Equipment for the production of blown up cereals. Technology for the production of dietary bread. Raw material supply channels

The process of losing weight is rarely without restrictions. Especially often the prohibitions apply to sweet and starchy foods. But a person is so arranged that he cannot do without bread, buns, cakes and cakes. Perhaps the worst thing is that the most dangerous foods for the figure include both flour and sugar! Against this background, a logical question arises: are bread useful? Maybe they can become a full-fledged substitute and reduce the usual craving for ruddy muffins?!

Is it worth replacing?

For a long time, bread was perceived as the main product on the table. Without bread, there was no meal, but it in itself could well satisfy a person's need for food. Most nutritionists do not advise completely abandoning bread, paying attention to the fact that there is a lot of fiber. But the fact is that modern man almost never eats wholemeal bread, with seeds or bran. We are accustomed to a soft, rich product made from white wheat flour. Such a bun is a real delicacy, especially if it is flavored with raisins, poppy seeds or cumin.

Fast food restaurants do make money by using bread with all sorts of toppings. A quick sandwich saturates well and pampers the taste buds. But such a product is rich in calories almost like a full meal. A big hamburger is comparable to three meals, and an hour after eating it, a person will feel hungry again. It is difficult to give up bread, but no one requires it. But you can find a worthy analogue. For example, whole grain bread.

What do the shops offer?

A wide variety of companies produce whole grain breads, as they are considered to be a natural product, environmentally friendly and dietary. Many people believe that eating bread allows you to reduce the total daily calorie intake. Nutritionists recommend eating such foods, but at the same time they do not pursue the goal of weight loss, but general improvement. Is it worth listening to such advice, and are bread useful? Especially when you consider that the manufacturers themselves call them

By the way, the production technology is very simple. If desired, you can make bread at home. They are healthier and tastier because only natural ingredients are used in this case.

How to make loaves?

A capacious tank must be filled with yeast dough and left for a while so that it ferments. Next, it needs to be shaped by making notches for baking. In a large oven you need to send a baking sheet with chopped bread. At the factory, the next step will be packaging and sending to the store for sale. The production technology has remained unchanged for many years. But at home you can bake crispbread from ready-made bread. These will be crackers that can be made tastier with spices, garlic or onions.

In production, rye-wheat flour, a certain amount of spices or spices are often used. The name of the loaves usually reflects the composition, purpose and recipe of creation. So, they can be home, dining, amateur or even sports. Among those who want to lose weight, lovers of such products predominate, since dry pieces of bread seem so harmless to the figure.

What are they

Let us dwell in more detail on the very essence of bread. This is a fundamentally new development of our generation. In appearance, they resemble smooth plates of light color with a porous consistency. A special technology for the production of bread is called the extrusion method and consists in mixing the grain mixture with flour and eggs. The mixture must be kept at a constant temperature. Hot air evaporates moisture from the mass, and therefore cakes are formed.

In fact, you can make bread from any culture. Wheat is more popular, but corn, barley, buckwheat or oats are also suitable. Crispbread tastes very dry, but they are really filling and can serve as a great snack. They can be eaten with the main course, sandwiches or even cakes can be made on their basis.

Benefit

So, it is worth answering the main question: are bread rolls useful? Yes, in their composition they are much healthier than regular bread. They also contain more vitamins and minerals, which is so necessary for the normal functioning of the human body. Why did so many buyers like these bread rolls? Their composition is good due to the fact that only lower-grade flour is used for cooking, which contains many times more useful minerals and vitamins.

The second reason to choose crispbread lies in the use of systemic nutritional supplements, including wheat bran, beta-keratin, as well as seaweed and carrots. These are natural products that, unfortunately, cannot be added to ordinary bread. It should also be noted that there is no yeast in such an analogue of bread, and therefore those people who cannot eat ordinary pastries can eat it. The most important advantage is the content of fiber, which is necessary for the body for the normal functioning of internal systems.

Who needs to eat bread?

The composition of this amazing product allows you to use it not only for dieters, but also for any modern person who has digestive problems. Fiber deficiency can cause numerous diseases, such as diabetes, atherosclerosis, kidney disease, and others. Breadcrumbs also contain a large amount vegetable protein. This substance is easily absorbed by our body. Are breadsticks good for humans? Yes, but at a reasonable dosage.

Bread is better suited for food for our body, but what can be said about their calorie content? These products do not contain yeast and excess moisture, so you can not be afraid of heartburn. In addition, they do not contain salt, so they do not retain fluid in our body. I must say that, despite the storehouse of benefits, bread rolls remain an ordinary food product and do not become a cure for excess weight. With reasonable consumption through such baking, you can improve the intestines, remove toxins from the body, and also improve the functioning of the gallbladder. There are a lot of B vitamins in the bread, and therefore they can also have a beneficial and calming effect on the human central nervous system.

Are crispbread good on a diet?

The calorie content of such a product is not so small as to eat it uncontrollably. There are an average of 300 kcal per 100 grams, which is higher than the calorie content of ordinary pastries. But you can get enough of bread faster, and therefore they take less. One piece is less than 13 grams, and it is more than enough for one snack. A good sandwich can be made if the snack for it is dietary. To do this, you can combine fat-free cottage cheese with grated garlic, herbs, peppers and cheese.

You can make sweet bread with bread, even if you can also use low-fat cottage cheese for it, natural yogurt and berry jam. Sometimes on a diet, you can even use bread for a cake. Their calorie content, of course, varies depending on the culture used in the production. For example, rice cakes are more tender and tastier, but also heavier in terms of calories.

How to make a choice?

In the store, eyes can run wide from the wealth of choice. In fact, everyone can buy a product to their liking. It is worth studying the characteristics of your body in order to make a purchase. If a person suffers from diabetes, then it is better to choose buckwheat bread. They are also ideal for those who want to lose weight. But oatmeal is good for people seeking to cleanse the skin, as well as for those suffering from neurodermatitis and kidney disease.

Such products help to increase human immunity to colds and various infections. Usually, reviews about wheat bread are left by those who want to improve bowel function, as it is a product rich in magnesium and potassium. Barley products also improve the work of the digestive tract, and rice cakes are a beauty product, as it improves complexion and smoothes the skin.

About the extrusion method

Can I eat bread made using the extrusion method? The composition of such products includes exclusively healthy cereals, such as pearl barley, wheat or buckwheat. The essence of extrusion is that the harvested grains are soaked for a while. Further, for the preparation of bread, an extruder operating at high temperatures is used. In fact, the process is similar to the creation of popcorn, only in the end a briquette is formed. Such baking is the most useful, since it does not contain chemical additives. These breads taste good, break easily and crunch loudly.

Focus on assortment

We must start with products at a democratic price. In general, there are no very expensive breads, but for example, the brands "Generous" or "Rye" will cost the cheapest. At the same time, one cannot hide the fact that they contain margarine, baker's yeast, salt and malt. The taste of bread is better than others, but the composition greatly let down. On the positive side, a high fiber content can be noted. There are 360 ​​kcal per 100 grams, which is too much.

Wheat crispbread with dried fruits "ECO-Bread" will cost a little more. They include wheat, raisins and dried apricots. The taste of such products is good, but the hardness of the bread just rolls over. Their calorie content is relatively small - only 244 kcal per 100 grams.

Very delicate taste of wheat and oat bread. They contain oatmeal, salt and sprouted wheat. They have an average calorie content, and they can be given to children as food.

Suitable for dieters are dry wheat and buckwheat bread "Zdravo", although they contain salt. For production the technique "extruder" is used. In appearance, the loaves resemble mugs of compressed swollen corn kernels. The manufacturer does not add anything harmful.

Interesting Dr.Korner loaves are of domestic origin, despite the foreign name. They can be divided into three groups: sweet, salty and classic. These breads have the largest range of flavors and the most interesting. The classic group includes 6 items, salty - two, and sweet - five.

Harm and contraindications

First of all, it is worth noting that Dr.Korner bread and others with the same manufacturing method will not bring harm to health. They can be fed to both children and adults. But more high-calorie and hard breads should not be given to babies because of the coarse fiber in the composition. By the way, their calorie content is no less than in ordinary bread, which means that people with excess weight or indigestion should not use such bread. Otherwise, the problems can only get worse.

The owners of the patent RU 2583088:

The invention relates to the baking industry. A method for the production of crispy bread is proposed, including the preparation of a nutrient mixture for liquid sourdough from rye flour, water and extract, fermentation of liquid rye sourdough, dough preparation, fermentation, shaping, proofing, baking, cutting and drying, while additionally adding to the composition of the flour when preparing the dough a vitamin-protein supplement is introduced in the form of flour from amaranth seeds, taken in a ratio with the rest of the flour as 1:8, and as an extract in the preparation of the nutrient mixture, the cultural liquid Medusomyces gisevi (infusion of Kombucha) is used, taken in an amount of 7-10% to mass of water, and the fermentation of liquid sourdough is carried out to an acidity of 12-15 degrees. In this case, flour from whole-ground amaranth seeds that have undergone heat treatment by roasting is used, and the culture liquid of Medusomyces gisevi with acidity pH=3.8-4.5 is used. The invention is aimed at increasing the content of proteins and dietary fiber, improving the rheological and organoleptic properties of finished products. 2 w.p. f-ly, 1 tab., 3 pr.

The invention relates to the baking industry, in particular to the production of bread.

A known method for the production of crispbread (GOST 9846-88. Crispbread. General specifications) in the form of dry fragile light tiles made from rye flour, by preparing tea leaves from flour, mixing it with a nutrient mixture, refreshing and fermenting liquid rye sourdough, selection for the production cycle, dough preparation, fermentation, pouring, proofing, stabbing, baking, cutting, drying the finished product.

The disadvantage of this method is the duration of the production process, as well as the low organoleptic and dietary properties of bread.

There is also known a method for producing crispbread with hop extract (patent RU No. 2363161), including the preparation of hop extract, the preparation of a nutrient mixture for liquid rye sourdough from flour, water and hop extract, taken in an amount of 2-6% by weight of water in the nutrient mixture, fermentation of liquid rye sourdough to an acidity of 9-13 degrees and its use for the production cycle, dough preparation, fermentation, molding on baking sheets, proofing, pricking, baking, cutting and drying the finished product.

The disadvantage of these loaves is the use of expensive raw materials, which increases the cost of the product; low dietary properties due to the low content of dietary fiber, as well as a sharp hop smell, which negatively affects the organoleptic properties of the product.

The problem solved by the invention is the development of a method for the production of crispbread with a preventive effect and improved consumer properties, as well as expanding the range of products for this purpose.

The technical result of the invention is to increase the content of proteins, dietary fiber, improve the rheological and organoleptic properties of finished products.

The technical result is achieved by the fact that in the method for the production of crispy bread, including the preparation of a nutrient mixture for liquid sourdough from rye flour, water and extract, fermentation of liquid rye sourdough, dough preparation, fermentation, molding, proofing, baking, cutting and drying, characterized in that that a vitamin-protein supplement in the form of flour from amaranth seeds, taken in a ratio with the rest of the flour as 1:8, is additionally added to the composition of the flour when preparing the dough, and the cultural liquid Medusomyces gisevi (infusion of Kombucha) is used as an extract in the preparation of the nutrient mixture, taken in an amount of 7-10% by weight of water, and the fermentation of liquid starter is carried out to an acidity of 12-15 degrees.

In this case, flour is used from whole-ground amaranth seeds that have undergone heat treatment by roasting. And the culture liquid of Medusomyces gisevi has an acidity of pH=3.8-4.5.

The cultural liquid of Medusomyces gisevi contains acetic acid bacteria and yeast fungi, and also has a rich vitamin and mineral composition - vitamins A, B 1 , B 2 , B 6 ; B 12 , PP, D; minerals - Ca, I, Zn, etc.; organic acids - malic, phosphoric, acetic, pyruvic, oxalic, glucuronic, citric, lactic; ethyl alcohol, mono- and disaccharides, enzymes. The optimal acidity of the applied infusion of kombucha was experimentally established, lower acidity of the infusion indicates the active stage of acetic fermentation and the accumulation of acetic acid. The introduction of kombucha infusion due to the presence of acetic acid bacteria, yeast fungi, ethyl alcohol, carbon dioxide has an activating effect on the vital activity of the fermentative microflora of the dough.

Amaranth seed flour contains biologically active substances - amaranthine, rutin, carotenoids. This flour has a high protein content (up to 16%), incl. amino acids - lysine, methionine and tryptophan, also contains 55-62% starch, pectins, micro - and macro elements. More than 50% of amaranth flour proteins are albumins and globulins with a balanced amino acid composition. The addition of amaranth flour not only improves the amino acid composition of the bread, but also increases the degree of their digestibility. It also contains 5-6% fats (which are mainly unsaturated fatty acids), while the lipid fraction contains up to 10% squalene, which is a powerful antioxidant. Due to the low density of squalene, when it enters the body, it is easily transported along with the blood to the tissues of various internal organs and participates in protein metabolism. In addition, flour contains vitamins A, D, B 1, B 2. And vitamin E (up to 0.2%) is present in the active, tocotrienol form, the antioxidant activity of which is 45 times higher than in the tocopherol (standard) form. Flour from whole-ground amaranth seeds, heat-treated by roasting, has a higher nutritional value and has a delicate golden color and a pleasant nutty smell.

The starch contained in amaranth seed flour is characterized by increased swelling, viscosity and gelatinization. The choice of this flour for use in bread is due not only to the possibility of enriching the product with a vitamin-protein complex. With the joint use of flour from amaranth seeds with sourdough based on Kombucha infusion, the rheological properties of bread are significantly improved compared to the use of other types of flour, which is due to the high lipolytic activity of enzymes and the optimal carbohydrate-amylase complex of flour. Under their influence, the sugar-forming and gas-forming ability of the dough increases, which makes it possible to increase the porosity of the product. The fermentation activity of yeast increases markedly. The rate of accumulation of acids increases, due to which the ripening time of the semi-finished product is reduced.

Experimentally, the optimal ratio of making flour from amaranth seeds to wheat flour was established as 1:8. Increasing the dosage of flour from amaranth seeds is impractical due to the appearance of a specific taste and a decrease in the elastic-plastic properties of the dough, and adding in a smaller amount does not give a noticeable effect.

The technological process for the production of crispbread includes the following operations.

Nutrient liquid for liquid sourdough is prepared by mixing rye flour, water and culture liquid Medusomyces gisevi (with acidity pH=3.8-4.5), taken in an amount of 7-10% by weight of water. Liquid rye sourdough is fermented until an acidity of 12-15 degrees is reached for 2 hours, then it is refreshed by selecting 50% of the finished sourdough for dough preparation and adding a nutrient mixture of rye flour, water and kombucha infusion to the remaining sourdough mass. The dough for crispbread is prepared in the ratio of the following components, kg: wheat flour of the 1st grade - 40, peeled rye flour - 47.5, flour from amaranth seeds - 12.5, yeast - 1.5, salt - 1.0, liquid rye sourdough with kombucha infusion - 82, then knead and ferment at a temperature of 30-32 ° C to an acidity of 6-8 degrees. The fermented dough is poured onto metal trays, the final proofing is carried out in a cabinet at a temperature of 35-40°C and a relative humidity of 70-75% for 15-20 minutes. Dough pieces are pricked and baked for 13-15 minutes at a temperature of 200-220°C, the baked products are cooled to a temperature of 20°C, cut, laid out on metal sheets, dried in a cabinet at a relative humidity of 65% for 40-60 minutes . Ready-made breads are packaged and packed in packs.

Examples of specific implementation.

The nutrient liquid for liquid sourdough is prepared by mixing rye flour, water and the culture liquid of Medusomyces gisevi (with acidity pH=4.5), taken in an amount of 7% by weight of water. Liquid rye sourdough is fermented until an acidity of 13 degrees is reached for 2 hours, then it is refreshed by selecting 50% of the finished sourdough for dough preparation and adding to the remaining sourdough mass a nutrient mixture of rye flour, water and Kombucha infusion with acidity pH = 3.8- 4.5. The dough for crispbread is prepared in the ratio of the following components, kg: wheat flour of the 1st grade - 40, peeled rye flour - 47.5, flour from amaranth seeds - 12.5, yeast - 1.5, salt - 1.0, liquid rye sourdough with kombucha infusion - 82, then knead and ferment at a temperature of 30 ° C to an acidity of 6 degrees. The fermented dough is poured onto metal trays, the final proofing is carried out in an oven at a temperature of 35°C and a relative humidity of 70% for 20 minutes. The dough pieces are pricked and baked for 15 minutes at a temperature of 220°C, the baked products are cooled to a temperature of 20°C, cut, laid out on metal sheets, dried in an oven at a relative humidity of 65% for 40 minutes. Ready-made breads are packaged and packed in packs.

The quality indicators of the resulting loaves are shown in the table.

Nutrient liquid for liquid sourdough is prepared by mixing rye flour, water and culture liquid Medusomyces gisevi (with acidity pH=4.0), taken in an amount of 10% by weight of water. Liquid rye sourdough is fermented until an acidity of 15 degrees is reached for 2 hours, then it is refreshed by selecting 50% of the finished sourdough for dough preparation and adding a nutrient mixture of rye flour, water and kombucha infusion to the remaining sourdough mass. The dough for crispbread is prepared in the ratio of the following components, kg: wheat flour of the 1st grade - 40, peeled rye flour - 47.5, flour from amaranth seeds - 12.5, yeast - 1.5, salt - 1.0, liquid rye sourdough with kombucha infusion - 82, then knead and ferment at a temperature of 32 ° C to an acidity of 8 degrees. The fermented dough is poured onto metal trays, the final proofing is carried out in an oven at a temperature of 40°C and a relative humidity of 70% for 20 minutes. The dough pieces are pricked and baked for 15 minutes at a temperature of 200°C, the baked products are cooled to a temperature of 20°C, cut, laid out on metal sheets, dried in an oven at a relative humidity of 65% for 60 minutes. Ready-made breads are packaged and packed in packs.

The quality indicators of the resulting loaves are shown in the table.

The nutrient liquid for liquid sourdough is prepared by mixing rye flour, water and the culture liquid of Medusomyces gisevi (with acidity pH=3.8), taken in an amount of 8% by weight of water. Liquid rye sourdough is fermented until an acidity of 12 degrees is reached for 2 hours, then it is refreshed by selecting 50% of the finished sourdough for dough preparation and adding a nutrient mixture of rye flour, water and kombucha infusion to the remaining sourdough mass. The dough for crispbread is prepared in the ratio of the following components, kg: wheat flour of the 1st grade - 40, peeled rye flour - 47.5, flour from amaranth seeds - 12.5, yeast - 1.5, salt - 1.0, liquid rye sourdough with kombucha infusion - 82, then knead and ferment at a temperature of 30-32 ° C to an acidity of 7 degrees. The fermented dough is poured onto metal trays, the final proofing is carried out in a cabinet at a temperature of 35-40°C and a relative humidity of 72% for 17 minutes. Dough pieces are pricked and baked for 14 minutes at a temperature of 210°C, the baked products are cooled to a temperature of 20°C, cut, laid out on metal sheets, dried in an oven at a relative humidity of 65% for 50 minutes. Ready-made breads are packaged and packed in packs.

The quality indicators of the resulting loaves are shown in the table. The food product is notable for its crunchy bite and light taste, and also retains these characteristics for a long shelf life.

Bread with the addition of amaranth seed flour is characterized by a pronounced nutty flavor, fairly good porosity and elasticity. The use of the proposed method of production allows the maximum use of the possibilities chemical composition proposed raw materials while improving the consumer properties of bread. Rich in vitamins, minerals, protein-carbohydrate complex necessary for the full growth and development of the body, crispy waffle bread can be successfully used as a modern product of healthy and preventive nutrition.

The claimed technical solution is implemented using industrially produced tools and materials and can be manufactured at a food enterprise.

1. A method for the production of crispy bread, including the preparation of a nutrient mixture for liquid sourdough from rye flour, water and extract, fermentation of liquid rye sourdough, dough preparation, fermentation, molding, proofing, baking, cutting and drying, characterized in that the composition of flour when in the preparation of the dough, a vitamin-protein supplement is additionally added in the form of flour from amaranth seeds, taken in a ratio with the rest of the flour as 1:8, and the culture liquid Medusomyces gisevi (kombucha infusion), taken in the amount of 7- 10% by weight of water, and the fermentation of liquid sourdough is carried out to an acidity of 12-15 degrees.

2. A method for the production of crispbread according to claim 1, characterized in that flour is used from whole-ground amaranth seeds that have undergone heat treatment by roasting.

3. A method for the production of crispbread according to claim 1, characterized in that the culture liquid of Medusomyces gisevi with an acidity of pH=3.8-4.5 is used.

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The invention relates to the baking industry. A method for the production of crispy bread is proposed, including the preparation of a nutrient mixture for liquid sourdough from rye flour, water and extract, fermentation of liquid rye sourdough, dough preparation, fermentation, shaping, proofing, baking, cutting and drying, while the composition of the flour when preparing the dough additionally a vitamin-protein supplement is introduced in the form of flour from amaranth seeds, taken in a ratio with the rest of the flour as 1:8, and the culture liquid of Medusomyces gisevi, taken in an amount of 7-10 by weight of water, is used as an extract in the preparation of the nutrient mixture, and fermentation of the liquid starter cultures are carried out to an acidity of 12-15 degrees. In this case, flour from whole-ground amaranth seeds that have undergone heat treatment by roasting is used, and the culture liquid of Medusomyces gisevi with an acidity of pH 3.8-4.5 is used. The invention is aimed at increasing the content of proteins and dietary fiber, improving the rheological and organoleptic properties of finished products. 2 w.p. f-ly, 1 tab., 3 pr.

There are many on store shelves. different varieties baking and a novelty in the field of baking - extruded crispbread is in great demand.

What is the technology for making crispy products? What is the innovation of the extrusion production process?

At the first stage, a wet mixture is prepared, consisting of grain, flour, eggs. The prepared mixture is sent to tanks with hot air, due to which light porous loaves are obtained in the form of briquettes from air grains.

Not suitable for these products. Rye flour. Often use rice, corn, buckwheat, wheat.

Bread production process

The process of production of extruded loaves begins with the preparation of raw materials. Further:

• The grain is sifted and cleaned of impurities. The moisture content of raw materials must be brought to 18-20%. The prepared grain is placed in a special bunker for four to six hours.
• After that, it is fed in parts weighing 5-6 kg into the loading hopper, then it enters the dosing compartment, and then into the sintering chamber, made in the form of a cylinder (this explains the appearance of the loaves).
• The bottom and top of the chamber looks like punches (parts for pressing).
• The punches, which have been heated to a temperature of 290-300 °C, heat the grain and compress it under high pressure (about 5 MPa).
• Then the upper punch rises up, thereby slightly opening the chamber. There is a temperature difference, due to which the grain explodes, as the moisture in its composition instantly boils. As a result, the grain acquires volume, porosity, occupying the entire space of the chamber.
• The lower punch pushes out the formed briquette, which enters the tank for finished products.

As you can see for yourself, the process is almost completely automated. Human participation is minimal. What a person controls is the temperature of the heater, the pressure readings, as well as the level of raw materials in the hopper.

The cost of equipment and technological parameters differ depending on the model. Small installations, weighing about 60 kilograms and measuring 3 x 4 x 5 meters, can produce 400-500 products per hour.

Extrusion is considered one of the most advanced technological processes used to make figured products from cereals or grains.

Our advantages

Almaz LLC sells special equipment with which you can set up your own production. You can buy high-quality extruders of different models from us.

Our company develops extrusion technologies and produces innovative equipment. Therefore, we are always glad to fruitful cooperation with our customers.

When ordering equipment from Almaz LLC, you get high quality at a moderate cost. Therefore, it is best to buy such installations by calling us or ordering them on the website online.

We wish you successful development of your business using our technical equipment!

Crispbread

The technological process for the production of crispbread consists of the following operations: preparation of raw materials for production, dough kneading, dough fermentation, molding of blanks, proofing of blanks, baking, drying, cooling and cutting layers into slices and subsequent packaging in packs.
Preparation of raw materials for production is carried out in a generally accepted manner. Salt in rye products is dosed in dry form. For other products, a sugar-salt solution is used. Pressed yeast is pre-dissolved in warm water. The dough for crispbread of all kinds is prepared in a non-dough method in a continuous dough mixer from the Swedish company Holschtrem.
Dosing of solutions of sugar, salt, melted fat and vegetable oil is carried out at the automatic dosing station VNIIKhP-0-6.
The initial temperature of the dough for rye bread is 28-29 ° C, for rye-wheat bread 31-35 ° C. The moisture content of rye dough is 53-54%, rye-wheat - 39-40%.

Dough fermentation is carried out in an eight-section cylindrical rotating hopper with a stainless steel cone bottom. 1 hour after fermentation, the dough is kneaded in the bunker with the help of air coming from a small compressor unit. The duration of dough fermentation is 1.5-2.5 hours, which corresponds to one complete revolution of the sectional hopper.

The fermented dough through the hatch in the bottom is sent to the intermediate hopper, and from it - to the funnel of the molding machine. From the funnel, the dough is fed to two horizontally located metal rolls, rolled out into a dough belt 3-4 mm thick and 1500 mm wide and fed to the lower belt conveyor, previously sprinkled with crumb crumbs. The dough strip is also sprinkled on top to prevent the dough from sticking to the pricking bars and cutting blades. The dough is pricked to prevent swelling on the surface of the loaves.
The shaped dough tape goes under the cutting device equipped with knives for longitudinal and transverse cutting into square tiles measuring 27.5 * 27.5 cm.

The proofing of the cut dough tape is carried out on a belt conveyor in the proofing chamber. The duration of proofing is 30-45 minutes, which is about 3 times longer than the duration of baking. The air temperature is 30-36 ° C for rye products and 33-34 ° C for rye-wheat products; relative humidity 80-90%. The thickness of dough pieces after proofing increases to approximately 5.5-6.5 mm.
Before baking, the surface of the dough band may in some cases be moistened with water or scalded with steam. Crispy bread is baked in a tunnel oven with a mesh hearth and electric heating.

The baking temperature for rye products is 200-360 ° C, for rye-wheat products - 200-290 ° C. The baking time depends on the type and weight of the products and ranges from 10 to 15 minutes.
After baking, the crispbread tiles are delivered to the conveyor cradles of the drying cabinet, where the temperature of the products gradually decreases, the moisture content partially decreases and it is distributed in the product. The drying time for rye-wheat products is 30-40 minutes, for rye products - up to 3.5 hours at an air temperature in an oven of 45-55 ° C.

Dried products are cooled on a special conveyor for 1-4 hours. During this time, finished products are cooled to room temperature and reach the set humidity.
After cooling, the loaves of bread are sent to a cutting machine, where they are cut into pieces of 12 × 5.5 cm. This size is adapted to the overall dimensions of the receiving device of the ZIG packaging machine.
The shelf life of plain crispbread is 4 months; dessert and dining rooms - no more than 3 months; amateur, for tea, with cinnamon, for beer, home - no more than 1.5 months from the date of manufacture.

Diet products

Dietary bakery products are products intended for therapeutic and preventive nutrition.
Dietary bakery products for medical nutrition are developed for people suffering from specific diseases.
Dietary bakery products for preventive nutrition are developed for the population of ecologically unfavorable regions and are intended for the prevention of various diseases.

The preparation of dietary products is carried out, as a rule, either in special shops of bakeries or in bakeries. Dough for dietary products is prepared mainly in a periodic way.

Attachments: from 430 000 rubles

Payback: from 3 months

Interest in healthy food and the search for alternatives to unhealthy muffins has led to the expansion of such a production niche as the production of bread. They do not increase cholesterol, do not affect body weight, and are tasty at the same time. The demand for such products is constantly growing, and there are not so many competitors yet. Opening your own crispbread production is a great chance for a stable and fairly high profit.

business concept

According to marketers, the demand for diet bread will increase annually by 15 percent for at least five years.

The volume of the bread market in our country now is more than 20 thousand tons. Extruder products are in particular demand.

You can make crispy slices from any cereal crops, add salt, spices, berries and fruit slices. Sometimes they produce stuffed products.

Especially useful and popular are whole grain products - extruder bread. Their production is more cost-effective than their "brothers" from flour - because of the fashion for a healthy lifestyle. It is worth taking advantage of the popularity of the product and start producing them.

The target audience here is mostly women, but men are also interested in proper nutrition. This should be taken into account when creating packaging and logo, website design. You should not focus only on the female audience: you will lose buyers of the stronger sex.

Even at the planning stage, think about the implementation scheme. Products can be distributed through small shops, but can be offered to large retail chains. It should be noted that even workshops with low productivity sell a quarter of products through wholesale buyers.

What is required for implementation?

Bread extruder

Renting a workshop and purchasing equipment is the main thing that will be required. The production facility must comply with sanitary and hygienic requirements for the production of food products. And it can be located in the suburbs, where rent is cheaper. The workshop itself and two warehouses adjacent to it occupy a room of at least 80 square meters.

An important point: the room should be as dry as possible.

It is required to concrete the floor and put iron doors to protect themselves from rodents.

From the equipment you will need:

• blowing machine for grain cleaning;
• centrifuge or separator for grinding;
• twin screw extruder;
• tanks.

One person can serve a small production, but during shift work there should be two operators on the staff.

It is important to find suppliers who offer quality grain. To save money and get an excellent result, it is worth visiting local farmers and agreeing on supplies.

Step-by-step instructions for starting production

After drawing up a business plan, which lists all expenses and calculates the expected profit, you need to formalize the IP (OKVED 10.72) and obtain permission from the sanitary inspection specialists, as well as a quality certificate. It is also required to create and certify technical conditions in the regional center of regulatory and technical documentation. Next steps to start a business:

1. Rent a suitable room with all communications and good wiring.
2. Make cosmetic repairs.
3. Purchase and install equipment (sometimes you can buy it by hand for half the price).
4. Buy quality grain.
5. Find operators.

When you go through all the points of the business plan, you can open production.

The technology for making bread is simple. The pre-cleaned grain is crushed in a centrifuge, mixed with water and passed through an extruder. There, the dough is heated and passes through a special mold. This results in a dry, crispy and very tasty product.

Financial calculations

To know how quickly investments will pay off, you need to accurately calculate all costs and predict financial losses.

Starting capital and monthly expenses

The initial investment will go primarily to the purchase of equipment. It will require at least 250,000 rubles. Rent in the suburbs is inexpensive, no more than 7,000 per month. What else will you have to spend money on starting a business (rubles):

• for documentation and specifications - 60,000;
• for the salary of employees for the first month - 30,000;
• to the cash register - 18,000;
• for the creation of a website and the development of packaging design - 15,000;
• for an advertising campaign - 15,000;
• for raw materials - 30,000;
• for transportation costs - 5,000.

The total amount of initial financial injections is 430,000 rubles.

What monthly expenses should be considered? They will include wages, rent and transport, as well as replenishment of the raw material base. On average, the amount will be 72,000 rubles.

How much can you earn, payback periods

The average productivity of a small installation is about 600 loaves per hour. 4,800 pieces will be produced per shift, 120,000 per month. Packing of extruder products of 16 pieces at a wholesale price costs an average of 32 rubles. One thing - two rubles. We multiply by 120,000 and get an income of 240,000 rubles. If you subtract monthly expenses and taxes, it turns out that the investment will pay off in three months.

Advantages and possible risks

The rapid growth of interest in products healthy eating suggests that the producer of bread will not remain without income. Entering a business is now somewhat more difficult, but the niche has not yet been fully occupied. Consider what advantages and possible risks a novice businessman needs to consider.

Business development is aimed at expanding the range of interesting flavors and fillings.

Bread is in constant demand regardless of the season. So the profit will be stable at low cost.