Reconstruction of sausage production line

Introduction

The meat industry is one of the largest branches of the food industry, providing the population with proteins, amino acids and trace elements necessary for organisms.

To increase the output of meat and meat products, new meat processing facilities are constantly being reconstructed and put into operation. There is a constant technical improvement of production technologies and equipping the enterprises of the meat industry of the agro-industrial complex of the country with co-temporary technological equipment.

An analysis of the nutrition of various groups of the population of the Russian Federation, conducted by the Institute of Nutrition of the AMNRF, indicates that at present, food consumption not only fully provides, but for a significant part of the population exceeds energy needs. At the same time, the need for proteins, primarily of animal origin, is only 80% satisfied.

It is necessary at the present stage that the range and quality of meat products meet the changing physiological needs of the country's population.

The production of high-quality meat products is a comprehensive cottage. Its solution depends on improving complex and waste-free technologies for processing agricultural raw materials, further automation and mechanization of enterprises, reducing raw materials, energy and labor costs, and increasing labor and production discipline.

One of the important tasks facing employees of the meat industry (in particular sausage production) is to further improve the quality of the product and its nutritional value, to more fully use the raw materials of various protein additives. To achieve this task, it is necessary to constantly improve all technological processes and bring them in rational and optimal modes, constantly monitoring the quality of raw materials and finished products at all stages of technical processing.

Increasing the production of meat and meat products to better meet the needs of the population is one of the tasks of the food program. It is important not only to increase the total production of meat products, but also to ensure their maximum production from each ton of processed raw materials, to increase the quality, nutritional value, product indicators and to diversify the range.

In domestic industrial practice, recipes of more than 200 types of various sausages and salty products are known, moreover, each of them has its own unique characteristic appearance, taste, composition, properties and shelf life. From this position, it is important to reconstruct the existing sausage workshop at the Yelizovsky Pig Complex SHP enterprise, which will increase the volume of production and economic efficiency of the enterprise.

2. Feasibility study

In the cities of Petropavlovsk - Kamchatsky and Yelizovo, the main supplier of products are local enterprises such as: SHP Yelizovsky Pig Complex.

Recently, the processing of agricultural products in small-capacity workshops has become increasingly widespread in our country. The development of small meat processing shops solves a number of problems with providing the population, especially the "outback," with meat products. These workshops are commissioned faster than large meat processing plants.

At the beginning of its work, the company was mainly engaged in boiled and smoked sausages, and there was no question of delicacies. Due to the fact that the company did not have the necessary equipment, but after several years this equipment was purchased and after adjustment, the company began to produce delicacies that quickly won their place in the markets of the city of Petropavlovsk and Yelizovo.

2.1 Region demand for finished products

The assortment that the plant currently has is: boiled sausages, smoked sausages, various smoked foods, as well as meat breads. The demand for meat products is one of the most important diets of the inhabitants of the peninsula.

SHP "Yelizovsky Pig Complex" among the factories whose products are characterized by good quality, large assortment and demand for products, the number of consumers has changed significantly over the years, and the meat industry on the peninsula has begun to increase. The shelves feature a wide variety of sausages and meat delicacies, including imported production. Today, about 60% of residents

The Kamchatka Territory prefers the products of the Yelizovsky Pig Complex agricultural enterprise, so it can be called the leader among such large local enterprises as Agrotek Holding CJSC and Yukidim CJSC.

2.2 Geographical location of the enterprise

The sausage workshop of the Yelizovsky Pig Complex agricultural complex is located on the 20 kilometer of the Yelizovskaya highway in the village of Nagorny, in the reconstructed building of the former food store. The meat processing plant is located 100 meters from the central road. The plant has convenient access roads, and is located in the vicinity of raw materials located on 19 km of the Yelizovskaya highway, which ensures the continuous operation of the meat workshop..

2.3 Climatic conditions of the area

The village of Nagorny is located in the south-west of Petropavlovsk-Kamchatsky. This area is characterized by the mildest winter and sunny autumn, as well as in the area in summer much warmer.

Winter here lasts from mid-November to mid-April inclusive. The average temperature of the two coldest months (January, February) does not fall below minus twenty degrees. There are almost no days with an average monthly temperature below minus thirty degrees. The climate of the region is dry. Wind speed up to 5-8 m/s, maximum wind speed exceeds 40 m/s. The transition from stable, sunny, warm autumn weather occurs most often quite sharply and quickly. In winter, Kamchatka is influenced by the Aleutian Depression, which often includes cyclones. The average temperature varies widely throughout the year. In summer, most of the time in Kamchatka and the adjacent waters of the seas is spread by the crest of the Pacific anticyclone. The average annual wind speed is 7 m/s, and the largest number of days with strong winds is 170. Relative humidity characterizes the degree of saturation. Extremely heavy precipitation in the form of rain and sleet is very characteristic of the region. The monthly rainfall reaches 1,5002,000 mm, and in some years exceeds 5,000 mm.

2.4 Regions Supplying Materials

The regions that supply raw materials (chicken ham) and spices, except for those that can be purchased from us on the peninsula, are Vladivostok or Khabarovsk, and pig carcasses are delivered in refrigerated machines from 19 km to a plant located 20 km.

2.5 Delivery of products to the consumer

The products are delivered to the consumer from the warehouses of the Yelizovsky Pig Complex to the outlets of the enterprise itself and through the wholesale and retail network according to the concluded supply agreements. Finished products are distributed in the Yelizovsky district, Peter and Paul Kamchatsky, Vilyuchinsk and in some small settlements of the Kamchatka Territory. All products are predominantly delivered by refrigerated machines of the company itself or by transport provided for this purpose.

Another important form of product marketing is the supply of municipal institutions of the Kamchatka Territory.

3.2 Description of production preparation technology "Semi-smoked pork sausage 1"

"Semi-smoked pork sausage 1" is made in accordance with the requirements of GOST R 52962003 "Smoked-boiled pork products. Specification, "as approved in the appropriate process instruction and recipe.

Raw Material Acceptance

For production of semi-smoked products from pork, pork semi-ducts are used according to GOST 759577 in a cooled state, the rules of at-capacity and volume of samples are carried out according to GOST 979273. Raw materials supplied to the production shop must comply with the norm of regulatory and technical documentation for products, as well as undergo expert analysis in the laboratory for the presence of pathogenic microorganisms and toxic elements, in accordance with the current instructions and rules of sanitary and epidemiological supervision.

Boning

Bumping is carried out in order to separate meat from bone and sort with the help of acutely honed knives. When collapsing, it is unacceptable to get small bones, pieces of periosteum and cartilage into the meat.

Crushing

Grinding is carried out in mincer with the diameter of the grid holes from 16 to 25 mm, for better further seeding and ripening.

Ambassador

The ground meat is placed in plastic boxes or other containers intended for this purpose. Mince is mixed with salt according to the formula in order to achieve a preserving effect, improved organoleptic and structural-mechanical characteristics.

Maturing

Maturation occurs at a temperature of 0 to 6 0C, lasting from 12 to 24 hours. During this period, muscle tissue softening, denaturation of salt-soluble protein occurs, as a result, the mince becomes more sticky. The exact length of ripening time is established by the production technologist.

Chopping, mixing with recipes components

Mince is chopped and mixed simultaneously with addition of recipe components during grinding, and ice can be added to prevent overheating of the mixture. One performs mixing till mince uniform in consistency. Temperature during grinding and mixing must not exceed 12 0С to 16 0С.

Preparation of Recipe Components

Recipe components are prepared in a separate room

Garlic is divided into slices, cleaned, washed in running cold water. Then it is minced with hole diameter of 2-3 mm. Who-can also be used in dried form, pre-soaked, or with the addition of the required amount of water directly when added to the stuffing mixture

Black pepper, allspice are milled and sieved through a sieve with the size of holes up to 0.8 mm in order to prevent large particles from entering the mince.

Sodium nitrite is used as a 25% solution.

Filling the shells with mince

The shells are filled with mince using hydraulic and vacuum syringes. It is recommended to use peaks with a diameter of 100 mm less than the diameter of the shell. The shell is tightly filled, especially compacting mince when tying the free end. Batons are bandaged with twine, threads or wrapped in the form of semi-rings (rings), commercial from-marks are applied. Air entering the mince during syringe is removed by piercing the shells. In the presence of special equipment and a marked shell, the shells are filled with mince, staples are applied to the ends of the bars with simultaneous manufacture and insertion of a loop under the clip, cutting the link between the bars. Batons should not contact each other to avoid slips.

Draft

Bandaged bars are hung on a rhea or frame and subjected to precipitation for from 2 to 4 hours at temperature from 40C to 8 0C, for structure compaction.

Heat treatment

Bars are dried and fried at temperature of 95 ± 5 0С, relative humidity of air from 10% to 20% and speed of its movement 2 m/s. 1520 minutes before the end of the roasting process, the humidity in the chamber is increased to 52 ± 3% in order to avoid excessive wrinkling of the shell. The bass number is kept on average from 40 to 80 minutes (depending on the diameter of the shell) until the temperature in the center of the batter is 71 ± 1 0С. Smoking is carried out immediately after roasting, gradually reducing the temperature in the chamber from 95 ± 5 0C to 42 ± 3 0C, maintaining the relative humidity of the smoke-air medium in the range from 60% to 62%, at a rate of 1 m/s, up to 8 hours. At the end of the heat treatment process, the product acquires the taste and smell of smoked products and is ready for consumption.

Cooling

Thermally treated batons are cooled in blowing chambers with the help of cold water.

Drying

Sausage is dried at temperature 11 ± 1 0С and relative air humidity 76.5 ± 1.5% until elastic consistency is acquired and standard weight fraction of moisture is achieved .

Packaging, labelling

Semi-smoked sausages are packed in wooden multi-turn boxes according to GOST 11354, boards - according to GOST 10131, polymer multi-turn, aluminum or in containers made of other materials allowed for use by the Ministry of Health of the Russian Federation, as well as in specialized containers or packaging equipment.

Containers for sausages must be clean, dry, without mold and foreign smell. Multi-turn packagings shall have a cover.

For local implementation, it is allowed to cover the container with wrapping paper as per GOST 8273, parchment, subparchment.

It is allowed to pack sausages in repaired and sanitary-treated multi-turn wooden containers, ensuring the safety and quality of products.

The gross mass shall not exceed 30 kg.

Semi-smoked sausage of one name is packed into each box or container.

Non-target bars of semi-smoked sausages weighing at least 300 g are allowed for local implementation. At the same time, the ends of the bar must be wrapped with a napkin of cellophane according to GOST 7730, parchment according to GOST 1341, under-parchment according to GOST 1760 or other materials allowed for use, and tied with a stamp, thread or rubber cladding. The number of non-target batons should not exceed 5% of the lot.

Transport marking - GOST 14192 with application of "Perishable cargo" manipulation mark and container weight.

It is allowed not to apply transport marking on multi-turn packagings with products intended for local sale.

Marking characterizing the product shall be applied on one of the end sides of the transport container with non-washable non-washing paint by means of a stamp, stencil or label gluing indicating:

name of manufacturer's enterprise, its subordination and trademark;

names and varieties of sausage;

date of manufacture;

gross masses, packagings;

designations of this standard.

Each packing unit of packaged semi-smoked sausages with a net mass of 50, 100, 150, 200, 250 g shall have a label in the form of a paint print on the film or pasted on it with an indication.

name of manufacturer's enterprise, its subordination and trademark;

name and grade of sausage;

nutritional and energy value;

net masses;

shelf life and storage conditions;

designations of this standard.

In addition, a check made of a thermally sensitive or self-adhesive check tape is glued to each packaging unit, indicating:

net masses;

date of manufacture.

Transportation and storage

Smoked-boiled products are transported by all modes of transport, in refrigerated or insulated vehicles in accordance with the rules for the transport of goods in force in the corresponding mode of transport.

Semi-smoked sausages are stored in suspended condition at room temperature not higher than 12 0С and relative air humidity 75% up to 10 days.

Sausages packed in boxes are stored at temperature of cooled room not higher than 6 0С and air humidity from 75% to 78%, not more than 15 days, and at temperature from minus 7 0С to minus 9 0С to 3 months. Semi-smoked sausages can be stored in non-cooled rooms at temperature not higher than 20 0С for up to 3 days.