Business plan for the production of gummies. Own business: candy production. Technology and equipment for the production of sweets. Chocolate sweets production technology

In this article:

Purpose of the project: substantiation of financial and economic efficiency and technically possible implementation of the production of chocolate sweets on the territory of the Russian Federation. The main criterion is a conservative scenario for the development of events; the prices are calculated taking into account inflation. The project has significant economic potential based on an assessment of the current state of the market.

Chocolate candy production project concept

It is planned to build production and storage facilities or rent them, install equipment for the production of products. An initial assortment of glazed fondant candies and chocolate is planned:

• oval-shaped chocolate glazed sweets with a chocolate fondant filling of a different taste. The mass ratio is 60/40%. Candy weight up to 12 grams;
• oval-shaped chocolate glazed sweets with jelly filling. Mass ratio 70/30%, candy weight up to 11.5 grams;
• chocolate bar weighing 100 grams, with a pattern.

Analysis of the confectionery market

The confectionery and chocolates (chocolate) market is resistant to economic crisis. Gifts and purchases for children, gifts and personal preferences make this segment of products quite popular among the broad consumer masses.

At the moment, the Russian market, in particular the business of producing chocolate sweets, is represented by a wide range of products in the form of chocolate: milk, porous, black or ordinary with various fillings; chocolates of the most varied shapes and fillings. In value terms, the segment of sales of chocolates and bars accounts for 1/3 of the total sales of confectionery products.

It should be noted that production of chocolates depends on the season, at the time of the greatest surge (holidays and pre-holidays), production can increase by 300%. The rest of the time, the plant can be loaded only at 30-60% of the planned capacity.

The most popular product is loose sweets and chocolate bars; sales are represented by regional offices of large confectionery companies. This has its advantages: the costs of delivery and payment of office representations increase the cost of their products by 6-8%.

For example, Nestle sweets have a cost of $ 3 per 1 kg, their sale in the regions is $ 8 for the same kilogram. The production of sweets in your region makes it possible to reduce the price of your own product of high consumer demand.

Consumer behavior towards confectionery

Active buyers of chocolates and chocolate are 65% of buyers, regardless of the season, buying these products 3-4 times a week, and 20% are inactive, buying once a week. Thus, taking into account the size of the population in the region, it is possible to calculate in advance the volume of production of chocolates and chocolate bars.

Production plan of the project

1. Rent of premises: production workshop and warehouse. Mandatory drawing up of a contract according to the established regulations. Construction of additional structures (office and household premises), rental of transport for the delivery of products to retail outlets.

2. Installation and installation of the necessary equipment, commissioning, launch of the production line.

3. Manufacturing process for the production of sweets.

The technology for the production of sweets consists of several stages:

- mixing the individual ingredients of the fondant mass;

- brewing process;
- molding or casting of the fondant mass into special oval shapes;
- passing the molds through the cooling systems;
- glazing of sweets with chocolate fondant;
- cooling;
- packaging of products in wrapping paper.

Chocolate bars production technology:

• mixing the ingredients of the chocolate mass;
• brewing process;
• casting into special molds;
• run through the cooling system;
• wrapping tiles in wrapping paper.

Equipment for the production of chocolates

It should be noted that the candy production line consists of four sections, each of which has its own range of equipment:

1. Section for the production of candy mass:

• universal cooker, used for cooking, mixing and emptying the mass, with automatic control;
• weighing device for dosing components of fondant or chocolate mass;
• loading pump for supplying the mass to the casting;
• dosing pump for flavors, acid, fondant and chocolate colors.

2. Installation of casting:

• servo-driven, electronically controlled One-shot casting unit;
• conveyor of molds for casting;
• cooling cabinet, including control cabinet and cold air preparation station;
• forms.

3. Line for the production of sweets (for enrobing the bodies):

• a table for feeding products to the glazing machine;
• enrobing machine;
• pump for return supply of excess mass.

4. Automatic candy wrapping packing line:

• distribution conveyors for supplying sweets to warehouses.

The technological scheme for the production of chocolates and chocolate bars is rather complicated, requiring highly qualified personnel and serviceable equipment.

The cost of purchasing equipment, renting premises is about $ 50,000, which is the start-up capital. The estimated time of self-sufficiency and profitability of the enterprise is 5-8 years. The expected profit per year is 36% of the start-up capital.

Analysis of income and expenses

The cost of rent (construction) and raw materials make up 77% of the total start-up capital, the next item in the cost column is for electricity, water and gas - 7.5-8%. The salary fund is 8% of total expenses, 3-5% insurance premiums and taxes, 7% other expenses, which include expenses for advertising and product promotion.

The dynamics of reducing the burden of expenses on the cost of production is calculated for 5 years, after which the expenses will stabilize and the price may remain fixed.

Production plan

Considering the structure of variable costs, one can see that the highest expenditures (over 77%) are spent on the purchase of raw materials. Thus, the calculation of the cost of production is:

the amount of expenses for raw materials + the amount of the salary fund and expenses for communications, rent, taxes + 6% to increase profits.

According to a more simplified formula:

the amount of expenses + 37-38% of the amount of expenses = the cost of 1 kg of sweets.

Product demand risk

In order for an enterprise to be considered profitable, it is required to calculate the minimum critical level of production, taking into account seasonal sales.

Payroll costs (per year) + taxes (per year) + utility and rental costs (per year) / divided by total annual income = minimum production in kg per day.

Thus, the minimum (critical) cost of sweets (taking into account the risk) is $ 6 per kg - this is the threshold value of the selling price for the production of chocolate and sweets, the minimum production volume per day is from 5 tons.

The candy business is risky because of its quality and design requirements. The packaging material for sweets and chocolate bars must match the positive image of the company.

Packaging material will be considered the cheapest if you make it yourself. This will require:

• special wrapping paper and foil (for chocolate) and cardboard (for making candy boxes);
• inkjet printer for printing;
• a computer.

The production of boxes for chocolates has its own manufacturing characteristics:

• the cardboard has a corresponding certificate, which allows it to be used in Food Industry;
• made according to the ready-made correction;
• can be used for automatic and manual packaging.

One of the main brands of the Saratov region is the confectionery factory "Saratovskaya", its abbreviated name is JSC "KONSAR". It is better known as Confashion. Let's talk a little about the factory today, and at the same time see how sweets are made.

The factory has existed for many years - it dates back to 1930, when in the form of an artel named after. Rosa Luxemburg was located in the city center (at the corner of Radishchev and Kutyakov Streets). Now the factory has a different address, and its assortment is wider.

Why is the factory one of the main brands in the region? So after all, its products are sold in most regions of Russia (more than 60 constituent entities of the country), as well as abroad (export is made to 12 countries of the former USSR, except for the Baltic countries, as well as to China and the USA). And in 2015, the factory became the best exporter of the region. But despite this, the factory is more of a regional manufacturer.

Photo taken from Denis djhooligantk

Let's take a look at the production of the factory's main commodity, candy. Confectioners call this type of production sugar. So, all the important sugary confectionery products are produced at Konsar: chocolates, caramel, toffee and chewing candies. They also sort gift sets. The products are constantly being updated.

Information stand for workers

The factory produces 18.5 thousand tons of sugar products per year on 14 production lines. By the way, the equipment at the factory is both domestic and foreign (Italian, German and Swiss). Equipment of different years, there is already old one. But it does its job well and there is no need to change it. In addition, all equipment undergoes periodic maintenance.

Although it should be said that the factory is constantly working to improve the quality of the assortment and the variety of the assortment. Therefore, new equipment is also bought - to open new lines. So, recently a line of sweets "One Shot" was opened with the most modern equipment of Italian origin. The peculiarity of this line is that the filling and the body are formed simultaneously.

And now let's get acquainted with the process of candy production itself. We will start the excursion from workshop No. 6 (there are 7 workshops in total in the factory, in which there are 40 lines for the production and packaging of confectionery products). This is a workshop for the production of the most expensive products - assorted chocolates, which are also used for gift sets (see the title photo). By the way, the factory produces about 1.5 million of these sets per year. For such sweets, by the way, real cocoa butter is used.

Start of the line - a machine with empty molds for sweets embedded in it

The workshop has 2 production lines (both German) - Knobel and Yubitek .
Yubitek is a line for the production of sweets with assorted fillings. It produces chocolates with a variety of fillings. Moreover, the forms of sweets are very diverse. Examples of sweets of this line - sweets and sets of sweets "Confession de Luxe", "Overture", "Miracle nut", "Cherry in chocolate".
And on the line Knobel make jigging sweets - sweets based on marzipan, truffle and praline.

As mentioned above, sweets have different shapes: a basket, a bottle, a hemisphere, etc. It depends on the terms of reference received on the line. Each form has its own dose chocolate glaze... Glaze, by the way, is also different. The factory uses bitter, milk and white chocolate for the glaze.

This is what a press looks like for giving the future candy different shapes. Now the simplest forms are being made - hemispherical.

The process of creating a candy is as follows: first, the machine forms the body of the candy (just the photo above), then the body comes in a cooling tunnel (10-14 degrees Celsius), then the filling is poured into the body. The filling and glaze are prepared ahead of time - in another workshop.

Top photo - a machine for shaping (on the right you can see finished products - then a conveyor line). Bottom right photo - the body of the candy after cooling.

There are 2 filling machines installed on the line (photo below) - in order to quickly switch from one to another when the raw material runs out. It also allows you to make sweets with two fillings at the same time.

And now the body of the candy is filled with filling.

And this is what marriage looks like. Such candies do not go on sale - they are processed for subsequent production (for example, they are used to fill waffles).

After filling with the filling, the bottom of the candy is made. To do this, the sweets are slightly warmed up (to melt the top a little), and then poured with chocolate and flattened.

End view

And at the very end of the line, the candies are “shaken out” of the mold and put on pallets for further sorting.
Some of the products go to the packaging line, and some to the warehouses.
Let's take a look at the packaging line first. Here, first, the sweets enter the wrapping machine. There are several such machines, each with its own wrapping.

General view of the machine

Sweets wrapping process

Finished sweets at the exit from the machine

Then, the wrapped sweets go to the packaging and packing.

Here we see the weight packaging of truffles.

Video of this line and the packaging of sweets

The kingdom of various sweets

Sweets are numbered here: each type is in a special tray under its own number.

And already according to these numbers, the process of assembling the kit is going on.

This is where various gift sets are formed: seasonal, festive and thematic. These are - in the form of assorted

Or such

The residents of the region can buy the products of the factory both in federal chain stores and in their own branded outlets (for example, in the well-known Chudesnitsa stores). Also, the factory has created an online store, which distinguishes the factory from others. This store is little known to the people of Saratov, and in vain - all ordered products will be delivered to your home free of charge. True, there are limitations there (for example, the minimum order value is 700 rubles), but a bonus system is provided.

By the way, the work clothes of the employees are strictly monitored here: white robes are strictly over all clothes and mandatory hats.

But candy is not the only thing that is made at the factory. The flour production of confectionery products is also presented here, which we will talk about next time.

In Russia, the chocolate market is developing rapidly. From 2013 to 2019, the consumption of chocolate increased from 6 to 8 kg per person per year. Despite the trend towards proper nutrition and a healthy lifestyle, they continue to buy sweets and candies: for themselves and their families, as a gift for a holiday. The chocolate business pays for itself in a matter of months and generates stable profits for the owners.

Chocolate Making Business Ideas

There are two models for organizing the technological process: home or industrial production of chocolate.

By choosing the first option, you can start a business at home in the kitchen with a minimum investment in equipment. But it will not be possible to register such a business officially, so the responsibility for working without registration with the Federal Tax Service and paying taxes will lie with you.

In the second case, you will have to comply with the requirements of the inspection authorities, rent and prepare a workshop, hire employees and establish a stream production of chocolate products.

Making handmade chocolate

"Chocolate boutique" is a concept that came to Russia in 2016. The boutique sells premium handmade chocolates made according to home recipes. The owners of such establishments rely on the uniqueness of the products, yielding to large workshops in terms of production.

The assortment of the chocolate boutique includes:

• dark, white and milk chocolate in tiles;
• chocolate with fruit and berry fillings;
• truffles;
• sweets with non-standard fillings;
• gift sets of different types of chocolate.

Customers can order custom kits, chocolate fountains, and even engraved chocolates.

The fashion trend in gourmet boutiques is a combination of incongruous tastes. Manufacturers of elite chocolate offer ginger, chili, candied fruit and even bacon as filling. They sell flavored candies exclusively in their original packaging.

Handmade chocolate is a delight for gourmets, so it will always find its buyer

Making fruit in chocolate

Strawberries, apples and bananas are in demand all year round... Combined with chocolate, they form a unique delicacy. The advantage of the chocolate-covered fruit production business is minimal competition in the Russian market. The disadvantage is the pronounced seasonality. In winter, the value of the fruit rises and the demand of the buyers falls.

A possible way out of the situation is to rent an area in a city shopping center to work even in the cold season, in a place with maximum traffic. In advertising, you can focus on the saturation of products with vitamins.

There is nothing tastier than fruit in chocolate: neither children nor adults can resist this delicacy

Making chocolate figurines

Manufacturing technology chocolate figurines simple - hot chocolate is poured into the molds, then cooled until solidified and the halves are removed. The edges of each are carefully heated and glued together. Figures are used to decorate cakes and pastries, they are presented for holidays to children and adults.

To make a chocolate butterfly or lace lace you need:

• melted chocolate;
• glass bowl for heating;
• Silicone forms.

Instead of molds, you can use any objects: cups, stacks, spoons, paper sheets and others. By combining different types of chocolate and adding food colors, pastry chefs give the figurines a unique design. Show your imagination and an unprecedented result will not keep you waiting.

Chocolate figurines are ordered to decorate wedding and anniversary cakes

Where to start: business registration

Chocolate production belongs to the food industry, so be prepared for numerous inspections by the SES and Rospotrebnadzor. Register a business before starting work by choosing one of the forms - LLC or IE.

Benefits of being an individual entrepreneur:

• registration in 5 working days;
• minimum state duty when registering a business;
• minimum of documents.

The main disadvantage of an individual entrepreneur is liability to creditors with all property. If you own an apartment, and the business has accumulated debts, be prepared for the property to be put up for sale.

Advantages of opening an LLC:

• financial responsibility within the authorized capital;
• a participant in a legal entity can exit it by alienating a share of the company;
• the company can be sold or donated if necessary;
• in case of suspension of activities, the organization does not transfer contributions to pension and insurance funds.

The disadvantages of an LLC are a complicated registration procedure and the need to contribute authorized capital from 10 thousand rubles, as well as a state fee of 4 thousand rubles. for the registration of the company.

When registering, choose a tax system that is comfortable for you. Small businesses should consider a simplified regime (STS 6 or 15%). When planning to open a large production, think about UTII (flat tax on imputed income). The amount and procedure for paying taxes depends on the chosen system.

Table: Comparison of Tax Regimes

Tax regime	Limits
	Revenue	Average number of employees	Average annual value of funds	Kind of activity	Capital structure
OSNO	Without Borders
ESHN	Without Borders	Without Borders	Without Borders	Agriculture	Without Borders
UTII	Without Borders	100 people	Without Borders		The share of participation of other organizations no more than 25%
Simplified taxation system 6%	RUB 60 million		RUB 100 million	Except for some activities
Simplified taxation system 15%
PSN	RUB 60 million	15 people	Without Borders	There is a list of activities	For sole proprietors

Obtain permits from Rospotrebnadzor and Pozhnadzor, as well as the conclusion of the SES about the possibility of starting work. Get a health certificate, even if you will make candies in minimal quantities.

Organization of home production of chocolate

An exclusive homemade confectionery can compete with large industries due to the quality of products, the use of natural ingredients and proven chocolate recipes. When working on your own, pay close attention to the quality of the product. Experiment with combinations of flavors, offer customers a variety of products. The disadvantage of a home business is the inability to officially register a company. This is due to the fact that the kitchen premises must be removed from the housing stock in order to organize food production in it. In this case, you assume all the risks associated with informal entrepreneurship.

Recipe and manufacturing technology

Observe the recipe and technological process when making chocolate - the taste and shelf life of the finished product depends on it.

The simplest homemade chocolate recipe:

1. Mix 5 tbsp. cocoa spoons, 7 tbsp. tablespoons of sugar and 150 ml of milk in a bowl. Bring the mixture to a boil over low heat, stirring constantly.
2. Gradually add 1 teaspoon flour and 50 g. butter... Continue stirring until smooth.
3. Pour hot chocolate into molds, after adding the filling (waffle crumbs, nuts, raisins) into it.

Choosing chocolate, customers first of all pay attention to the appearance and taste.

When the chocolate cools down, you can eat it. You can store homemade sweets for 2-6 months at temperatures up to 17 degrees. Chocolate may only be transported in vehicles equipped with cooling systems.

The weight of the candy should not exceed 3–6 g, so that the client can put it whole in his mouth and taste it without biting off.

Requirements for the premises

The technical conditions for the production of chocolate are determined by GOST 31721–2012. In the document, you will find information on the quantity of ingredients for the manufacture of various types of cocoa-based products, as well as the requirements for the equipment and workshop. Despite the lack of registration and verification, try to comply with the maximum requirements of the standard. The room must be ventilated, with an artificial temperature regime and a low level of humidity. The optimum temperature for storing chocolate is up to 17 degrees.

Purchase of equipment and raw materials

A home bakery can be opened with minimal investment if you work to order and use kitchen equipment. Purchase raw materials for the production of chocolate:

• chocolate mass or cocoa;
• cacao butter;
• sugar;
• vanilla;
• emulsifiers;
• milk or cream.

Buy quality ingredients. To save money, replacing cocoa butter with palm, and cocoa with carob, you risk the taste of future chocolate.

At home, use a coffee grinder to grind cocoa beans into powder

With the development of your business, start purchasing professional equipment:

• a high-power juicer for producing cocoa butter;
• a sander for removing excess moisture;
• temper for fast crystallization of chocolate;
• various shapes and stencils.

The cost of a home kit for the production of elite sweets does not exceed 150 thousand rubles.

Sales and advertising company

Sell ​​candy directly to customers at first. To do this, create groups on social networks, take attractive product photos and post ads. Invite friends and acquaintances to groups, set up targeted advertising for members of competing groups.

When you develop a business and open a kitchen outside the home, having received permission from the SES, negotiate with retail chains and coffee houses that do not have cooking and supply sweets for sale. The main thing is to comply with the terms of delivery and storage of goods.

Financial calculations

Home production does not require any special costs and pays off within a few months.

Table: costs of starting a business

Table: systematic costs

Planned income

The cost of one bar of exclusive handmade chocolate is 200 rubles, the cost of making it is 25–35 rubles, depending on the filling. On average, 200 tiles can be sold per month, the total income is 40 thousand rubles. The net profit per month is 15 thousand rubles, the payback period for the home business is 5 months.

Business plan for the production of chocolate on an industrial scale

Industrial production is different from home production. You will not be able to cope with the volume of production alone, you will need to involve employees. Equipment for a full-fledged workshop costs dozens of times more, and the manufacturing technology is more complicated than home-made.

At the enterprise, the first thing to do is to hire a technologist. He will be responsible for the chocolate making process and work out the recipes. Buy raw materials only after working out each recipe.

To obtain chocolate, cocoa beans are fried, ground and mixed with the remaining ingredients in a conche machine, and then cooled and formed into tiles.

The process of making chocolate in the workshop is automated and includes the following stages:

• dosing of components;
• initial mixing;
• mixing in a conche machine up to 3 days;
• heating the chocolate mass up to 50 degrees;
• filling in forms;
• cooling to 33 degrees and holding for 40 minutes;

Production different varieties chocolate differs in the initial set of ingredients and technology adjustments. To make porous chocolate, it is enough to add air when loading raw materials for conching, and for bitter chocolate you will have to use more cocoa powder.

Room selection

To organize a chocolate shop, a room with an area of ​​60 sq. m. Requirements for the workshop:

• is not part of the housing stock;
• equipped with ventilation;
• there are sinks with cold and hot water;
• walls are tiled with tiles up to 1.5 m from the floor;
• the rest of the walls are painted.

To make the tiles and candies perfectly even, buy a molding machine from the workshop

In the room, equip a place for a warehouse of products with an optimal temperature, as well as an office and directly a workshop with equipment.

Purchase of equipment

The cost of purchasing equipment ranges from 1 to 10 million rubles. Industrial equipment for the chocolate shop:

• ball mill for mixing ingredients;
• boiler for kindling butter;
• mixing conche machine;
• refrigeration equipment;
• temper for crystallization of chocolate.

In conche machines, the chocolate mass is kept with constant stirring for 24-72 hours

Accessory equipment:

• conveyors;
• ventilation system;
• thermostats;
• planetary pumps;
• hoods;
• molding equipment;
• packing unit;
• printing press for making wrappers.

Purchase of raw materials

Chocolate is made from cocoa beans, which can be purchased in Africa, Australia, Asia. There are three types of beans suitable for making chocolate:

• "Creole" - selected top class beans;
• "Outlander" - of average quality;
• "Pumpkin" - low-grade beans.

Cocoa beans go through three stages before they turn into powder:

• frying at a temperature of 150 degrees;
• separation of liquid and husk;
• grinding into powder.

In addition to powder, buy cocoa butter, sugar and milk, as well as filling ingredients if you plan on making candy.

Don't skimp on ingredients: the more natural ingredients, the higher the quality of the chocolate

Staff recruitment

Hire employees for the normal functioning of the workshop. Make sure everyone has valid health records.

Composition of employees:

• manager;
• accountant;
• technologist;
• confectioners;
• driver;
• cleaner.

Enter into nondisclosure agreements with the employees of the company's recipe.

Assortment formation

Large confectionery factories use a similar recipe, and their production volumes do not allow producing exclusive chocolate in small batches. In a small workshop, you can make chocolate according to original recipes by varying the composition of the components and filling.

Together with the technologist, evaluate the production capabilities, calculate the estimated production volumes. Develop your own specifications. Based on the planned purchases of raw materials, create a menu. Make them out and post them on the company's website or in a group on social networks.

The assortment of the high-end chocolate boutique usually includes handmade chocolates and cakes, as well as beautifully packaged gift baskets.

Possible distribution channels and advertising

Chocolate lovers (82%) buy their favorite product in supermarkets at the same time they purchase other goods. At the same time, 21% of them are ready to specially go to the store for chocolate. Milk tiles are most often chosen, less often bitter ones. White chocolate is loved by only 4% of customers. Chocolate boutiques with exclusive varieties of their favorite product are gaining momentum.

Probable distribution channels for products:

• supermarkets;
• off-chain grocery stores;
• stalls, tents;
• coffee shops, cafes;
• fairs, exhibitions.

• shops, coffee houses;
• internet, social networks;
• city ​​magazines;
• release of own catalogs;
• sponsoring events.

So that your product does not get lost on store shelves, do not skimp on original packaging and memorable advertising.

Business calculations

Calculations are shown using the example of a workshop with an area of ​​60 sq. m., equipped with everything necessary and operating under license.

Table: opening costs

Table: recurring costs

Expected income

The cost of one chocolate bar is 100 rubles, the cost of making it is 20–35 rubles. On average, 5200 tiles can be sold only through retail chains per month, the total income is 520 thousand rubles. The net profit per month is 260 thousand rubles, the payback period for the home business is 2 years.

Business profitability reaches 200% even when using natural ingredients. If you replace cocoa powder and cocoa butter with cheap analogs, it will increase by another 1.5 times.

Franchise or own brand

You will need impressive capital to start your chocolate business from scratch. There is an exit. When in doubt, buy a franchise. Notable chocolate factories working on franchising:

• "Shantimel";
• Podarilli;
• Frade.

Franchise benefits:

• work under a well-known brand;
• proven production technology;
• the opportunity to buy equipment at a discount / lease;
• consulting assistance;
• business mechanics;
• feeling of teamwork.

Disadvantages of franchising:

• the need to pay the franchise seller a monthly fee - royalties;
• high business value;
• overestimated requirements for the incoming partner;
• the need to comply with the terms of the franchisor.

The buyer of a franchise always runs the risk of running into an unscrupulous company, which, instead of the existing mechanisms for effective work, only gives a couple of instructions on how to do business.

The Confael franchise allows you to ensure stable turnovers and gives you the opportunity to get higher profitability compared to a business created from scratch

Newbie mistakes

Beginners in the chocolate business are often mistaken. The key problem is the underestimation of consumer needs. This is especially true for manufacturers in small towns. They rely on the uniqueness of the product, not paying attention to consumer qualities. As a result, the client receives an exclusive candy in an expensive package, but it tastes obscene. Naturally, the client does not come again. In general, in provincial cities, people make excessive demands on the quality of food, compliance with which is the key task of an entrepreneur.

Having decided to start a chocolate business and have enough funds, don't hesitate. Assess the market in your city, analyze the demand of potential buyers. Calculate your expenses and income and get started. When in doubt, choose a popular franchise and follow the proven methods of professionals.

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Candy is a product that almost all people love. For this reason, many people who want to start their own business pay attention to this product. The fact is that the confectionery market is quite resistant to various economic fluctuations. Gifts, purchases for children, and personal preferences make this segment very attractive among a relatively large number of buyers. In the event that you still firmly decided to open your own business in this area, then the first thing you cannot do without is without a line for the production of sweets.

Candy production technology

In order to have an idea of ​​how a line for the production of various types of sweets functions, you need to have an idea of ​​some basic concepts.

First, you need to decide what these favorite sweets are all about. So, sweets are confectionery products that are obtained from candy masses with a soft consistency.

Ingredient mixing apparatus

This product has a rather high nutritional value, has more than 1,000 varieties and is diverse in shape, taste and composition.

The technological process of making sweets includes several stages:

• The first stage is the mixing of the ingredients that are included in the fondant mass.
• Further, the resulting mixture is formed and cast into special molds.
• At the next stage, the forms with the fondant mass are run through the cooling system.
• Then the glazing takes place.
• The final stage is product packaging.

Cooking candy masses

Formation of candies from fondant mass

Candy mass is a confectionery mass that is used to prepare sweets. They are all divided into:

• Fondant. They are obtained from lipstick, which is prepared on the basis of sugar and milk syrups by introducing various flavoring and aromatic additives into it.
• Praline and marzipan. Praline masses are obtained from roasted nuts, and marzipan masses are obtained from raw or roasted ones.
• Whipped. These masses are obtained in the process of churning foaming agents and syrup and with the obligatory introduction of flavoring and aromatic additives.
• Liqueur. These are masses, which are saturated solutions of sucrose, to which milk, fruit preparations, flavoring and aromatic additives are added, and alcohol (cognac, liqueur, etc.) is an obligatory component.
• Roasted nuts. All roasted masses are divided into hard and soft. Hard roasted nuts - a mass obtained by melting sugar with the addition of nuts to it (for example, “Prometheus” sweets come out of the confectionery production line). Soft roasted nuts - a fruit mass that is boiled with nuts or candied fruits.
• Cream. These are foamy masses that were formed as a result of churning the latter with fats, flavoring and aromatic additives, milk syrup.
• Fruit jelly. These masses are distinguished by a jelly-like structure and are divided into fruit, jelly-fruit and jelly. Fruit is obtained from fruit and berry puree; jelly-fruit - from the same puree as the first, but with the addition of agar, and jelly - with the addition of agar, agaroid and starch.

Candy molding

Candy forming line Molding is the process of giving candy to a specific shape and appearance. Most often, on lines for the production of sweets, this process is carried out by the casting method, because thanks to this, sweets of various shapes can be obtained. Such molding is carried out in special forms, which are pre-stamped in starch.

Candy glazing line

Glazing is carried out for several reasons at once. Firstly, this process protects the product body from external influences, and secondly, it increases nutritional value the product, thirdly, gives a beautiful appearance and, fourthly, affects the taste. Glazing is the process of coating a candy with a thin layer of various masses (chocolate, fat and others).

Packaging and storage

Candy packaging line

This is the final stage when wrapping and packaging of the final product is carried out on the line for the production of sweets. The final product is wrapped in foil or label. Most of the sweets are produced in wrapped or packaged form. Finished products are stored at temperatures up to +18 degrees, air humidity should not exceed 75% in a well-ventilated area.

Chocolate sweets production technology

If we talk about lines for the production of chocolates, then they are all automated and highly mechanized, with the exception of expensive sweets made exclusively by hand.

Handmade sweets

The production of this beloved sweet product takes place in special factories in confectionery shops, therefore, at the initial stages of opening your business in this area, you need to think over and study a lot of subtleties concerning both the technological side of the issue and the legal one.

At the moment there are several lines for the production of chocolates:

• The Shell Chocolate Line is a traditional technology that makes chocolate bars and other filled solid products.
• Line with One Shot technology - the production of chocolates is carried out in one stage.

In addition, the technology for the production of chocolates cannot be imagined without the following equipment: tempering machine, conche machine, chocolate and ball mills, sugar mill, refrigeration tunnels, storage tanks. The set of necessary equipment directly depends on what kind of chocolate you plan to produce.

Fondant candy production technology

The fondant candy production line includes the following equipment:

Chocolate glazed fondant sweets

• Cooking boiler.
• Filter.
• Equipment for the preparation of fondant masses.
• Steam generator.
• Tempering machine.
• Jigging machine.

Making fondant sweets is also a special process that consists of certain stages. At the initial stage, the syrup is prepared, followed by its boiling, then - the process of filtering and churning the fondant mass. Then, before the tempering process (one of the main stages in the production of chocolate), the fondant mass is dosed and mixed. After that, the final product is formed directly. And the final stage on the fondant sweets production line involves the packaging of the finished product.

The confectionery industry is considered one of the leading industries when it comes to food processing. If you believe the figures, then in terms of the volume of products it is ranked second in the world. That is why, if you decide to start a business in this area, first of all, you need to take care of purchasing high-quality lines for the production of sweets.

Video: Handmade sweets

Photo

Ivan Anisimov

The confectionery factory "Pobeda" in Russia has two production facilities, and both of them are located in the Moscow region, in the Yegoryevsky district. Various confectionery products are made here, from chocolate bars and sweets to marmalade. All factories are full-cycle production. That is, the chocolate for the manufacture of chocolate bars and sweets at the factory is made independently and according to own recipes... This year the company opened a branch in Latvia - in this way it plans to establish supplies to the European market. The Village went to Yegoryevsk to see what and how sweets are made from.

Preparation of raw materials

From the outside, the building does not in any way hint that chocolate rivers flow through pipes inside, and mountains of sweets and marmalade go along conveyors. Factory as a factory. But as soon as we went inside, we immediately smelled the smell of chocolate. It became clear - we are exactly on the spot. As usual, putting on disposable gowns, slippers, shoe covers and washing our hands, we went to production.

It all starts from the warehouse and ends with it - raw materials are stored separately, there is a room for finished products. The raw materials are packed in boxes and large bags, some of which we see the words “Made in Ivory Coast”, “Made in Malaysia” or “Made in the Netherlands.” To make chocolate, among other things, you need cocoa butter and cocoa liquor, and for candy fillings - vegetable fat (it uses a fraction of palm oil) .Also, the equivalent of cocoa butter is sometimes added to the fillings - a mixture of palm oil with other exotic oils.

The first stage in the preparation of the components is melting, since they are all solid. All this happens in ovens: an employee unpacks a cardboard box containing a large rectangular briquette of grated beige cocoa, vegetable fat or cocoa butter (ovens for the latter two are called "fat melters") and throws it into the oven. The temperature there is about 85 degrees for grated cocoa and 65-70 degrees for cocoa butter and vegetable fats(the temperature is not universal, everything is individual for different equipment and raw materials). It is important that there are three separate fireboxes: for confectionery fat, for grated cocoa and for cocoa butter. Their streams do not mix unless the recipe needs it. Then the components, which are already in a liquid state, go through pipes to the tank, where they are weighed. Dry ingredients such as cocoa powder, sugar and various substitutes (stevia, fructose, lactose), powdered milk(whole, fat-free), dry cream or whey are poured by employees into metal tanks, then they are automatically dosed using a vacuum.

Confectionery factory"Victory"

LOCATION

Yegoryevsk, Moscow region

OPENING DATE: 1999 year

EMPLOYEES: 1,558 people in the company (more than 700 of them -
at the factory)

PLANT AREA: 35,000 sq. m

pobedavkusa.ru

Cooking chocolate mass

After the components are prepared, all of them are piped to the recipe station. Here they are weighed again and, according to the recipe, go to the shop for making chocolate masses. Here, in a container with a capacity of one and a half tons, all the ingredients are found and mixed with cocoa butter and sugar. But the mass is not yet ready: it is tough and the sugar crunches in it. It is necessary to grind the sugar crystals into powder. This takes place in a special container, where there is a pair of metal shafts that grind the mass down to 90 microns. Then it is passed through five-roll mills, which look like huge rotating rolling pins directed vertically. The mass is passed between the shafts and gradually reaches the last one, from which it is removed with a metal knife.

In the form of shavings, it enters the conche machine, where it is kneaded for 10-12 hours. The conching process is responsible for shaping the flavor in the chocolate mass. By stirring, heating, opening or closing the metal shutters, you can change the taste. For example, if it is milk chocolate, then when it is heated to 80 degrees and closed metal shutters, all the cocoa aroma remains inside, and the sugar is caramelized, so you can get a mass with a caramel taste at the exit. If the factory wants to soften the taste of dark chocolate, then the metal curtains are opened on the conche machine to release the acids from the grated cocoa.

The filling for chocolates is prepared in a similar way - all the ingredients are ground in five-roll mills and kneaded in conche machines. Only cocoa butter with soft vegetable fat is taken as a basis. In wafer sweets, the filling differs from chocolate in texture, components and manufacturing principles. It is prepared in a ball mill - a container in which metal balls not only grind the ingredients, but also beat them a little.

Manufacture of chocolates and chocolate

Chocolate mass with a temperature of 28 to 31 degrees is fed to an automatic installation, along which it travels to molds for chocolate bars. The molds are preheated so that the chocolate does not freeze immediately after hitting them. After the form is filled, it first passes through the vibration zone: the conveyor shakes it so that, firstly, excess air bubbles come out of the chocolate, and secondly, this way the chocolate will be distributed exactly along the given edge.

Then the molds go to the refrigeration tunnel, where the chocolate spends from 20 to 40 minutes at a temperature of 10-15 degrees. After the chilled molds are automatically turned over using a special drum, the tiles can be easily removed from them. This happens because at low temperatures the chocolate shrinks by a millimeter and becomes smaller in shape. The number of people on this line works to a minimum: one employee monitors the supply of mass to the installation, the other monitors the weight of the product. Metal detectors are installed everywhere: chocolate must be safe, free of foreign inclusions.

The tiles go to the packaging machine: everything happens here automatically. Then the product is manually packed into boxes, the workers check the dates, the integrity and correctness of the packaging. Those products that do not fit the check are sent to the container with a scrap. True, such a marriage is not thrown away, but recycled and put into production again. Chocolate with additives like nuts and raisins is not made here, all this is made on the site in Klemenovo.

The candy mass is also heated first. Both the chocolate mass and the filling are fed to the installation at the same time. In order not to mix them, the masses are diluted through their channels, which go to the nozzles - holes. Inside such a nozzle there is another one: the filling is fed through the inner hole, and the chocolate mass is fed through the outer, with a slight delay. Then the sweets also pass the vibration zone and enter the refrigeration tunnel. If the candy should contain a nut, then a special nut-packing machine adds it: needle fingers dip the nut into the filling. Near the exit from the tunnel (at the factory it is called "evacuation of sweets"), a knock is periodically heard: when the molds are turned over, they knock on them so that nothing remains inside. Further - automatic packaging and packaging: some sweets are put in bags, others - in boxes.

The finished dough is fed through a distribution pipe to a storage tank, to which a comb is connected, which distributes the dough over the plate. The volume of one portion of dough is calculated so that when you close this frying pan with flaps into a small cage, the dough is distributed over the entire surface. The covered pan enters the oven and the sheet is baked for three minutes. After that, all the sheets fall into a special chamber: the oven can bake waffles unevenly, and in this cabinet the moisture content of all sheets is balanced.

Then the filling is spread on the waffles. It is pre-whipped in a mixer to a certain density, cooled and fed to the rollers under pressure. Their principle of operation is the same as that of a roll-on deodorant: as soon as a sheet comes up, a roller passes over it, transferring the filling to the waffle. Then another waffle sheet is superimposed on top, automatically pressed, and then the workpiece enters the cooling cabinet. After that, the product, which looks like a cake, is served for slicing: the knives first cut it in length and then in width. Special rollers and guides separate the candies from each other. Then all the waffles are poured with chocolate, pass through the vibration zone and again go to the refrigeration tunnel, from where they go directly to the packing and filling department.

By the way, the employees of the factory can try everything that is produced here. True, not in the workshop, but they can take with them a handful of sweets and chocolates for lunch. All finished products are sent to the warehouse, and from there to stores in Russia, the CIS countries, Germany and even the USA.