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WITH create e shop A By production cottage cheese

Introduction

1. Technological part

1.1 Characteristics of cottage cheese 5% fat GOST 31449-2013

1.2 Technological process for the production of cottage cheese with 5% fat content, produced by the acid-rennet method on a semi-automatic line of OSKON LLC

1.3 Rationale technological modes and operations in the production of cottage cheese with 5% fat content, produced by the acid-rennet method on a semi-automatic line of OSKON LLC

2. Practical part

2.1 Initial data for product calculations

2.2 Scheme of the technological direction of milk processing

2.3 Calculation of cottage cheese

2.4 Calculation and selection of process equipment

2.5 Calculation and selection of technological equipment for the production of cottage cheese on the automated line of OSKON LLC

Conclusion

List of sources used

Introduction

Cottage cheese is a fermented milk protein product that is produced from pasteurized normalized or skim milk, as well as from buttermilk by fermentation with sourdough followed by removal of part of the whey from the resulting curd by self-pressing, pressing, centrifugation and (or) ultrafiltration.

The day and place where cottage cheese was born is not known to us. However, earlier the ancient Romans knew and prepared this snow-white product. The Roman scientist and writer Marcus Terence Varro speaks about this. For the purpose of fermenting milk, a clot was used, extracted from the stomach of a calf, kid or lamb feeding on the milk of the mother. And another Roman writer and philosopher Lucius Columella said that cottage cheese in the 1st century AD was preferred by both rich and poor, consumed it both in its ordinary form and together with honey, milk and even wine. There is an old belief that the favorite dish of God Krishna was cottage cheese. Krishna called cottage cheese a gift of nature, which adds physical and intellectual strength to people, and is also considered a healing product. In India, it was believed that if you break a pot of cottage cheese, then luck and happiness will favor you for a whole year. Therefore in holidays In the squares they placed pillars, at the top of which pots of cottage cheese were attached. Those who wanted to gain prosperity and good luck tried to knock down the pots with canes and stones. Those who did knock down the pot were given sweet cakes made from cottage cheese as a gift, in addition to a year's supply of happiness from Krishna. In Ancient Rus', cottage cheese was known and adored, they ate it every day, but they called it cheese, and food products made from it were called cheese. The manufacturing process was very easy. In a slightly cooled oven, they placed yogurt in a pot, which served as the basis for cottage cheese. After a few hours, the pot was taken out, and its contents were poured into a linen bag that was shaped like a cone. The whey was decanted, and what remained was placed under a press. This is how cottage cheese was made. Of course, made using this method, it had a very short shelf life, as it spoiled instantly. Then the clever Russian people came up with an unusual method of preserving cottage cheese. Immediately after the press, the product, which had already reached the level of readiness, was again placed in the pot and placed in the oven and again under the press. This procedure was carried out 2 times. Already after this kind of treatment, the curd became completely dry, then it was laid out very tightly in a clay dish, melted butter was poured on top and lowered into the cellar. This kind of product could be stored for several months, which was very important during periods of high milk production. The drier the curd was, the more expensive it was. Delicious cottage cheese Yaroslavl and Ryazan provinces were famous in Rus'. Until these times, cottage cheese was loved in Russia; now it is produced in industrial scale. Cottage cheese can now be purchased at any fat content.

Cottage cheese provides considerable benefits to the entire body, and there are almost no contraindications to its consumption. The main necessary substance in cottage cheese is casein, which is a protein that is easily digestible by the human body. The amino acid composition of casein is considered impeccable for the purpose human body, it is considered simply necessary after active sports, as it effectively restores muscle mass. Cottage cheese can be useful in consumption for liver diseases, disorders of the cardiovascular system, diabetes and obesity. In addition, the use of cottage cheese promotes faster restoration of bone tissue after fractures. By the way, in case of fractures, for the fastest rehabilitation, it is more correct to eat cottage cheese. The minerals contained in cottage cheese contribute to the formation and strengthening of bone tissue. The amino acids contained in cottage cheese help prevent liver diseases. B vitamins protect against atherosclerosis. Low-fat cottage cheese is included in many diets for weight loss and “fasting days.”

1. Technological part

1.1 Characteristics of cottage cheese 5% fat GOST 31449-2013

Table 1 - Organoleptic indicators cottage cheese 5% fat content

Table 2 - Physico-chemical parameters of cottage cheese with 5% fat content

Table 3 - Microbiological indicators of cottage cheese

1.2 Technological process for the production of cottage cheese with 5% fat content, produced by the acid-rennet method on a semi-automatic line of OSKON LLC

Reception of milk according to GOST 31449-2013.

Cleaning (cold) milk.

Cooling milk to 4-6 oC.

Temporary reserve of milk at 4 °C for no more than 12 hours.

Heating milk to (43±2) oC.

Normalization of milk in the stream (43±2) оС according to mass fraction fat taking into account the mass fraction of protein.

Pasteurization of the mixture (78±2) °C, 10-20 s.

Cooling the mixture to the fermentation temperature (30±2) oC in the cold season

and (28±2) оС in the warm season.

Fermentation of the mixture by adding 5% starter to pure cultures mesophilic streptococci with the addition of aromatic streptococci (Lactococcus lactis, Lactococcus cremoris, biovar diacetylactis).

Adding calcium chloride to the mixture at the rate of 400 g of anhydrous calcium chloride per 1000 kg of milk in the form of a 30-40% aqueous solution.

Adding rennet powder in the form of a 1% aqueous solution at the rate of 1 g of powder per 1 ton of mixture.

Stir the mixture for 10-15 minutes.

Fermentation of the mixture for 7-9 hours at (30±2) oC until acidity (61±5) oT.

Cutting the curd into cubes with a rib size of 2x2x2 cm.

(Heating the curd to a temperature of (40±2) oC with holding time for 30-40 minutes.)

Cooling the curd to 8 oC.

Separation of whey from curd curd using a single-drum separator.

Dehydration of curd using a conveyor-type dehydrator

Packing cottage cheese in consumer containers - parchment with a capacity of 250 g.

Additional cooling of packaged and packaged cottage cheese in the refrigeration chamber to a temperature of (4±2) oC.

Storage at the manufacturer (4±2) °C, no more than 18 hours.

Shelf life at (4±2) °C is more than 72 hours from the end of the technological process.

1.3 Justification of technological modes and operations in the production of cottage cheese with 5% fat content, produced by the acid-rennet method on a semi-automatic line of OSKON LLC

Milk is accepted on the basis of GOST 31449-2013 "Raw cow's milk". Milk is obtained from healthy animals in farms that are free from infectious diseases in accordance with veterinary legislation.

Table 4 - Organoleptic characteristics of cow's raw milk

Table 5 - Physico-chemical parameters of cow's raw milk

Table 6 - Microbiological parameters of cow's raw milk

Cold purification of raw milk. Filtering milk is a mandatory operation. Milk purified from mechanical impurities is more High Quality with extended shelf life.

Cooling raw milk. After cleaning, milk must be cooled immediately, otherwise its quality will deteriorate sharply. The purpose of cooling milk is to create conditions that significantly slow down the development of microorganisms in it. Storing unrefrigerated milk quickly leads to a loss of bactericidal properties and an increase in the amount of microflora. The bactericidal phase is the time during which microorganisms entering milk do not develop in it and even partially die. During the bactericidal phase, milk has bactericidal properties. The bactericidal properties of milk are due to the presence of antibacterial substances in it (lysozymes, leukocytes, normal antibodies, some enzymes, etc.).

Temporary storage of milk. During transportation and storage, raw milk is subject to secondary microbial contamination, as well as mechanical, temperature and light influences, which can lead to a deterioration in its quality and the occurrence of defects. During prolonged storage of cold raw milk, the integrity of the structure of the shells of fat globules is disrupted, and casein micelles disintegrate into submicelles, lipolysis and proteolysis begin and taste defects arise: “rancid” and “bitter”, respectively.

Heating milk. Heating milk before separation (normalization) reduces its viscosity and improves the result of the process. At higher milk temperatures, the degree of fragmentation of fat globules increases and coagulation of whey proteins can occur.

Normalization of milk. Normalization is a targeted change in the composition of milk in order to obtain a finished product that meets the requirements of the standard for the mass fraction of milk components (fat and protein) provided in the stream. The separation (normalization) process obeys Stokes' law:

Where V- rate of release of fat globules, cm/s;

R- average radius of the working part of the separator plate, cm;

n- rotation speed of the separator drum, s-1;

r- fat globule radius, cm;

s, s1- density of plasma and fat, kg/m3;

µ - viscosity, Pa s.

Pasteurization of the normalized mixture. Pasteurization is the process of heat treatment of milk at a temperature from 63 ° C to a point below the boiling point of milk. The main goal of pasteurization is the complete destruction of pathogenic and toxin-forming microflora; maximum reduction in the total number of microorganisms and inactivation of enzymes. Theoretical basis milk pasteurization were developed by the Soviet scientist G.A. Cook. Numerous studies have established the dependence of the pasteurization temperature t and exposure time Z in the form of an equation:

Where 36.84 and 0.48- constant values.

Mode of pasteurization of milk during the production of cottage cheese. Milk is pasteurized at a temperature of 76-80 oC with a holding time of 15-20 s. This mode is considered sufficient to destroy microflora in the normalized mixture and obtain a clot convenient for further processing. Increasing the pasteurization temperature leads to the formation of clots with low synergistic ability; When processing the clot, a large amount of dust with whey is released.

When making cottage cheese, it is necessary to remove excess whey from the curd. Therefore, milk processing modes are chosen that would contribute to obtaining a dense, but easily whey-releasing curd.

Cooling the normalized mixture to fermentation temperature.

The temperature of fermentation and ripening contributes to the production of cottage cheese of standard acidity and moisture. The fermentation temperature must be optimal for the development of sourdough microflora. At higher temperatures, the size of the protein particles of the curd and the degree of moisture release increase, which can result in an overly dried product with a crumbly consistency.

Fermentation of the normalized mixture. The taste and consistency of the product depends on the composition of the starter. The inclusion of an energetic acid-forming agent in the sourdough composition results in the production of a dense, prickly curd with intensive whey separation. The starter is added in an amount of 1-5%.

Stirring the fermented mixture. The mixture is stirred to distribute the starter evenly throughout the mass.

After this, a 40% solution of calcium chloride is added to it at the rate of 400 g of anhydrous salt per 1 ton of milk to restore the salt balance and clotting ability of the milk. As a result, the coagulation of milk is improved, the curd structure is improved, the loss of fat and protein into whey is reduced during processing, and the separation of whey is accelerated. Rennet or pepsin is added in the form of a 1% solution at the rate of 1 g per 1 ton of milk. Rennet is added simultaneously with the starter. Increasing the acidity of milk increases the activity of the added rennet, which improves the quality of the curd. With the acid-rennet method of cottage cheese production, protein coagulation occurs as a result of the formed lactic acid and the added rennet.

Fermentation of the normalized mixture. The main physicochemical processes that occur during the production of cottage cheese are the fermentation of milk sugar and the coagulation of casein, which depends on it, with the formation of a curd. As a result of these processes, a certain consistency, taste and smell of fermented milk products are formed.

The essence of lactic acid fermentation comes down to the following:

c - galactosidase

lactose glucose galactose

As a result of enzymatic transformations, two molecules of pyruvic acid are formed from glucose and galactose.

glucose pyruvic acid

Pyruvic acid is reduced to lactic acid by the action of an enzyme.

lactate dehydrogenase

pyruvic acid lactic acid

Thus, from one molecule of milk sugar four molecules of lactic acid are formed. The overall equation for lactic acid fermentation can be presented as follows:

c - galactosidase

lactose lactic acid

When producing cottage cheese using the acid-rennet method, lactic acid and added rennet extract. Under the action of rennet, casein is converted into paracasein, which has an isoelectric point in a less acidic environment, pH 5-5.2. At the isoelectric point, casein and paracasein particles aggregate upon collision, forming chains or threads, and then a spatial network, in the cells or loops of which the dispersion medium with fat globules and other components of milk is captured. Gelation occurs. The end of ripening is determined by the type and acidity of the curd. During the fermentation of milk, the fermented milk taste and smell of cottage cheese are formed. In cottage cheese, along with lactic acid, diacetyl and acetaldehyde, volatile acids (acetic, propionic, etc.), as well as free amino acids, actively accumulate. The readiness of the curd is determined by acidity by taking a sample from the curd maker. The finished clot gives a smooth break with shiny edges, releasing a transparent light green serum. If the curd is not yet ready, the fracture will have a flabby appearance with the release of cloudy whey. Incorrect determination of the readiness of the clot entails a deterioration in the quality of the clot and a decrease in its yield. The readiness of the curd is most accurately determined by its acidity.

Stirring the curd curd. To speed up the release of whey, the clot must be stirred. As a result of mixing, a clot with a homogeneous, evenly distributed dispersed phase is formed. The curd curd is thoroughly mixed for 5-10 minutes; longer stirring increases the loss of dry matter from the whey.

Table 7 - Scheme of technochemical control of cottage cheese production on the Oskon automated line

	Controlled index	Frequency of control	Sample selection	Control methods, measuring instruments
Reception of milk	Organoleptic indicators	Daily	In every batch	According to GOST 31449-2013
	Temperature, °C			According to GOST 26754-85
	Acidity, єТ			According to GOST 3624-92
	Mass fraction of fat, %			According to GOST 5867-90
	Density, kg/m			According to GOST 3625-84
	Mass fraction of protein, %	Daily	In every batch	Formol titration according to GOST 25179-90
	Purity group according to standard			According to GOST 8218-89
	Weight, kg			Scales with NPV 500 kg
	Naturalness	If you suspect falsification		Carrying out a stall test. Determination of freezing point
Cooling and intermediate storage	Shelf life, h
	Acidity, єТ			According to GOST 3624-92
	Temperature, °C			According to GOST 26754-85
	Net weight, kg			Scales with NPV 500 kg
Heating milk	Temperature, °C			GOST 6651-75
Normalized mixture	Organoleptic indicators			Organoleptically
	Mass fraction of fat, %	Daily		According to GOST 5867-90
	Density, kg/m3			According to GOST 3625-84
	Weight, kg	Periodically 1 time per month	In every batch
Pasteurization of the mixture	Temperature, °C	Daily		Chart tape, thermometer
	Holding time, s			Determined by the design of the holder
Cooling the mixture	Temperature, °C	Daily		Thermal converter
Leaven	Organoleptic indicators		In every container	Visually
	Acidity, єТ			According to GOST 3624-92
	Sourdough purity based on bacterial composition	Periodically		Microscopy of a stained preparation
Fermentation of the mixture	Temperature, °C	Daily	In every batch	Thermal converter
	Sourdough mass, kg	Daily
Fermentation of the mixture	Curd acidity, pH, temperature			Titrometric, pH meter
	Serum acidity, oT	Daily	In every batch	According to GOST 3624-92
	Duration, h
Fermentation of the mixture	Clot quality			Visually
Separating curds from whey	Time, min	Daily	In every batch
	Mass fraction of moisture in cottage cheese, %			According to GOST 3626-73
Serum during separation	Mass fraction of fat, %	Daily	In every batch	According to GOST 3625-84
Cooling the curd	Temperature, оС			According to GOST 26754-85
Packing cottage cheese				Laboratory scales
	Marking quality			Visually
Storing cottage cheese	Temperature, оС			Thermometer
	Relative humidity, %			Psychrometer
Finished product	Organoleptic indicators	Daily	In every batch	According to OST 49 25-85
	Mass fraction of fat, %			According to GOST 5867-90
	Moisture content, %			According to GOST 3626-73
	Acidity, oT			According to GOST 3624-92
	Temperature, оС			Thermometer according to GOST 26754-85
	Phosphatase			According to GOST 3623-73

Table 8 Scheme of microbiological control of cottage cheese production

Objects under study	Analysis name	Where is the sample taken from?	Periodicity control	Breedings
Raw milk	Reductase test	Average milk sample from each supplier	1 time per decade
	Inhibiting substances
Milk for starter culture after pasteurization		From VDP, starters, tubs	once every 10 days
	Pasteurization efficiency test	From VDP, starters, tubs	In cases of detection of heat-resistant lactic acid rods in starter cultures
Sourdough using pure cultures on a sterilized pier.	Clotting time, acidity	Selectively from one batch can	Daily if the duration of ripening increases
	Microscopic preparation
Milk pasteurized from the bath	Coli bacteria		At least 2 times a month
	Presence of heat-resistant lactic acid sticks	Selectively from the bath	In cases where the defect “excessive acidity” appears
Fermented milk and curd	Coli bacteria		At least 2 times a month
Cottage cheese after pressing and cooling	Coli bacteria	From the controlled party	At least once every 3 days
	Microscopic preparation
Packaging materials	Total bacteria count	From every batch	2-4 times a year
	Coli bacteria
Rennet powder	Total bacteria count		each batch
	Coli bacteria

2. Practical part

2.1 Initial data for product calculations

Table 9 - Enterprise operating mode

Table 10 - Distribution of raw materials by assortment

Table 11 -

Initial data for product calculation.

2. 2 Cottage cheese calculation

Annual capacity of the enterprise - (Myear), T.

Where MSM - shiftable capacity of the enterprise, t;

n- Estimated number of work shifts.

Mass fraction of protein in milk - (Bm), %.

Where A, B- Normalization coefficients

Zhm - mass fraction of milk fat, %.

Mass fraction of fat in the normalized mixture - (Wcm),%.

Where Kn- normalization coefficient.

Mass fraction of fat in cream before fermentation for sour cream - (Zhz.sl),%.

where Zhsm is the mass fraction of fat in sour cream, %;

Zhz- mass fraction of fat in the starter, %;

Az- volume fraction of introduced starter, %.

The mass of cream remaining during normalization in the flow is (MSL), kg.

Where Psl- loss of cream,%;

MSl"- mass of cream excluding losses, kg.

Loss of cream - Psl, kg

Psl, = Msl, - Msl,

Psl, = 5053.69 - 5037.01 = 16.68 kg.

Mass of normalized mixture - ( Mn.cm), kg.

Where Mon.cm- loss of normalized mixture, %;

Mn.cm- mass of the normalized mixture excluding losses, kg

Loss of normalized mixture - ( Mon.cm) kg.

Weight of starter with skim milk - ( Mz), kg.

Weight of fermented mixture -

(Mz.cm), kg.

Mass fraction of fat in the fermented mixture - ( Zhz.cm), %.

Weight of cottage cheese taking into account losses during packaging - ( Mtv.f), kg

Where HP- consumption rate of cottage cheese during packaging, kg/kg.

Cottage cheese loss - ( PTV), kg.

Serum mass - ( Msy c), kg.

Where Nv.syv- rate of whey yield from the mass of the normalized mixture, %.

Serum loss - ( Psyv), kg.

Quantity of plastic cups - ( CBD), PC.

Where Mbr- volume of plastic cups

Rennet mass - ( Ms.f), G.

Mass of water for preparing a 1% solution - ( Mv), G

Weight of 1% aqueous solution of rennet - ( Mr.s.f), G.

Mass of calcium chloride - ( Mx.k), kg.

Mass of water for preparing a 40% solution - ( M"v), kg.

Weight of 40% aqueous solution of calcium chloride - ( Mr.h.k), kg.

Table 21 - Summary table of product calculations

Milk movement	Name of raw materials, finished product	Weight of raw materials, kg
	Sourdough starters
Finished product
	serum
Finished product
	serum
Semi-finished products	Normalized mixture

2.4 Calculation and selection of process equipment

Selection of equipment for receiving and storing raw milk

Reception of milk into a workshop with a capacity of 30 t/cm is provided for 2 times, 3 hours per shift.

Delivery of raw materials to the workshop is provided 100% in tank trucks - ( Mm). milk acid rennet semi-automatic

Hourly supply of milk in milk tanks - ( Mch), t/h.

Where Mm- mass of milk entering the workshop per shift, t

Tnorm- standard duration of milk acceptance, hours.

Based on the hourly milk supply, we select one receiving line with a capacity of 10 t/h.

The actual operating time of the milk receiving line is (TD), h.

Where P r.l - productivity of the selected receiving line, t/h.

To store raw milk, we select containers designed to receive 80% of the mass of milk per day - ( Mm.hr), t.

Where Mm.day- mass of milk taken per day, i.e.

Number of containers for storing raw milk - ( Ke), brand B2-ОХР-50 with a volume of 50 m3 .

Where Ve- capacity of the container, i.e.

2.5 Calculation and selection of technological equipment for the production of cottage cheese on the automated line of OSKON LLC

Hourly productivity of equipment for thermal and mechanical processing of milk - ( Mch), t/h.

Where Mm.pr. - mass of milk sent for the production of dairy products, t;

Tef - effective operating time of the unit per shift, h.

Teff = Tcm - Tpz, = 12-2.5 = 9.5 h

Tsm - shift duration, hours;

Tpz - preparatory and final operating time of equipment, h,

Based on the calculated ( Mch) we select equipment for thermal and mechanical processing of milk with an appropriate productivity, rounding up, with a productivity of 5,000 t/h

Duration of equipment operation - ( That), h.

Where About- equipment productivity, kg/h.

Duration of filling the tank - ( MMR).

Where MMR- mass of milk, mixture or product for temporary reservation, kg.

Number of tanks - ( Kr), PC.

Table 21 - Summary table for equipment selection

Name equipment	Equipment brand	Productivity, kg/h; capacity, kg	Weight of raw materials, semi-finished products, finished products, kg.	Duration of equipment operation, filling, h	Preparatory and final time, h	Quantity, pcs
Self-priming pump
Station for receiving and recording milk
Centrifugal pump
Milk separator for cold milk purification
Automated plate cooling unit
Raw milk storage tank
Centrifugal pump
Automated plate pasteurization and cooling unit
Cream separator with normalization device
Container for raw cream
Container for normalized mixture for cottage cheese
	P8-ONTS1-12.5/20
Plate heater
Cottage cheese maker
Rotary pump
Cooler for curd curd
Single drum whey separator	OTS-T-1B-5.0
Conveyor type dehydrator	OTS-T-K-5.0
Container for storing cottage cheese before packaging
Single screw pump for cottage cheese
Cottage cheese filling machine	"ALUR-1500 TM"
Serum pump
Serum reservoir

Conclusion

The quantity of domestic products: half-fat cottage cheese and sour cream in the retail chain is not enough, significantly lags behind the requests of the Ministry of Health of the Russian Federation and is replenished with imported dairy products. However, the shelf life of sour cream and dietary cottage cheese does not exceed 72 hours, and imported products with long term storage is available with preservatives. In recent years, the number of dairies and workshops producing whole milk and fermented milk products has significantly decreased.

It is possible to fill the shortage of such products only by creating workshops and departments for their production at existing and newly built factories.

The proposed project will solve the problem of supplying cottage cheese and sour cream to the population of the city and region of up to 50 thousand people. The assortment may vary depending on the needs and required age characteristics of the population. The selected equipment will ensure an increase in the volume of production of the required dairy products per capita.

List of sources used

1 Federal Law of the Russian Federation. Technical regulations for milk and dairy products. - 2010

2 GOST 31453-2013. Cottage cheese. Technical conditions.

3 GOST 31452-2012. Sour cream. Technical conditions.

4 TU 9229-110-04610209-2002. Pasteurized whey.

5 TU 9222-363-00419785-04. Soft dietary cottage cheese.

6 Order No. 1025 of December 31, 1987 “On approval of standards for consumption and losses of raw materials in the production of whole milk products at dairy industry enterprises”

7 Order No. 415 Consumption standards for skim milk in the production of soft dietary cottage cheese

8 SanPiN 2.3.4-551-96. Sanitary rules and regulations "Production of milk and dairy products"

9 SanPiN 2.3.2-560-96. "Hygienic requirements for the quality and safety of food raw materials and food products."

10 Golubeva L.V. Design of dairy industry enterprises with the basics of industrial construction. - St. Petersburg: GIORD, 2006.

11 Gorbatova K.K. Biochemistry of milk and dairy products. - St. Petersburg: GIORD, 2003

12 Zalashko M.V. Biotechnology of whey processing. - M.: Agropromizdat, 1990.

13 Kalinina L.V., Ganina V.I., Dunchenko N.I. Technology of whole milk products: Textbook. - SPb.: GIORD, 2008.

14 Kasyanov G.I., et al. Technology of products for baby food.

Rostov, "March", 2001

15 Krus G.N.,. Khramtsov A.G., Volokitina Z.V., Karpychev S.V. Technology of milk and other dairy products. Moscow "Kolos". 2004.

16 Kuznetsov V.V., Lipatov N.N. Technologist's Directory dairy production. Technology and recipes. T.6. Technology of children's dairy products. - SPb.: GIORD, 2004.

17 Kuznetsov V.V., Shiler G.G. Technological equipment of dairy industry enterprises: Directory, part 1. - M.: DeLi print, 2008.

18 Rostrosa N.K. Course and diploma design of dairy industry enterprises.-M.: Agropromizdat, 1989.

19 Stepanova L.I. Directory of dairy production technologist. Technology and recipes. Whole milk products. Volume 1. St. Petersburg, - St. Petersburg: GIORD, 2000.

20 Stepanenko P.P. Microbiology of milk and dairy products

Voskresensk ed. "Lyra" 2005

21 Tkal T.K. Technochemical control at dairy industry enterprises. - M.: Agropromizdat, 1990.

22 Shalygina A.M., Kalinina L.V. General technology milk and dairy products. -M.: "KoloS", 2004

23 Khramtsov A.G., Vasilisin S.V. Directory of dairy production technologist. Technology and recipes. T.5. Products made from skim milk, buttermilk and whey. - St. Petersburg: GIORD, 2004.

24 Khramtsov A.G. Examination of secondary dairy raw materials and products obtained from them: Guidelines. SPb.: GIORD, 2002.

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Current page: 5 (book has 19 pages total) [available reading passage: 13 pages]

2.4. Defects of liquid fermented milk products

The defects of fermented milk drinks and measures to prevent them are presented in table. 2.8.

Table 2.8

Vices and measures to prevent them

2.5. Cottage cheese and products made from it

Cottage cheese is a fermented milk product produced using starter microorganisms - lactococci or a mixture of lactococci and thermophilic lactic acid streptococci and the method of acid or acid-rennet coagulation of proteins with subsequent removal of whey by self-pressing, pressing, centrifugation and(or) ultrafiltration.

High nutritional and biological value cottage cheese is responsible for its significant content of not only fat, but also proteins that are especially complete in amino acid composition, which makes it possible to use cottage cheese for the prevention and treatment of certain diseases of the liver, kidneys, and atherosclerosis. Cottage cheese contains a significant amount of Ca, P, Fe, Mg and other minerals necessary for the normal functioning of the heart, central nervous system, brain, for bone formation and metabolism in the body. Particularly important are the salts Ca and P, which are in the cottage cheese in the most convenient state for absorption.

In addition to direct consumption, cottage cheese is used to prepare various dishes, culinary products and a large assortment of curd products. A list of the main types of cottage cheese indicating the mass fraction of dry substances is presented in table. 2.9.

Table 2.9

Cottage cheese product range

In terms of organoleptic, physicochemical and microbiological indicators, cottage cheese and curd products must meet certain requirements (Table 2.10–2.12).

Table 2.10

Physico-chemical indicators of cottage cheese

Table 2.11

Organoleptic characteristics of cottage cheese

Table 2.12

Microbiological indicators of cottage cheese

Depending on the mass fraction of fat, cottage cheese is divided into:

– low-fat (no more than 1.8% F);

– low-fat (not less than 2.0; 3.0; 3.8% F);

– classic (not less than 4.0; 5.0; 7.0; 9.0; 12.0; 15.0; 18.0% F);

– fatty (not less than 19.0; 20.0; 23.0% F).

Based on the method of clot formation, there are two methods for producing cottage cheese: acid rennet And acid.

Acid method. It is based only on the acid coagulation of proteins by fermenting milk with lactic acid bacteria and then heating the curd to remove excess whey. In this way, low-fat and low-fat cottage cheese is produced, since when the curd is heated, significant loss of fat occurs into the whey. In addition, this method ensures the production low-fat cottage cheese more delicate consistency. The spatial structure of clots of acid coagulation of proteins is less strong, formed by weak bonds between small casein particles and releases whey worse. Therefore, to intensify the separation of whey, heating of the curd is required.

At rennet-acid method In milk coagulation, the curd is formed by the combined action of rennet and lactic acid. When casein transforms into paracasein, it shifts its isoelectric point from pH 4.6 to 5.2. Therefore, the formation of a clot under the action of rennet occurs faster at a lower acidity than when proteins are precipitated with lactic acid; the resulting clot has less acidity, and the technological process is accelerated by 2–4 hours. During rennet-acid coagulation, calcium bridges formed between large particles provide high strength to the clot. Such clots separate whey better than acidic ones, since the spatial structure of the protein is compacted faster in them. Therefore, heating the curd to intensify the separation of whey is not required at all or the heating temperature is reduced.

Full-fat and semi-fat cottage cheese is produced using the rennet-acid method, which reduces the loss of fat into whey. During acid coagulation, calcium salts are released into the whey, and during rennet-acid coagulation, they are retained in the curd. This must be taken into account when producing cottage cheese for children who need Ca for bone formation.

In the production of cottage cheese, the raw materials used are milk prepared at least 2nd grade, premium spray-dried milk, skim milk with an acidity of no more than 21 °T, cream with a fat content of 50–55% and an acidity of no more than 12 °T, cream plastic, meeting the requirements of regulatory documentation.

There are two methods for producing cottage cheese (Fig. 2.3):

– traditional– from normalized milk;

– separated– from skim milk with subsequent enrichment of skim cottage cheese with cream.

Rice. 2.3. Methods for producing cottage cheese

2.5.1. Cottage cheese production traditional way

Depending on the equipment used, there are several options for producing cottage cheese using the traditional method (from normalized milk).

Normal way(V bags) (Fig. 2.4)

Rice. 2.4. Technological scheme for producing cottage cheese in the usual way (in bags)

When producing cottage cheese in the usual way, milk is fermented in special baths VK-1 or VK-2.5.

Prepared milk is normalized in order to establish correct ratio between the mass fractions of fat and protein in a normalized mixture, ensuring the production of a product with a standard mass fraction of fat and moisture. Normalization is carried out taking into account the actual mass fraction of protein in the processed raw materials and the normalization coefficient, which is established in relation to the type of cottage cheese, specific production conditions, and methods of cottage cheese production. In order to correctly establish the normalization coefficient, control production of cottage cheese is carried out quarterly. Normalized milk is sent for pasteurization at 78–80 °C with a holding time of 10–20 s. Milk pasteurized and cooled to a temperature of 4 ± 2 °C before processing into cottage cheese can be stored for no more than 6 hours. For optimal conditions for the development of lactic acid microflora, milk is fermented with pure cultures of mesophilic lactic acid streptococci at a milk temperature of 30 ± 2 °C in cold times year and 28±2 °C – in warm weather. At in an accelerated manner ripening uses a symbiotic starter prepared from pure cultures of mesophilic and thermophilic streptococci at a milk ripening temperature of 32 ± 2 °C.

With the rennet-acid method of producing cottage cheese, in addition to the starter culture, calcium chloride and milk-clotting enzymes are added to the milk. CaCl is added at the rate of 400 g of anhydrous CaCl per 1000 kg of milk in the form of a solution with a mass fraction of CaCl of 30–40%. After this, rennet powder or pepsin or the enzyme preparation VNIIMS is introduced into the milk in the form of a solution with a mass fraction of the enzyme of no more than 1%. The dose of an enzyme with an activity of 100,000 IU per 1000 kg of fermented milk is equal to 1 g. Rennet powder or the VNIIMS enzyme preparation is dissolved in drinking water, preheated to 36 ± 3 °C, and pepsin in fresh filtered whey at 36 ± 3 °C. After fermentation, the milk is stirred for 10–15 minutes and left alone until a curd forms. With the acid-curd method, milk is fermented until a curd with an acidity of 60–65 (±5) °T is obtained, depending on the type of cottage cheese. The higher the fat content of the cottage cheese, the lower the acidity of the curd. The duration of milk fermentation is 6–10 hours. With the acid method, milk is fermented until a curd with an acidity of 75–80 (±5) °T is obtained. The duration of milk ripening is 8–12 hours. It is important to correctly determine the end of ripening, since if the curd is not fermented, it turns out sour cottage cheese spreadable consistency. The curd is cut with wire knives into cubes measuring 2 x 2 x 2 cm. First, the curd is cut along the length of the bath into horizontal layers, then along the width into vertical layers. The clot is left alone for 30–60 minutes to release the serum. To intensify the release of whey, the curd is heated using the acid method to a whey temperature of 40–44 (± 2) °C, depending on the type of curd. The higher the fat content of the cottage cheese, the higher the heating temperature. With the rennet-acid method, the curd heating temperatures are reduced and amount to 36–40 (± 2) °C. The curd is kept at these temperatures for 15–40 minutes.

The released whey is released from the bath through a fitting and collected in a separate container. The curd is poured into calico or lavsan bags measuring 40 x 80 cm, 7–9 kg each, the bags are filled to three-quarters of the volume. They are tied and placed in several rows on a press cart. Under the influence of its own mass, whey is released from the clot. Self-pressing occurs in the workshop at a temperature of no more than 16 °C and lasts for at least 1 hour. The end of self-pressing is determined visually, by the surface of the curd, which loses its shine and becomes dull. Then the cottage cheese is pressed under pressure until ready. During the pressing process, the bags of cottage cheese are shaken and rearranged several times. To avoid an increase in acidity, pressing must be carried out in rooms with an air temperature of 3–6 °C, and upon completion, the curd must be immediately cooled to 12 ± 3 °C using coolers of various designs or in bags or trolleys in the refrigerator compartment. The finished product is packaged in small (consumer) and large (transport) containers. Cottage cheese is stored until sale for no more than 36 hours at a temperature of no more than 4 °C and humidity 80–85%, including at the manufacturing plant for no more than 18 hours.

At cottage cheese makers with a pressing bath

Curd makers with a pressing bath (TI-4000) are used to produce all types of cottage cheese, while the labor-intensive process of pressing cottage cheese in bags is eliminated.

The curd maker consists of two double-walled baths with a capacity of 2000 liters with a tap for draining the whey and a hatch for unloading the curd. Pressing baths with perforated walls are fixed above the baths, onto which filter fabric is pulled. Using a hydraulic drive, the pressing bath can be raised up or lowered almost to the bottom of the ripening bath.

Accordingly prepared milk enters the baths. Here, sourdough, solutions of calcium chloride and rennet are added to it, and in the same way as with the usual way cottage cheese production, leave for ripening. The finished curd is cut with the knives included in the curd maker’s kit and kept for 30–40 minutes. During this time, a significant amount of whey is released, which is removed from the bath with a separator (a perforated cylinder covered with filter fabric). In its lower part there is a pipe that slides into the bathtub pipe. The separated whey enters the sampler through a filter fabric and a perforated surface and exits the bath through a pipe. This preliminary removal of whey increases the efficiency of pressing the curd.

For pressing, the perforated bath is quickly lowered down until it comes into contact with the surface of the curd. The speed of immersion of the pressing bath into the curd is set depending on its quality and the type of curd being produced. The separated whey passes through the filter fabric into the perforated surface and is collected inside the pressing bath, from where it is pumped out every 15–20 minutes.

The downward movement of the pressing bath is stopped by the lower limit switch when a space filled with pressed curd remains between the surfaces of the baths. This distance is established during experimental production of cottage cheese. Depending on the type of cottage cheese produced, the pressing time is 3–4 hours for full-fat cottage cheese, 2–3 hours for low-fat cottage cheese, 1–1.5 hours for low-fat cottage cheese. With the accelerated ripening method, the duration of pressing full-fat and semi-fat cottage cheese is reduced by 1–1.5 hours.

At the end of pressing, the perforated bath is raised, and the curd is unloaded through the hatch into the carts. The cart with cottage cheese is lifted upward and tipped over the cooler hopper, from where the cooled cottage cheese is supplied for packaging.

On mechanized lines using mesh baths (Fig. 2.5)

Rice. 2.5. Cottage cheese production on mechanized lines using mesh baths

In this technology there is no such operation as pressing cottage cheese. Therefore, to create conditions for more efficient whey separation, temperature and other parameters in this case differ from traditional ones. Prepared milk is fermented with starter at a temperature of 28–32 °C in the cold season and 26–30 °C in the warm season; with the accelerated ripening method, a symbiotic starter of mesophilic and thermophilic streptococci is used and fermented at 30–34 °C. The amount of starter is 3–5% of the amount of fermented milk.

The end of milk fermentation is considered to be the formation of a moderately dense clot with an acidity of 70–95 °T, depending on the type of cottage cheese. The fattier the cottage cheese, the less acidic the curd. The duration of fermentation is 5–12 hours. To speed up the separation of whey, the finished curd is slowly heated by introducing steam or hot water into the interwall space of the bath. Optimal temperature heating the clot (based on whey) 45–50 (±10) °C. The heated curd is kept for 20–30 minutes and stirred 3–5 times during the holding period. The total heating duration, including holding time, should not exceed 2 hours. The heated curd is cooled by at least 10 °C by feeding cold or ice water.

The separation of whey from the curd on lines with mesh baths complete with VK-2.5 baths is carried out by removing the whey (no more than two-thirds of the total mass) through the drain valve of the bath. To separate the remaining whey, the mesh bath is raised above the bath using a telepher device. In this case, the whey flows into the bath, and the curd undergoes self-pressing. The duration of separation of whey from the clot is 10–40 minutes. The separation of whey from the curd on lines with a set of Ya2-OVV equipment is carried out as follows: part of the released whey (no more than 2/3 of the total mass) is removed through the whey drain valve. The remaining whey, together with the curd, is carefully poured down the tray into a mesh bath located in a self-propelled cart. To separate the whey from the curd, the mesh bath is lifted above the trolley using a traverse. In this case, the whey flows into the bath, and the curd undergoes self-pressing (10–40 minutes). Subsequent cooling of the curd is carried out by immersing a mesh bath with curd in the cooled whey and keeping it in it for 20–30 minutes. The cottage cheese is cooled to 13 ± 5 °C. Fresh, pasteurized curd whey, cooled to a temperature of no more than 5 °C, is used as a cooling medium. The duration of serum storage at a temperature of no more than 8 °C is 1 day. After cooling 2 grid baths with cottage cheese, the cooling medium is replaced with fresh one. To separate the whey, the mesh bath is raised above the bath using a telepher device. In this case, the whey flows into the bath, and the curd undergoes self-pressing. The duration of separation of the cooling medium from the curd is 20–30 minutes. Using a tipping device, the curd is unloaded into a storage bath and fed by a screw for packaging.

On mechanized lines Ya9-OPT-2.5 and Ya9-OPT-5

The mechanized line Ya9-OPT-5 with a milk production capacity of 5000 l/h is the most advanced and is used for the production classic cottage cheese. The finished curd is mixed for 2–5 minutes and fed into a direct-flow jacketed heater using a screw pump. Here the curd is quickly (2–5 minutes) heated to a temperature of 42–5 4 °C (depending on the type of cottage cheese) by supplying hot water (70–90 °C) into the shirt. The heated curd is cooled in a cooler with water to 25–40 °C and sent to a two-cylinder dehydrator covered with filter fabric. The moisture content in the finished curd is regulated by changing the angle of inclination of the dehydrator drum or by changing the temperature of heating and cooling of the curd.

The finished cottage cheese is sent for packaging and then to refrigerator for additional cooling.

2.5.2. Separate method of cottage cheese production

The separate method has a number of advantages. Fat loss in production is significantly reduced; fat savings per 1 ton of full-fat cottage cheese is 13.2, half-fat – 14.2 kg. The separation of whey from the curd is facilitated, a greater possibility of mechanization of technological operations is created, as a result of which labor productivity increases. The quality of cottage cheese increases as a result of a decrease in acidity. This is facilitated by adding to low-fat cottage cheese fresh pasteurized cream, the acidity of which is almost 20 times less than the acidity of cottage cheese, and at the same time, cooled cream reduces the temperature of the cottage cheese, which prevents a further increase in the acidity of the finished product.

The production of cottage cheese from skim milk can be carried out using any available equipment, including separator-curd maker, with further mixing it with cream (Fig. 2.6).

With this production method, milk intended for the production of cottage cheese, after heating to a temperature of 40–45 °C, is sent for separation to obtain cream with a fat content of at least 50–55%, which is then pasteurized at a temperature of at least 90 °C, cooled to 2 –4 °C and sent for temporary storage.

Rice. 2.6. Technological scheme for producing cottage cheese using a separate method

The resulting skim milk undergoes the usual preparation for coagulation, as mentioned above, namely: pasteurization at 78–80 °C for up to 20 s, cooling to a ripening temperature of 30–34 °C, and sent to a ripening tank with a special mixer. Sourdough, calcium chloride, and milk-clotting enzyme are also served here. The mixture is thoroughly mixed and left to ferment until the acidity of the curd is 90–100 °C, since during the subsequent separation of the curd into curd and whey in a special separator-curd separator, the nozzles of this separator may become clogged if the curd has less acidity.

In order for the curd curd to be better separated into the protein part and whey, after thorough mixing it is fed with a special pump into a plate heat exchanger, where it is first heated to 60–62 °C, and then cooled to 28–32 °C and sent under pressure to separator-curd maker, where it is separated into whey and curd.

When producing full-fat cottage cheese by dehydration, separation is carried out until the mass fraction of moisture in the curd is 75–76%, and when producing semi-fat cottage cheese – up to 78–79%. The resulting curd mass is cooled on a plate cooler for cottage cheese to 8 °C and sent to a mixer, where pasteurized chilled cream (50–55% fat content) is supplied by a dosing pump, and everything is thoroughly mixed.

The finished cottage cheese is packaged on automatic machines and sent to a storage chamber.

Cottage cheese with cream

Curd cottage cheese is a crumbly dairy product made from curd raw materials with the addition of cream and table salt. Heat treatment of the finished product and the addition of consistency stabilizers are not allowed.

By appearance grain cottage cheese is cheese mass, the curd grains in the mass are clearly visible and covered with cream. By chemical composition and taste properties approaching cottage cheese. To produce cottage cheese Very great importance has the dry matter content in skim milk, which affects not only the structure of the grain and its yield, but also the rate of ripening of milk (Fig. 2.7).

The prepared milk is separated at 34–40 °C to obtain cream with a fat mass fraction of 13–20%, skim milk with a fat mass fraction of 0.05% and non-fat solids< 8,5 %. Сливки пастеризуют при температуре 92±2 °C с выдержкой 15–20 с, гомогенизируют при температуре 26–30 °C и давлении 10–15 МПа, охлаждают до температуры 5–8 °C и выдерживают 10–12 ч. Обезжиренное молоко пастеризуют при температуре 72 ± 2 °C с выдержкой 15–20 с. Заквашивают молоко при температуре 30 ± 2 °C при fast way ripening and 21 ± 2 °C for a long time. A starter made from cultures of mesophilic lactic acid streptococci is used. Ferment is added to milk in an amount of 50–80 kg per 1000 kg of milk with a quick ripening method and 10–30 kg with a long-term method. After adding the starter to the milk, add a 30–40% solution of calcium chloride at the rate of 400 g of anhydrous salt per 1000 kg of milk and a solution of rennet powder or pepsin or the VNIIMS enzyme preparation at the rate of 0.5–1 g per 1000 kg of milk (activity 100,000 units ). Then the milk is mixed for 30–40 minutes with an interval of 10–15 minutes. Milk fermentation ends after 5–7 hours with a quick fermentation method and after 10–12 hours with a long fermentation method. The acidity of the whey at the end of ripening should be in the range of 46–48 °T, provided that the mass fraction of dry substances in the milk is 8.5–9.5% and 49–55 °T when the mass fraction of dry substances is more than 9.5%. The pH of the curd at the end of ripening is 4.6–4.9.

Rice. 2.7. Technological scheme for the production of grain cottage cheese

Both ripening modes have advantages and disadvantages. The advantages of the long-term method of milk fermentation are the following: the process is usually carried out at night, which allows the main work to be organized only during the day shift; less starter required; the taste and aroma of the product improves, since the biochemical process of aroma formation is slower than the process of acid formation. The disadvantages of the long-term method of fermenting milk are that the duration of the product preparation cycle increases; low turnover of baths; Due to the fact that there is no monitoring of the ripening process at night, fluctuations in the ripening temperature are possible, which can lead to deterioration in the quality of the curd.

The advantages of the short-term ripening method are as follows: the technological cycle ends quickly; the ripening process is under control at all times; less possibility of contamination of the product with foreign microflora; baths are better used. Disadvantages of this fermentation method: a larger amount of starter is required; the finished product is obtained with a less pronounced aroma.

Regardless of the chosen method, the temperature of milk fermentation must be maintained within the established limits throughout the entire fermentation time. Lowering the fermentation temperature can cause a significant delay in the process and contribute to a flabby curd.

At the end of ripening, the curd is processed. This is one of the main technological operations in the production of grain cottage cheese, since it affects the transition of milk solids into grain, its uniformity, composition and quality of the finished product. If the acidity of the curd when cut is too low, the grain will be rough and rubbery. If on the contrary, then the clot particles will be brittle, the grain will be heterogeneous with high content protein dust in whey, with a mealy consistency of the finished product. When boiled, such grain easily falls apart, and when mixed with cream, it loses its shape and turns into a curd mass. The finished curd is cut with wire knives into cubes measuring 8, 10 or 12, 14 cm along the edge. The cut curd is left alone for 20–30 minutes to release the whey. Then water is added to the bath, the temperature of which is 45 ± 2 ° C, to reduce the acidity of the whey to 36–40 ° T. The mass of water should be 10–15% of the mass of the contents in the bath. After adding water to the bath, the grain is carefully mixed and gradually begins to heat up, introducing it into the interstitial space hot water. It is necessary to heat the grain, especially in the first stage to a temperature of 38 ± 2 °C, very carefully and evenly so that it does not brew and the temperature of the contents in the bath increases by 1 ° every 10 minutes. In this case, you need to mix the grain only to keep it in suspension. Subsequent heating of the bath contents to 48–55 °C must be done faster so that the temperature increases by 1 ° every 2 minutes. After the temperature in the bath has risen to the required level, the grain is kneaded for 30–60 minutes to compact it. The suitability of the grain is periodically checked. The finished grain, pre-cooled in tap water, should retain its shape when lightly squeezed in the hand. At the end of boiling, the whey is removed from the bath and the grain is washed and cooled at the same time. The grain is washed with water in two stages: I – water with a temperature of 16 ± 2 °C is added in an amount of 40–50% of the initial mass of the fermented milk, stirred for 15–20 minutes and the water is removed; II – water with a temperature of no more than 8 °C is added in an amount of 30–40%, stirred for 15–20 minutes and removed. Then the grain is dried. To do this, it is moved to the walls of the bath so that a groove is formed in the middle for the free flow of whey, and left for 1–2 hours. During drying, the bath must be closed. The moisture content in the finished grain should be no more than 80%. The duration of drying depends on the consistency and size of the grain and the thickness of the layer. Grain that is soft and contains a lot of dust dries more slowly than grain that is coarser and more uniform in structure. Salt is added to the cooled cream and then added to the skim grain. Mix the grain with cream and salt in a mixer. When manually packing into large containers, cream of 20% fat content is used, when packing into small containers using automatic machines - 13–15% fat content. B good mixed product The grains should be evenly covered with a layer of viscous cream. Stored homemade cheese at a temperature of 0–6 °C no more than 36 hours, including at the manufacturer’s factory no more than 24 hours.

Cottage cheese production using the traditional method involves the production of low-fat, semi-fat and full-fat cottage cheese from normalized milk. Based on the method of curd formation, there are two methods of producing cottage cheese: acid and acid-rennet. With the acid-rennet method of producing cottage cheese, milk coagulates - the curd is formed by the combined effect of rennet and lactic acid. The acid-rennet method for producing cottage cheese produces full-fat and semi-fat cottage cheese, which reduces the loss of fat into the whey. With acid coagulation, calcium salts go into the whey, and with acid-rennet coagulation they are stored in the curd. This must be taken into account when producing cottage cheese for children who especially need calcium for bone formation.
As raw material for use good quality fresh whole and skim milk with an acidity not exceeding 20°T. For fats, milk is normalized taking into account its protein content (by protein titer), which gives more accurate results.
Normalized and purified milk is sent for pasteurization at 78-80°C with a holding time of 20-30 s. Pasteurization temperature affects physicochemical characteristics curd, which, in turn, affects the quality and yield of the finished product - cottage cheese. Yes, when low temperatures pasteurization, the curd turns out to be insufficiently dense, since whey proteins almost completely go into the whey, and the yield of cottage cheese decreases. As the pasteurization temperature increases, the denaturation of whey proteins involved in the formation of the curd increases, increasing its strength and enhancing its moisture-holding capacity. This reduces the intensity of whey separation and increases the yield of the product - cottage cheese. By regulating pasteurization and curd processing modes and selecting starter strains, it is possible to obtain curds with the desired rheological and moisture-retaining properties.
Pasteurized milk is cooled to the fermentation temperature (in the warm season up to 28-30°C, in the cold season - up to 30-32°C) and sent to special baths for making cottage cheese. The starter for the production of cottage cheese is made from pure cultures of mesophilic lactic acid streptococci and added to milk in an amount of 1 to 5%. Some experts recommend introducing into the starter Streptococcus acetoinicus. The duration of ripening after adding the starter is 6-8 hours.
With the accelerated fermentation method, 2.5% of the starter prepared from cultures of mesophilic streptococcus and 2.5% of thermophilic lactic acid streptococcus are added to the milk. The ripening temperature with the accelerated method increases in the warm season to 35°C, in the cold season - up to 38°C. The duration of milk fermentation is reduced by 2-3.5 hours, while the release of whey from the curd occurs more intensely. To improve the quality of cottage cheese, it is advisable to use a direct method of preparing the starter using sterilized milk, which allows you to reduce the dose of ferment to 0.8-1% while guaranteeing its purity.
With the acid-rennet method producing cottage cheese in a traditional way after adding the starter, add a 40% solution of calcium chloride (at the rate of 400 g of anhydrous salt per 1 ton of milk), prepared in water boiled and cooled to 40-45°C. Calcium chloride restores the ability of pasteurized milk to form a dense curd under the influence of rennet, which separates the whey well. Immediately after this, rennet or pepsin is added to the milk in the form of a 1% solution at the rate of 1 g per 1 ton of milk. Rennet is dissolved in water boiled and cooled to 35°C. In order to increase its activity, a pepsin solution is prepared with acidic clarified whey 5-8 hours before use. To speed up the turnover of curd baths, milk is fermented to an acidity of 32-35°T in tanks, and then pumped into curd baths and calcium chloride and enzyme are added.
The readiness of the curd is determined by its acidity (for full-fat and low-fat cottage cheese it should be 58-60°T, for low-fat cottage cheese - 75-80°T) and visually - the curd should be dense, give even smooth edges at the break with the release of transparent greenish whey. Fermentation with the acid method lasts 6 hours, with the acid-rennet method - 4-6 hours, with the use of an active acid-forming starter - 3-4 hours. It is important to correctly determine the end of ripening, since under-fermented curd results in sour curd with a spreadable consistency.
To speed up the release of whey, the finished curd is cut with special wire knives into cubes with a side size of 2 cm. In the acid-rennet method of cottage cheese production, the cut curd is left unheated for 40-60 minutes. for intense serum release.
To further separate the whey, the curd is self-pressed and pressed. To do this, it is poured into calico or lavsan bags of 7-9 kg (70% of the bag’s capacity), they are tied and placed in several rows in press carts. Under the influence of its own mass, whey is released from the clot. Self-pressing takes place in the workshop at a temperature not exceeding 16°C and lasts at least 1 hour. The end of self-pressing is determined visually by the surface of the curd; its shine is lost and the clot becomes dull. Then the cottage cheese is pressed under pressure until ready. During the pressing process, the bags of cottage cheese are shaken and rearranged several times. To avoid an increase in acidity, pressing must be carried out in rooms with an air temperature of 3-6°C, and upon completion, the curd must be immediately cooled to a temperature not higher than 15-8°C using coolers of various designs, the most successful of which are two-cylinder ones.
The finished cottage cheese is packaged using automatic machines into small and large containers. Cottage cheese is packaged in clean, steamed wooden tubs or clean aluminum, steel, tinned wide-mouth flasks or cardboard boxes with parchment or plastic film liners. Cottage cheese is packaged in small packages in the form of bars weighing 0.25; 0.5 and 1 kg, wrapped in parchment or cellophane, as well as in cardboard boxes, bags, glasses made of various polymer materials, packed in boxes with a net weight of no more than 20 kg.
Cottage cheese is stored according to TU 9222-180-11419785-04 for sale for no more than 72 hours. at a temperature in the chamber of 2-8°C and humidity of 80-85%. If the shelf life of the cottage cheese is exceeded, due to enzymatic processes that do not stop, defects begin to develop in the cottage cheese [Kalinina, L.V. Technology of whole milk products. [Text]: textbook. allowance / L.V. Kalinina, V.I. Ganina, N.I. Dunchenko. St. Petersburg: GIORD, 2004-248 p. ]

The fermented milk product, known in Russia as cottage cheese, and in European countries as “young cheese,” is popular in our country. Tasty, satisfying and healthy, it has been instilled in Russians since childhood. Now there are many manufacturers of this food product on the market, but despite this, the business of its production has great prospects. Consumption of dairy products per person in the Russian Federation is 252 kg/g. For comparison, in the USSR in 1990 the norm was 386 kg/g. In the countries of the USA and Western Europe it is now 390 kg/g.

The data shows that the domestic market has room to grow. New manufacturers required - a good product will always find a buyer. In the article we will present a business plan for opening a line that produces cottage cheese, study the features of the business, and carry out economic calculations of the return on investment of the business.

Demand for cottage cheese products in Russia

Cottage cheese is a fermented milk protein product obtained from fresh milk. It is bought by all categories of the population - it is suitable for both children's and diet food.

The market for curd products in Russia is studied annually. Lately, production and consumption volumes have been unstable (there have been ups and downs), but in general the indicators have been growing. In 2015, 1 average Russian bought and ate 9 kg of this product (compared to 2011 - an increase of 0.7 kg).

Experts predict that by 2020-2022. sales will grow by 10-13% every year (average forecast).

Long-term prospects are bright: the physiological norm of consumption is 18 kg per year (versus 9 kg in 2015). The need will continue to grow - this is an opportunity for new manufacturers.

Market assessment

In 2017, 493.1 thousand tons of cottage cheese were produced (21% more than in 2016). Most of the goods were created in the European part of Russia (CFD). The Central Federal District accounted for more than 41% of the total production volume.

The average price increase for this product in the period from 2015 to 2018. amounted to 16.4% (up to 193.9 thousand rubles per 1 ton). The average price of 1 kg of fatty product in 2018 is 290.4 kg (retail).

The largest companies:

• Danone Industry LLC;
• OJSC Wimm-Bill-Dann;
• LLC "Dairy Business";
• Molvest LLC;
• CJSC "Yantar"

Several well-known regional manufacturers:

• "Ostankino Dairy Plant"
• "RostAgroComplex"
• "Dmitrov Dairy Plant"

Competition is high, consumers are more often looking for a high quality product.

Initial investment in the production of branded cottage cheese

Items that will require the most expenses: equipment for cottage cheese and raw materials. The salary is set high enough (the exact amount depends on the position) to motivate employees to work responsibly and hold on to their jobs.

Table 1. The amount of initial costs for a cottage cheese production business.

We will open a business in a city with a population of up to 1 million people. Additional expenses include costs for utilities, advertising, and cosmetic repairs.

Technological scheme of own production

The factory production scheme is as follows:

1. Dairy raw materials are being prepared. After quality assessment, the milk is pasteurized (processed at high temperature for 30 minutes).
2. Separation is carried out (separation of cream from the milk mass).
3. Ferment is added to the milk. Within a few hours, fermentation occurs, that is, the process of product formation itself. There are several ways (more on that below).
4. After coagulating the protein, the whey is squeezed out of the resulting clots. They are left for a certain time to completely remove any remaining liquid from them.
5. The clots are left in a special tub or trolley for pressing. Using a wire knife curd cut into small cubes (0.2 m each).

After cooling, the product is packed into containers (briquettes, flasks, boxes) and stored in the refrigerator.

How high-quality cottage cheese is made in production

Making cottage cheese at home is easy. You will need milk, sour cream and a container for fermentation. You need to boil the milk, then cool it to 30°C and put sour cream in it (calculated at 100 grams per 2 liters of milk). The mixture is left in a warm place for 9 hours to ferment. Afterwards, the resulting mass is transferred to gauze, squeezed out and hung for self-pressing and final removal of the whey.

Several methods are used in industry:

• Traditional. Similar to the technology for producing cottage cheese at home.
• Acid rennet. Lactic acid and rennet are used for fermentation.
• Separated. The most common in the industry for the production of cottage cheese with full automation.

Traditional cottage cheese technology

Using this method, an almost fat-free product is made.

First, the raw milk is prepared: separated to normalize the fat composition and pasteurized. Milk is heated to 78°C for half an hour - this removes pathogenic microorganisms while maintaining beneficial properties.

Afterwards the mass is cooled to 28-32°C. Rennet and calcium chloride are added to it for subsequent ripening.

After the protein has coagulated, the resulting clots are separated, pressed and cooled (to stop the fermentation process). Protein product packaged and stored in refrigeration chambers.

The technology for producing cottage cheese has several disadvantages, the main ones being the duration of the process and the need manual labor. There is a risk of intestinal infections getting into the cottage cheese. The best option for producing cottage cheese at home.

Acid rennet

Medium/high fat cottage cheese is prepared using this method. The main ingredients are rennet and lactic acid. In a certain proportion (from 1 to 5% of the total mass), a starter culture - lactic acid streptococcus - is mixed with milk. If you don’t have your own laboratory in production, you can buy leaven in special laboratories; if available, you can make it yourself using a certified method.

Then rennet is added to the mixture - a catalyst for the protein coagulation process. The enzyme is prepared in advance - 6 hours in water heated to a temperature of 35°C.

After the curds are formed, they are also pressed and the remaining whey is removed from them. The product is packaged and sent to the refrigerator for cooling and storage.

Separated

This method of making cottage cheese in production was developed in the Soviet Union and has been used since the 1960s. Its essence is the production of a low-fat product with further combination with cream to achieve the desired fat content.

The separate method is used in large industries: it optimizes costs, minimizes fat loss and fully automates the process. Special tables have been developed that calculate the exact consumption of cream. This method helps speed up the whey separation process.

Milk pasteurization is carried out in special production lines, and fermentation is carried out in containers with automatic mixers. The resulting curds are subjected to heat treatment to destroy harmful microorganisms, and then enter separators to separate the whey. At the end, the cottage cheese is mixed with cream in the required proportions.

Equipment for the production of cottage cheese

The business plan considers an automated line for the production of cottage cheese A-TL-3 worth about 1.5 million rubles. Produced using traditional or acid-rennet methods. Equipment for the production of cottage cheese meets the requirements of GOST.

Cottage cheese production in factories is carried out in the presence of:

• cottage cheese makers RT, 2 pcs.;
• curd curd pressing units UTS-500;
• semi-automatic loading ATL;
• filling machine (12-25 packs/min);
• rotary pump.

Maintenance will require 2-3 people. It can produce up to 1.8 tons (75 kg/hour) per day.

The filling machine can pack the product into briquettes, plastic bags or plastic containers.

Also, to produce cottage cheese you will need a pasteurization bath. It is needed for the preparation of milk and refrigeration units for storing the finished product.

Raw materials

The production of cottage cheese requires milk and starter culture.

More on preparatory stage you need to thoroughly study the market for suppliers of dairy raw materials, find suitable milk producers/sellers.

It will be needed in large quantities and constantly, so look for a supplier near your workshop. This, firstly, will reduce logistics costs, and secondly, will ensure regular supply of milk (lower risk of supply interruptions).

It is better to cooperate only with trusted suppliers who have quality certificates and permission from the Sanitary and Epidemiological Supervision Authority.

Before starting work, the entrepreneur must already have contracts for the supply of milk.

There are now many sourdough starter manufacturers - it’s easy to find a product at the right price and in the required quantity.

Room

All requirements for production premises specified in SanPiN 2.3.4.551-96 “Production of milk and dairy products”.

The space of a mini-factory should be divided into several rooms - a work shop with equipment (at least 30 sq. m), administrative rooms, an area for workers, a bathroom.

It is necessary to have all communication systems - electricity, water (according to GOST 2874-82), ventilation, heating.

The walls in the production workshop are tiled, the floors are waterproof, non-slippery, and inert to acids.

It is recommended to order development architectural project with a master plan and justification for decisions on the arrangement of the workshop.

Staff

Modern machines are automated and do all the work themselves. This allows you to reduce the workforce and labor costs. But the staff needs to be trained and taught how to operate the equipment. When purchasing a production line, you can agree on employee training from the selling company. A minimum of 2 people will be required to operate.

We also need experienced specialists who know how to process milk and make high-quality cottage cheese (2 people).

A minimum of 1 driver is required (you can hire your own car). It is important to find a sales manager who will create a product distribution network. An accountant at the initial stage of development can be hired through outsourcing. A handyman will be required for loading and unloading work.

A workforce of 8 people is enough to launch and develop a small production of high-quality cottage cheese.

Business documentation

First, select the form of business activity to conduct business - an individual or legal entity, individual entrepreneur or LLC.

Businessmen planning to open a large plant need to work in the form of an LLC - then they can enter into profitable contracts for raw materials and sales (with wholesalers). An individual entrepreneur can sell goods to his friends or supply them to small stores.

When registering, indicate OKVED code 15.51.14 “Production of cottage cheese and curd products.”

First, get permits from the Fire Inspectorate and the Sanitary and Epidemiological Station. Based on the results of all checks, a license will be issued (valid for 5 years).

The first batch of goods is sent for certification. If the requirements of GOST 31534-2012 are met, the entrepreneur will receive a quality certificate, which he can present to contractors when organizing sales.

Sales channels for finished products

Cottage cheese is a perishable product. You need to start producing it when sales channels have been established.

If the business operates in the form of an LLC, potential buyers will be:

• Retail Stores;
• trade and retail food chains;
• wholesale centers engaged in resale;
• manufacturing companies that manufacture products based on / with the addition of our product;
• enterprises Catering(canteens, cafes/restaurants).

An individual entrepreneur will be able to sell goods to friends and acquaintances through “ word of mouth"and organize sales "from the car" - that is, purchase special vehicles and sell in residential areas. Loyal customers will soon appear who are determined to buy his specific product.

Promotion

The level of competition in the segment is high, and to succeed, a businessman needs to make sure that consumers recognize and want to buy his product. Firstly, you need to produce a high-quality product, and secondly, think through your marketing activities in advance. There are several low-cost promotion methods:

• advertising in the media (in particular, in newspapers);
• promotion in in social networks, order advertising in VKontakte groups;
• leaflets and other POS materials for distribution and posting in high-traffic areas.

Selling in areas using your car is useful not only for sales, but also for promotion. This way you can train customers to look for your specific product in grocery stores. This method requires additional costs, but it is effective.

Profitability and payback: financial plan

The initial investment will be 3.88 million rubles.

The equipment productivity per hour is 75 kg; in an 8-hour day, 600 kg of product can be produced. In a month (22 days) it is realistic to produce 13.2 tons.

For cooking 1 kg fermented milk product you need 6.67 kg of milk. This means that 88 tons of raw milk will be required per month (1 kg costs 15 rubles). Accordingly, the amount of monthly expenses is approximately 1.8 million rubles. (including other articles).

The average cost of 1 kg is 150-200 kg (wholesale). In a month you can sell products worth 2.24-2.64 million rubles.

Net monthly profit will be 440-840 thousand rubles. The difference between these values ​​is large, since the range of wholesale and retail prices on the market is large (the price depends on the fat content and quality of the product).

Payback period is from 5 to 9 months.

Table 2. Economic justification business ideas.

When concluding long-term supply contracts, a business is attractive for investment. However, there are many manufacturers and intermediaries on the market. To attract customers, you may have to offer goods at lower prices - because of this, the payback period will increase.

With the development and improvement of positions, you can expand. Start producing curd products, open your own farm - this will allow you to increase the range and reduce costs.

Opening a mini-factory for the production of cottage cheese with proper development will allow the entrepreneur to receive a source of large income with the prospects of further transformation into a large enterprise. And besides, there will always be dairy products at home, the freshness and usefulness of which you will not have to doubt.

Technological process of cottage cheese production acid method includes the following technological operations:

acceptance of raw materials and quality assessment;

F milk filtration;

ABOUT refrigeration and temporary backup (if necessary);

- heating and cleaning;

- normalization;

- pasteurization and cooling;

- fermentation;

- ripening;

- cutting the clot;

- boiling the curd;

- partial cooling of the curd;

- separation of whey from the clot;

- cooling the cottage cheese;

- package;

- marking;

- additional cooling in consumer packaging;

- Quality control;

- storage.

Acceptance and quality assessment of raw materials. For the production of cottage cheese, the following types of raw materials are used: raw cow's milk of at least 2 grades, cream, skim milk, whole and skim milk powder, powdered cream, starter cultures and bacterial concentrates, enzyme preparations (including transglutaminase, which increases the product yield by 15%) , calcium chloride, drinking water. When assessing the quality of milk Special attention pay attention to the presence of inhibitors, protein content in milk and the number of somatic cells.

Cleaning produced in separator-cleaners at a temperature of 35-40 o C.

Normalization– made by adding skim milk or cream. The fat content of normalized milk is determined taking into account the mass fraction of protein in milk (page 37).

Pasteurization milk is carried out at 78 + 2 o C with a shutter speed of 15-30 seconds.

Fermentation. When using a starter consisting of mesophilic microorganisms(milk, cream, flavor-forming streptococci) fermentation temperature is 26-28 o C.

Often used accelerated method fermentation by using a starter consisting of a mixture of thermophilic and mesophilic microorganisms in a 1:1 ratio. In this case, the fermentation temperature is 35–37 o C (or 32-34 o C depending on the starter used). In this case, the fermentation time is reduced by 2-4 hours.

The starter is added in an amount of 3-5%, depending on the activity of the starter and the required fermentation time. After adding the starter, the milk is stirred for 15-20 minutes. Then milk ferment until a curd is obtained with an acidity of 75-80 (80-90 o T) for low-fat cottage cheese and 58-65 (70-80 o T) for cottage cheese with an ppm of fat of 9% or more. The optimal acidity of the curd when cutting a curd depends on the type of starter used, the mass fraction of SNF in the milk and the acidity requirements ready-made cottage cheese. The recommended acidity of the whey obtained after cutting the clot is no more than 55 o T.

The curd should be quite dense, without separating the whey. The readiness of the clot is determined by breaking: to do this, insert a spatula into the clot at an angle and remove it along with the clot; the break should be smooth, shiny, with a separation of light green whey.

The duration of ripening is 6-12 hours with the usual method and 5-7 hours with the accelerated method. When using direct fermentation starters, the ripening time increases to 8-14, sometimes up to 16-18 hours when using mesophilic cultures (regular method) and 6-8 hours when using thermophilic cultures (accelerated method).

To speed up the separation of whey clot cut into cubes with an edge of 2 cm.

Then the clot is slowly (over 1-1.5 hours) heated to a temperature boiling 36+ 2 o C (low-fat) or 38 + 2 o C (5% cottage cheese), with exposure for 20-50 minutes.

To obtain a more delicate consistency of the cottage cheese, it is recommended to reduce the boiling temperature of the curd to 34-37 o C. The layers of cottage cheese are carefully moved from the edges of the bath to the center for uniform boiling.

Clot boiled(that is, kept at the above temperature) for 20-30 minutes, then start cool, supplying cold water into the interstitial space, reducing the temperature by 10-12 o C. Then part of the whey is removed from the bath.

The curd is poured into lavsan bags measuring 40x80 cm. The bags are filled 75-80% or the curd is transferred to a press trolley with a perforated bottom.

Self-pressing carried out for 1-2 hours, it is advisable to transfer the bags. It is recommended to combine self-pressing with cooling in order to stop the development of microflora and peroxidation of the product.

Pressing must be combined with cooling. It is carried out in a cold room with a temperature of 2-6 o C. For pressing, presses or drums with a supply of ice water or brine are used, for example, an installation for cooling and pressing cottage cheese UPT.

The brine is served 40 minutes after the start of rotation. The end of pressing is determined by the moisture content in the curd.

You can also use drum or belt type whey separators with a drainage tape, various installations for pressing curd, screw curd coolers, curd separators, pressing baths, etc.

Cottage cheese packaging Cottage cheese, cooled to 4 + 2 o C, packaged on special machines in consumer packaging. Next, the quality of the cottage cheese is assessed and sent for storage.

Store cottage cheese at a temperature of 4 + 2 o C, including at the manufacturing plant for no more than 18 hours. The shelf life of the product is determined by the manufacturer.