Today there are many types of marmalade - fruit, fruit and berry, chewing, jelly. The production of marmalade in Russia is very developed, but not all manufacturers can offer a truly high-quality product.
The best option would be to produce marmalade using pectin - this is the most “natural” marmalade that can be made from any fruit or berry. The production of jelly marmalade on agar is no less developed (also a natural thickener, which is obtained from algae). In addition to agar, sugar, molasses, flavoring additives are used, natural juices. If we talk about the “naturalness” of such marmalade, then it would be optimal to use fruit juices, exclusively natural dyes and flavors. It's far from real marmalade, but it's still tasty and quite useful product. It is also possible to produce dietary marmalade, without sugar, with natural sweeteners (stevia extract).
Production chewing marmalade requires the use of another thickener - gelatin. Gelatin is of animal origin. Its use allows you to obtain marmalade of the desired consistency and hardness. The naturalness of such marmalade is equal to the naturalness of marmalade on agar.
Marmalade production technology:
- 1. Preparation of components (fruit puree, berry puree, juices, other components, depending on the recipe).
- 2. Preparing molasses.
- 3. Preparation of marmalade mass by mixing fruit purees, sugar, molasses, pectin and other additives, depending on the recipe.
- 4. Boiling the mass.
- 5. Forming marmalade (shaped marmalade, marmalade in layers).
- 6. Cooling the marmalade.
- 7. Decoration.
- 8. Packaging.
Marmalade recipe.
Today, each manufacturer himself determines the recipe for his marmalade. Some produce marmalade according to classic recipe(fruit-berry), others - based on fruit juices, fruits and pectin/agar/gelatin (fruit-jelly), some make marmalade based on sugar, molasses and gelling agents with the addition of natural dyes and flavors, and others - with the addition of artificial ones (jelly). Therefore, it is impossible to give a clear recipe. On average, the marmalade mass contains from 0.8% to 1% agar, or from 1% to 1.5% pectin; from 50% to 65% sugar; 20% to 25% molasses, 23% to 24% water. It is worth noting that the modern consumer has become more demanding of the quality of sweets, including marmalade. First of all, this concerns the composition of the product - the more it contains natural ingredients, all the better.
Equipment for the production of marmalade.
If we talk about mass production, then the availability of high-quality modern equipment ensures the production of high-quality marmalade that meets all requirements and standards.
The marmalade line consists of the following machines:
- 1. Digesters. They are necessary for preparing molasses, boiling fruit purees, and marmalade mass.
- 2. Marmalade pouring machine. This machine allows you to prepare shaped marmalade, sliced. Also, the machine can deposit marmalade onto cookies.
- 3. Cooling tunnel.
- 4. Glazing and decorating line.
- 5. Packaging line.
- 6. Rotary Conveyors.
Depending on the manufacturing technology, as well as on the gelatinous base, marmalade is divided into two main types: fruit and berry and jelly.
Fruit and berry marmalade, depending on the fruit and berry raw materials used as a base ( applesauce or puree from stone fruits) and depending on the method of molding are divided into the following types: molded, which is produced in the form of small products of various shapes, with a base of apple or creamy puree, covered sugar crust, which is produced in the form of small rectangular bars, with a base of applesauce; layered, which is produced in the form of rectangular layers, cast directly into containers.
Jelly marmalade is divided into the following types: molded, which is produced in the form of small products of various shapes; carved, which is produced in the form of orange and lemon wedges; curly, which is produced in the form of berries and fruits.
Marmalade are confectionery products made from fruit puree with sugar and having a jelly-like consistency.
To give the product a certain color, taste and aroma in the production of marmalade, it is used food colorings, essential oils, vanillin, organic acids (citric, tartaric, malic, lactic). Mainly produce apple marmalade, in the production of which purees from other types of fruit are sometimes added to applesauce to improve taste qualities. Marmalade, which is based on puree from apricots, plums, dogwoods and other fruits or berries (except apples), is called “pat”.
To obtain a good gelling consistency of marmalade, the original puree must have a relative viscosity of at least 2.8 and a pH of 3.2.
The recipe for molded marmalade includes molasses. Due to the content of dextrins, molasses has significant viscosity and helps to obtain a product with a denser consistency.
Good results are obtained by adding sodium salts of citric or lactic acids to the mixture of sugar and puree in an amount of 0.2-0.3% (relative to the mixture). Thanks to the buffering properties of these salts, the concentration of the apple-sugar mixture increases, at which it hardens. This makes it possible to remove most of the moisture by evaporation, sharply reducing the drying time of the products. In addition, the jelly is more durable.
In the case of processing poorly gelling puree, pectin or a pectin-containing concentrate obtained from apple pomace should be added to the marmalade recipe.
The puree received for processing is passed through a finisher, and the sugar is sifted and subjected to magnetic separation.
Cooking of the marmalade mass is carried out in vacuum apparatus equipped with mixers. Boiling is carried out under a gradually increasing vacuum - the pressure drops from 67 to 34 kN/m 2 (the vacuum increases from 250 to 500 mm Hg). Cooking lasts no more than 20 minutes, after which molasses is added to the mass, heated to 50 ° C and strained through a sieve. The marmalade mass, containing 62-68% dry substances, is unloaded from the vacuum apparatus and mixed with dyes and essences.
When unloading the marmalade mass, a sample is taken to check the rate of gelation and the quality of the resulting jelly. If the sample hardens slowly, then sugar is added to the product. If gelling occurs quickly, but the resulting jelly is not strong enough, pectin and acid are added to the product.
In continuously operating cookers, a mixture of puree and sugar, having a concentration of 55-57%, is driven through coils using a plunger pump. Boiling in coils is carried out under atmospheric pressure and lasts 1-2 minutes. From the coil, the welded mass, having a temperature of 106-108 ° C, enters the receiving cone, which serves as a separator. Here juice vapors are separated from the product and its concentration reaches 67-79%.
Depending on the degree of drying and the nature of further processing of the marmalade mass, the following types of fruit and berry marmalade are distinguished.
Plastic marmalade. To obtain this product, the hot marmalade mass is packaged in plywood boxes, which are lined with moisture-proof (parchment) paper inside. Before packaging, boxes with the product are kept in a dry, well-ventilated room for gelling for 12-24 hours. The outer layer of the product dries out and forms a crust with a fine crystalline structure. After this, the surface of the product is covered with moisture-proof paper and the boxes are packed.
Plast marmalade has a humidity of 29-33%. The total sugar content in it is 68%, including about 40% reducing sugars.
Piece marmalade. Piece marmalade consists of individual pieces (pieces) of one shape or another. Marmalade of this type is distinguished between molded and carved.
To obtain molded marmalade, the hot marmalade mass is poured into molds made of stainless steel or ceramics. The product arriving for bottling contains 30-31% moisture and has a temperature of 80-85° C. After gelling, the marmalade is removed from the molds.
The frozen marmalade mass is dried with heated air. The drying temperature at the beginning of the process is 35-40° C, at the end - 55-65° C. During the first drying period, the air temperature should be low so that a crust does not form, which prevents the evaporation of moisture.
During the drying process, the wetting moisture present on the surface of the product evaporates relatively easily. In its place, capillary moisture comes from the inner layers of the product, which is also quickly removed. However, as the product dries, the viscosity of the product increases, making it difficult for moisture to move from the inner layers to the outside.
At the beginning of drying, capillary moisture predominates and the process proceeds at a constant speed. When the bound water begins to evaporate, the drying rate drops significantly.
The higher the humidity gradient, which promotes the transfer of moisture from the inner layers to the outside, the greater the drying rate. A significant temperature gradient delays drying, since under the influence of thermal and moisture conductivity, moisture rushes from the outer layers to the center.
Due to the difficulty of removing moisture, the drying process, despite the small size of the piece-shaped marmalade, is long and lasts 6-10 hours.
During drying, a thin crust forms on the surface of the product, covering the product with a continuous layer.
The dried marmalade is cooled in well-ventilated chambers at a relative air humidity of no more than 70% and a temperature of 15-20°C.
Chilled marmalade is packaged in cardboard boxes lined with waxed paper inside. Paper is also placed between the rows of marmalade to prevent it from sticking together.
The mass of each piece of molded marmalade is 10-25 g. Finished product contains 22-24% moisture with a total amount of sugars 75%, including reducing sugars 20-32%.
To obtain carved marmalade, the hot marmalade mass is poured into wooden boxes in a layer of 1.5-2 cm. After the mass has gelled, the resulting marmalade layer is cut into bars weighing up to 20 g, and then dried to a moisture content of 18-20%. Carved marmalade is sprinkled with powdered sugar and packaged similarly to molded marmalade.
Marmalade is a confectionery product produced from gelling fruit and berry puree and/or gelling agent, sugar or its substitutes and other types of raw materials with the addition of an anti-crystallizer, food additives and/or aromatics. Marmalade is characterized by a gelatinous structure. The surface of the marmalade can be glazed or unglazed. Marmalade products are well digestible, have high taste and dietary properties.
Depending on the type of gelatinous base, marmalade is divided into:
for fruit and berry – based on gelling fruit and berry puree;
jelly - based on gelling agents;
jelly-fruit – based on a gelling agent in combination with gelling fruit and berry puree.
Depending on the molding method, the following types of marmalade are distinguished:
molded (including pat) - molded by casting marmalade mass into rigid shapes or shapes stamped in bulk food product(granulated sugar);
plastic – molded by casting marmalade mass into a container;
carved - molded by casting marmalade mass followed by cutting into individual products.
Marmalade is made unglazed and glazed with chocolate or confectionery glaze.
A variety of jelly marmalade is “Jelly marmalade”, “Strawberry”, “Jelly bars in chocolate”. Marmalade products coated with chocolate include shaped marmalade “Berry in Chocolate”.
Fruit and berry marmalade is a semi-solid body. When cut with a knife, the fruit-marmalade jelly forms non-stick cut surfaces and sharp edges. During storage, there should be no separation of liquid from inside the jelly.
Marmalade jelly with the necessary physical and mechanical properties is formed during the transition of pectin sol into a gel from aqueous solutions of pectin. For the formation of jelly, a certain amount of jelly is required - pectin, sugar and acid at certain pH values.
Pectin provides material for the jelly frame. The higher the concentration of pectin in the jelly, the stronger the resulting jelly will be. However, the strength of pectin jelly depends to a greater extent on the quality of the pectin than on its quantity (pectin from winter Antonov apples and wild game). The presence of sugar is necessary for the formation of pectin jelly. The importance of sugar in the process of gelation lies in its water-removing effect. In the production of fruit marmalade, the technological function of sugar coincides with its taste value. The role of the acid is to displace pectic acids from their salts. The resulting pectic acids from pectinates are capable of gelatinization. Thus, the overall gelling ability of the solution increases. To increase the gelling ability of pectin, it is not the amount of acid introduced that is important, but the pH value of the solution (concentration of hydrogen ions). The optimal pH value is 3.0 – 3.2.
The best condition for the formation of fruit marmalade jellies is considered to be a content of about 65% sugar, 1% pectin, 1% acid and 30 - 32% water, subject to the use of modifier salts.
This ratio can be obtained with a ratio of granulated sugar and puree of 1: 1. To increase the resistance of fruit marmalade to crystallization, part of the sugar can be replaced with molasses. Molasses can be completely or partially replaced with invert syrup, calculated based on dry substances. The actual consumption of puree in recipes is specified in accordance with laboratory tests, depending on the content of dry substances and the gelatinizing ability of the puree.
Technology system The production of fruit and berry marmalade consists of preparing a recipe mixture, followed by boiling to a marmalade mass, molding, gelatinization, drying and cooling the marmalade, and packaging.
Applesauce entering production varies in its gelling ability, therefore, from different batches of puree, a blend mixture is prepared, standard in its gelling ability based on laboratory data.
The puree for blending is mixed in mixers equipped with stirrers.
The recipe mixture is prepared by mixing fruit and berry puree, granulated sugar, molasses and lactate or sodium citrate (modifier salts) in a mixer. The dosage of modifier salts depends on the acidity of the puree and is 0.2 - 0.3% by weight of the recipe mixture. The recipe mixture with a mass of dry substances of about 55% is sent for boiling in a continuous manner in a coil cooking column with a steam separator or in a batchwise manner until the moisture content is from 31 to 40%.
The use of modifier salts allows the marmalade mass to be boiled down to a lower humidity, which reduces the process of drying the marmalade.
With a continuous production method, the marmalade mass is fed from the receiving funnel of the container into the mixer above the casting head. Flavors, acids, and dyes are also dosed here. The marmalade mass is thoroughly mixed and sent for molding in a marmalade-casting machine or manually.
Formed marmalade is produced in a continuous manner. The formation of the marmalade mass is carried out by casting a molding conveyor into metal molds. There are holes at the bottom of the molds. Forms with marmalade mass are sent to stand at an air temperature of 20 o C and within 4 - 6 minutes the temperature of the marmalade decreases and reaches the point at which pectin begins to gel. The duration of marmalade standing in the molds is about 30 – 40 minutes.
The selection of marmalade from the molds is carried out mechanically using compressed air supplied from below to the holes. Air passing through the holes in the bottom of the molds pushes the marmalade onto the sieves. The marmalade selected from the molds is sent for drying, the purpose of which is to remove excess moisture from the marmalade and form small crystals of sucrose on its surface. Marmalade is dried in various types of dryers (chamber, cabinet, tunnel) at a temperature of 55 - 70 o C for 6 - 7 hours. After drying, the marmalade is cooled to 20–30 o C in a workshop or special chambers for 45–120 minutes.
Plast marmalade It is a dense cutting mass, molded into glasses or boxes made of polymer materials, board or plywood boxes, and corrugated cardboard boxes. The cast marmalade mass is left to cool for the purpose of gelatinization and is then sent for packaging.
Pats- marmalade products made from apricot or plum puree. Apricot puree pectin differs from apple pectin in that the jelly obtained from it is more dense, cannot be cut with a knife, and is difficult to remove from rigid forms. The ratio of apricot puree and granulated sugar in the pata recipe is 1: 1.2 –1.5.
The recipe mixture is boiled to a temperature of 112 - 115 o C and a humidity of 15 - 18% and molded by casting into starch, powdered sugar or on a smooth table surface. The process of jelly formation lasts 30–40 minutes. Then the pat is cleared of starch or excess sugar and placed in boxes.
Jelly marmalade- these are products made on the basis of gelling substances (agar, agaroid, furtselaran, pectin), with the addition of granulated sugar, molasses, acid and flavorings and dyes. Fruit and berry supplies and juices are also added to the recipe. In this case, the marmalade loses its transparency. Granulated sugar acts as a filler and adds sweetness to the products. Molasses is used as an anti-crystallizer for sucrose. The acid in marmalade made from agar, agaroid, and furtselaran has a purely taste effect.
Different types and varieties of jelly marmalade differ from each other mainly in the type of gelling agent used, the method of molding and external finishing.
The production of jelly molded marmalade on agar consists of soaking, washing and swelling of the agar (if necessary), boiling the agar-sugar-treacle syrup, preparing the marmalade mass, molding and gelatinization, removing from the molds and sprinkling with granulated sugar, drying and cooling the marmalade with subsequent packaging.
Granulated sugar is added to the dissolved agar and last resort syrup. The agar-sugar-molasses mixture contains 30-33% moisture and is boiled to a moisture content of 25-27%. The temperature of the finished syrup is 106-107 o C. The finished syrup is pumped into a tempering machine, where it is cooled to a temperature of 55-60 o C. The cooled mass enters the mixer above the casting head of the molding unit, where an emulsion of acid, essence and dye is simultaneously dosed. The marmalade mass is thoroughly mixed and sent for molding. Molding is carried out as in the production of fruit and berry marmalade. The duration of gelation on agar is much longer (140-90 minutes) than that of marmalade on pectin, since the temperature at which agar begins gelation is 40 o C. Optimal conditions for the process of agar gelation the temperature is 10-15 o C and the relative air humidity is 60-65%. After the gelatinization process, the marmalade is taken out of the molds, sprinkled with sugar, placed on sieves and then enters the drying chamber. Drying takes place for 6-8 hours at an air temperature of 50-55 o C and a relative air humidity of 20-40%.
Cooling of dried marmalade is carried out in the workshop premises (3-5 hours) or in a cooling cabinet at a temperature of 15-20 o C for 40-60 minutes. After cooling, the marmalade is separated from excess sugar on a vibrating sieve and placed in boxes or boxes.
The production of jelly marmalade on agaroid is somewhat different from the technology of marmalade on agar, which is due to the specific characteristics of agaroid. The process of gelation of an agaroid solution with sugar occurs at high temperatures (about 70 o C).
When preparing syrup, granulated sugar is first dissolved and agaroid is added to the sugar solution. This is because water solution Agaroid is quite viscous and can burn to the heating surface.
Inject into the boiled agaroid-sugar syrup to a humidity of 28-30% at a temperature of 80 o C invert syrup V small quantities, which is caused by the need to increase the content of reducing substances in this marmalade due to its high tendency to sugaring.
Dye and flavorings are added to the cooled jelly mass (up to 72 o C) while stirring. After acidification, the mass on agaroid is immediately sent for molding. Further, the production process is similar to that described above.
Jelly marmalade with pectin. To prepare pectin-sugar-treacle syrup, dry or water-swollen pectin is used.
Pectin is poured into a running mixer with a stirrer; the duration of pectin swelling in water is 15-20 minutes (the ratio of water to pectin is 25:1). The duration of swelling of pectin in water is 15-20 minutes and then the solution is sent for complete dissolution by boiling for 2-3 minutes into an open digester. Then modifier salts are added and granulated sugar is added. After the granulated sugar is completely dissolved, molasses is introduced.
The finished pectin-sugar-molasses syrup with a moisture content of 39-41% is boiled in a coil cooking column with a steam separator until the dry matter content is 75-66%. Heating steam pressure 0.3-0.4 MPa. The prepared marmalade mass is molded by casting at a temperature of 80-85 o C. Next, the process of preparing marmalade is similar to that described earlier.
Three-layer jelly marmalade consists of two jelly (outer) and one whipped (middle) layer. The jelly layers have a gelatinous structure, and the middle one has a foamy structure.
Preparation of the mass for the jelly layers is basically the same as described above. The mass for the middle layer is obtained by churning agar-sugar-treacle syrup with a dry matter content of 76-78% and a temperature of 60-62 o C egg white. During the process of churning the syrup, applesauce and flavorings are added to it. Next, the mass for each layer is formed by casting one jelly layer. After it has stood and structured for 35-40 minutes, a layer of churned mass is cast onto the jelly layer. The third (jelly layer) is cast onto the second after its structure formation.
When the process of structure formation ends in all layers, the layer is cut into individual products with disk (for longitudinal cutting) and corrugated (for transverse cutting) knives. The chopped marmalade is sprinkled with granulated sugar, placed on sieves and dried at a temperature of 30-35 o C for 10-12 hours.
Jelly-fruit marmalade is made on the basis of gelling agents in combination with a gelling agent fruit puree. It is produced in the form of small figures of various configurations, the surface of which is sprinkled with granulated sugar or covered with a thin crystalline crust, or glossy.
The technology of jelly-fruit marmalade includes stages of production of both fruit and berry and jelly marmalade.
The main indicators of the quality of marmalade are humidity (15-33%), content of reducing substances (20-40%), acidity (7-18 degrees), content of sulfurous acid (0.01%) or benzoic acid (0.07%).
Questions for self-control.
1. Classification and assortment of marmalade products.
2. Characteristics of jelly-formers, conditions for their jelly formation.
3. Justification of the recipe for fruit and jelly marmalade.
4. Forming methods various types marmalade.
5. Marmalade quality indicators
However, the level of competition in this segment is very high; today there are about 10 large manufacturing enterprises and the same number of small ones. This can be explained quite simply: low cost of equipment and ease of production.
According to experts, the taste requirements of buyers in large cities increasingly prefer more expensive marmalade with the addition of natural juices. The cheaper jelly-shaped one is also popular, however, it is in great demand in settlements where the income per capita is no more than 10 thousand rubles.
Manufacturers are increasingly trying to diversify the range of marmalade they produce, including lean types of marmalade, adding various fillers. However, not all enterprises can afford to update their equipment and, accordingly, in this regard, they only change the form of their products without making significant changes to the marmalade.
For example, when producing fructose-based products or various jelly candies, many enterprises try to target the most specific and labor-intensive segments. IN in this case There is a predominance of domestic production, which is associated with high transport costs for imported products and their shelf life, and the population is more confident in domestic products.
As for the raw material (pectin, agar) for making marmalade, our factories actively use it, both Russian and imported. Although, paradoxically, imported raw materials often cost much less than domestic ones.
Varieties of marmalade
When using various raw materials, several types of marmalade products are obtained, including: jelly, which is made on the basis of gelling agents; fruit and berry - made on the basis of gelling fruit and berry puree; jelly-fruit - made using gelling agents and fruit and berry puree.
Modern domestic entrepreneurs give greater preference to the production of jelly marmalade, which, in addition to its excellent taste (which, by the way, is not inferior to fruit and berry marmalade), is more economical in terms of its production. So, for its production you need a gelling component agar (agaroid), dyes, food acids, shock absorbers, syrup from molasses and sugar.
Depending on the form of marmalade products, they are also distinguished: sliced marmalade - the whole marmalade mass is divided into separate parts; plastic marmalade - the entire mass is immediately poured into a container; molded marmalade - accordingly, the mass is poured into molds.
Necessary equipment for production
First of all, this is a marmalade-making apparatus, as well as steam digesters, which are used to cook masses of different colors. In addition, a steam generator (to generate steam), cooling and drying cabinets, a tempering machine, and a string cutting machine are required. If you aim to produce mixed types of marmalade products, as well as marshmallows, then you need a churning machine that produces an opaque layer, and you will also need a tubular apparatus. In addition, it is necessary Silicone forms, as well as trays for drying products.
The cost of used equipment is 550-700 thousand rubles. To a greater extent, the cost depends on performance, equipment and working condition.
The premises for such production must be at least 250 square meters. m in area. The cost of renting such premises per month will be in the range of 50-60 thousand rubles. The number of personnel can be limited to a maximum of 8 workers, who must work in shifts.
Marmalade production technology
To prepare jelly marmalade, first of all, you need agar (or pectin). Remember that the production technology is determined by the selected raw materials. So, the manufacturing process takes place in several stages. First, the gelling components are washed and soaked, after which a syrup is prepared from prepared sugar, agar and molasses. Then the jelly mass is boiled, after which it is cooled and cast into molds. Afterwards, the marmalade begins to gel, then the product is taken out of the mold and dried for 45-60 minutes at a temperature of about 40 degrees. After all, the marmalade is sprinkled with sugar, then dried again, cooled and transported for packaging.
The process of making fruit and berry marmalade is somewhat different. First, the raw materials and the recipe mixture are prepared, then the marmalade mass is boiled, cut and poured into molds, after which it is dried (if it is molded marmalade) or allowed to stand (if it is sheet marmalade), then packaged and packaged. The recipe mixture is prepared on the basis of blended pureed fruit and berry puree (usually apple) with sugar and molasses. Modifier salts (disodium phosphate or sodium lactate) are also added to the puree, which reduce the viscosity of the mass during cooking and reduce the rate of hardening. Then the mixture is thoroughly mixed and sent to cookers for boiling at a temperature of about 85 degrees. If this process occurs in a periodic manner, then a spherical vacuum apparatus is needed for these purposes. Then the mass is cooled and cut (at the same time, dyes, acids and flavors are added). This happens in tanks with a stirrer in a periodic manner. After all, the mass is mixed again and sent for casting into molds, or immediately packaged. Casting into molds takes place in marmalade-casting machines, after which the marmalade is laid out on perforated aluminum sheets, where it is dried.
There are several types of dryers: conveyor, chamber and cabinet. Since drying occurs at a high temperature, after this the marmalade needs to be cooled in special chambers (you can just indoors, which is undesirable) at 15-30 degrees. Then the already cooled marmalade can be transferred for packaging in boxes or bags.
Remember that it is the specifics of the technology that directly affect the final cost of the product. In other words, jelly-shaped marmalade is cheaper than shaped marmalade. However, curly marmalade is also in great demand. There are requirements for raw materials, appearance and quality of products, which are controlled by GOST 6442-89.
It is also necessary to know that the wet surface of marmalade, its deformation, rough crust, unexpressed taste, etc. are signs of poor quality products. It is also necessary to remember about the shelf life of the finished product.
Sales of products
The existing rather intense competition in this industry forces entrepreneurs different ways win over its customers: the quality of the marmalade, the price, and the wide range.
However, almost all confectionery factories focused on the production of marmalade do not deal with issues of positioning their own trademark on the market, sparing the costs, which will be very impressive when conducting a quality marketing campaign.
It is best to organize the sale of your products in large retail chains. However, if your company is relatively young, it may be difficult to enter into contracts with them. In this connection, on initial stage You can start producing weighted, rather than packaged, marmalade, and sell it, to begin with, in retail grocery stores.
You also shouldn’t skimp on product packaging. Retailers, as a rule, prefer so-called “TVs” (boxes covered with transparent film), in which weighted marmalade is packaged. They allow the buyer to evaluate appearance goods. As for packaged marmalade, as a rule, they use bright and transparent packaging, where its lower part is covered with a pattern to disguise the sprinkled sugar.
Thus, to organize your own marmalade production business, you need starting capital in the amount of 1 million rubles. Productivity per month is 25-35 tons, where profitability will depend on the price of raw materials and be 20-40%. Thus, with the minimum production volumes (25 tons) of marmalade per month, cash flow will vary within 700 thousand rubles. - 1 million rubles.
Prepared by editors: "Business GiD"
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Federal Agency for Education
State educational institution of higher professional education
Tula State University
Department of Food Production
Coursework
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Introduction
Marmalade production technology
Machine and hardware diagram of a mechanized flow line for the production of marshmallows with pectin
Operating principle and calculation of the digester
Conclusion
Bibliography
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This paper examines technological equipment for the production of marmalade, in particular, a digester with a mechanical stirrer. Its mechanical calculation and performance calculation are given, and appropriate conclusions are drawn about the advantages and disadvantages of the selected tempering machine.
Introduction
The confectionery industry, along with other sectors of the food industry, is designed to satisfy the food needs of the population. Pleasant taste, delicate aroma, attractive appearance, high calorie content and digestibility of confectionery products are provided by a variety of high-quality raw materials: sugar, molasses, honey, flour, fruits, eggs, cocoa beans, nuts, food acids, gelling and aromatic substances.
Confectionery products have been known to mankind since time immemorial. The main raw material for the manufacture of these products was originally honey. In Rus' already in the 15th century. There was a gingerbread industry.
The production of confectionery products accelerated in our country at the beginning of the 20th century, when industrial production of sugar from beets was established. However, the production was artisanal; they prepared lollipops, sweets, cakes, chocolate drink etc. Since the 60s of the 19th century. Factory production of confectionery products began to develop.
At the beginning of the twentieth century. confectionery production was concentrated only in large cities. In the middle of the century, new enterprises were built and put into operation, equipped with progressive equipment for that time and mechanized flow lines. Appearance large quantity confectionery factories in the East and South of the country made it possible to significantly reduce the costly transportation of confectionery products and bring their production closer to places of consumption. During that period, based on the achievements of science and technology, the technology of many types of confectionery products underwent significant changes.
Nowadays, the confectionery industry is a highly mechanized production facility, equipped modern technology for the production of caramel (candy, with fruit and milk fillings, with layered filling), sweets (from praline masses, fondant and milk, toffee), marshmallows on pectin and agar, chocolate, etc. The growth in the production of confectionery products is accompanied by a significant increase in the quality and expansion of the range.
Great contribution to the creation and improvement of equipment and technology confectionery production contributed by the All-Russian Research Institute confectionery industry and scientists from industry universities in Russia.
In the Concept of State Policy in the Field healthy eating of the population of the Russian Federation for the period until 2005, it is planned to create conditions that provide various age and professional groups of people with rational nutrition, taking into account traditions, habits, the state of the economy and the requirements of medical science. In the field of confectionery production, the problem of increasing the share of products with high nutritional and biological value, including 20-30% of products enriched with vitamins, minerals, and dietary supplements. At the same time, measures are being taken to bring the quality and safety indicators of products in accordance with the recommendations of major international organizations, such as the World Trade Organization, the World Health Organization and the World Food Organization.
The paper examines equipment for the production of marmalade.
Marmalade production technology
The diagram for the production of marmalade is shown in Fig. 1.
Rice. 1. Technological scheme for the production of jelly molded marmalade based on pectin
Preparation of pectin-sugar-treacle syrup. Dry commercial pectin powder or pectin swollen in water is used. Dry powder is used if pectin dissolves well in water upon preliminary swelling.
Boiling of the syrup is carried out in a continuous way, for example in a coil cooker (33-A5) or periodically in a filling vacuum apparatus (brand 31 A), as well as in an open digester (for example, brand MZ-2S-244B).
In the continuous method, pectin swollen in water is most often used. For its preparation, high-speed mixers, as well as special pectin solvents, can be used. The mixer is a container with a stirrer. The drain fitting of the container is connected to a pump, which can pump pectin swollen in water into a dissutor or open digester, i.e., recirculate the mixture. In the latter case, a significant hydraulic shock is created, which prevents dry pectin from clumping when it is loaded into the mixer.
Water at a temperature of (45 ± 5) °C is poured into a mixer or pectin solvent from a measuring cup in a quantity of 20-25 times relative to pectin. Turn on the mixer and pump and add pectin. The duration of swelling of pectin in water is 15-20 minutes. A pectin solution can be prepared in a special pectin solvent. Pectin swollen in water is pumped into a dissutor or open digester and dissolved by boiling for 2-3 minutes.
Then sodium lactate is added and granulated sugar is added. Once the granulated sugar has dissolved, molasses is added. Pectin-sugar-treacle syrup with a dry matter content of (59 ± 1)% is drained, filtered through a sieve or a double layer of gauze, into a receiving storage container in front of the coil cooker. The syrup is boiled to a dry matter content of (76.5 ± 1)% at a heating steam pressure of (0.3 ± 0.1) MPa.
In the batch method of boiling syrup in an open digester, both dry pectin powder and pectin swollen in water are used. When using pectin swollen in water, the order of loading the components is the same as indicated above. When using dry pectin powder, first prepare a dry mixture of pectin and granulated sugar so that the pectin is distributed evenly in the water without clumping. To prepare the dry mixture, for each part of pectin powder, take 3-5 parts by weight of granulated sugar and mix thoroughly. The granulated sugar used to prepare the dry mixture is then subtracted from the total amount of granulated sugar provided for in the recipe for the preparation of pectin-sugar-molasses syrup.
Water is poured into an open digester in 20-25 times the amount of pectin powder and the dry pectin-sugar mixture is added with constant stirring. Pectin is dissolved in water by boiling for 3-5 minutes. Then sodium dictate is added and granulated sugar is added. Molasses is added at the end of boiling the syrup.
Preparation of marmalade mass. Carry out continuous or periodic methods. With the continuous method, pectin-sugar-treacle syrup is continuously fed into the mixer above the hopper of the marmalade-making machine using a plunger dosing pump (for example, brand Zh7-ShDS). An emulsion of acid, essence and dye is continuously dosed into the same mixer along with the syrup using a pump (for example, YARK-3 brand). The marmalade mass is thoroughly mixed and enters the hopper of the marmalade-making machine.
With the batch method, prepare the marmalade mass in separate portions. A certain amount of pectin-sugar-treacle syrup is loaded into a tempering machine or container with a stirrer and a heating jacket, the appropriate amounts of acid, essence, and dye are added and mixed. The resulting marmalade mass is sent for molding.
Indicators of marmalade mass:
Mass fraction of reducing substances, % - 14+2
Temperature, °C - 85 ±5
pH - 3.1 ±0.1
Molding and gelation of marmalade mass. These operations, as well as the selection of marmalade from the molds, are carried out in a continuous or periodic manner.
The process of jelly formation of the marmalade mass and the strength of the resulting jelly are influenced by three main factors: pectin concentration, dry matter content in the mass and pH. With an increase in the concentration of pectin and the content of dry substances in the mass, as well as with a decrease in the pH value, the process of jelly formation proceeds faster, and the strength of the resulting jelly increases. By varying the values of these factors within acceptable limits, their optimal values are selected to ensure normal conditions for the formation and gelation of the mass. The prepared portioned marmalade mass is molded by hand over a certain period of time. To prevent gelation from occurring in the marmalade mass during this period, it should be prepared with more low content dry matter, and increase the pH value.
Machine and hardware diagram of a mechanized flow line for the production of pectin marmalade
The line (Fig. 2) includes a recipe and cooking complex, a marmalade-making machine and a dryer. The puree, previously rubbed on a rubbing machine through a sieve with a cell diameter of 1.5 mm, is pumped into mixers 1, which are used to prepare a blended puree in order to obtain homogeneous mass puree with the required acidity and gelling ability.
