are engraved, and the name of a gingerbread in the middle. A layer of dough with a filling is placed on the engraved surface of the stencil, which is lightly greased with vegetable oil, and pressed with a hand and a wooden block. After that, with a light blow of the stencil on the table, the molded dough is freed from the mold. The dough for mats is formed by rolling into a layer. The thickness of the blank for the rugs is 11-13 mm. The rolled layer is cut into strips, placed on sheets and sent to baking.For baking gingerbread, continuous conveyor ovens are most often used. Baking is made on stencils, steel tape or mesh. Gas or electric heating is used. Before baking, the surface of some varieties of gingerbread is greased with eggs and a pattern is applied. The surface of the rugs is lubricated with cold water and pierced in several places to prevent swelling of the upper crust. The baking mode for raw gingerbread is 7-12 minutes at a temperature of 220-240C. At the same time, deviations are allowed for some types of raw gingerbread. For example, "Mint" type gingerbread cookies are baked at a lower temperature (190-210 ° C). This mode is adopted in order to avoid the appearance of a dark color on their Surface. Gingerbreads of the "Autumn" type are baked at a higher temperature (250 ° C) and for a longer time. For gingerbreads of the "Tulskie" type, an even higher temperature is recommended for baking (265-270 ° C), but the baking time is reduced to 5-6 minutes. Custard gingerbreads are baked for 7-12 minutes at a temperature of 210-220 ° C, gingerbreads - 25-40 minutes at a temperature of 180-200 C. When baking gingerbread, basically the same processes occur as when baking cookies. A significant increase in the duration and relatively low baking temperatures compared to the baking temperatures of sugar cookies are associated with the increased thickness of the dough pieces used in the manufacture of gingerbread. The baking time can be changed depending on the moisture content of the dough pieces, the oven temperature and the degree of filling. The baking process can be roughly divided into three periods. During the first period, which lasts approximately 1 min, moisture is not removed from the sample. The surface temperature of the layer reaches 60 ° C, while the central layers rise by only 2-3 ° C. The second baking period is characterized by a variable rate of moisture release. During this period, the surface of the layers is dehydrated. The moisture flow is directed towards the interior of the sample. The third baking period is a period of constant moisture-yielding rate. The moisture content of the central layers does not change, and dehydration occurs from the surface layers. By the end of baking, the temperature of the surface layer reaches 175 ° C, and the central layers - slightly above 100 ° C. After baking, the gingerbread cookies are cooled for 20-22 minutes to a temperature of 40-45 ° C. When baking on steel nets or belts, cooling is carried out without removal, directly on these surfaces. Removal occurs only when the products are easily detached from the mesh or steel strap. When baking on stencil sheets (after leaving the oven), they are installed together with the products on whatnots or fixed racks. After such pre-cooling, the products are easily removed and fed to the final cooling. In the process of cooling the gingerbread, their moisture content is significantly reduced. This process slows down as the temperature decreases. Most types of gingerbread must be finished. Gingerbread finishing is understood as covering the surface with a layer of glaze. As a result, the surface of the gingerbread is covered with a glossy, marble-like crust of crystallized sugar. cooling, the surface of the gingerbread takes on the luster of sugar crystallized from the syrup. A layer of sugar helps to preserve freshness, inhibits staleness, in addition, after glazing, the taste of the gingerbread also improves. (40 parts) with heating up to 110-114 C. Processing in a dragee boiler is carried out for 1-2 minutes. Then the gingerbread cookies are unloaded and dried at a temperature of about 60 C. The drying time is 9-10 minutes. Thereafter, it is additionally cooled by blowing with air. At mechanized enterprises, gingerbread is glazed in continuous units. This unit is a drum rotating on a horizontal axis, inside of which gingerbread and syrup are continuously fed with a temperature of 90-95 ° C. When the drum rotates, the gingerbread cookies, doused with sugar syrup, move inside the drum to the inlet. The duration of the process is up to 50 s. After cooling, the surface of the gingerbread becomes shiny from the sugar crystallized from the syrup. The sugar layer contributes to the preservation of freshness, inhibits staleing, in addition, after glazing, the taste of the gingerbread also improves.

The technological process of making gingerbread consists of the following stages:

• Preparation of raw materials
• Preparation of semi-finished products from flour (dough)
• Dough formation
• Baking and cooling gingerbread
• Replication (glazing) of gingerbread

PREPARATION OF RAW MATERIALS.The raw materials for the production of gingerbread must comply with the requirements of applicable standards and technical instructions.

The preparation of raw materials must be carried out in compliance with the requirements of technology and sanitary rules for public catering enterprises.

PREPARATION OF SEMI-FINISHED PRODUCTS FROM FLOUR (Dough). Raw method.The raw materials provided by the recipe are loaded into the bowl of the kneading machine in the following sequence: sugar or sugar syrup, water, burnt, honey, molasses, invert syrup, melange, essence, dry perfume, bicarbonate soda, flour.

All raw materials, with the exception of flour and chemical leavening agents, are mixed for 2-10 minutes in a kneading machine. Sugar is dissolved in water and evenly distributed in the mixture. The duration of stirring depends on the room temperature: at temperatures above 18-20 0 С, short-term stirring is necessary, which excludes the possibility of tightening the dough.

The kneading of the dough is continued for 4-12 minutes, depending on the capacity of the kneading machine, the room temperature and is stopped after a homogeneous mass of binder and loose consistency is obtained.

The following method of kneading raw dough is also used:

Pre-prepared sugar syrup (temperature 35-40 0 C) is mixed with all raw materials without flour and chemical leavening agents for 1-2 minutes, and then add the data to the components and continue to mix for 5-12 minutes.

The amount of water required for kneading the dough is calculated according to the formula:

X \u003d 100C / 100-A \u003d B

Where X is the amount of water for one batch, l;

С-mass of raw materials dry matter, kg;

B-weight of raw materials for one batch (without water), kg;

A is the required moisture content of the dough,%.

The moisture content of raw dough should be in the range from 23.5 to 25.5, and for gingerbread "Tula" with manual cutting from 18 to 20%.

The temperature of the dough after kneading should not exceed 22 degrees C, therefore it is necessary to use raw materials, including water, not higher than 20 0 C. When using semi-finished products obtained by heating (invert and sugar syrup), they should be pre-cooled to a temperature of 20 0 C

These technological parameters must be maintained when kneading raw dough, since the moisture and temperature of the dough affect its properties and the quality of the gingerbread.

The use of invert syrup or artificial honey instead of sugar, as well as rye flour along with wheat flour improves the quality of raw gingerbread cookies, reduces their shrinkage during storage.

Brewing method.The preparation of the dough by the custard method consists of three stages: brewing flour in sugar-honey, sugar-treacle and other syrups, cooling the brew, kneading the brew with all other types of raw materials provided for in the recipe.

To prepare the tea leaves, sugar-honey, molasses and water are loaded into an open digester and heated to a temperature of 70-75 0 С (until the sugar is completely dissolved).

The resulting syrup is poured through a sieve into a kneading machine at a temperature not lower than 68 0 С, gradually adding flour. Chilling the syrup to a lower temperature will reduce the quality of the gingerbread.

The duration of the kneading in the kneading machine is 10-15 minutes, the moisture content of the infusion should be 19-20%. The dough should be evenly mixed and free from lumps and other traces of impurity.

After kneading, the tea leaves are cooled on baking sheets. The dough is matured in a specially designated room at a temperature of 28-30 0 С.

After cooling the choux pastry, it is kneaded, combined with the rest of the components provided by the recipe and kneaded until a homogeneous consistency is obtained for 30-40 minutes. The dough should be evenly mixed and have a creamy consistency.

The finished dough should have a temperature of 29-30 0 С and a humidity of 20-22%.

Dough shaping.For forming the dough, forming and jigging machines, metal recesses of various shapes and sizes, and wooden carved forms are used.

The dough is molded with a metal notch as follows: the finished dough weighing 5-6 kg is placed on the table, previously covered with a thin layer of flour. The dough is shaped into an oblong layer, gradually rolled out with a wooden rolling pin to a layer thickness of 8-11 mm. The dough layer should have a uniform thickness, since the gingerbread cookies of different thicknesses are baked unevenly.

The dough is formed by pressing the recess on the rolled dough layer. After 5-6 presses, the recess is freed from the dough pieces and laid out in equal rows on baking sheets.

To prevent the dough from sticking to the groove, it is periodically immersed in flour. The pieces remaining after molding are added to the undivided dough, evenly distributing it over the surface, and then rolled out with a rolling pin. gingerbread technological cooking classification

The filling dough is molded in several ways using metal grooves and wood carvings.

The dough with a metal groove filling is formed as follows: the dough is rolled out with a rolling pin to a thickness of 3-11 mm. A filling is applied to half of the rolled layer. Then both halves of the layer are glued in a circle to each other.

Form the dough with a round or oval notch so that the protruding parts with the filling are in the center of the stamp.

This method of forming the dough is used for products without a pattern or inscription on the surface.

The dough with filling with wooden carved molds is formed as follows: molds are used, consisting of two parts. One part of the form, which is engraved with a design and inscription, forms the top of the gingerbread. On the formed dough without a pattern and inscription, lay out the filling in an even layer and cover with the formed dough with a pattern and inscription. Then the edges of the two dough pieces are squeezed so that they are firmly glued, and the filling cannot come out.

Before baking, the surface of some types of gingerbread is greased with an egg, sprinkled with sugar, crumbs, crushed nuts, decorated with raisins, candied fruits and kernels of nuts.

The baking mode depends on the thickness of the dough pieces. The thicker, the lower the baking temperature and duration.

Circulation (glazing) of gingerbread.Sugar syrup for replicating gingerbread is prepared in an open cooking pot by dissolving sugar in water in a ratio of 1: 0.4 when heated to a temperature of 110-114 ° C.

Circulation (glazing) of gingerbread with sugar syrup is carried out as follows: gingerbread (3-4 kg) are loaded into a container and poured over with hot sugar syrup.

In terms of organoleptic and physicochemical indicators, the gingerbread should meet the requirements of GOST 15810-80 "Gingerbread Confectionery Products".

The production of gingerbread is one of the most profitable types of business that even a person who is not too knowledgeable in the intricacies of the culinary arts can do. Moreover, the prospects for the development of the gingerbread business are truly stunning. Thus, according to marketing research data from STK Group, the capacity of the domestic market alone has the prospects for direct growth in consumption of about 3.7 thousand tons of finished products of various types of gingerbread and similar to them in terms of the market segment and production technology, gingerbreads. We should not forget about the possibilities of exporting products, which have been talked about a lot lately.

• Gingerbread cooking technology
• Pros and Cons of Gingerbread Making and Selling Business
• How much money you need to invest and how much you can earn on making and selling gingerbread
• Permission and OKVED code for a gingerbread business
• A step-by-step plan for starting a business for preparing the sale of gingerbread
• How to choose equipment for business
• What documents are needed for business
• Which taxation system to specify

Gingerbread cooking technology

Gingerbread is a confectionery product, rectangular, round, oval or complex shaped, made of special gingerbread dough, with the addition of jam, spices, chopped berries, nuts, honey or candied fruits. As a rule, an inscription or a simple drawing is minted on top of a gingerbread plate in various ways and a layer of confectionery glaze is applied.

A feature of the gingerbread dough in the finished product is a long shelf life, which is why this culinary sweetness is popular as a souvenir.

It should also be noted that domestic gingerbread cookies have good and glorious long-standing traditions, which are also known abroad. So, in particular, the family's Tver gingerbread cookies, at the end of the 19th century, maintained their own brand stores in the main European capitals and made excellent money on this.

Pros and Cons of Gingerbread Making and Selling Business

The most important, and in many ways, the determining factor is that this kind of production, of course, not on an industrial scale, can be located at home. At the same time, a very significant item of expenses is deleted, rent of premises

Gingerbread dough, unlike yeast dough, does not impose increased requirements on the quality of flour. This is also an extremely important factor. Since in the preparation of a number of the same bakery products, the indicators of gluten and IDC in the grain of the food group and the flour obtained from it are decisive. First of all, we are talking about the possibility of using cheap flour of the 2nd grade

The finished product is stored for a very long time, which makes it possible by several orders of magnitude to reduce the severity of the issue on the efficiency and speed of implementation of the finished product and its stocks

A fairly simple technological process of preparation, such operations as proofing, maturation of the dough do not require increased requirements for the temperature and humidity regime.

The main components for production are available and do not require special conditions during transportation and storage

The most time-consuming processes of kneading and shaping the dough are easily mechanized using available means.

It is clear that the gingerbread business, like any other, has its pitfalls and negative sides:

High competition, and many players in the market have a long and proven tradition of production. Entering the market and reclaiming your niche is not easy

One of the conditions for winning the sympathy of the consumer is the production of a high-quality product and exclusively on natural ingredients, which allows us to cut off large, but ordinary manufacturers who base their own recipes with various modifiers, essences and other ersatz products. It follows that your own recipe based on exclusively natural products will have an overestimated cost and, as a result, a reduced competitive potential.

In the case of the use of exclusively manual labor for kneading, molding the dough, the wages fund grows significantly, when it comes to attracting hired workers to production, the maximum possible mechanization of manual labor imposes increased requirements on the size of the initial capital

The production of food products causes certain difficulties in terms of compliance with sanitary and hygienic requirements, both for premises, transport, and personnel.

How much money you need to invest and how much you can earn on making and selling gingerbread

Having weighed all the pros and cons of a purely organizational nature, you can begin to develop a disposition on the economic front.

The calculation will be made on the example of the recipe for the "Tula jubilee gingerbread", which is distinguished by technological simplicity and stability of the output of the finished product

Flour of the 2nd grade - 100 kg, / of which for the dust of the molding table 0.75 kg /

Granulated sugar, for dough and glaze - 35 kg

Molasses - 45kg, / in the case of using natural honey, the conversion factor is 0.45 /

Margarine - 2 kg

Vegetable oil - 0.55kg

Baking soda - 0.4 kg

Conditioned drinking water by moisture capacity - 26 l

A mixture of spices ginger powder, cloves and cinnamon, chopped - 0.04kg

Output of finished products 175 pcs.

Proceeding from the fact that the prices for the products and finished products indicated in the recipe can vary significantly in the regions of the country, for an objective calculation, you should substitute the numbers that are objective for your area, subtract the associated production and non-production costs and get the cost and projected profit indicators.

So, on average in the Russian Federation, the average cost of a kg of a finished product is 28.47 rubles, with the same average selling price in retail of 62.74 rubles.

As a general information, it should be added that for a small production with a finished product productivity of the order of 1000-1400 kg per month, the expected level of profitability should be in the range of 45-60% and should not be lower than 35%.

Permission and OKVED code for a gingerbread business

It should be recalled that the production of gingerbread and gingerbread is regulated by OKVED 10.72.32. and before the start of production, it is necessary to acquire the necessary package of permits.

As a conclusion, I would like to note that starting with a small production of gingerbread, as an exclusively family business, an entrepreneur in a short time will be able to massively increase not only production volumes, but also the range of sweet pastries. It is worth actively looking for opportunities to reduce costs by optimizing costs and, of course, looking for new sales markets, not stopping at already well-developed ones. Excellent preservation of products, their excellent transportability and resistance to adverse factors opens up very broad prospects for both qualitative and quantitative growth of your enterprise.

A step-by-step plan for starting a business for preparing the sale of gingerbread

The organization of the gingerbread business is not much different from other activities related to the baking of confectionery. The entrepreneur's action plan includes:

1. Registration of activities with the tax service, obtaining permits.
2. Rental of premises and its arrangement in accordance with the regulations of the regulatory authorities.
3. Purchase of equipment.
4. Purchase raw materials.
5. Find a sales market.
6. Advertise, create a website.

Carrying out marketing research, drawing up a business plan will greatly simplify the work of a novice entrepreneur. Having an action plan in hand to start the production of gingerbread is much easier.

How to choose equipment for business

For the automated process of making sweets, you will need to purchase special equipment:

• Apparatus for kneading dough;
• Gingerbread kettle;
• Apparatus for product decoration;
• Electric oven for baking products;
• Equipment for packing.

The equipment is purchased depending on the needs of production. In addition, it is necessary to buy furniture for arranging a warehouse, a special uniform for staff. For the delivery of gingerbread you will need a car

What documents are needed for business

The first thing to do is to register an individual business or LLC. Next, it is necessary to obtain approval from the SES for the premises, to approve the recipe and production plan. In addition, the entrepreneur must conclude a contract for garbage removal, disinfection of premises.

Which taxation system to specify

The optimal choice of the taxation system for individual entrepreneurs is the simplified tax system with a rate of 6%, which is calculated from the income received. This system can also be used when registering a legal entity.

Gingerbread confectionery products are national Russian products with a pronounced sweet taste, spice smell and soft texture. They are very popular with consumers.

The assortment of gingerbread products is quite large and includes about 90 items. One of them is gingerbread - a baked semi-finished product sandwiched with filling.

Depending on the cooking technology, gingerbread products are divided into custard (with flour infusion) and raw (without flour infusion).

The process of making custard gingerbread products differs in that when kneading the dough, flour is brewed in sugar-honey or sugar-syrup syrup.

Due to differences in the recipe and dough production technology, raw and custard gingerbread products differ significantly in taste. Custard products have a more pleasant taste and aroma, and retain freshness longer than raw products.

To increase the shelf life of raw gingerbread, half of the prescription amount of wheat flour is replaced with rye flour, and part of the sugar is replaced with invert syrup and honey.

To improve the quality and shelf life of gingerbread products, enzyme preparations (amilorizin P10X), surfactants (churning paste) and fruit and berry powders are introduced into the recipe.

Gingerbread products are classified into unfilled gingerbread, filled gingerbread and gingerbread with or without filling. Fruit filling is used as a filling - from applesauce or a mixture of apple and fruit-berry puree, fruit filling from jam or fruit podvarka. The filling makes up 10 ... 17% of the gingerbread mass.

Gingerbread can be glazed or unglazed. Glazing is done mainly with sugar syrup, and the glaze is about 15%.

Gingerbread products can be of various shapes - mainly round and oval with a convex surface. By size and shape, they are divided into small (round, oval and curly) and gingerbread (rectangular).

The thickness of the gingerbread products depends on their type and is about 14 ... 30 mm.

In shape, color, taste and smell, surface condition, gingerbread products must correspond to their name, taking into account flavoring additives. They should not have any foreign smell and taste. In a fracture, they should represent baked products without traces of impurities, with uniform porosity.

According to physical and chemical indicators, the mass fraction of moisture in gingerbread products is 13 ... 22%, the mass fraction of fat is 1.5 ... 7.0%, the alkalinity is not more than 2 mass fraction of ash insoluble in 10% hydrochloric acid - 0.1%.

In terms of microbiological parameters and the content of toxic elements, gingerbread products must comply with the applicable standards.

The raw materials for the production of gingerbread products are wheat, rye and soy flour, granulated sugar, honey, molasses, melange, fat, chemical leavening agents, flavorings, dyes, raisins, nuts, candied fruits, etc. (Table 6.9).

Wheat flour with medium and low quality of gluten is used in the production of gingerbread products.

The production of gingerbread products is carried out in a batch or continuous way on flow-mechanized lines, where the dough can be kneaded on an emulsion. Emulsions are prepared in the same way as in the production of sugar and lingering dough.

Gingerbread production technology consists of preparing raw materials for production, dough preparation, molding, baking, cooling, glazing (for glazed gingerbread) and packaging, transportation and storage.

Dough preparation is carried out in dough mixing machines (MT-70), MT-100, GU-SHTL, TM-63) with P - and Z-shaped blades and consists of syrup preparation and dough preparation.

To prepare the syrup, hot water (70 ... 80 ° C) is poured into a temperature machine or into a container with steam heating, granulated sugar, honey, molasses or invert syrup, condensed milk are loaded. The mixture of raw materials is mixed until the granulated sugar is completely dissolved and heated to 65 ... 70 ° C. The finished syrup is cooled to 50 ... 65 "C when making custard gingerbread and to 30 ... 40 ° C for raw gingerbread.

When preparing raw dough on syrup, it is mixed with other types of raw materials, and in the last turn, chemical leavening agents and wheat flour are introduced. The process of dough formation is 7 ... 12 minutes.

When preparing raw dough without syrup, the sequence of loading raw materials into the kneading machine should be strictly observed: granulated sugar, water at a temperature of 20 ° C, honey, molasses, melange, flavors, chemical leavening agents and wheat flour.

All raw materials without flour and chemical leavening agents are mixed for 2 ... 10 minutes, and then chemical leavening agents and flour are introduced. Kneading is performed within 4 ... 12 minutes. The duration of the dough kneading depends on the air temperature in the workshop, the temperature of the water during kneading, the rotation of the working bodies and the volume of the kneading machine.

The dough is considered ready when the mass becomes homogeneous with an even distribution of all raw materials. Finished temperature

The dough should not be higher than 20 ... 22 ° C, since an increase in temperature leads to its tightening and subsequently deformation of products is observed.

The moisture content of the raw dough is about 23.5 ... 25.5%.

When preparing choux pastry, the stages of brewing preparation and cooling are additionally introduced. The prepared syrup with a temperature of 50 ... 65 ° C is fed into a kneading machine with a steam jacket. At the working stroke of the machine, flour is gradually introduced in the amount prescribed by the recipe. The duration of the infusion kneading depends on the number of revolutions of the blades per minute and averages 5 ... 15 minutes. The brewing temperature is 48 ... 53 ° С, the humidity is 19 ... 20%.

The brew can be cooled in the dough mixer itself with a water jacket to a temperature of 28 ... 35 ° С or in special chests in the workshop room to a temperature of 25 ... 27 ° С. Correct and sufficient cooling of the brew ensures high product quality. From insufficiently cooled tea leaves, gingerbread cookies are denser and irregular in shape.

To prepare the dough, the chilled brew and all the rest of the raw materials provided for by the recipe are loaded into the kneading machine. The dough is kneaded for 30 ... 60 minutes and depends on the method of cooling the infusion, its aging, the number of revolutions of the dough-kneading machine blades, as well as the temperature of the cooled infusion. In the case of cooling the infusion in the kneading machine, the raw materials provided for by the recipe are introduced into it, and the kneading lasts only 10 minutes.

The temperature of the finished dough should be about 28 ... 36 ° С, the humidity, depending on the variety, should be 18 ... 23%.

Round shaped gingerbread is molded on forming and jigging machines FPL, A2-SHFZ with laying dough pieces on baking sheets or A2-SHFZ-01 for placing dough pieces directly on the belt under the confectionery oven.

The dough loaded into the hopper of the head of the forming machine is fed * by grooved rollers to the dies and is pushed through an opening in the form of a rope. With the help of string cutting, the dough strands are cut into individual pieces and placed on baking trays or on a conveyor belt of the oven.

During molding, the products are given a certain shape, and a drawing or inscription is applied to individual ones.

Gingerbread dough is also molded on stamping machines, where products of a certain size and shape are cut from the dough band.

Gingerbread dough can be hand molded. A rolled out dough sheet with a thickness of 8 ... 11 mm is formed by a metal recess of a certain shape by pressing the recess on the dough sheet. To apply a pattern to the surface, the dough layer is rolled with a toothed rolling pin.

To apply certain patterns to the surface of gingerbread products, a wooden form is used in the form of a board with an engraved pattern or inscription. Gingerbread cookies molded into wooden forms are called printed. They are shaped like birds, fish, animals.

Gingerbread products with filling are formed using metal grooves and wooden carved forms. Some part of the dough is rolled into a layer and spread with a filling. Extracted from a wooden form, a layer of TSTA with a pattern is placed on top of the filling. Both layers of dough are joined at the edges so that the filling is inside. The resulting dough piece of three layers (two layers of dough and filling) is sent to baking.

In the mechanized method of forming the dough with filling, it is loaded into the hopper of the machine, which consists of a tube-in-tube nozzle and a punching drum. The dough comes out in the form of a dough tube with a filling inside. Further, the dough rope with the filling goes under the stamping drum, where workpieces of a certain shape are cut.

For rugs, the dough is molded in the form of a layer according to the size of a metal baking sheet.

Before baking, the surface of some gingerbreads and gingerbreads is smeared with melange, sprinkled with granulated sugar, nuts, candied fruits, etc.

Baking of dough pieces is carried out in rotary ovens, in baking cabinets and in continuous tunnel or conveyor ovens. Before baking, the dough pieces pass through a humidification chamber.

Gingerbread cookies are baked for 7 ... 12 minutes at a temperature of 190 ... 240 ° C. The baking temperature is reduced to 190 ... 210 ° C when unglazed gingerbread is produced in order to avoid the appearance of a darker color. The rugs are baked at a temperature of about 200 ° C for 25 ... 40 minutes.

Cooling. Unglazed gingerbread cookies are cooled to a temperature of 25 ... 35 ° С for 20 ... 22 minutes, and glazed ones - to a temperature of 45 ... 50 ° С within 5 ... 10 minutes.

When baking in continuous ovens, the gingerbread cookies are cooled by moving directly on the grid inside the cooling device due to cold air (10 ... 12 ° C). The cooling device is installed directly after the furnace.

The gingerbread cookies are removed after cooling only if they are completely separated from the mesh belt or sheet.

Glazing of gingerbread with sugar syrup is performed to decorate the surface and preserve the freshness of the products. Glazing of gingerbread includes the stages of preparation of syrup, glazing, drying and standing of the glazed products.

Glazing syrup with a ratio of granulated sugar and water of 100: 40 is boiled down to a dry matter content of 77 ... 78% and a density of 1340 ... 1400 kg / m3.

The finished syrup is fed into a heated tank to maintain its temperature at about 90 ... 95 ° C and served for thalamation.

Glazing of gingerbread is carried out in a small pot by thorough mixing, then they are removed with a fork and laid out on nets. Glazing of gingerbread can be done in dragee pots.

Drum-type machines (A2-TK2-JI) are used for continuous glazing of gingerbread. When the drum rotates, along the inner surface of which a spiral is welded, the gingerbread is glazed and moved to the outlet.

After glazing, the gingerbread cookies are placed on mesh cassettes or a conveyor in one row with the convex side up and sent for drying into special chambers, first at a temperature of 60 ° C for 5 minutes (air speed 4 m / s), and then at a temperature of 20 ... 22 ° C for 3 min.

After drying, the gingerbreads stand for 2 hours in the workshop and are sent for filling, packaging, storage.

Shelf life of gingerbread products from the date of manufacture (in days):

Raw unglazed (except mint) gingerbread and gingerbread - 20;

Raw and custard gingerbread like mint in winter - 15;

Raw and custard gingerbread like mint in the summer - 10;

Raw and glazed gingerbread and gingerbread in the summer - 20;

Custard gingerbread in the summer - 20;

Custard gingerbreads in winter - 30;

Custard gingerbreads - 20;

Mats with a fat content of more than 11% - 15.

Gingerbread production on a mechanized line. Wheat flour is fed for sifting into beetroot and then by auger is transferred to the flour hopper. With the help of the auger, the flour is transferred to the truck scales (Fig. 13).

To prepare the dough, the necessary components of the raw materials are loaded into the kneading machine, where flour and chemical leavening agents are delivered last.

The prepared dough is transported by means of a trolley for molding to a forming-depositing machine. Molded dough

Fig. 13. Technological scheme for the production of gingerbread: 1,4- flour homemade machines; 2 - flour burat; 3 - auger; 5 - bunker; 6- auto scales; 7- kneading machine; 8 - cart; 9-forming-jigging machine; Yu-conveyor furnace; II - cooling cabinet; 12 - transfer conveyor; 13 - ejector; 14 - a container for syrup with a steam jacket; 15 - apparatus for glazing gingerbread; 16- conveyor for cooling products; 17 - drying cabinet; 18- laying conveyor; 19- laying products

The billets are fed for baking into a conveyor oven, then into a cooling cabinet. After cooling in the cabinet, the gingerbread cookies are additionally cooled on the conveyor in the workshop conditions. After that, the spreader is sent to the glazing machine, where sugar syrup is continuously fed from a heated tank. Glazed gingerbread cookies are fed into a cooling cabinet for drying, followed by standing and laying on conveyors.