A positive aspect and an indisputable advantage of the business for the production of semi-finished products is the ability to change the range, depending on the needs of the market. There are many types of meat dishes, and even cutlets and meatballs can be produced during the shift. At the same time, equipment for the production of pancakes or semi-finished meat products does not even need to be reconfigured.

Frozen products are a product subject to certification. To obtain permission to sell products to the distribution network, you need to register the workshop as an enterprise. When choosing a form of ownership, it should be taken into account that large retail chains prefer to work with LLCs. Permits for activities must also be obtained from the sanitary and epidemiological station. A declaration of conformity is issued for the products.

Production technology

The quality of raw materials affects the taste of meat semi-finished products. It must be fresh, and usually accompanies each batch of goods with a veterinary certificate. When entering the meat products workshop, the raw materials are additionally controlled.

The technology consists of several operations:

• preparation of raw materials;
• minced meat preparation;
• product formation;
• packaging, warehousing and sale.

If the meat is purchased in carcasses, then you need to cut it. This process is called deboning. From raw materials, all bones and veins must be isolated. Next, it is ground into minced meat. If the product is prepared from a pork-beef mixture, then the raw materials are taken in a 50/50 ratio. Spices and other ingredients are added to the already crushed main raw materials. It can be onions, bread, water, salt. The temperature of the mixture ready for shaping should not exceed 14 degrees, otherwise not only the taste of the product is violated, but also its bacterial characteristics. Often in modern industries, natural raw materials are partially replaced with vegetable ones. Soy is added to minced meat, eggs are replaced with egg powder and so on. You need to be careful with them, as they affect the taste of the final product.

Products are formed on a molding machine. Then meat semi-finished products are subjected to shock freezing.

What equipment is needed?

The workshop for the production of frozen semi-finished meat products is equipped with the following equipment:

Band saws for meat and bones	These installations help to butcher meat, cut it without the formation of bone fragments. The first stage of preparation of raw materials, thanks to their use, occurs quickly and efficiently. Band saws are designed in such a way that they allow you to adjust the thickness and height of the cut. All surfaces that directly touch the products are made of stainless steel. The productivity of such installations is on average 300-500 kg/h. The price of the equipment depends on this indicator. It starts from 45 thousand rubles and can reach 270 thousand rubles. You can buy domestically produced machines in the workshop, as a rule, imported machines are more expensive.
Meat grinder	Industrial meat grinders in the semi-finished meat workshop are equipped with a set of grates with different diameters. Thanks to this, it is possible to obtain minced meat of different consistency for different semi-finished products. Meat grinders can be placed on the floor or on the table, depending on the design. Professional meat grinders with sufficient production capacity cost from 10 thousand rubles. The upper threshold is not limited. There are models that cost 400 thousand rubles. Optimal for production, and therefore the most commonly used, are the models of the Belarusian production of MIM. Their productivity is 80 kg/h. This is quite enough to serve a small meat products workshop. For very large enterprises, there is equipment with a capacity of 1150 kg / h. It is mainly of European production.
Meat mixer	An installation that ensures uniform mixing of all minced ingredients. In addition, it is saturated with oxygen and its taste improves. The cost of meat mixers in the semi-finished meat workshop also directly depends on productivity. The order of prices is from 50 to 300 thousand rubles. When choosing, you need to pay attention to the volume of the working bowl. For small and medium production, a 50 liter tank will suffice. Such units are produced by domestic enterprises.
Patty molding machine	This device is needed to give products a certain shape and size. The weight of cutlets or meatballs will also always be the same. The car is completed with holes (matrices) different on a configuration. They allow the production of a wide range of products. The price of this equipment depends on the number of products produced and ranges from 24 thousand rubles to 450 thousand rubles. The productivity of such devices, on average, is 2-2.5 thousand pieces / hour. This is enough to equip a medium-sized meat products workshop.
meat cutting machine	It helps to cut semi-finished products into identical slices. Meat can be cut fresh or frozen. It does not affect the quality. Such machines are characterized by high productivity (180-400 cuts per minute). They cost from 700 to 1500 thousand rubles. There is no equipment of domestic manufacturers on the market, so it should be bought only from an imported manufacturer.
Equipment for packing	Usually, tray sealers are bought for packaging semi-finished products. They can simultaneously complete from 1 to 4 packages. The cost of such a machine ranges from 150 to 1000 thousand rubles. Small and medium-sized enterprises successfully use domestic CAS equipment in their production.
Refrigerators and freezers	Low-temperature refrigerators and freezers are used. Different chambers are used to store frozen and chilled products. To equip a small semi-finished meat workshop, you will need two of them. The internal volume of each must be at least 10 cubic meters. m.

The demand for fresh meat products is constantly growing. The main competition is developing between the segments of chilled and frozen products. There is still a place in this niche for everyone, because different types of semi-finished products are clearly separated by purpose, distribution channels.

The volume of meat consumption in Russia has been constantly increasing over the past 10 years. Even according to the results of the depressive 2015, there is an increase (3%) compared to the previous period. At the same time, the production of semi-finished products is growing most actively, as well as their consumption. This is due to the employment of the population, the accelerated dynamics of modern life. To understand whether this direction is promising for small businesses, we briefly characterize:

• features of the Russian market of meat products;
• types of products, preferences, distribution network;
• technologies and equipment for meat processing;
• regulation of this type of business.

Supply and demand for semi-finished products

About 50% of the total volume of meat (Russian and imported) is sold raw. Approximately 30% - goes to sausage products, 5% - canned food, about 15% - the production of semi-finished meat products and supplemented with other ingredients. In recent years, their consumption has increased by 10-15% annually, while sausages - by only 5% (Fig. 1).

Almost a tenfold increase is a response to ever-increasing demand. But production is distributed unevenly across regions (Fig. 2). Traditionally, over 60% falls on the Central and North-Western districts, where large meat processing plants are concentrated. According to experts' forecasts, consumption of these products will grow in the next 3 years, the highest rates are expected in the periphery.

Increased demand has changed the strategy of large meat holdings (Fig. 3). If earlier they focused on the production of sausages, sausages, and other delicacies, then in the last two years they have been actively re-profiled into raw semi-finished products. This, of course, will lead to increased competition. The developed capacities of giant enterprises, their own raw materials base, the possibility of acquiring imported equipment and new technologies put small businesses in obviously unfavorable conditions.

Most large meat processing plants produce frozen products. The transition from sausage production to products for cooking, the purchase of new technologies - increases its cost. Standard packages are also inconvenient: small ones are expensive for the manufacturer, large ones do not suit the buyer. Goods by weight are now in high demand.

Small businesses find a place in this niche for several reasons. Proximity to sales outlets saves transport costs. And the price in times of crisis is the main regulator of consumer demand. In addition, more and more buyers are choosing chilled meat over freezing; even if the cost is higher by 10 - 15%. Since the shelf life of such products is up to 7 days, retailers take them from local producers. However, they often complain about the poor assortment, low quality of goods.

Varieties of products, sales directions

Meat semi-finished products are produced from all types of meat: beef, pork, poultry, including offal. Currently, their range includes about 40 units. Products are usually divided into two broad categories: chilled and frozen. According to the manufacturing technology, they are:

1. natural. Large, small-sized products, mainly from chilled meat: brass beef and pork, steaks, natural cutlets, shish kebab, stew, soup sets.
2. Breaded. Ready-to-cook dishes from fresh and thawed meat in liquid (with egg) crumb crumbs: offal, chops, rump steaks.
3. Chopped. Products from low-grade raw materials, often with the addition of bread, spices: cutlets, steaks, meatballs. This group also includes packaged and loose minced meat.

Mixed semi-finished products with the addition of dough and, to a lesser extent, vegetables are widespread on the Russian market (Fig. 4). The undisputed leader is dumplings, they even came up with a special vending machine for them.

Sales channels for products:

1. Retail chains- their share is about 50%. Dumplings, cutlets sell well in outlets of all kinds. Sliced ​​​​(shish kebab, goulash), minced meat, pancakes, pasties, manti - prevail in the markets, supermarkets. Both frozen and chilled products are sold.
2. Specialized Culinary occupy approximately 10%. These are ordinary stores selling goods from the counter. Own culinary workshops allow us to prepare a diverse range of ready-made dishes, quickly respond to seasonal changes, changing tastes and needs. They sell finely chopped meat in marinades, kebabs, goulash, khinkali, cabbage rolls.
3. HoReCa segment- about 14% of semi-finished meat products are sold through it. It is developing faster than anyone, thanks to the spread of fast food. Buyers - restaurants, bars, canteens, fast food cafes. Frozen products are supplied to public catering establishments more often, large-scale high-tech production wins here.

Main trends for 2016 - 2019:

1. Increasing demand for chilled products; increase in the proportion of poultry meat: chicken and turkey.
2. Expansion of the range of dishes in sauces, marinades of the original recipe; with vegetable ingredients.
3. Displacing traditional products with new, original dishes of the national cuisine of the peoples of the world.
4. Growth in the consumption of expensive semi-finished products, ready-to-eat meals.

How to open a workshop for the production of semi-finished products

If an entrepreneur decides to open a meat business, first you need:

• determine in which market segment to work, select an assortment;
• find, master, develop recipes taking into account modern technologies;
• purchase professional equipment, transport for delivery.

The technological process, for example, for natural semi-finished products includes:

• defrosting carcasses, half carcasses (defrosting) in the amount of daily processing - if necessary, if the workshop is located separately from the place of slaughter;
• washing, drying, cutting into large cuts, trimming, stripping;
• preparation of portioned, small-sized, chopped products on special machines;
• packing of goods in functional containers, sealed bags, labeling;
• cooling (freezing), storage, transportation to a warehouse.

As for the recipe, buyers prefer semi-finished meat products with a minimum degree of processing. For example, if these are chickens, then they are simply cut into half carcasses, breasts, wings, etc. However, there is a growing demand for "convenient" products, balanced in composition, with different ingredients, allowing you to prepare a dish in quick culinary ways. For this, modern packaging such as "protective atmosphere", "gaseous environment" is used. Experts believe that owning them will soon become a pass to the natural chilled food segment.

Inexpensive equipment for all types of processing is produced by Russian factories. It can be picked up separately, or you can purchase a ready-made modular workshop for the production of semi-finished products. The set depends on the future assortment. As a rule, the equipment of the workshop is formed by: band saws, cutting presses, meat grinders of various capacities, machines for applying breadcrumbs, cutlet or dumpling machines. If there is no work experience, it is advisable to find a supplier providing comprehensive services, including training, information support. Often such equipment is purchased on lease. The main selection criteria: an integrated approach (multifunctional lines) and rationality - the ability to ensure the sale of the entire volume of products.

Organizational and legal issues

Production of meat, other food products with it (semi-finished products, canned food, sausages); rules for storage, transportation, packaging, labeling are regulated by the Technical Regulations of the Customs Union "On the safety of meat and meat products" (TR CU 034/2013). This document contains all the requirements, manufacturing conditions and classification of products with different meat content, for example:

• meat - (> 60%) with the addition of other ingredients;
• meat-containing - (5 - 60%), with the inclusion of flour, eggs, cereals, water;
• meat and vegetable - (30 - 60%) using herbal ingredients.

Only the main groups are listed, in fact there are many more. After the development of the relevant GOSTs, their name will be indicated when marking. In accordance with the Regulation, manufacturers are required to issue one of three documents:

• veterinary certificate- fresh unprocessed meat (veterinary organization of the Ministry of Agriculture);
• state registration certificate— meat products for baby food (Rospotrebnadzor);
• declaration of conformity(DoS) - processed meat, including semi-finished products (certification body).

Declaration is carried out according to three schemes: for the period of storage, 3 and 5 years (Fig. 5). The accredited laboratory of the Customs Union has the right to conduct tests, draw up and register DoS.

Each manufacturer must have a package of documents, including technical documentation, laboratory test reports and DoS. As for the sale of meat products, it does not have any special differences, and is regulated by general rules for retail trade.

Summing up. For small enterprises, it is unprofitable to manufacture finished products, since it is difficult for them to compete in terms of quality with sausages, sausages from large meat processing plants. It is more practical to produce fresh products that do not require deep processing of meat and do not duplicate common well-known brands. It is cheaper, does not require the development of complex processes, the involvement of qualified specialists.

The technology for the production of semi-finished meat products provides for the manufacture of various types of meat products and, accordingly, the availability of certain technological equipment used for its production. The production process for the production of semi-finished meat products can be carried out both centrally at specialized enterprises, and locally in any supermarket equipped with special equipment for the production of semi-finished products.

Cutting process

In the case of the sale of meat products directly at retail outlets, the technology for the production of semi-finished meat products provides for the presence of the following devices at the distributor:

Upon completion of the cutting stage and the preparation of raw materials, it is possible to start manufacturing semi-finished products, the production process of which will be determined depending on the type of manufactured products and the equipment used for this.

The meat raw material frozen in the form of blocks is crushed by means of a special crusher. In some cases, meat raw materials made by means of a meat-and-bone separator can be used to make minced meat, but this minced meat will be of lower quality. Upon completion of the grinding procedure, the prepared minced meat is passed through a special grinder, followed by the addition of pork fat, prepared water, salt, spices and other additives provided for in the recipe.

Upon completion of the procedure for grinding and mixing minced meat, the finished mass is placed in the hopper of the semi-finished product molding device, with the help of which the minced meat is shaped into a finished product with a given weight for each portion. Depending on the volume of production, this procedure is carried out by means of a rotary or screw molding system for the finished product. So, for example, in the molding unit, cutlets are given the necessary shape, followed by laying out the semi-finished product on a conveyor belt. After that, depending on the recipe for the manufacture of each specific semi-finished product, the products are fed either to the ice creaming unit, followed by dry or liquid breading to the breading plant, or directly to the breading plant, bypassing the ice creaming procedure. At the final stage of the semi-finished meat production technology, the finished products are placed on special trolleys with subsequent transportation to a special shock freezing chamber or, alternatively, automatic feeding by a belt conveyor to a spiral quick-freezing unit.

The duration of freezing of ready-made semi-finished products in various freezers can vary significantly, for example, in a shock freezing chamber, the freezing time for a cutlet weighing 85g will be at least 2 hours. While in a spiral, quick-freezing unit, the freezing time of the same cutlet will be no more than 45 minutes. Upon completion of the freezing procedure, ready-made semi-finished products are to be packed in special plastic bags and cardboard containers of the required size, followed by storage in a low-temperature refrigerator.

Meat semi-finished products from minced meat

The technology for the production of semi-finished meat products provides for the production of these products in the widest range using various manufacturing recipes.

Moscow cutlets
An example is Moscow cutlets, the raw material for manufacturing, which is ground beef with the addition of the following ingredients:

• wheat bread;
• raw fat;
• pepper;
• salt;
• water.

Ready cutlets have an oval-flattened shape.

Fire cutlets
For the production of Pozharsky cutlets, semi-fat pork is used as the main raw material with the addition of the following ingredients to minced meat:

• wheat bread;
• pork melange;
• pepper;
• salt;
• water;
• in some cases, onions.

amateur cutlets
For the preparation of Amateur cutlets, minced meat is used, made from semi-medium, medium and high-fat beef with the addition of the following components to the prepared minced meat:

• wheat bread;
• pepper;
• salt;
• water and other ingredients.

During the production process, a large cutlet is formed and wrapped in breadcrumbs.

beef schnitzels
The main raw material for the production of beef schnitzels is minced beef meat with shaping the product into a flat, oval cake.

The Kiev's cutlets
For the manufacture of cutlets in Kiev, pork with a fat content of at least 30% is used with the addition of the following ingredients to the minced meat:

Meatballs
The recipe for making meatballs is similar to the preparation of Moscow cutlets with the difference that the meatballs are shaped like balls.

Zrazy
The recipe for making zrazy involves the use of ground beef with the addition of hard chopped eggs mixed with ground breadcrumbs and fried onions.

Rump steak
Such a meat product as a rump steak is a slightly beaten piece of meat weighing 115 g cut from a meat fillet or a thick edge, followed by wetting in a whipped mixture of water, fresh eggs and salt, it is also possible to add allspice.

Steak
Beefsteak is one of the varieties of steak made from the head part of the tenderloin, while chopped beefsteak is similar in its manufacturing recipe to the recipe for making cutlets.

Kneli
Quenelles are balls with minced eggs and cream, made from minced meat, fish or chicken.

meatballs
Such a meat product as meatballs are small round cutlets made from minced meat.

Semi-finished products include products made from natural and minced meat without heat treatment. These are products that are maximally prepared for culinary processing.

Meat semi-finished products are divided into: natural (large-sized, small-sized, portioned, portioned breaded); chopped; semi-finished products in the test; chopped meat.

Natural semi-finished products. These are pieces of meat pulp of various weights, cleaned of tendons and coarse surface films. Natural small-sized semi-finished products also include meat-and-bone pieces of meat with a certain bone content. Semi-finished products are released chilled or frozen. The raw material is meat in chilled or frozen states. Meat of bulls, boars, rams, meat frozen more than once, and lean meat is not used.

Large-sized semi-finished products. Depending on the type of meat, large-piece semi-finished products are divided into four groups:

• - the first group: from beef - the longest muscle of the back (dorsal part, lumbar part), tenderloin (lumboiliac muscle, located under the bodies of the last thoracic and all lumbar vertebrae), hip part (upper, inner, lateral and outer pieces); from pork - loin, tenderloin; from lamb - the hip part;
• - the second group: from beef - the scapular part (shoulder and shoulder parts), the subscapular part, the chest part, as well as the hem (supracostal muscles removed from the 4th to the 13th rib, remaining after the separation of the subscapular part, brisket and longissimus muscle back) from beef of the 1st category of fatness: from pork - hip, scapular, cervical-subscapular parts; from lamb - scapular part, loin;
• - the third group: from beef - cutlet meat and beef trimmings of the 2nd category; from pork - brisket; from lamb - brisket, cutlet meat;
• - the fourth group: from pork - cutlet meat. Cutlet meat (for example, beef) - pieces of meat pulp from the neck, flank, intercostal meat, pulp from the tibia, radius and ulna, trimmings obtained by stripping large-sized semi-finished products and bones.

Portion semi-finished products. They are made from large-sized semi-finished products, cut manually or on special devices across the muscle fibers obliquely or perpendicularly. Assortment of portioned semi-finished products: from beef - natural steak (from tenderloin), langet (two thinner pieces from tenderloin than steak), entrecote (from the longest back muscle), rump steak (from the longest back muscle or the most tender pieces of the hip part - upper and internal), natural zrazy (from the same pieces of the hip part), beef wind (from the side and outer pieces of the hip part).

The range of portioned semi-finished products from pork includes: natural cutlet (from the loin), escalope (from the longest muscle of the back), wind pork (from the neck and shoulder part), tenderloin, schnitzel - from the hip part.

Portion breaded semi-finished products: rump steak (from beef), natural cutlet and schnitzel (from pork and lamb). For portioned breaded semi-finished products, pieces of meat are lightly beaten to loosen the tissues and rolled in finely crushed white bread crumbs to preserve the meat juice.

Small-sized semi-finished products. From beef they get: beef stroganoff (from the tenderloin, the longest muscle of the back and the upper and inner piece of the hip part), azu (from the side and outer pieces of the hip part), goulash (from the scapular and subscapular parts, as well as the hem), soup set (meat and bone pieces weighing 100-200 g with the presence of pulp at least 50% by weight of a serving), beef for stewing (pieces of ribs with pulp at least 75% by weight of a serving), brisket on kharcho (with a pulp content of at least 85% by weight of a serving) .

Small-sized semi-finished products from pork are represented by the following names: roast (from the hip part and loin with a fat content of not more than 10%), goulash (the same as beef goulash), meat for barbecue (from the hip part), stew (pulp content not less than 50% of the serving weight), home-style stew (the content of bones is not more than 10% and adipose tissue is not more than 15% of the serving weight).

Large-sized semi-finished products are sold mainly by weight, portioned - packaged, the mass of the product is 125 g (tenderloin 250 and 500 g), small-sized - portions of 250, 500 and 1000 g (meat and bone).

In the production of natural semi-finished products, salting and massaging can be used. The composition of the brine includes salt, phosphates, granulated sugar; for some items, a sprinkling of spices and decorative spices is used.

Semi-finished products in the test. The specifications developed by VNIIMP present the traditional and new assortment of dumplings, as well as other semi-finished products in dough: meat sticks, manti, khinkali. According to other specifications, several dozen types of dumplings are produced, designed for buyers with both high and low incomes. The composition of minced dumplings includes trimmed beef and pork, onions, black or white ground pepper. To prepare the dough, use flour of the highest grade (sometimes the 1st grade) with a normalized quantity and quality of gluten, egg products.

Meat sticks are cylindrical or rectangular in shape up to 10 cm long. Manty is a dish of Uzbek cuisine. They are larger than dumplings. They are not boiled in water, but steamed in a special dish - manti-kaskan. Khinkali is a dish of Transcaucasian cuisine such as dumplings in the form of a rhombus, a square. Meat for manti and khinkali is chopped larger than for dumplings and sticks, minced meat for these products contains an increased amount of onion.

Ravioli in minced meat also contain mushrooms and rennet cheese, they have the shape of a semicircle, rectangle, square.

Chopped semi-finished products. They are prepared from minced meat with the addition of other ingredients according to the recipe. The traditional assortment of chopped semi-finished products includes: Moscow, homemade, Kyiv cutlets, rump steak, beef steak. The main raw materials in their production are beef and pork cutlet meat, trimmed beef of the 2nd grade, trimmed fatty pork. During the years of the economic crisis, the range of chopped semi-finished products expanded due to the use of cheaper raw materials - mechanically deboned poultry meat, soy protein preparations, mainly textured soy flour, vegetables, cereals.

The recipe for cutlets consists of cutlet meat: Moscow - beef, Kyiv - pork, domestic - beef cutlet and fatty pork in half. The composition of all items includes (%): wheat flour bread - 13-14, onion - 1-3, water - 20, breadcrumbs - 4, salt, pepper, in Kiev - egg melange. The rump steak uses hydrated soy protein instead of bread; in a steak - beef cutlet meat - 80%, sausage bacon - 12%, water - 7.4%, pepper, salt, no breading. It is allowed to replace 10% of raw meat in cutlets with soy concentrate or texturate and in all items 20% of raw meat with mechanically deboned poultry meat. Chopped semi-finished products are produced chilled (0-6 °С) and frozen (not higher than -10 °С).

Chopped meat. Minced meat is obtained from meat by grinding it on a top with a lattice hole diameter of 2-3 mm. The traditional range of minced meat: beef, pork, homemade, lamb, special meat and vegetable. For the production of minced meat, meat frozen more than once, boars, bulls, lean, pork with signs of yellowing is not allowed. The main raw material for minced meat: beef cutlet meat or trimmed beef of the 2nd grade (minced beef), semi-fat pork or pork cutlet meat (minced pork). The composition of homemade minced meat includes (%): beef (50) and pork (50) meat; special minced meat - beef (20), pork (50), soy concentrate (30).

Meat chopped semi-finished products after manufacturing can be raw chilled or raw frozen. As an example, the following chopped raw semi-finished products can be given: cutlets, meatballs, hamburgers, schnitzels, steaks, rump steaks, kebabs, meatballs, meatballs, quenelles and croquettes.

To prepare minced meat for chopped semi-finished products, frozen meat raw materials (blocks) are crushed in a crusher. Also, for the preparation of minced meat, mechanically deboned meat obtained on a meat and bone separator can be used.

Then the minced meat is passed through the top. Pork bacon is added to minced meat, which is pre-crushed on a top or on a bacon cutting machine. Salt, water pre-chilled with ice, additives, spices are added to the minced meat and everything is mixed well in a meat mixer. A cutter can also be used for mixing.

Minced meat ready for molding semi-finished products is loaded into the bunker of the machine for molding semi-finished products, where the product of the required shape and weight is molded, for which, depending on the volume of production, a rotary or auger product molding system is used. In the molding machine, the patties are formed and dosed onto a belt, after which the product can be sent to the ice cream machine and / or breading machine for thin and dry breading, respectively.

Then the cutlets are sent on trolleys to the shock freezing chamber or automatically by conveyor to the spiral quick freezer in case of high line capacity. The duration of freezing cutlets w75x20 mm weighing 85 g in a shock freezing chamber is 2 hours, and in a spiral quick freezer - 40-45 minutes. After freezing, cutlets are packed and moved to a cold store for storage.

Main raw material.

Beef, pork, lamb, horse meat, as well as the meat of other types of slaughter animals are used as the main raw materials.

Do not use double-frozen meat and pork with darkened bacon.

Along with meat raw materials, various protein preparations of plant and animal origin (soya, blood, milk proteins, etc.) are widely used, as well as melange, egg powder, vegetables and other components, depending on the direction of use of the meat product.

Auxiliary materials.

Auxiliary materials for all products are salt (1.2% by weight of minced meat), black pepper (0.04-0.08%) and water (6.7-20.8%) added to minced cutlets to increase its juiciness. The introduction of isolated soy protein, high-protein milk concentrate in minced meat in the amount of 10-20% allows replacing up to 10% of meat, improving their organoleptic qualities, increasing nutritional and biological value, increasing water-binding capacity, and reducing losses during frying. When preparing auxiliary raw materials, onions and vegetables are washed and chopped. Bread is soaked and also crushed. Melange is thawed in advance in baths with water, the temperature of which is not higher than 45C.

Basic technological equipment.

Crusher of frozen blocks - a machine for grinding deep-frozen meat (with a temperature of up to - 30 ° C) for further processing on a cutter or top. At the same time, preliminary defrosting of the product is not required, which allows preserving the taste of the product and preventing loss of nutrients.

The crushing of the block, depending on the subsequent destination of the raw material obtained after the crusher (pieces of the size of a fist or into slices), can be carried out on a machine with a rotating shaft with knives or rollers or on a guillotine-type machine.

The grinder for meat is designed for industrial grinding of meat, meat products, fats in order to produce sausages and other food products.

The meat grinder is the main machine in the production lines for the production of sausages and semi-finished products. The quality of the products obtained directly depends on how finely and accurately the top cuts the lumpy meat.

The principle of grinding lumpy meat used in meat grinders has not changed for many years: the meat in the receiving hopper is captured by an auger or augers and fed through a housing with internal ribs to a cutting tool, which is a set of fixed grates, usually consisting of three pieces, and movable knives, consisting of two pieces.

Different tops for meat, despite the same method of grinding and the apparent simplicity of design, have completely different quality of grinding. It is affected by even minor design features inherent in each of the designs, as well as the degree of wear of both the cutting tool and the housing with the screw.

Meat mixer. The purpose of the meat mixers is to mix the crushed products with spices and other ingredients. Usually minced meat, cereals and other products are mixed in meat mixers.

The main components of the meat mixer are the bowl, the lid and the mixing mechanism.

Dezha is a mixing bowl connected to a kneading unit. Usually the meat mixer bowl is made of stainless steel with a smooth surface, which greatly facilitates its cleaning and operation in general. The meat mixer is designed in such a way that it contributes to uniform mixing of all minced meat ingredients. Mixing takes place by means of kneading screws.

The design features of the bowl (dezha) and the blades of the meat mixer ensure an even distribution of the ingredients over the minced meat.

Meat mixers are vacuum and open (non-vacuum). Mixing minced meat in a vacuum mixer ensures a dense, pore-free structure of minced meat, increases the color fastness of products.

All meat mixers have protective mechanisms. In particular, it is a mechanism for blocking one or more kneading augers when the bowl lid is opened. The process of loading and unloading raw materials is usually fully automated.

Meat-and-bone separators, or minced meat machines, are used to separate meat from bone in the production of edible minced meat, chicken or fish.

The minced meat obtained in this way can be used for the production of high-quality products, since it retains the structure of muscle tissue.

The principle of operation of the machine is that the incoming raw material is loaded into the separator hopper without prior grinding (with some exceptions). Pork or beef bones are recommended to be pre-shredded into fist-sized pieces, without the need for an additional grinder, which optimizes the use of production space.

All designs of mechanical separators are based on the principle of separation, taking into account the physical characteristics of the processed raw materials.

Using various pressures, meat or other product is forced through the slotted or round holes of the separating head, and bones, cartilage and (or) veins are removed through the front of the machine. The product output is adjusted manually using the cones at the front of the separating auger and the restrictor.

The minimum temperature increase in the case of an incoming raw material temperature of 0-2ºC (this temperature is optimal) is usually 1-2ºC for chicken, 4-7ºC for turkey, and approximately 10ºC for beef.

Cutter - turns meat into soft airy minced meat for cooking boiled sausages, sausages, sausages. The cutter grinds products in a vacuum. Fast rotating knives (up to 4500 rpm) instantly turn meat into minced meat, which retains its natural color, vitamins and nutrients in the absence of oxygen. Thanks to the processing without access to air, the quality of the final product and its shelf life are significantly increased.

Cuttering is the process of fine grinding of meat raw materials. The duration of cuttering significantly affects the quality of minced meat. Cuttering lasts an average of 5-12 minutes, depending on the minced meat being prepared, the design features of the cutter, the shape of the knives, and the speed of their rotation. Cuttering not only ensures the proper degree of meat grinding, but also the binding of the added ice. And it is the cutting process that largely determines the quality of the final product.

Ice maker. In the meat processing industry, a large amount of water ice is required for the production of various products. Flake ice produced on flake ice machines is optimal for use. It has a flat shape, thanks to which it has a large heat exchange surface, so it cools the minced meat better than other types of ice.

The temperature of the produced flake ice at the exit from the ice generator is up to minus 12°C, the thickness is from 0.8 to 2.8 mm. The productivity of the machines is from 380 kg to 23 tons / day.

Lard cutter - allows you to cut into cubes, strips or circles fresh, boiled and frozen (up to - 5 ° C) meat, lard, as well as ready-made sausages, ham, vegetables. Products containing bones should not be cut.

Machine for molding semi-finished products. After grinding meat raw materials, adding other ingredients, mixing and cooling, the minced meat is ready for molding. With the help of forming equipment, you can give products a variety of shapes.

Breading machine. The next stage after the molding of chopped meat products is the stage of breading (coating) of the product. The breading process consists of three operations - pre-sprinkling, liquid breading and coating with breadcrumbs. Various combinations of these operations or all three coatings may be used in the manufacturing process. However, there are standards for the amount of sprinkling used, the amount of which should not exceed 30% by weight of the finished product.

In fact, breading improves the product in many ways: it makes the product more juicy while retaining moisture and flavor. Breading makes products more attractive. In addition, breading increases the weight of products, increasing the cost.

Pre-sprinkling is often used in the manufacture of breaded products to improve the adhesion of the wet breading. This operation is very important for products with a wet or greasy surface. For this operation, flour or a dry protein mixture for breading is usually used.

There are many different types of dry breading used in the manufacture of meat products. They come in a variety of sizes, shapes, textures, colors and flavors. Finely ground breadings are very popular and traditional. They give the product an airy look and feel like a homemade product.

Laying machine. Liquid breading plays a very important role in the coating technology for semi-finished meat products. When preparing products, two types of breading can be used: yeast and unleavened. The choice of one type or another depends on the recipe of the product. Liquid breading is a mixture of various ingredients that may include flour, starches, eggs, milk, spices and herbs, leavening agents and stabilizers.

When applying a liquid breading in order to increase adhesion, it is used in combination with dry breadings. In this case, fresh breadings with different viscosities are more often used.

Equipment for the laying of minced meat semi-finished products from minced meat raw materials (minced meat) of beef, veal, pork, lamb without filling (cutlets, hamburgers, meatballs and other similar products).

Shock freezer. Now the freezing of products occurs thanks to a special technology for removing heat from the product. At the same time, the temperature drops and at a certain point the water in the product begins to turn into ice crystals.

The product is considered frozen if its temperature is -6 degrees. In meat, 75 percent of the water freezes at minus 5°C; 80 percent - at minus 10°C; and 90 percent - at minus 20 degrees.

Freezing products is used primarily for their long-term storage.

Technologically, the freezing process can take a different amount of time. Best of all, product quality is preserved by quick (shock) freezing. As a result of this process, very small ice crystals are formed inside the product, which has a positive effect on the quality of the product, since there is minimal damage to the tissue of the product.

It was for these purposes that special devices were created - shock freezing chambers. They allow you to quickly freeze a product or dish, while maintaining its beneficial properties.

Packing machine. Filling and packaging machines, multiheads (electronic high-precision weighers), packaging systems for food or non-food small-piece, free-flowing, non-dusty products. The equipment uses the principle of weight dosing and is used for packaging.

Refrigerated warehouses and storage chambers include: a heat-insulating circuit (chambers) with doors and a refrigeration supply system.

As a heat-insulating circuit, chambers made of PPU sandwich panels with refrigerated doors produced by our own factory are used. The refrigeration system includes: a refrigeration compressor unit, a condenser, an oil cooler, a circulation receiver and a pumping station (in the case of a pump-circulation refrigerant supply scheme), an electrical control panel, refrigerant pipelines and electrical cable lines.

Meat semi-finished products are raw meat products prepared for heat treatment (boiling, frying). The centralized production of semi-finished products at modern enterprises in the form of portions in hygienic packaging leads to a reduction in the cost of portioned dishes, and also increases labor productivity and service culture at retail and public catering enterprises, contributes to the development of progressive methods for the sale of meat products and facilitates the technology of cooking at home

The technological scheme for the centralized production of large-sized, portioned, small-sized, chopped semi-finished products is practically the same as in public catering enterprises operating on raw materials, but additionally includes cooling of semi-finished products, their packaging and transportation.

Portioned (natural and breaded) and chopped semi-finished products are placed on the liners of plank, plywood, aluminum, polymer multi-turn boxes without wrapping in cellophane, in one row, semi-obliquely, so that one semi-finished product is partially above the other. Each box should contain no more than three inserts.

Large-sized and small-sized semi-finished products are placed in the same boxes, but without liners.

A label is put into the container, and a label is stuck on the box, which indicates the name of the manufacturer, the name of the semi-finished products (type of meat), the number of semi-finished products (pieces, kg), the date and hour of their manufacture, the shelf life and sale.

Before sale, semi-finished products are cooled to a temperature of 6-8°C. Shelf life and sale at a temperature not exceeding 8 ° C (in hours): large-sized semi-finished products - 48, portioned natural - 36, portioned breaded - 24, small-sized - 24, chopped (natural and cutlet mass) - 14.

Each batch of semi-finished products must have a quality certificate (certificate). Procurement enterprises produce the same range of large-sized, portioned and small-sized semi-finished products as enterprises operating on raw materials. However, during centralized production on the tenderloin, thick and thin edges, the tendon is not removed from the outside.

Such portioned semi-finished products, such as rump steak, schnitzel, chops, are allowed to be produced without beating, loosening and breading in order to avoid loss of juice and soaking of the breading during transportation and storage. Natural zrazy can be unstuffed. In these cases, beating, loosening, stuffing is carried out at pre-cooking enterprises. Portioned semi-finished products are produced: sliced ​​- weighing 80 or 125 g, rump steaks, schnitzel, cutlets chops without breading - 70 and 110 g each.

With the centralized production of chopped semi-finished products, the cooking technology is somewhat different from that provided for in the Collections of Recipes. So, for chopped steaks, the bacon is crushed on a lard and sent to a meat mixer.

In the centralized production of products from cutlet mass, it is not necessary to squeeze the soaked bread before combining it with meat, since this reduces the acidity of the semi-finished product, increases its pH, and creates favorable conditions for the development of microorganisms. In this case, water is continuously fed into the neck of the meat grinder simultaneously with pieces of bread.

In order to mechanize the main stages of the production of minced meat products, a meat grinder or a cutter, a meat mixer, a cutlet semi-automatic machine, a bath for soaking bread, and a grinding mechanism for preparing breading are installed at procurement enterprises.

With the centralized production of products from cutlet mass, it is possible to replace bread with semolina and mold the mass in the form of sausage loaves in the shell.

The range of chopped products produced centrally is as follows: Moscow cutlets, home-made cutlets, Kiev cutlets, lamb cutlets, chopped steak, chopped schnitzel, natural chopped cutlets, lula-kebab.

All semi-finished products must meet the requirements of regulatory and technological documentation for their weight, shape, size, organoleptic characteristics. For some semi-finished products, humidity, fat content, bones, connective tissue are also regulated.

Beef goulash should contain no more than 10% fat, pork - no more than 20%, lamb stew should contain no more than 20% bones, fat - 15%. In meat for lamb skewers, fat should be no more than 16%, from pork - no more than 20%, in roasted pork - 20%, etc.

In cutlets, the moisture content should be no more (in%): in Moscow - 68, homemade - 66, lamb - 65; bread - no more than 18% in home-made and no more than 20% in Moscow cutlets (including breadcrumbs).

The surface of large pieces is even, without tendons. No signs of spoilage, sunburn, sliminess, etc. are allowed. Natural portioned semi-finished products should have a slightly moist, but not sticky surface. The edges of breaded semi-finished products are even; the thickness of the breading layer is not more than 2 mm. The smell is characteristic of this type of meat.

The consistency of muscle tissue on the cut of chilled meat is dense, elastic; thawed - softer. The shape of the pieces of small-sized semi-finished products is correct, the release of juice is not allowed. The color and smell are natural, characteristic of this type of meat. The surface of semi-finished products from minced meat is evenly breaded, without cracks or broken edges.

Compliance with the mass should be monitored by piece weighing at least 10 products. Allowed weight deviation for individual semi-finished products within ± 3%.

Large-sized semi-finished products. Roast beef are made from tenderloin, thick and thin edges.

They are cleaned from surface films, and the tenderloin is cleaned from tendons. For uniform heating, the semi-finished product is formed from two cuts, folding the head with the tail and tying it with twine. Sometimes the semi-finished product is wrapped with a thin layer of bacon to give the dish juiciness. Used for frying.

Canned stewed meat prepared from the upper, inner, side, outer pieces of the hip part weighing 1.5-2 kg.

stuffed meat prepared from the same parts as the stew. Before heat treatment, the meat is stuffed with a lard needle or a knife along the fibers with long sticks of carrots, white roots, bacon.

boiled meat prepared from the scapular, subscapular parts, brisket, hem (meat of category I). Beef intended for cooking is cut into pieces weighing 1.5-2 kg.

Portion semi-finished products. Steak cut at a right angle from the thickened part of the tenderloin (head) 2-3 cm thick, lightly beaten off.

Fillet cut from the middle part of the tenderloin, 4-5 cm thick, sometimes tied with twine to avoid deformation during heat treatment.

Langet cut at an acute angle from a thin part of the tenderloin (tail), two pieces per serving, 1-1.2 cm thick. The semi-finished product is slightly beaten off.

Entrecote cut from thick and thin edges at a right angle, 1.5-2 cm thick. Pieces have an oval-oblong shape.

Rump steak cut from thick and thin edges, upper and inner pieces of the hip part, 0.8-1 cm thick, beaten off, moistened in a lezon, breaded in breadcrumbs.

Zrazy chops cut from the side and outer pieces of the hip part, 1-1.5 cm thick, beat off, put the minced meat in the middle, roll it up in the form of sausages and tie it with a thread or twine. For minced meat, browned onions are combined with boiled chopped eggs or mushrooms, parsley, ground breadcrumbs; add salt, pepper and mix.

beef cut from the side and outer pieces of the hip part, 2-2.5 cm thick. Portion - one or two pieces of pulp of irregular quadrangular or oval shape, approximately equal in weight.

Small-sized semi-finished products. beef stroganoff cut from tenderloin, thick and thin edges, upper and inner pieces of the hip part. From a large piece, layers are cut across the fibers, beaten off and cut into sticks 3-4 cm long, weighing from 5 to 7 g.

Roast cut from the thick and thin edges, from the upper and inner pieces of the hip part into pieces weighing 10-15 g.

Meat for barbecue - slices weighing 30-40 g are cut from the tenderloin, sprinkled with salt, pepper and pricked on a skewer interspersed with pieces of bacon half as thick.

Azu cut from the lateral and outer pieces of the hip part into cubes 3-4 cm long, weighing 10-15 g.

Goulash - from the pulp of the scapular and subscapular parts, brisket, trim pieces weighing 20-30 g. The fat content should not exceed 10%. Before cutting the semi-finished product, large pieces from the surface film are not cleaned.

Prepared from lamb and pork

Large-sized semi-finished products. Pork ham is prepared from pork ham, which is sometimes not skinned. The ham is completely rolled.

For a dish lamb (pork) fried use the pulp of the shoulder blade, which is rolled up, turning inward the upper and lower edges of the shoulder blade. The formed semi-finished product is tied up with twine. They also prepare a spatula for cooking and stewing.

For cooking lamb or pork stew stuffed the pulp of the scapula is preliminarily stuffed with carrots and parsley, chopped sticks, and then rolled up.

Portion semi-finished products. Cutlets natural from lamb and pork cut from a loin with a rib bone. A portion piece is cut obliquely (at an angle of 45 ") along the costal bone, cutting the flesh 2-3 cm from its lower end. The bone is cleaned from films and pulp residues. The cutlet is beaten off and trimmed, giving an oval shape.

Cutlets chops they are prepared in the same way as natural ones, but the semi-finished products are moistened in a lezon and breaded in breadcrumbs.

Shashlik Karski cut from the kidney part of the loin, one piece per serving. The semi-finished product has a rectangular shape. It is marinated. For pickling, chopped meat is placed in a non-oxidizing

dishes, sprinkle with lemon juice, citric acid or vinegar, sprinkle with finely chopped onions, salt, ground pepper, parsley or dill. You can add vegetable oil. Put in the refrigerator for 4-5 hours. The kidneys are marinated along with the meat. Before frying, half a kidney is put on a skewer, then meat and a medium-sized tomato.

Escalope cut from the ribless (kidney) part of the loin in two pieces per serving, 1-1.5 cm thick. The semi-finished product is given an oval-flat shape.

Schnitzel chop is cut from the ham into pieces 2-2.5 cm thick, oval-oblong in shape. Pieces are beaten off, films and tendons are cut, moistened in lezon and breaded in breadcrumbs.

lamb,porkwind cut from the shoulder part, one or two pieces per serving, 2-2.5 cm thick, without cleaning the surface film.

Small-sized semi-finished products. Meat for barbecue cut from a ham or loin without ribs, into pieces weighing 30-40 g. Before heat treatment, the meat is marinated and then put on a skewer in 5-6 pieces.

Roast cut from the loin and pork ham in the form of sticks weighing 10-15 g.

Goulash cut from the pulp of the scapular and neck parts of pork into pieces weighing 20-30 g, with a fat content of not more than 2% of the weight of a portion of the semi-finished product.

Pilaf cut from the pulp of the shoulder blade of lamb into pieces weighing 10-15 g.

Stew chop lamb or pork brisket into pieces with a bone, weighing 30-40 g. It is allowed to use meat and bone pieces of lamb from the loin from the 1st to the 4th rib.

Semi-finished minced meat

Cutlet meat is the main raw material for the production of chopped semi-finished products. It is ground in a meat grinder or cutter. Minced meat is used to prepare natural semi-finished products and semi-finished products with the addition of bread and other components. Pieces of cutlet meat should be stripped of tendons and coarse connective tissue. To improve the taste and juiciness of finished products, raw fat (5-10% of the mass of meat) is included in the composition of lean cutlet meat. In pork cutlet meat, the content of adipose tissue is allowed not more than 30% and connective tissue - not more than 5%. In cutlet meat from beef, lamb, veal, the content of both fats and connective tissue should not exceed 10%.

Chopped natural semi-finished products. The meat is cut into pieces, combined with raw lard and ground in a meat grinder or cutter. Water (8-12% of the mass of meat), salt, pepper are introduced into the prepared mass, thoroughly mixed and semi-finished products are formed. Semi-finished products can be

Not breaded (steak, natural cutlets, kebab, meatballs) and breaded (natural chopped schnitzel, Poltava cutlets).

Steak chopped made from beef. Bacon cut into cubes (5x5 mm) is added to the chopped mass, portioned, and the products are given a flattened-rounded shape. product thickness 2 cm.

Cutlets natural chopped prepared from lamb or pork, giving the products the shape of cutlets - oval-flattened with one pointed end.

Lula kebab prepared from cutlet lamb meat. Pulp with lamb fat (fat tail), raw onions are passed 2-3 times through a meat grinder. Onion not only flavors the meat, but also softens it, as it contains proteolytic enzymes. Add pepper, salt, citric acid to the cabin, mix well and put in the refrigerator for 2-3 hours for pickling. After that, they are portioned, shaped into small sausages.

Meatballs finely chopped onions, raw eggs, ground pepper, salt, water are introduced into minced meat, knead well and cut into balls of 7-10 g each. They are put in soups on vacation.

Schnitzel natural chopped prepared from pork, lamb, beef. The semi-finished product is given a flat-oval shape, moistened in a league zone and breaded in breadcrumbs, the thickness of the products is 1 cm.

Cutlets Poltava made from beef. In the chopped mass, add lard, cut into small cubes, chopped garlic and mix. Then they are portioned, shaped into cutlets and breaded in breadcrumbs.

Chopped semi-finished products with bread(products from cutlet mass). To prepare products with the addition of bread, cutlet meat minced in a meat grinder is combined with stale wheat bread (20-25% by weight of meat) of the 1st or highest grade, previously soaked in water or milk (total amount of liquid 30-35% by weight of meat) and squeezed, salt, pepper are added and again passed through a meat grinder, water is added and thoroughly kneaded (whipped). From the cutlet mass with a bread content of 25% of the mass of meat, cutlets, meatballs, schnitzels are formed. From the cutlet mass with a slightly smaller amount of bread (about 20% of the mass of meat), meatballs, chopped zrazy, roll, meatballs, Moscow, Kiev, lamb, homemade cutlets are prepared.

cutlets- products of an oval-flattened shape with one pointed end, breaded in breadcrumbs (their thickness is 1-2 cm, width - 5, length - 10-12 cm).

meatballs- flattened-rounded products, 2-2.5 cm thick, 6 cm in diameter, breaded in breadcrumbs.

Schnitzels- products of an oval-flattened shape, 1 cm thick, breaded in breadcrumbs

Meatballs- products in the form of balls with a diameter of 3 cm, breaded in flour. Chopped sautéed onions are added to the cutlet mass. Instead of bread in shredded meat Zrazy chopped- minced meat is placed in the middle of the cake from the cutlet mass 1 cm thick, the edges are connected, breaded in breadcrumbs, molded in the form of a brick with oval edges. For minced meat, they take passivated onions, chopped eggs, parsley, salt, pepper and mix everything. You can also stuff with an omelette cut into small slices.

Roll- on a moistened napkin, gauze or plastic wrap, spread the cutlet mass in the form of a rectangle 1.5-2 cm thick, minced meat is placed in the middle of it along the length. The mass is connected with a napkin so that one edge of it is slightly on the other, after which the roll is rolled from the napkin onto a greased baking sheet, seam down. The surface of the roll is smeared with an egg, sprinkled with breadcrumbs, sprinkled with fat, pierced in several places.

Meatballs- cutlet mass with the addition of raw onions is cut into balls weighing 10-12 g and breaded in flour.

Moscow cutlets are made from cutlet meat of beef with the addition of raw fat and onions.

Cutlets Kyiv - pork with raw fat and onions. Breaded in breadcrumbs.