There are many in the world variety of sauces. One of my favorite sauces is plain mustard. She happens different tastes, and has long been present on our tables, in almost every family.

If you have a desire to organize your own profitable business, you can consider the option opening of a mustard production plant. Moreover, the cost of such production will be minimal. You will not need to purchase raw materials at a high price, and mount expensive equipment. So open a mustard factory even small businesses can do it. At right approach to a detailed business plan, your production will pay off in a short time.

Room.

A mustard production workshop needs a room with a height of at least three meters, connected to the water and electricity supply, equipped with ventilation and natural light. In such a room it will be necessary to make repairs, taking into account all SES requirements. Or try renting a space at a business Food Industry. There should be several additional rooms in your premises - a change house for staff, for warehouses - raw materials, containers and finished products.

Raw material.

To make mustard you will need:

mustard powder
Vinegar
Water
Vegetable oil
Salt
Sugar
Spicy additives

Equipment.

Before purchasing equipment, decide whether you will produce only mustard or will additionally produce other sauces. After all, mustard, as a rule, seasonal product and the peak of its implementation falls on the cold season. So it's worth considering releasing additional sauces such as ketchup and mayonnaise. Thus, you will stabilize your income throughout the year. But then you will have to invest an order of magnitude more money. But the decision is yours. If you produce only mustard, then our industry offers ready-made lines for the production of this product. Installation of equipment and training of employees is included in the cost of the finished line.

The finished line includes:

digester
Mixer
Vibrating sifter
Open digester
Rotary pump
Rubbing machine.

The productivity of such a line is 250 kg per shift, the cost is about 220 thousand rubles. The theoretical profitability of such production is 50 thousand rubles in the presence of a permanent sales market.

To produce several sauces, you will have to buy a more expensive production complex. It includes:

Long pasteurization bath
Homogenizing module
Centrifugal pump
Technological scales
Stainless steel table

Decide on the packaging right away. Since it is necessary to choose the right equipment for packaging. Beneficial to use plastic packaging, it is much cheaper glass containers which will reduce the production cost.

Dispenser for viscous and liquid product
Container sealing machine
Compressor

Even if you open a workshop for the production of only mustard, over time, you can buy additional equipment and increase the range.

Staff.

Be sure to hire an experienced technologist, and the number of workers will depend on the size of your production (there may be two for a start) and a sales manager who will directly deal with the sale of finished products. The accountant may be visiting.

For implementation, consider all sorts of options– contracts with supermarkets, small shops, small fast food stalls, etc.

Costs and income.

The cost of 1 kg of mustard powder is approximately 52 rubles. In a month, you produced 500 kg of the product - this is 2500 packages of 200 g), which means that the cost of all manufactured products will approximately be 26 thousand rubles. The revenue for the entire product is about 76 thousand rubles, subject to full implementation. The cost of rent, raw materials, wages, etc. will amount to about 32 thousand rubles. Profit after paying taxes will be about 15 thousand rubles.

The invention relates to the food industry. In the production of mustard powder, mustard seeds are cleaned, conditioned for moisture and seed size, crushed, and the shells are separated from the kernel. The kernels are crushed to the following fractional composition, wt.%: halves of the kernels are not more than 15, the passage through a one-millimeter sieve is not less than 85, there are no whole kernels. Moist heat treatment is carried out with live steam to a moisture content of 10%, then dried to a moisture content of 4-5%, bringing the temperature of the pulp to 100-115 o C. Pressed, the cake is crushed, when crushed, 5-7% of white mustard seeds are additionally added, or 5-7 % yellow mustard, or 5-10% mixture of seeds of white and yellow mustard in a ratio of 1:1 by weight of cake and sieved. This allows you to get a mustard powder of adjustable sharpness. 1 tab.

The invention relates to the oil and fat industry and relates to methods for the production of mustard powder. The well-known technological process for the production of mustard powder includes the following operations: cleaning mustard seeds, conditioning seeds in terms of moisture and size, hulling them, separating the shell from the kernel, grinding it, moisture heat treatment, pressing, crushing the cake and sifting to separate the powder (see Technology Manual production and processing of vegetable oils and fats. L., 1960, vol. I, pp. 256, 265), taken as a prototype. However, the mustard powder obtained by this method quickly loses its qualities: characteristic spicy taste and hotness, necessary in the manufacture of ready-made food mustard and mustard plasters, because. at high temperature pressing and pressing the oil, inactivation of the myrosinase enzyme occurs, which promotes the hydrolysis of sinigrin and the formation of allyl isothiocyanate (AITC), which gives the mustard powder its specific properties. The task that was solved when creating the invention is to obtain mustard powder with desired properties. The technical result is the production of mustard powder with adjustable sharpness, i. e. with controlled content of allyl isothiocyanate. The specified technical result in the implementation of the invention is achieved by the fact that in the known method for the production of mustard powder, the grinding of the core is carried out to a fractional composition, wt.%:

Kernel halves - No more than 15

Passage through a one-millimeter sieve - No more than 85

Whole Kernels - None

Moist heat treatment of the kernel is carried out with live steam to a moisture content of 10%, then dried to a moisture content of 4-5%, bringing the temperature of the pulp to 100-115 o C, and when crushing the cake, 5-7% of white mustard seeds, or 5-7% of seeds are additionally added yellow mustard, or 5-10% of a mixture of white and yellow mustard seeds in a ratio of 1:1 by weight of cake. Grinding the core to the specified fractional composition allows achieving the most complete destruction of the cellular structure of the core, which contributes to a better extraction of oil during pressing. Mustard seeds contain thioglucoside sinigrin and the enzyme myrosinase, in the presence of water hydrolysis of sinigrin occurs and allyl is formed. mustard oil, which determines the sharp taste of mustard. Treating seed kernels with live steam and increasing the temperature to 100-115 o C, increase the yield fatty oil by 2-3% due to more complete disclosure of seed cells and a decrease in oil viscosity. But at the same time, the inactivation of the myrosinase enzyme occurs, and the hydrolysis of sinigrin with the release of allyl isothiocyanate is incomplete, as a result of which the mustard powder loses its properties. characteristic properties: pungent and pungent taste. The addition of whole mustard seeds to the cake at the grinding stage in the amount of 5-10% by weight of the cake, in which the myrosinase enzyme is preserved in its native state, allows for the hydrolysis of sinigrin more completely and obtain set quantity AITC and, accordingly, control the degree of sharpness of the final product, i.e. powder. In the claimed method, it is possible to obtain the content of AITC from 0.67 to 1.20% in terms of absolute dry matter. The method is carried out as follows. Mustard seeds on separators are cleaned from impurities and mineral debris, metal impurities are removed using magnets installed before and after the separators. The moisture content of seeds entering production should be 6.5 - 7.0%. After cleaning, the seeds are calibrated by size on sifters or separators. Collapse of mustard seeds is carried out on roller machines, after which the core is separated from the husk on aspiration cereal shakers. For normal preparation for pressing, the seed kernels are crushed on four-roller rollers to a fractional composition, wt.%:

Halves of kernels - No more than 15

Whole Kernels - None

The crushed kernels are fed into the first vat of the brazier, where they are steamed with live steam to bring the humidity up to 10%. There is a partial hydrolysis of sinigrin. In the 2 lower vats of the brazier, the pulp is dried to 4-5% moisture and heated to a temperature of 115 o C, the myrosinase enzyme is inactivated. After pressing, the mustard cake with partially reacted sinigrin and partially inactivated myrosinase is fed for grinding to VS-5 five-roll machines, followed by separation of the powder on sifters. Partial inactivation of the myrosinase enzyme is replenished by adding to the cake at the grinding stage 5-7% of white or yellow mustard seeds, or 5-10% of a mixture of white and yellow mustard seeds in a ratio of 1: 1 by weight of the cake. By changing the amount of whole seeds supplied, the content of allyl isothiocyanate in the powder is regulated. The research results are summarized in the table.

CLAIM

Halves of kernels - No more than 15

Passage through a one-millimeter sieve - Not less than 85

Whole Kernels - None

Moist heat treatment is carried out with live steam to a moisture content of 10%, then dried to a moisture content of 4 - 5% with the pulp temperature brought to 100 - 115 o C, and when crushing the cake, 5 - 7% of white mustard seeds, or 5 - 7% of yellow mustard seeds are added. mustard, or 5 - 10% of a mixture of white and yellow mustard seeds in a ratio of 1: 1 by weight of cake.

The consumption of ketchup, mustard and mayonnaise exceeds three kilograms per person per year, so pasty sauces and seasonings will always be in demand.

Food business organization

It is necessary to register an LLC of the future mini-factory and decide on strategic partners involved in the sale of products (wholesale warehouses, bases). Supermarkets are especially important, they prefer to do business with reliable manufacturers, because they provide maximum sales.

Study of regulations and state standards GOST 9159-71, GOST R 53590-2009 and GOST R 52141-2003.

A room is selected that meets sanitary and hygienic standards and is purchased technological line for the production of paste products.

A business plan is being formed (which must include the daily output, all costs and net profit). Return on sales is key and should be over 55% for payback in a year.

To confirm the quality of any type of pasty products, certification is required with the appropriate package of documents, according to which the products will be manufactured. These can be GOSTs (Extra category without artificial preservatives) or branded specifications(TU) for other categories.

mayonnaise manufacturing technology

The composition of mayonnaise is not regulated by GOST. The main ingredients are vegetable oil (more than 30%), eggs, sugar (xylitol), salt, milk. It is necessary to have three vats in the workshop (for liquid eggs, oils and pastes).

Eggs are pasteurized, pumped into a cooling tank. Then added soybean oil and diluted in apple cider vinegar spices. The unit stirs the mixture at room temperature for six minutes until smooth and get a mayonnaise paste.

After selective laboratory quality control of mayonnaise in terms of color, smell, viscosity and other parameters, it is poured by a dispenser into packaging containers (disposable double-layer bags, plastic).

ketchup technology

Tomato paste is diluted with water, mixed in a digester with sugar (sorbitol), salt, fruit puree, starch, stabilizers, dye. Before pouring into jars, bags and plastic cups, a laboratory test is carried out with a refractometer for the mass content of dry substances of tomatoes and for other parameters (aroma, consistency). Hot pouring (80 degrees) ensures optimum quality.

Mustard production

Crushed seeds (17%) are added to a mixture of pepper, turmeric, salt, vinegar, water (up to 60%) and mixed for about an hour before breaking the grains. The mass is poured into a stone mill with adjustable grinding, where the grains are ground with stones to a cream at a temperature of 60 degrees. Seasoning parameters are checked and poured into jars.
Grain mustard differs from powder seasoning in sweetness, and in french mustard acid is replaced with grape juice.

Five people are enough to service the ketchup, mayonnaise and mustard production line. To stimulate the pace of sales, it is recommended to give discounts to wholesalers and supplement products with promotional booklets, to hold discount sales promotions.

Working directly with supermarkets brings the most bang for your buck, and the quality of the product will work for itself. Sales of full-fat mayonnaise far outpace low-calorie mayonnaise because consumers care about quality, not price. And if we take into account that the market is not yet saturated with pasty products (the growth trend is more than 2%), then the production of ketchup, mustard and mayonnaise guarantees a stable profit.

Today, in the conditions of mini-productions, the development of various sauces, ketchup, etc. LLC "NZPO" - Molpromline ™ develops and manufactures equipment and production lines for the manufacture of sauces such as soy sauce, mustard sauce, horseradish sauce, tkemali, adjika, etc.

Vacuum homogenizing plant in mustard production

For production small volumes mustard, perfectly suited commercially produced by our plant, vacuum homogenizing unit UG-GURT. If you are going to produce more than two tons of finished products per day, we are ready to manufacture a mustard production line for you.

Appointment UG-GURT

Homogenizing unit type UG-GURT is designed for emulsification, mixing and heat treatment liquid and pasty products.

Working principle of vacuum homogenizing plant

The working capacity of the unit has a jacket for heating and cooling the product and a heat-insulating casing. Inside the vessel there is a mixing device of a special type with perforated blades, a baffle and floating scrapers that prevent the formation of sticking during heating of the product and ensure good heat exchange between the coolant (coolant) and the product being processed.

On the cover of the unit there is a stirrer drive, a hatch for loading dry components, a vacuum chamber for connecting the device to the vacuum system, a pipe for loading liquid components, and a fitting for returning the product from the circulation channel. At the bottom under the tank is located, combining the work of a homogenizer and a rotary-pulsation apparatus, a disperser with two funnels for introducing fat phases and bulk components into the product during circulation.

Products other than mustard

• Dairy - soft curd, kefir, condensed milk, processed cheese, recovery of powdered milk, cream.
• Oil and fat - combined oils, margarines, mayonnaise, pastes.
• Fruit and vegetable - jams, marmalade, ketchups, sauces, jams, purees, pastes.
• Confectionery - creams, fillings, chocolate-nut pastes, chocolate icing, honey.
• Non-alcoholic - juices, nectars, drinks.
• disinfectants. Cosmetic - creams, shampoos, balms, gels, ointments, toothpastes.
• Pharmaceutical - ointments, emulsions, gels.
• Chemical - detergents, glues, varnishes, varnishes,

Technical characteristics of mustard plants

Table mustard

Table mustard (food) is a ready-to-eat seasoning made from mustard powder - ground mustard cake.

Mustard - annual plant cruciferous family, there are Sarepta, white, black and Abyssinian. Mature seeds contain up to 47% mustard oil, which is used not only for salads, frying vegetables, baking bread, the production of sweets and canned food, but also in the soap, textile and pharmaceutical industries.

Today is being developed wide range of of this sauce - Mustard "Russian", "Russian"; "European"; "Piquant"; "English", sauce with mustard "Remoulade" (Slovak cuisine), etc.

For the preparation of table mustard (food), the following types of raw materials are used:
• mustard powder according to GSTU 1829;
• sunflower oil according to GOST 1129 or others vegetable oils,
• granulated sugar according to DSTU 2316 (GOST 21);
• edible salt according to DSTU 3583 (GOST 13830);
• food vinegar according to DSTU 2450;

Technological process of mustard production

Water is loaded into the mixer, heated to 60-70°C, prepared sugar and salt are added, after complete dissolution, the solution is brought to a boil, allowed to boil, and cooled to 60°C.

Mustard powder is sifted, loaded into a homogenizer, and hot sugar-salt solution is gradually introduced. Mixing is carried out until a homogeneous mass is obtained.

The mixed mass is kept for 12-15 hours in a warm place for “ripening”. Then add flavored vinegar, vegetable oil and mix thoroughly. After that, maturation continues for a day.

Making Flavored Vinegar

Preparation of flavored vinegar 0.1-0.2% spices are added to 80% vinegar essence and infused for a day.

The richness of the flavors of all varieties of mustard depends on the composition of the flavored vinegar, the amount of sugar, salt and vegetable oil. The composition of flavored vinegar may include allspice and bitter pepper, Bay leaf and cinnamon, cloves and nutmeg, cardamom and garlic.

Ready mustard It is a homogeneous spreading mass - yellow with a reddish-brown tint.

By physical and chemical indicators mustard must meet the requirements:
• Mass fraction of solids 32-43%.
• Titratable acidity (in terms of acetic acid) – 1,5-1,7 %
• Mass fraction total sugar – 5-16 %
• Mass fraction table salt – 1,5-3,0 %

You can buy equipment for the production of mustard, horseradish, adjika, tkemali according to pre-agreed options, dimensions and productivity. The price of equipment for the production of mustard, horseradish, adjika, tkemali is always negotiable due to the unpredictability of costs.

The invention relates to the oil and fat industry. When processing mustard seeds into crushed seeds, 25-30 wt.% water is added before pressing. The mixture is heated to 35-45 o C and incubated for 15-20 minutes. Then again dried at 80-110 o C to a moisture content of 5-6 wt.%. This makes it possible to obtain an oil with the aroma and taste of mustard, and due to the presence of essential mustard oil, to increase the shelf life from 6 to 12 months. 1 tab.

The invention relates to the food industry and can be used in the production of fragrant edible mustard oil containing substances inherent in table mustard. A well-known technological process for processing mustard seeds includes the following operations: cleaning the seeds from mechanical impurities, conditioning them in terms of moisture and size, hulling the seeds and separating the shell (husk) from the kernel, grinding the kernel, pressing, filtering the oil (Guide to the technology for obtaining and processing vegetable oils and fats, L., VNIIZh, vol. 1, book one, 1975, pp. 568-584; At present, aromatic vegetable oils, which are used in the production of sauces, mayonnaise and other condiments, are increasingly being used. The purpose of the present invention is to obtain an aromatic edible mustard oil containing substances inherent in table mustard, as well as to increase its shelf life from 6 to 12 months. This goal is achieved by adding 25-30 wt.% of water to the crushed mustard seeds before pressing, the mixture is heated to a temperature of 35-45 o C and kept at this temperature for 15-20 minutes, i.e. carry out the hydrolysis reaction natural substance sinigrin, which is part of mustard seeds, resulting in the formation of essential mustard oil, which gives the specific aroma and taste of table mustard to fatty edible mustard oil. In addition, the presence of essential mustard oil significantly slows down the oxidation processes that occur in the oil during storage, thereby increasing the shelf life of the oil from 6 to 12 months. Example. 100 kg of mustard seeds are taken, cleaned of mechanical impurities, conditioned in size, crushed, the shell (husk) is separated from the kernel, the kernels are crushed and 25-30 kg of water (25-30 wt.%) are added, the mixture is heated to a temperature of 35-45 o C and maintained at this temperature for 15-20 minutes. Then the mass is again heated to a temperature of 80-110 o C, dried to a residual moisture content of 5-6 wt.% water and pressed known ways. Mustard oil, obtained by the proposed method, has a specific aroma and taste inherent in table mustard and its shelf life is increased up to 12 months. The table shows the quality indicators of aromatic edible mustard oil obtained by known technology and the proposed method during its storage. Table data show that fragrant edible mustard oil obtained by the proposed method has lower acid and peroxide numbers than oil obtained by known technology, due to this, the shelf life of the oil increases from 6 months according to GOST 8807-94 to 12 or more. Thus, the proposed method allows to obtain fragrant edible mustard oil and increase its shelf life.

Claim

A method for processing mustard seeds, including cleaning the seeds from mechanical impurities, conditioning them in size, hulling, separating the shell (husk) from the kernel, grinding, pressing, filtering the oil, characterized in that 25-30 wt. % water, the mixture is heated to 35-45 o C and maintained at this temperature for 15-20 min, then heated again to 80-110 o C and dried to a residual moisture content of 5-6 wt.% water.