About the company. Technology for producing food mustard

One of the simplest sauce production technologies is the production of mustard. Such production does not require either expensive raw materials or complex equipment. Therefore, even small entrepreneurs can afford to implement such a business project. With a properly drawn up business plan and pre-thought-out methods for selling products, this production can pay for itself quite quickly. The main thing is to carry out the necessary certification of production and products, organize the purchase of raw materials and the sale of finished goods.

Room.
For a mini-workshop for the production of mustard, you need to find a room about 3 meters high, with water supply, natural lighting, electricity, and ventilation. It will also need to be repaired to comply with sanitary and hygienic standards. It may be possible to find a completely finished premises, for example, a former food industrial workshop. And, of course, do not forget that additional rooms for warehouses will be needed finished products, raw materials and containers.

Raw materials for mustard production.
The raw materials for making mustard are: mustard powder, water, vinegar, mustard or vegetable oil, spices, salt and sugar.

Equipment.
Before choosing equipment, you need to decide whether you will produce only mustard or several sauces. Mustard is to some extent seasonal product, the demand for it drops in the summer, but is consistently high in winter and autumn. By producing several sauces, such as mayonnaise and ketchup, you will achieve more stable income, even if you pause mustard production in the summer. But investments, accordingly, will require completely different ones.
In any case, the decision is up to you, and if you limit yourself to the production of mustard alone, you can purchase a ready-made line for its production. This means that the specialists themselves will bring your premises into proper form and condition, install equipment and train employees.

The equipment for such a workshop will consist of: a vibrating sifter, a digester, an open digester, a mixer, a rotary pump and a grinding machine.

A ready-made mustard production line with a capacity of 250 kg per shift costs 220,000 rubles. Its sellers promise an income of 50,000 rubles per month, however, if there is a market and the business is built correctly.

If you decide to release multiple different products, then you will have to purchase a more advanced special kit for the production of sauces. It consists of: a universal homogenizing module, a long-term pasteurization bath, a centrifugal pump, special table from stainless steel, technological scales.

It is better to decide on the packaging of finished products in advance, since the equipment for packaging also depends on this. Of course, it is much more profitable to pack mustard in plastic packaging; it is an order of magnitude cheaper than glass, which will further reduce the cost finished product. For packaging in plastic packaging you will need: a dispenser for liquid and viscous products, a special installation for sealing packages and a compressor.

Prices for all equipment will vary depending on the manufacturer and configuration. But by purchasing equipment for the production of sauces, even if at first you will only produce mustard, you can always expand your range.

Staff.
As for personnel, you will need an experienced technologist, and finding ordinary workers without experience and training them will not be difficult. The number of employees will depend on the scale of your production, but for starters, two employees, a sales manager, and a technologist will be enough. You can find an accountant coming.

If everything is relatively simple with the production and organization of a mini-workshop, then you will have to rack your brains over the sale of the finished product. This is where you need a good manager who can negotiate wholesale purchases with stores and supermarkets and think through the right system of discounts. It doesn’t make sense to invest a lot of money in advertising at first; let the main advertising be the catchy packaging and quality of the product.

You can also try to negotiate directly with the owners of several small stores. At correct recommendations sellers, buyers will get used to both your yet unknown products and the fact that the product is of high quality. There is also the option of cooperation with supermarkets that sell private label products. All you have to do is take orders and pack the goods in the required packaging. Of course, for such cooperation you will need to prove the quality of your products and their compliance with GOSTs. But you won’t have to think about promoting your own brand or worry about sales.

Investment and return on investment.
The cost of 1 kg of mustard is approximately 52 rubles. When producing 500 kg of finished products per month (250,000 packages of 200 grams each), the cost of the finished product will be equal to 25,500 rubles.
The retail price will be approximately 75,500 rubles, monthly expenses will be about 32,000 rubles (premises rent, raw materials, etc.), and the net profit after taxes will be almost 15,000 rubles.

So, with an initial investment of 300,000 - 350,000 rubles in a mini-workshop, even with minimal output, you will completely recoup the investment in less than two years and receive a net profit.

Do you have a Business Idea? On our website you can calculate its Profitability Online!

The invention relates to food industry. During production mustard powder Mustard seeds are cleaned, conditioned according to moisture content and seed size, crushed, and the shells are separated from the kernel. The kernels are crushed to the following fractional composition, wt.%: halves of kernels no more than 15, passage through a one-millimeter sieve no less than 85, whole kernels are absent. Moisture-heat treatment is carried out with live steam to a humidity of 10%, then dried to a humidity of 4-5%, bringing the temperature of the pulp to 100-115 o C. The pulp is pressed, crushed, and when crushing, additionally add 5-7% of white mustard seeds, or 5-7 % yellow mustard, or 5-10% mixture of white and yellow mustard seeds in a 1:1 ratio by weight of the cake and sifted. This allows you to get mustard powder with adjustable pungency. 1 table

The invention relates to the oil and fat industry and concerns methods for the production of mustard powder. Famous process the production of mustard powder includes the following operations: cleaning mustard seeds, conditioning the seeds for moisture and size, dehulling them, separating the shell from the kernel, grinding it, moisture-heat treatment, pressing, grinding the cake and sifting to separate the powder (see Guide to the technology of production and processing vegetable oils and fats. L., 1960, vol. I, cc. 256, 265), adopted as a prototype. However, mustard powder obtained by this method quickly loses its qualities: characteristic pungent taste and pungency required in the manufacture of finished food mustard and mustard plasters, because at high temperature Pressing and squeezing the oil inactivates the enzyme myrosinase, which promotes the hydrolysis of sinigrin and the formation of allyl isothiocyanate (AITC), which gives mustard powder its specific properties. The problem that was solved when creating the invention was obtaining mustard powder with given properties. The technical result is the production of mustard powder of adjustable pungency, i.e. with controlled allyl isothiocyanate content. The specified technical result when implementing the invention is achieved by the fact that in known method in the production of mustard powder, the kernel is crushed to the fractional composition, wt.%: Kernel halves - No more than 15 Pass through a one-millimeter sieve - No more than 85 Whole kernels - None Moisture-heat treatment of the kernel is carried out with live steam to a humidity of 10%, then dried to a humidity of 4-5 % with bringing the temperature of the pulp to 100-115 o C, and when grinding the cake, additionally add 5-7% white mustard seeds, or 5-7% yellow mustard seeds, or 5-10% a mixture of white and yellow mustard seeds in a ratio of 1: 1 by weight of the cake. Grinding the kernel to the specified fractional composition allows for the most complete destruction of the cellular structure of the kernel, which contributes to better oil extraction during pressing. IN mustard seeds contains the thioglucoside sinigrin and the enzyme myrosinase; in the presence of water, sinigrin is hydrolyzed and allyl mustard oil is formed, which determines the pungent taste of mustard. By treating seed kernels with live steam and increasing the temperature to 100-115 o C, the yield of fatty oil is increased by 2-3% due to more complete opening of seed cells and a decrease in oil viscosity. But at the same time, the myrosinase enzyme is inactivated, and the hydrolysis of sinigrin with the release of allyl isothiocyanate does not occur completely, as a result of which mustard powder loses its characteristic properties: pungency and pungent taste. Adding whole mustard seeds to the cake at the grinding stage in an amount of 5-10% of the mass of the cake, in which the myrosinase enzyme is preserved in its native state, allows the hydrolysis of sinigrin to be carried out more completely and obtain a given amount of AITC and, accordingly, control the degree of pungency of the final product, i.e. . powder. In the proposed method, it is possible to obtain an AITC content of 0.67 to 1.20% in terms of absolutely dry matter. The method is carried out as follows. Mustard seeds on separators are cleaned of foreign impurities and mineral debris; metal impurities are removed using magnets installed before and after the separators. The moisture content of seeds entering production should be 6.5 - 7.0%. After cleaning, the seeds are calibrated by size using sieves or separators. Hulling of mustard seeds is carried out on roller machines, after which the kernel is separated from the husk using aspiration grain shakers. For normal preparation for pressing, seed kernels are crushed on four-roller rollers to the fractional composition, wt.%: Half kernels - No more than 15 Pass through a one-millimeter sieve - No less than 85 Whole kernels - None The crushed kernels are fed into the first vat of the roaster, where they are steamed with live steam bringing the humidity to 10%. Partial hydrolysis of sinigrin occurs. In the 2 lower vats of the roaster, the pulp is dried to 4-5% humidity and heated to a temperature of 115 o C, the myrosinase enzyme is inactivated. After pressing, mustard cake with partially reacted sinigrin and partially inactivated myrosinase is fed for grinding on five-roller VS-5 machines, followed by separation of the powder in sieves. Partial inactivation of the myrosinase enzyme is compensated by adding 5-7% white or yellow mustard seeds, or 5-10% a mixture of white and yellow mustard seeds in a 1:1 ratio by weight of the cake, to the cake at the grinding stage. By changing the amount of whole seeds fed, the content of allyl isothiocyanate in the powder is adjusted. The research results are summarized in a table.

Formula of invention

A method for producing mustard powder, including cleaning mustard seeds, conditioning the moisture content and size of the seeds, hulling them, separating the shell from the kernel, grinding it, moisture-heat treatment, pressing, grinding the cake and sifting, characterized in that the kernel is crushed to a fractional composition, wt. .%:
Halves of cores - No more than 15
Passage through a one-millimeter sieve - Not less than 85
Whole kernels - None
moisture-heat treatment is carried out with live steam to a humidity of 10%, then dried to a humidity of 4 - 5%, bringing the temperature of the pulp to 100 - 115 o C, and when grinding the cake, 5 - 7% of white mustard seeds, or 5 - 7% of yellow mustard seeds are additionally added mustard, or 5 - 10% of a mixture of white and yellow mustard seeds in a 1: 1 ratio by weight of the cake.

Company today

Story

Sarepta mustard oil was valued throughout the world as a standard of purity. The reason for this was a special technology - the mustard seed was kept in barns for 3 years at a constant temperature, and only then it went into production. After this, the oil was of special purity - transparent, light amber in color, without sediment. After filtration, it still stood for 3 months. In 1859, the company “Heirs of I.K. Glich" received the right to be called "Supplier of the Court of His Imperial Majesty." In 1910, Emperor Nicholas II honored the celebration of the 100th anniversary of the Glich trading company with a visit. Since then, Sarepta, along with French Dijon, has been one of the mustard capitals of the world.

Currently, the largest processor in Russia of a unique crop of its kind - mustard, is the Volgograd mustard oil factory "Sarepta" - a descendant of the Glich creamery, which took the historical name of the settlement where Sarepta mustard gained worldwide fame. The enterprise survived the revolution, did not stop production during the Great Patriotic War, and retained technology and qualified personnel.

Museum reserve

In 1989, on the site of this unique German settlement - “a little Paradise on Earth”, the state historical, ethnographic and architectural museum-reserve “Old Sarepta” was created. To the museum website

Mustard Neitz, whose business was continued by his son-in-law Johann Kaspar Glitsch, gained access to to the royal table Emperor Alexander I.

The “Imperial Blessing” of 1810 can rightfully be considered the beginning of the mustard industry in Russia.

Mustard processing is becoming the leading industry in the Sarepta settlement; it determines the economy of the territory and the well-being of its residents.

A new Glich mustard factory with brick buildings and a steam engine is launched.

The factory is undergoing a complete modernization of technological processes.

Sarepta's mustard products are exported to Germany, Denmark, Poland, the USA and China.

The Glich factory is renamed the Founder plant.
The plant's activities did not stop even during the defense of Stalingrad.

The modern mustard plant “Gorchichnik” is launched, which includes the first-born of the mustard industry, the “Osnovatel” plant and an oil and fat plant.

Mustard oil becomes a strategic raw material and is reserved by the State Reserve structures.

The mustard plant received its current name
LLC "Volgograd Mustard Creamery "Sarepta"

The company is part of a group of companies
UG Group

A unique, unparalleled technology for obtaining natural essential oil, the process of processing mustard oil seeds has become waste-free.

Launch of an automated line for the production of natural essential oils mustard oil and feed concentrate.

Received a certificate of the international quality management system
ISO 9001:2008

The production of mustard packets has been resumed.

The raw materials department was reconstructed, modern seed cleaning equipment and an automated transport unloading system were installed.

The mustard powder production site was reconstructed and modern imported equipment was installed, ensuring quality at the level of the world's best brands.

Production of the premium Sarepta product line was launched

The Sarepta plant today is a preserved and enhanced production tradition, an industry leader in the supply and processing of mustard oil seeds, the developer and owner of a unique technology for deep processing of raw materials, providing the maximum range of finished products in the industry. The technology is unsurpassed in terms of economic efficiency and is protected by patents. The company itself is part of the UG Group holding company.

In 2009, VGMZ Sarepta LLC confirmed its reputation as a reliable supplier of quality products, having successfully passed an independent examination and received international quality management certification ISO 9001.

Also, Sarepta brand products have been repeatedly awarded at international food exhibitions and meet the requirements of kosher and halal, which is also confirmed by international certificates.

Every day, products are shipped from the plant to various parts of the world - Russia, Canada, Japan, Germany, we are developing long-term and fruitful cooperation with our partners and are working to create new business relationships.

The history of mustard production in Russia began in the seventies of the 18th century. At a reception with Empress Catherine II, Count N.A. Beketov tried her favorite delicacy. This was mustard oil, which Catherine ordered for the imperial table from distant England and which cost the royal treasury “a pretty penny.” Nikita Afanasyevich promised to grow mustard on Russian lands, the oil of which will taste better than English.

He begins experiments on developing a new mustard variety on his Otrada estate in Tsaritsyn district. After a series of failures, Beketov for the first time cultivated a new variety of mustard, crossing wild mustard with English and French, and this is how the Sareptskaya mustard variety, which is widely popular today all over the world, was developed.

The Empress reacts favorably to the news. “His Excellency Nikita Afanasyevich Beketov was presented with a gold medal from the society as a sign of excellent honor and pleasure in witnessing gratitude for the sent model of the economic mill of his invention, for the spread of mustard sowing in the Tsaritsyn village of his Otrada and for the improvement of squeezing oil from it. This award gives the right to His Excellency Nikita Afanasyevich Beketov to supply mustard oil to the court of His Majesty the Emperor,” wrote the Economic Bulletin in 1795.

Experiments on the production of mustard oil were continued by the Volga Germans of the Sarepta settlement, with their usual accuracy establishing the industrial production of Sarepta mustard and mustard oil. In 1810, the German missionary Johann Caspar Glitsch organized steam production for the processing of mustard oil seeds - this year is rightfully considered the beginning industrial production Sarepta mustard and mustard oil.

Today, in the conditions of mini-productions, production is also widespread various sauces, ketchups, etc. NZPO LLC - Molpromline™ develops and produces equipment and production lines for making sauces such as soy sauce, mustard sauce, horseradish sauce, Tkemali, Adjika, etc.

Vacuum homogenizing plant in mustard production

For the production of small volumes of mustard, the commercially produced vacuum homogenizing unit UG-GURT is ideal. If you are going to produce more than two tons of finished products per day, we are ready to manufacture a mustard production line for you.

Purpose of UG-GURT

Homogenizing installation type UG-GURT is intended for emulsification, mixing and heat treatment liquid and paste products.

Operating principle of vacuum homogenizing unit

The working capacity of the unit has a jacket for heating and cooling the product and a heat-insulating casing. Inside the container there is a special type of mixing device with perforated blades, a bumper and floating scrapers that prevent the formation of burns during heating of the product and ensure good heat exchange between the coolant (coolant) and the product being processed.

On the cover of the unit there is a stirrer drive and a hatch for loading dry ingredients, a vacuum chamber for connecting the device to the evacuation system, a pipe for loading liquid components, as well as a fitting for returning the product from the circulation channel. Below the container is located, combining the operation of a homogenizer and a rotary-pulsation apparatus, a dispersant with two funnels for introducing fat phases and bulk components into the product during circulation.

Products manufactured besides mustard

• Dairy - soft cottage cheese, kefir, condensed milk, processed cheese, recovery of milk powder, cream.
• Oil and fat - combined oils, margarines, mayonnaise, pastes.
• Fruit and vegetable - jams, jams, ketchups, sauces, confitures, purees, pastes.
• Confectionery - creams, fillings, chocolate and nut pastes, chocolate glaze, honey.
• Non-alcoholic - juices, nectars, drinks.
• disinfectants. Cosmetic - creams, shampoos, balms, gels, ointments, toothpastes.
• Pharmaceutical - ointments, emulsions, gels.
• Chemical - detergents, adhesives, varnishes, polishes,

Technical characteristics of mustard production plants

Table mustard

Table mustard (food) is a ready-to-use seasoning made from mustard powder - ground mustard cake.

Mustard - annual plant of the cruciferous family, there are Sarepta, white, black and Abyssinian. Ripe seeds contain up to 47% mustard oil, which is used not only for preparing salads, frying vegetables, baking bread, production of sweets and canned food, but also in the soap, textile and pharmaceutical industries.

Today a wide range of this sauce is produced - Mustard “Russian”, “Russian”; "European"; "Savory"; “English”, sauce with mustard “Remulad” (Slovak cuisine), etc.

To prepare table (food) mustard, the following types of raw materials are used:
• mustard powder according to GSTU 1829;
• sunflower oil according to GOST 1129 or other vegetable oils,
• granulated sugar according to DSTU 2316 (GOST 21);
• table salt according to DSTU 3583 (GOST 13830);
• food vinegar according to DSTU 2450;

Technological process of mustard production

Water is loaded into the mixer, heated to 60-70°C, prepared sugar and salt are added, after complete dissolution, the solution is brought to a boil, allowed to boil, and cooled to 60°C.

The mustard powder is sifted, loaded into a homogenizer, and a hot sugar-salt solution is gradually introduced. Kneading is carried out until a homogeneous mass is obtained.

The mixed mass is kept for 12-15 hours in a warm place for “ripening”. Then add flavored vinegar, vegetable oil and mix thoroughly. After this, ripening continues for 24 hours.

Making Flavored Vinegar

Preparation of flavored vinegar: 0.1-0.2% spices are added to 80% vinegar essence and infused for 24 hours.

The richness of the flavors of all varieties of mustard depends on the composition of the flavored vinegar, the amount of sugar, salt and vegetable oil. Flavored vinegar may contain allspice and hot pepper, bay leaf and cinnamon, cloves and nutmeg, cardamom and garlic.

Ready mustard is a homogeneous spreadable mass - yellow with a reddish-brown tint.

By physical and chemical parameters mustard must meet the following requirements:
• Mass fraction of dry substances 32-43%.
• Titratable acidity (in terms of acetic acid) – 1,5-1,7 %
• Mass fraction of total sugar – 5-16%
• Mass fraction table salt – 1,5-3,0 %

You can buy equipment for the production of mustard, horseradish, adjika, tkemali according to previously agreed upon options, dimensions and productivity. The price of equipment for the production of mustard, horseradish, adjika, and tkemali is always negotiable due to the unpredictability of costs.

The invention relates to the food industry. When producing mustard powder, mustard seeds are cleaned, conditioned for moisture and seed size, crushed, and the shells are separated from the kernel. The kernels are crushed to the following fractional composition, wt.%: halves of kernels no more than 15, passage through a one-millimeter sieve no less than 85, whole kernels are absent. Moisture-heat treatment is carried out with live steam to a humidity of 10%, then dried to a humidity of 4-5%, bringing the temperature of the pulp to 100-115 o C. The pulp is pressed, crushed, and when crushing, additionally add 5-7% of white mustard seeds, or 5-7 % yellow mustard, or 5-10% mixture of white and yellow mustard seeds in a 1:1 ratio by weight of the cake and sifted. This allows you to get mustard powder with adjustable pungency. 1 table

The invention relates to the oil and fat industry and concerns methods for the production of mustard powder. The known technological process for the production of mustard powder includes the following operations: cleaning mustard seeds, conditioning the seeds for moisture and size, collapsing them, separating the shell from the kernel, grinding it, moisture-heat treatment, pressing, grinding the cake and sifting to separate the powder (see Technology Guide production and processing of vegetable oils and fats. L., 1960, vol. I, cc. 256, 265), adopted as a prototype. However, the mustard powder obtained by this method quickly loses its qualities: the characteristic pungent taste and pungency, necessary in the manufacture of ready-made food mustard and mustard plasters, because at high temperatures of pressing and oil extraction, the enzyme myrosinase is inactivated, which promotes the hydrolysis of sinigrin and the formation of allyl isothiocyanate (AITC), which gives mustard powder its specific properties. The problem that was solved when creating the invention was to obtain mustard powder with the desired properties. The technical result is the production of mustard powder of adjustable pungency, i.e. with controlled allyl isothiocyanate content. The specified technical result when implementing the invention is achieved by the fact that in the known method of producing mustard powder, the kernel is crushed to the fractional composition, wt.%:

Kernel halves - No more than 15

Passage through a one-millimeter sieve - No more than 85

Whole kernels - None

Moisture-heat treatment of the kernel is carried out with live steam to a humidity of 10%, then dried to a humidity of 4-5%, bringing the temperature of the pulp to 100-115 o C, and when grinding the cake, 5-7% of white mustard seeds, or 5-7% of seeds are additionally added yellow mustard, or 5-10% mixture of white and yellow mustard seeds in a 1:1 ratio by weight of the cake. Grinding the kernel to the specified fractional composition allows for the most complete destruction of the cellular structure of the kernel, which contributes to better oil extraction during pressing. Mustard seeds contain the thioglucoside sinigrin and the enzyme myrosinase; in the presence of water, sinigrin is hydrolyzed and allyl mustard oil is formed, which is responsible for the pungent taste of mustard. By treating seed kernels with live steam and increasing the temperature to 100-115 o C, the yield of fatty oil is increased by 2-3% due to more complete opening of seed cells and a decrease in oil viscosity. But at the same time, the myrosinase enzyme is inactivated, and the hydrolysis of sinigrin with the release of allyl isothiocyanate does not occur completely, as a result of which mustard powder loses its characteristic properties: pungency and pungent taste. Adding whole mustard seeds to the cake at the grinding stage in an amount of 5-10% of the mass of the cake, in which the myrosinase enzyme is preserved in its native state, allows the hydrolysis of sinigrin to be carried out more completely and obtain a given amount of AITC and, accordingly, control the degree of pungency of the final product, i.e. . powder. In the proposed method, it is possible to obtain an AITC content of 0.67 to 1.20% in terms of absolutely dry matter. The method is carried out as follows. Mustard seeds on separators are cleaned of foreign impurities and mineral debris; metal impurities are removed using magnets installed before and after the separators. The moisture content of seeds entering production should be 6.5 - 7.0%. After cleaning, the seeds are calibrated by size using sieves or separators. Hulling of mustard seeds is carried out on roller machines, after which the kernel is separated from the husk using aspiration grain shakers. For normal preparation for pressing, seed kernels are crushed on four-roller rollers to the fractional composition, wt.%:

Halves of cores - No more than 15

Whole kernels - None

The crushed kernels are fed into the first vat of the roaster, where they are steamed with live steam, bringing the humidity to 10%. Partial hydrolysis of sinigrin occurs. In the 2 lower vats of the roaster, the pulp is dried to 4-5% humidity and heated to a temperature of 115 o C, the myrosinase enzyme is inactivated. After pressing, mustard cake with partially reacted sinigrin and partially inactivated myrosinase is fed for grinding on five-roller VS-5 machines, followed by separation of the powder in sieves. Partial inactivation of the myrosinase enzyme is compensated by adding 5-7% white or yellow mustard seeds, or 5-10% a mixture of white and yellow mustard seeds in a 1:1 ratio by weight of the cake, to the cake at the grinding stage. By changing the amount of whole seeds supplied, the content of allyl isothiocyanate in the powder is adjusted. The research results are summarized in a table.

FORMULA OF THE INVENTION

Halves of cores - No more than 15

Passage through a one-millimeter sieve - Not less than 85

Whole kernels - None

Moisture-heat treatment is carried out with live steam to a humidity of 10%, then dried to a humidity of 4 - 5%, bringing the temperature of the pulp to 100 - 115 o C, and when grinding the cake, 5 - 7% of white mustard seeds, or 5 - 7% of yellow mustard seeds are additionally added mustard, or 5 - 10% of a mixture of white and yellow mustard seeds in a 1: 1 ratio by weight of the cake.