Production of chopped semi-finished products. Abstract: Chopped semi-finished products Hardware technological scheme for the production of chopped semi-finished products

30.04.2020

Chopped semi-finished products include:

cutlets - homemade, Moscow, Kyiv, peasant, Krasnodar, meat and cabbage, meat and potato in Belarusian, meat and vegetable, Yakut, Transbaikal, Buryat, spicy;
meatballs - low-calorie children's;
schnitzel - Moscow, special;
beefsteak - urban, beef, youth;
rump steak;
minced meat - beef, pork, homemade, lamb, special, offal, for steaks;
meatballs - Kyiv, Ostankino, meat and vegetable, Leningrad, children's;
meat croquettes;
dietary dumplings;
kyufta in Moscow.

Chopped semi-finished products are produced in chilled and frozen form. Chopped semi-finished products are made from beef, pork, lamb and offal. For the manufacture of all types of chopped semi-finished products, meat is used in a cooled, chilled and thawed state, which, in terms of quality, must meet the requirements of the relevant regulatory and technical documentation. Depending on the type of chopped semi-finished products, cutlet meat (beef, pork, mutton), trimmed beef of I and II grades, semi-fat, fatty, single-grade pork, raw beef and pork fat, sausage unsalted bacon are used. Of the by-products, trimmed meat of beef and pork heads, light pork and beef, trimmed meat trimmings are used. In addition to meat and animal fats, soy and milk protein preparations, blood plasma, wheat bread, chicken eggs and melange, rice and semolina, bread flour, onions and vegetables (cabbage, potatoes, carrots), as well as milk, butter, drinking water and spices.

The technological process for the production of chopped semi-finished products and minced meat is shown in Figures 1 and 2.

Each type of chopped semi-finished products must meet the relevant organoleptic and physico-chemical parameters. For cutlets, rump steak, and meatballs, a rounded flattened shape is characteristic, for schnitzels - oblong, for minced meat and steaks - rectangular (in the form of briquettes), for meatballs - spherical or elongated-spherical.

On the cut, chopped semi-finished products should look like well-mixed minced meat.

Quality requirements for chilled chopped semi-finished products

All types of chopped semi-finished products produced chilled, except for natural minced meat, must have a smooth, well-shaped surface without cracks and breaks, with even edges and the same layer of breading flour over the entire surface of the semi-finished product. The consistency should be homogeneous, sufficiently viscous, without coarse inclusions (tendons, small bones, cartilage, poorly soaked and insufficiently crushed pieces of bread). From above and on the break, semi-finished products should have a characteristic smell of fresh meat raw materials. Deviations in the mass of the 1st semi-finished product ± 5% are allowed. The mass of 10 pieces should not have deviations to the smaller side. The temperature inside the semi-finished product when shipped from the enterprise should be no higher than +6 °C.

Equipment for the production of chopped semi-finished products

The device and operation of the top

All tops have a fundamentally the same device of the actuator. In the body of the top there is a working chamber for processing the product, which is a fixed hollow cylinder, inside which there are ribs that prevent the product (meat) from turning relative to the screw. The location of the ribs can be helical or longitudinal (parallel to the axis of the working cylinder). The direction of the helical ribs is opposite to the direction of the screw turns.

To advance the product in the working chamber, feed it to the knives and push it through the knife grates, a rotating auger with a pitch of turns decreasing towards unloading is used.

A feature of the auger is the creation of pressure sufficient to move the meat through the cutting mechanism without squeezing the liquid phase contained in the product.

The cutting tool of the top consists of a fixed scoring grid, rotating cross-shaped knives and fixed knife grids with different hole diameters and
clamping nut. The most widespread gratings with a diameter of 200 and 160 mm.

The degree of meat grinding depends on the size of the outlet grate openings. With a small degree of grinding (16-25 mm), one cutting plane is sufficient, the top is assembled with one knife and one grate; with thinner (2-3 mm) the number of cutting planes should be increased.

The top consists (Figure 1) of the working chamber (1); ribs (3) located on the inner surface of the working chamber; feeding device - auger (2); a cutting tool consisting of a scoring grid (4), knife grids (5, b), clamping nut (7); loading bowl, electric motor, bed.

The top works as follows: from the loading bowl, the raw material is fed using a screw (or a system of screws) to the cutting mechanism (grid and knife), fixed with a clamping nut. The auger rotates from its own motor through a gear train. During the rotation of the auger, the pressure is created in the chamber, which is necessary to push the meat through the cutting mechanism.

The quality of meat grinding can be judged by the nature of its outflow from the neck of the top. With good grinding quality, the minced meat comes out of all the holes in the grate and flows in even streams. And when it's bad, it flows out in zigzag streams and mainly along the edge of the grate. If the top does not work properly, its neck heats up. In this case, the top must be disassembled and troubleshooted: sharpen the knives, assemble the cutting mechanism correctly, monitor the continuous supply of meat and prevent the top from running idle.

The device and operation of the cutter

Cutters are meat mincers with fast-rotating sickle-shaped knives.

They are used for medium and fine grinding of meat. Cutters are of periodic and continuous action. They differ in the ways of loading and unloading raw materials (manual or mechanical), the location of the knife shaft, the number of speeds of the knife shaft, the presence or absence of programming devices, a hermetic bowl lid and a vacuum system. In the cutter, not only the grinding of raw materials takes place, but also its mixing. The cutter (picture 2) consists of:

Beds (1);
Bowl mounted on a vertical shaft (2);
Knife horizontal shaft (3);
Cutting tool (4);
V-belt transmission (5);
Unloading disk (6);
Electric motor.

The cutting mechanism of the cutter consists of sickle-shaped knives rotating on a shaft, a steel comb that cleans the blade of the knives from meat. The sickle-shaped knives are installed in such a way that there is a minimum gap between the blade of the knives and the bowl of the cutter. The number of sickle-shaped knives depends on the size (capacity) of the bowl, usually 6 sickle-shaped knives are installed, but they can be from 3 to 12. They are mounted in bulk with an open or closed nest.

The raw material is fed into the bowl, which rotates slowly. The inner surface of the bowl has the shape of a semicircle. The bowl rotation shaft is located vertically, and the knife shaft is horizontal. The sickle-shaped knives, during rotation, pass against the surface of the bowl and, after each revolution, cut the incoming raw material. The knives are covered with a lid and are crescent-shaped in order to ensure high speed cutting with sliding along the surface of the bowl. Ready chopped minced meat is unloaded from the bowl using the unloader mechanism, the working body of which is a plate (disk): when the latter rotates, the minced meat is ejected from the bowl.

Main technical indicator cutter is the capacity of the bowl in liters. Cutters are available with a capacity of 120, 200 and 300 liters.

Cutting technology

Cupping should ensure not only the proper degree of meat mincing, but also the binding of such an amount of added water or ice that is necessary to obtain a high-quality product at a standard moisture content.

The duration of cuttering significantly affects the quality of minced meat. During the processing of meat on a cutter, mechanical destruction of tissues occurs during the first 2-3 minutes, the surface of meat pieces increases significantly, after which swelling and binding of water added to the cutter begins and a new viscous-plastic structure is formed.

The total duration of cutting is 8-12 minutes. It depends on the design features of the cutters, the shape of the knives, the speed of their rotation. For the optimal duration of cuttering, the duration of the process is taken, in which all indicators of minced meat and finished products reach the highest values. These indicators include stickiness, water-binding ability of minced meat, consistency and yield of finished products. With excessive cuttering, the minced meat overheats. In order to prevent overheating of minced meat in the cutter, cold water or ice is added at the beginning of cuttering in such a way as to keep the minced meat temperature at the level of 12-15 °C. With an increase in the content of adipose tissue, the amount of water and ice decreases.

When processing on a cutter different types raw materials, beef or lean pork is loaded first, and then bold and fatty pork.

Water is added when processing beef and lean pork. An excess amount of moisture, as well as overcutting, leads to the formation of broth-fat edema in the process.
heat treatment.

The device and operation of the meat mixer

Meat mixer L5-FMB (Figure 3) consists of a frame (1), an electric motor (2) with a drive (3), a bowl (reservoir) (4), in which two kneading spirals (5) rotate towards each other, a lattice cover (6), and unloading hatches (7). The bed is a welded frame, closed on all sides with quick-release facing sheets. The kneading spirals are driven by V-belts and gears. Tank hatches are designed for unloading minced meat, they are tightly closed with lids. The lattice cover is interlocked with the electric motor, which ensures that the kneading spirals are turned off. The lid in the raised state can be fixed using a special device.

The crushed meat raw materials and other components are loaded into 2/3 of the volume of the container with the lid open. Mixing is carried out until all components are evenly distributed, the finished minced meat is unloaded using kneading spirals with open unloading hatches.

Cutlet production

Raw material preparation

Meat, bacon, raw fat, onion, garlic are crushed on a top with a grate opening diameter of 2-3 mm. For peasant cutlets, meat raw materials are preliminarily ground on a top with a lattice hole diameter of 12-16 mm. For chopped Moscow schnitzel, fatty pork is crushed on a top with a lattice diameter of 9-12 mm. The lard is crushed on a lard cutter, cutter or manually, before cutting it is frozen to -2 ° C.

Fresh onions are crushed on a top with a lattice diameter of 2-3 mm. If dried onion is used, it is pre-soaked for 2 hours in water at a temperature of 15-17 °C.

The bread is cut into pieces, soaked in water and crushed on a top with a grate opening diameter of 2-3 mm. You can grind bread without pre-soaking. At the same time, water is supplied to the neck of the top simultaneously with pieces of bread, the amount of which must be taken into account when compiling minced meat.

Melange is pre-thawed in baths with water at a water temperature not higher than 45 ° C. Thawed melange is not subject to storage. Egg powder is mixed with water in a ratio of 274 g of egg powder and 726 g of water.

Bread flour is sifted and passed through magnetic traps. Salt is used in dry form with preliminary screening.

In order to improve the quality of the semi-finished product and ensure the output in fried form, it is recommended to use pork cutlet meat with a fat content of up to 30%. For homemade cutlets and chopped steaks, beef cutlet meat should be selected with a fat and connective tissue content of not more than 15%.

Minced meat preparation

For its preparation, batch mixers or continuous mince preparation units are used. Raw materials are sequentially loaded into the mixer according to the recipe. Mixing is carried out for 6-8 minutes until a homogeneous mass is formed. To lower the mince temperature during mixing, it is recommended to add flake ice, instead of 20% of the consumed water, the mince temperature should not exceed 8-12 °C.

Forming cutlets

Cooked minced meat is molded on automatic machines AK2M-40, flow-mechanized lines K6-FLK-200, V2-FPA.

The device and principle of operation of the cutlet machine AK2M-40

Cutlet machine AK2M-40 is designed for dosing and molding cutlets.

The cutlet machine (figure 4) consists of a body (1), a loading hopper (2) with a bladed screw (11), a molding table (3) with sockets (4), a disk (5) with a scraper (14), a mass regulator (13 ), electric motor (9).

Figure 4 - Cutlet machine AK2M-40

Cooked minced meat is loaded into the bunker, from where the minced meat is fed by a bladed screw to the hole located at the bottom of the minced bunker. Under the hopper, a working table with nests rotates, and out of five forming nests, only one is fed to the hopper opening. At this point, the piston in the seat drops to the bottom position. With a paddle screw, the minced meat is squeezed into the nest of the table and fills its entire volume due to the pressure created by the rotating blades of the screw in the bunker. With further rotation of the table with sockets, the rod, sliding along the copier, moves the piston upwards, while pushing the molded cutlets from the table surface, from where they are thrown onto a disk under the action of centrifugal force, from which they are manually placed in trays.

The mass of cutlets made on the machine can be adjusted by changing the position of the copier in height - this changes the volume of the cylinder filled with minced meat.

Cooling of semi-finished products

Cutlets intended for sale in a chilled form, after molding and placing on trays-liners, are sent to the cooling chamber.

Cooling is carried out at a temperature of 0 to 4 °C until the temperature inside the semi-finished product reaches no higher than 4 ± 4 °C.

Packaging, labeling and storage of cutlets

Chopped chilled semi-finished products placed in trays are packed in reusable wooden, metal or polymer boxes. Boxes are closed with lids or inserts. It is recommended to stack no more than four trays in one box.

The weight of one box should not exceed 20 kg. It is allowed to release chilled chopped semi-finished products wrapped in 5-10 pieces in parchment, sub-parchment, plastic film bags, which are then heat-sealed, clamped with aluminum staples or sealed with adhesive tape.

A semi-finished product of one name and one mass is placed in each box. A label is placed in the box indicating the name of the manufacturer, his subordination, the name of the semi-finished product, indicate the license plate of the packer, the quantity of the product, weight, price, number of pieces, as well as the date and time of completion technological process, shelf life and sale.

The shelf life and sale of chilled chopped semi-finished products at a temperature of 0 ° C to 6 ° C from the end of the technological process is not more than 12 hours, including
at the factory - no more than 6 hours.

Production of semi-finished minced meat natural

Natural minced meat is made from chilled beef, pork and lamb of I and II fatness categories. When trimming for the manufacture of natural minced meat, all cartilage, tendons, connective tissue must be removed, and when trimming pork, excess fat is also removed, leaving no more than 3 (> -50%. Trimmed beef, pork, lamb are crushed on a top with a diameter of holes in the output grid 2- 3 mm without adding water.

The minced meat is packaged in parchment, subparchment, cellophane and other transparent films, in portions of 250 and 500 g. Natural minced meat is prepared from one beef, pork or lamb or a mixture of beef and pork in various proportions. Packed manually or on special machines for packaging and packaging of minced meat.

The device and principle of operation of the automatic machine AP1M

Designed for filling and packaging minced meat in parchment or foil in the form of briquettes of 250 g. bunker.

The machine (figure 5) works as follows: the packaging material from the roll (1) enters the guide roller (3), then the adjustable sectors (4) guide the packaging material between the knives (5), which cut the reaming of a certain length. The levers (6) feed the reamer onto the forming die (5) under the punch (7). The presence of a scan on the matrix is controlled by a probe (9) and in case of its absence, the machine automatically stops. The punch pushes the reamer through the die, giving it the shape of a box, which is inserted into the socket of the carousel table (12). The dispenser (10) of the hopper with a screw feeder (11) fills the box with a certain portion of minced meat, and the package valve closing mechanism (13) wraps the package. The pre-pressing mechanism (14) gives the bag its final shape. The bag is automatically removed from the forming table slot and the forming table bag remover (17) feeds the bag to the package tipper (16) which turns the bag closed side down. In this form, the package enters the conveyor (15), from where it is removed manually and placed in a container.

Production of chopped frozen semi-finished products

For the manufacture of chopped frozen semi-finished products, trimmed meat from beef, pork, offal and fatty raw materials of all types of livestock is used in a cooled, chilled and thawed state; milk and dairy products, eggs and egg products; onions, garlic, cereals, salt, spices and other auxiliary materials. It is allowed to use egg powder instead of 1 kg of melange or 24 chicken eggs; dried onion at the rate of 225 g instead of 1 kg of fresh; whole milk powder at the rate of 1 kg instead of 8 liters of pasteurized whole milk.

It is not allowed to use meat and products frozen more than once, pork with signs of yellowing of the fat, meat of bulls and boars, meat with signs of putrefactive decomposition.

Raw materials are selected according to the recipe and prepared in accordance with the requirements of technological instructions.

Minced meat is prepared on the equipment of continuous or periodic action. First, beef is loaded into the mixer, then cold water is added in an amount of 18-20% to the mass of raw meat, milk, salt, onions, spices, rice or semolina, and 2-3 minutes before the end of mixing, pork or bacon is added. The crushed raw materials with all components are mixed for 4-5 minutes until a uniformly mixed mass is formed.

Cooked minced meat is molded on molding machines.

Meatballs are molded in the form of checkers (cylindrical shape) with a diameter of 20 mm and a height of 20 mm, the weight of one meatball is 7-9 g.

Meat croquettes, dietary quenelles, Moscow-style kufta are formed in the form of checkers with a diameter of 36 mm and a height of 30 mm, each weighing 30 g.

Forming meatballs on the FFP machine

The FFP machine is designed for dosing and molding meatballs.

It consists of a frame, an electric motor (1) with a gear (2), a minced meat hopper (7) with an auger (5) located in it, a forming drum with nests (4) and a socket (3) located above it, an eccentric-vane pump (9), designed to force minced meat into the socket, a belt conveyor for feeding trays, a vibrating knife (6) for separating meatballs from the drum (Figure 6).

Minced meat from the hopper is fed by an auger into an eccentric-vane pump, which pumps it into a socket that fits snugly against the cylindrical surface of the drum in its upper part, and fills the nests. When the drum is rotated 180°, the pistons push the meatballs out of their nests onto a tray in which they are transferred to the freezer.

In chambers, meatballs are frozen at an air temperature not higher than -18 ° C, in quick freezers - at a temperature of -30 ° C ... - 35 ° C until the temperature inside the semi-finished product reaches no higher than -10 ° C.

Ready frozen semi-finished products should not be sticky, deformed. The taste of the finished product is characteristic of this type of product with a pronounced aroma of spices and spices. The mince is juicy. Foreign smells and tastes are not allowed. Frozen semi-finished products are packaged in cardboard boxes weighing 350, 500 1000 g. They are stored at a temperature not exceeding -10 ° C for no more than 1 month.

Introduction

4. Settlement part

findings

Bibliographic list

Introduction

Meat chopped semi-finished products enjoy well-deserved recognition of the consumer and every year take an increasingly strong place in the diet of the population.

For businesses Catering these semi-finished products are of particular value, since without them it would be impossible to satisfy the demand of visitors for such widely popular and favorite dishes as steak, beef stroganoff, etc., even in the most limited quantities. cattle, which contains only two tenderloins (with a total weight of no more than 3 kg), it would be possible to cook at best 20-25 servings of steak, langet or beef stroganoff, i.e. quantity, in no way satisfying the needs of a large dining room and restaurant / 12 /.

The advantage of chopped semi-finished meat products is that, by facilitating and reducing the work of blank shops, reducing the time required to prepare a hot meat dish or snack, they allow increasing the throughput of the enterprise. Meat processing plants produce semi-finished products under conditions that fully guarantee the freshness, good quality, purity and hygiene of products. The technological process and the recipe are built in such a way that for this type of semi-finished product only that part of the meat is used, which strictly corresponds to the product in terms of tissue structure, fatness, quality and culinary properties /9/.

Every year, chopped semi-finished meat products will be supplied to catering establishments in a wider and more varied assortment, every year these products will increase the range of dishes and snacks, reduce and facilitate production processes cooking with maximum preservation of all the taste and nutritional properties of the best gourmet and gourmet dishes / 10 /.

meat chopped semi-finished product

In recent years, there has been a significant increase in the demand for semi-finished products that do not require a significant investment of time for cooking at home and in public catering establishments. Meat semi-finished products, as a rule, are produced in packed and packaged form, which also determines their high consumer qualities.

The range of meat chopped semi-finished products is constantly expanding as a result of the use of various combinations of meat raw materials with vegetables, cereals, flour and other protein components. Thanks to the use of flow-mechanized lines in the production of semi-finished meat products, their external design improves, packaging is improved /9/.

Minced meats of various recipes are becoming more common, from which you can cook a large number of various dishes.

1. Feature and theoretical basis production of meat chopped semi-finished products

Meat is one of the most important food products with excellent culinary qualities. It is easily combined with various products - vegetables, cereals, pasta, cooked as side dishes. Along with high-grade proteins, it contains fat and so-called extractive substances, which contribute to better digestion of food / 12 /.

For the preparation of semi-finished products, meat processing plants use the meat of cattle, sheep and pigs.

Depending on the structure of meat tissues, mechanical processing and culinary purpose, all semi-finished meat products are divided into natural, breaded, minced and culinary cutting meat. In addition, the industry puts on sale such semi-finished products as frozen dumplings / 9 /.

Meat chopped semi-finished products - a portioned product made from chopped meat raw materials with additives (minced meat). Meat chopped semi-finished products after manufacturing can be raw chilled or raw frozen. As an example, the following chopped raw semi-finished products can be given: cutlets, meatballs, hamburgers, schnitzels, steaks, rump steaks, kebabs, meatballs, meatballs, quenelles and croquettes.

Chopped semi-finished products. Cervical, femoral, scapular muscles, containing coarser and tougher connective tissue, are the main raw materials for the preparation of chopped semi-finished products.

Careful grinding of meat on special technically advanced machines and the addition of fat, eggs, spices to minced meat ensures good quality for these semi-finished products.

Moscow cutlets contain beef meat (any fatness category) - 25 g, raw bacon - 4.47 g, wheat bread - 7 g, as well as onion, pepper, salt and water. Prepared minced meat is given an oval-flattened shape. Cutlet weight 50 g.

Amateur cutlets are made from beef carcasses of fatty, above-average and medium fatness. After stripping, the pulp is crushed, mixed with spices, white bread and other constituent parts, molded in the form of a large cutlet with a pointed end and breaded in ground breadcrumbs. Semi-finished product weight 75 g.

Pozharsky pork cutlets are made from semi-fat pork (45 g) with the addition of egg melange (2 g), wheat bread (South), pepper, salt and water. At the request of the customer, meat processing plants add onions to Pozharsky pork cutlets, as well as to amateur cutlets. Cutlet weight 75 g.

Kyiv cutlets are made from pork containing up to 30% fat. The semi-finished product recipe contains approximately 30 g of pork, 7 g of wheat bread, onion, pepper, salt, water. The weight of one cutlet is 50 g.

Beef schnitzel is made from minced beef meat of the best quality, shaped like a flat oval cake. Schnitzel weight 100 g.

Pork schnitzel differs from pork pozharsky cutlets in weight and shape. The pork schnitzel is given a flat oval shape. This semi-finished product weighs 100 g.

Meatballs are ball-shaped. They are made according to the same recipe and from the same raw materials as Moscow cutlets.

Zrazy is made from ground beef stuffed with hard chopped eggs mixed with fried onions and ground breadcrumbs.

Beefsteak - a dish of fried beef, originally one of the types of steak, steak from the head of the tenderloin. Often there is such a subspecies of steak as chopped (often passed through a meat grinder) steak, which is the prototype of the cutlet. Beefsteaks are also classified into fried and "rare".

A rump steak is a lightly beaten piece of meat weighing 115 grams, cut from a thick end or loin, moistened with a beaten mixture of fresh eggs, water and salt.

Meatballs - small round cutlets made from minced meat (originally chops).

Meatballs - a dish that is balls of minced meat or fish, cooked with the addition of finely chopped onions, herbs and spices. Sometimes, to improve the consistency of meatballs, soaked loaf or bread is added to the minced meat. Usually meatballs are about the size of a walnut.

Kyufta is a kind of meatballs made mainly from lamb. A traditional dish from the Middle East and South Asia.

Quenelles are balls of meat, fish and chicken meat, with cream and egg /12/.

2. Technological scheme for the production of minced meat semi-finished products and features

meat chopped semi-finished products - a portioned product made from chopped meat raw materials with additives (minced meat). Meat chopped semi-finished products after manufacturing can be raw chilled or raw frozen. As an example, the following chopped raw semi-finished products can be given: cutlets, meatballs, hamburgers, schnitzels, steaks, rump steaks, kebabs, meatballs, meatballs, quenelles and croquettes.

To prepare minced meat for chopped semi-finished products, frozen meat raw materials (blocks) are crushed in a crusher. Also, for the preparation of minced meat, mechanically deboned meat obtained on a meat and bone separator can be used.

Then the minced meat is passed through the top. Pork bacon is added to minced meat, which is pre-crushed on a top or on a bacon cutting machine. Salt, water pre-chilled with ice, additives, spices are added to the minced meat and everything is mixed well in a meat mixer. A cutter can also be used for mixing.

Minced meat ready for molding semi-finished products is loaded into the bunker of the machine for molding semi-finished products, where the product of the required shape and weight is molded, for which, depending on the volume of production, a rotary or auger product molding system is used. In the molding machine, the patties are molded and dosed onto a belt, after which the product can be sent to the ice cream machine and / or breading machine for thin and dry breading, respectively.

Then the cutlets are sent on trolleys to the shock freezing chamber or automatically by conveyor to the spiral quick freezer in case of high line capacity. The duration of freezing meatballs ø75x20 mm weighing 85 g, in a shock freezing chamber is 2 hours, and in a spiral quick freezer - 40-45 minutes. After freezing, cutlets are packed and moved to a low-temperature refrigerator for storage /12/.

Beef, pork, lamb, horse meat, as well as meat of other types of slaughter animals are used as the main raw materials /4/.

Do not use double-frozen meat and pork with darkened bacon.

Along with meat raw materials, various protein preparations of plant and animal origin (soya, blood, milk proteins, etc.) are widely used, as well as melange, egg powder, vegetables and other components, depending on the direction of use of the meat product (Figure 2.1) / 4/.

Figure 2.1 Technological scheme for the production of chopped semi-finished products

3. Main process equipment

1.Crusher of frozen blocks - a machine for grinding deep-frozen meat (with a temperature of up to - 30 ° C) for further processing on a cutter or top. This does not require prior defrosting of the product, which allows you to preserve the taste of the product and prevent loss of nutrients.

The crushing of the block, depending on the subsequent destination of the raw materials obtained after the crusher (pieces the size of a fist or into slices), can be carried out on a machine with a rotating shaft with knives or rollers or on a guillotine type machine /2/.

.The grinder for meat is designed for industrial grinding of meat, meat products, fats in order to produce sausages and other food products.

The meat grinder is the main machine in the production lines for the production of sausages and semi-finished products. The quality of the products obtained directly depends on how finely and accurately the top cuts the lumpy meat.

The principle of grinding lumpy meat used in meat grinders has been unchanged for many years: the meat in the receiving hopper is captured by the auger or augers and fed through the body with internal ribs to the cutting tool, which is a set of fixed grates, usually consisting of three pieces, and movable knives, consisting of two pieces.

Different tops for meat, despite the same method of grinding and the apparent simplicity of design, have completely different quality grinding. Even minor influences design features inherent in each of the designs, as well as the degree of wear of both the cutting tool and the housing with the screw /7/.

.Meat mixer. The purpose of the meat mixers is to mix the crushed products with spices and other ingredients. Usually minced meat, cereals and other products are mixed in meat mixers.

The main components of the meat mixer are the bowl, the lid and the mixing mechanism.

Dezha is a mixing bowl connected to a kneading unit. Usually the meat mixer bowl is made of of stainless steel with a smooth surface, which greatly facilitates its cleaning and operation in general. The meat mixer is designed in such a way that it contributes to uniform mixing of all minced meat ingredients. Mixing takes place by means of kneading screws.

The design features of the bowl (dezha) and the blades of the meat mixer ensure an even distribution of the ingredients over the minced meat.

Meat mixers are vacuum and open (non-vacuum). Mixing minced meat in a vacuum mixer ensures a dense, pore-free structure of minced meat, increases the color fastness of products.

All mixers have defense mechanisms. In particular, it is a mechanism for blocking one or more kneading augers when the bowl lid is opened. The process of loading and unloading raw materials is usually fully automated /3/.

.Meat-and-bone separators, or minced meat machines, are used to separate meat from bone in the production of edible minced meat, chicken or fish.

The minced meat obtained in this way can be used for the production of high-quality products, since it retains the structure of muscle tissue.

The principle of operation of the machine is that the incoming raw material is loaded into the separator hopper without prior grinding (with some exceptions). Pork or beef bones are recommended to be pre-shredded into fist-sized pieces, without the need for an additional grinder, which optimizes the use of production space.

All designs of mechanical separators are based on the use of the separation principle, taking into account physical characteristics processed raw materials.

Using various pressures, meat or other product is forced through the slotted or round holes of the separating head, and bones, cartilage and (or) veins are removed through the front of the machine. The product output is adjusted manually using the cones at the front of the separating auger and the restrictor.

Minimum temperature rise in case of incoming raw material temperature 0-2 º C (this temperature is optimal) - usually 1-2 º C on the chicken, 4-7 º C on a turkey, and about 10 º C on beef /6/.

.Cutter - turns meat into soft airy minced meat for cooking boiled sausages, sausages, sausages. The cutter grinds products in a vacuum. Fast rotating knives (up to 4500 rpm) turn meat into minced meat with lightning speed, which retains its natural color, vitamins and nutrients in the absence of oxygen. Thanks to the processing without access to air, the quality of the final product and its shelf life are significantly increased.

.Ice maker. The meat processing industry requires a large amount of water ice. Flake ice produced on flake ice machines is optimal for use. It has a flat shape, thanks to which it has a large heat exchange surface, so it cools the minced meat better than other types of ice.

The temperature of the produced flake ice at the exit from the ice generator is up to minus 12°C, the thickness is from 0.8 to 2.8 mm. Machine productivity from 380 kg to 23 tons/day/7/.

.Lard cutter - allows you to cut into cubes, strips or circles fresh, boiled and frozen (up to - 5 ° C) meat, lard, as well as ready-made sausages, ham, vegetables. Products containing bones are not subject to cutting / 6 /.

8.Machine for molding semi-finished products. After grinding meat raw materials, adding other ingredients, mixing and cooling, the minced meat is ready for molding. With the help of forming equipment, it is possible to give products a variety of shapes /2/.

.Breading machine. The next stage after the molding of chopped meat products is the stage of breading (coating) of the product. The breading process consists of three operations - pre-sprinkling, liquid breading and coating with breadcrumbs. Various combinations of these operations or all three coatings may be used in the manufacturing process. However, there are standards for the amount of sprinkling used, the amount of which should not exceed 30% by weight of the finished product.

In fact, breading improves the product in many ways: it makes the product more juicy while retaining moisture and flavor. Breading makes products more attractive. In addition, breading increases the weight of products, increasing the cost.

Pre-sprinkling is often used in the manufacture of breaded products to improve the adhesion of the wet breading. This operation is very important for products with a wet or greasy surface. For this operation, flour or a dry protein mixture for breading is usually used.

There are many various kinds dry breading used in the manufacture of meat products. They come in a variety of sizes, shapes, textures, colors and flavors. Finely ground breadings are very popular and traditional. They give the product an airy appearance and resemble a homemade product /7/.

.Laying machine. Liquid breading plays a very important role in the coating technology for semi-finished meat products. When preparing products, two types of breading can be used: yeast and unleavened. The choice of one type or another depends on the recipe of the product. Liquid breading is a mixture of various ingredients that may include flour, starches, eggs, milk, spices and spices, leavening agents and stabilizers.

When applying a liquid breading in order to increase adhesion, it is used in combination with dry breadings. In this case, fresh breadings with different viscosities are more often used.

Equipment for laying minced meat semi-finished products from minced meat raw materials (minced meat) of beef, veal, pork, lamb without filling (cutlets, hamburgers, meatballs and other similar products) /6/.

.Shock freezer. Now freezing of products occurs thanks to special technology heat removal from the product. At the same time, the temperature drops and at a certain point the water in the product begins to turn into ice crystals.

The product is considered frozen if its temperature is -6 degrees. In meat, 75 percent of the water freezes at minus 5°C; 80 percent - at minus 10°C; and 90 percent - at minus 20 degrees.

Freezing products is used primarily for their long-term storage.

Technologically, the freezing process can take a different amount of time. Best of all, product quality is preserved by quick (shock) freezing. As a result of this process, very small ice crystals are formed inside the product, which has a positive effect on the quality of the product, since there is minimal damage to the tissue of the product.

It was for these purposes that special devices were created - shock freezing chambers. They allow you to quickly freeze a product or dish, while maintaining its useful properties / 3 /.

.Packing machine. Filling and packaging machines, multiheads (electronic high-precision weighers), packaging systems for food or non-food small-piece, free-flowing, non-dusty products. The equipment uses the principle of weight dosing and is used for packaging /2/.

13.Refrigerated warehouses and storage chambers include: a heat-insulating circuit (chambers) with doors and a refrigeration supply system.

As a heat-insulating circuit, chambers made of PPU sandwich panels with refrigerated doors produced by our own factory are used. The refrigeration system includes: a refrigeration compressor unit, a condenser, an oil cooler, a circulation receiver and a pumping station (in the case of a pump-circulation refrigerant supply scheme), an electrical control panel, refrigerant pipelines and electrical cable lines /6/.

. Settlement part

The calculation of the amount of raw materials and spices is carried out in accordance with the recipe for semi-finished products, the data are summarized in table 4.1

Table 4.1 Calculation of raw materials for the production of cutlets

Raw materials, spicesNorms, g (per piece) Requirements for raw materials according to the assignment "Homemade" "Moscow" "Piquant" Cutlet beef meat28.050.023.75085Fat trimmed pork29.7--1485 Cutlet pork meat--16.8840Fat raw beef or pork or unsalted bacon trimmings-8.94- 447 Frozen white cabbage--36.5 1825 Wheat flour bread13.014.0-1350 Wheat flour--10.8540 Breadcrumbs4.04.03.26563 Fresh peeled onions2.01.05.4420 Melange or eggs chicken 2.0-2.4220 Black or white ground pepper 0.10.060.0410 Edible table salt 1.21.21.1175 Drinking water 20.020.8-2040Total: 10010010015000

Based on the results of calculating the amount of raw materials and spices, it is carried out in accordance with the recipe for semi-finished products. By individual task it was necessary to calculate the need for raw materials for 5 packages of each type of cutlets, in a package of 10 pieces of cutlets.

For the production of "Homemade", "Moscow" and "Piquant" cutlets, a total of 15000g (15kg) of raw materials is required.

5. Requirements for the quality of meat chopped semi-finished products

Semi-finished products must comply with the requirements of this standard, the document for semi-finished products of a specific name, in accordance with which they are manufactured, produced according to the technological instruction regulating the production process, in compliance with the rules of veterinary inspection of slaughter animals and veterinary and sanitary examination of meat and meat products, veterinary and sanitary regulations use and processing of imported meat and meat products at meat processing enterprises of Russia, sanitary rules for meat industry enterprises approved in the prescribed manner, and hygienic requirements for the safety and nutritional value of food products established by regulatory legal acts of the Russian Federation / 11 /.

On the cut, chopped semi-finished products should look like well-mixed minced meat. The taste and smell of chopped semi-finished products in raw form should be characteristic of good-quality raw materials, in fried - characteristic of a fried product. The surface of breaded semi-finished products should be evenly sprinkled with breadcrumbs.

In chopped semi-finished products they regulate mass fraction moisture, fat, table salt, bread, as well as the mass of one serving / 8 /.

According to organoleptic indicators, semi-finished products must comply with the requirements specified in table 5.1/4/.

According to physical and chemical indicators, semi-finished products must comply with the requirements specified in tables 5.2 and 5.3 / 1, 5 /.

Table 5.1 Indicators of the organoleptic evaluation of meat

Indicator nameCharacteristic Appearance and cut viewShape, surface condition on the cut corresponding to this name of the semi-finished product, taking into account the prescription components used, including spices, sauces, marinades and breading provided for by the recipe Taste and smell Characteristic of this name of the semi-finished product, taking into account the prescription components used, including spices, sauces, marinades and breading provided for in the recipe Color Peculiar to the color of the semi-finished product of lumpy or chopped meat raw materials used in this item, taking into account the recipe components used, including spices, sauces, marinades and breading provided for in the recipe

Table 5.2 Physical and chemical parameters of semi-finished meat products

Name of indicator Norm for semi-finished meat products Categories ABVGD Mass fraction of protein, %, not less than 16121086 Mass fraction of fat, %, not more than 183550 Regulated in the document in accordance with which semi-finished products are made Mass fraction of starch, %, not more than 234 Mass fraction of sodium chloride, %, not more than 1.8 Mass fraction of total phosphorus ( R 205Mass fraction of bread, % Regulated in the document in accordance with which semi-finished products are made Mass fraction of filling or coating, % Regulated in the document in accordance with which semi-finished products are made Temperature in the thickness of the semi-finished product °

Table 5.3 Physical and chemical parameters of meat-containing semi-finished products

Name of the indicator Norm for meat-containing semi-finished products Categories High-pressure milk mass fraction of protein, %, not less than 975 Mass fraction of fat. %, not more than 35Regulated in the document in accordance with which the semi-finished products are manufactured Mass fraction of starch, %, not more than 6 Mass fraction of sodium chloride, %, not more than 1.8 Mass fraction of total phosphorus (P 205), % Regulated in the document in accordance with which the semi-finished products are manufactured Mass fraction of bread, % Regulated in the document in accordance with which semi-finished products are made Mass fraction of filling or coating, % Regulated in the document in accordance with which semi-finished products are made Temperature in the thickness of the semi-finished product, ° Regulated in the document in accordance with which the semi-finished products are manufactured

6. Packaging, labeling, storage conditions, transportation and terms of sale of minced meat semi-finished products

Each type of chopped semi-finished products must meet the relevant organoleptic and physico-chemical parameters. For cutlets, rump steak and meatballs, a rounded flattened shape is characteristic, for schnitzels - oblong, for minced meat and steaks - rectangular (in the form of briquettes), for meatballs - spherical or elongated-spherical.

The classification of semi-finished minced meat, dumplings, minced meat for baby food is presented in clause 3 of GOST R 51187-98 "Semi-finished minced meat, dumplings, minced meat for baby food. General technical conditions".

Meat chopped semi-finished products, dumplings, minced meat for rational, preventive and medical nutrition children must comply with the requirements of GOST R 51187-98 "Semi-finished minced meat, dumplings, minced meat for baby food. General specifications" / 8 /.

Marking. In accordance with clause 4.3 of GOST R 51187-98, the marking of consumer packaging for meat, chopped semi-finished products, dumplings, minced meat is determined in accordance with clause 4.1 of GOST R 51074-2003 indicating additional information(clause 4.2.2.2 GOST R 51074-2003):

Thermal state (chilled, frozen);

Date of manufacture and date of packaging;

On the label of minced meat semi-finished products, dumplings, minced meat intended for preventive and therapeutic nutrition of children, the purpose is additionally indicated.

On packs or packages with dumplings, the method of preparation / 11 / must be indicated in a typographical way.

Transport marking - in accordance with GOST 14192-96, with an additional stamp "Baby food" and with the use of handling marks (Ch. 4 GOST 14192-96) "Perishable goods", "Temperature limitation".

It is allowed not to apply transport marking on reusable containers with products intended for local sale /1/.

Package. In accordance with clause 4.4 of GOST R 51187-98, chopped semi-finished meat products are packed in corrugated cardboard boxes in accordance with GOST 13513-86, polymer reusable boxes in accordance with GOST R 51289-99, aluminum, as well as specialized containers or equipment containers.

Reusable containers must have a lid. In the absence of a lid, it is allowed for local sale to cover the container with parchment, subparchment or wrapping paper /5/.

Acceptance rules. According to Chapter 5 of GOST R 51187-98, the acceptance rules and the amount of samples are determined in accordance with Chapter 6 of GOST R 52675-2006/1/.

Semi-finished minced meat products are accepted in batches.

A batch is considered to be semi-finished products from minced meat of the same mass and name, produced during one shift and issued with one quality document.

Transportation. According to clause 7.1 of GOST R 51187-98, chopped semi-finished meat products, dumplings, minced meat are transported in refrigerated trucks in accordance with the rules for the transportation of perishable goods in force in road transport (Rules for the transportation of perishable goods by car in intercity traffic (section 13 of the Rules for the carriage of goods by road)) /11/.

Storage (clause 7.2 of GOST R 51187-98). Chopped meat products, minced meat should be stored refrigerated at a temperature of 0 to 4 ° C for no more than 12 hours. In a frozen state at a temperature not exceeding minus 18 ° C - no more than 30 days, in sealed packaging - no more than 3 months / 1 , 5/.

The shelf life of minced meat products, dumplings, minced meat, guaranteeing the safety, quality and safety of products, should be standardized by a regulatory document for a specific type of product, taking into account the "Conditions, terms of storage of perishable products" (Appendix 1 to SanPiN 2.3.2.1324-03 "Hygienic requirements for shelf life and storage conditions of food products") /8/.

findings

Meat chopped semi-finished products - a portioned product made from chopped meat raw materials with additives (minced meat). Each type of chopped semi-finished products must meet the relevant organoleptic and physico-chemical parameters. On the cut, chopped semi-finished products should look like well-mixed minced meat. The taste and smell of chopped semi-finished products in raw form should be characteristic of good-quality raw materials, in fried - characteristic of a fried product / 11 /.

And it is precisely because of this that chopped semi-finished meat products enjoy a well-deserved recognition of the consumer and every year take an increasingly strong place in the diet of the population.

Bibliographic list

1.Antipova, L.V. Methods for the study of meat and meat products [Text]: textbook / L.V. Antipova, I.A. Glotova, I.A. Rogov. - M.: Kolos, 2001. - 376 p.

2.Bautin, V.N. Mechanization and electrification of agricultural production [Text] / V.N. Bautin, V.E. Berdyshev, D.S. Buklagin. - M.: Kolos, 2000. - 536s.

.Bredikhin, S.A. Technological equipment of meat processing plants [Text] / S.A. Bredikhin, Yu.V. Kosmodemyansky, L.L. Nikiforov. - 2nd ed., corrected. - M.: Kolos, 2000. - 392s.

.Gizatullin, R.S. Laboratory workshop on milk and meat processing / R.S. Gizatullin, S.G. Kanareikina, L.A. Zubairova; BashGAU. - Ufa, 2011. - 210s.

.Zayas, Yu.F. The quality of meat and meat products [Text]: account. allowance / Yu.F. Zayas. - M.: Kolos, 1996. - 480s.

.Ivashov, V.I. Technological equipment of meat industry enterprises [Text]: textbook / V.I. Ivashov. - Part 1: Equipment for slaughter and primary processing. - M.: Kolos, 2001. - 552 p.

.Ivashov, V.I. Technological equipment of meat industry enterprises [Text]: textbook / V.I. Ivashov. - Part 2: Equipment for meat processing. - St. Petersburg: GIORD, 2007 - 464 p.

.Rogov, I.A. General technology of meat and meat products. Book 1 [Text]: textbook. allowance / I.A. Rogov, A.G. Zabashta, G.P. Kazyulin. - M.: - KolosS, 2009. - 568 p.

Plan

1. GENERAL CHARACTERISTICS and RANGE of chopped semi-finished products

2. GRINDING THE MEAT

3. COMPOSITION

4. FORMING SEMI-FINISHED PRODUCTS

5. PACKAGING AND PACKAGING

1. GENERAL CHARACTERISTICS and RANGE of chopped semi-finished products

Chopped semi-finished products - portioned products made from minced meat, compiled in accordance with the recipe, the basis of which is chopped (chopped) meat.

Mostly semi-finished products from the meat of slaughter cattle come into trade: chopped steak, cutlets and meatballs.

Chopped semi-finished products are characterized by high nutritional value (Table 1.1), digestibility and taste.

Table 1.1

The main raw material for chopped semi-finished products is cutlet meat, which can be replaced with trimmed meat. As an additional raw material for steaks, bacon is used, for cutlets - raw fat, onions, wheat bread soaked in water, etc. Auxiliary materials for all products are salt (1.2% of the mass of minced meat), black pepper (0.04-0 00%) and water (6.7-20.8%) added to minced cutlets to increase its juiciness. The introduction of sodium caseppate, isolated soy protein, coprezpptate (high-protein milk concentrate) in minced meat in the amount of 10-20% allows replacing up to 10% of meat, improving their organoleptic qualities, increasing nutritional and biological value, increasing water-binding capacity, and reducing losses during frying .

In the production of chopped semi-finished products, meat and additional raw materials are crushed on a top, sequentially loaded into a mixer, where salt is added in the form of a solution, pepper, and, if provided for by the recipe, eggs and other raw materials. Minced meat is mixed until a homogeneous mass is formed. To lower the temperature of the mass while stirring, ice is added to the mixer instead of 20% of the water provided for in the recipe. Minced meat is molded in automatic machines of high productivity. The shape of the products is round, the meatballs are cylindrical (with a diameter of 28 mm and a height of not more than 15 mm). Products are placed on trays, cutlets are breaded with breadcrumbs flour. The meatballs are then frozen to a temperature not exceeding -10°C and packaged in boxes of 350 g.

Chopped beef steak is prepared from beef cutlet meat or trimmed meat of the 2nd grade (80%), unsalted bacon (12%), cut into pieces 3x3 mm, auxiliary materials. Portion weight - 50, 75 and 100 g.

Moscow cutlets are made from beef meat (50%), wheat bread (14%), raw beef or pork fat (9%), onion, breading flour and auxiliary materials.

Kyiv cutlets are produced, like Moscow cutlets, but from pork, with a fat content of about 30%

Homemade cutlets are prepared from beef and pork meat, taken in an amount of 30.5% each (recipe No. 1) or 42 and 10%, respectively (recipe No. 2), with the addition of eggs, melange or blood serum (2%) to the minced meat.

Special cutlets are made from the pulp of chicken or turkey legs ((> 2%), wheat bread (14%), water (21.4%), salt (0.5%), breadcrumbs (4%).

Cutlets are produced in portions of 50 and 100 g.

School cutlets, which have a high biological value due to the combination of meat and milk raw materials and are intended for children of school age, are made from beef and pork cutlet meat, skimmed dry milk, wheat bread, breadcrumbs and auxiliary materials.

Ost and k and n s fried fries are made from beef trimmed meat of the 1st grade (78%), onion (16%), raw beef fat, bacon trimmings or fatty pork.

K y ev s k e f r and k adel k and are prepared from trimmed beef of the 1st grade (38%), bold pork and pork cheeks or trimmings (42%), onions (0%), dry milk and eggs. The average weight of one meatball is 10 g.

Meatballs are intended for cooking both first courses (cooked in 1.5-2 liters of water until cooked) and second courses (breaded in flour, fried in oil, tomato puree, spices, broth are added and stewed until tender).

For the nutrition of preschool children and school age recipes for meatballs for children have been developed - from beef and pork cutlet meat, semolina, whole milk powder, onions and auxiliary materials, and Leningrad ones, the raw material for which is also melange, and boiled rice is used instead of semolina. The mass of one meatball is 7-9 g.

Procurement catering enterprises produce special cutlets for sale - from chicken or turkey meat (02%), bread (14%), water (22%), salt and breadcrumbs, in portions of 50 and 100 g.

Abroad (USA, Sweden, the Netherlands and other countries) produce chopped pressed frozen semi-finished products such as natural portions (steaks, langets, entrecote, etc.). These semi-finished products are prepared from meat with a high content of connective tissue (cutlet meat, meat trimmings, etc.). They are produced from block frozen boneless meat, which is cut into scales, mixed, pressed in the form of bars, the latter are cut into slices, which are packed on vacuum packaging machines and frozen. Semi-finished products retain the structure, water-binding capacity, juiciness and taste of natural meat.

2. GRINDING THE MEAT

The degree of meat grinding has a great influence on the taste of chopped semi-finished product. With fine grinding, for example, when cutting, the aroma and taste of the semi-finished product will be noticeably worse than those prepared from meat chopped on the shelf. This is due to the strong binding of aromatic and flavoring substances by the finely ground meat structure, and due to the significant binding of water during chewing, less meat juice is released and the taste of the product is felt weaker. In semi-finished products from hand-boned meat, organoleptic properties are more pronounced.

Nevertheless, semi-finished products often enter the trading network, especially dumplings made from finely ground meat. Of course, finely minced meat retains water better, which is what some manufacturers take advantage of by adding water to minced meat to get additional yield without taking into account a noticeable deterioration in taste.

In the manufacture of chopped semi-finished products, the meat is ground on tops. Industrial tops differ little in design from domestic meat grinders, they are simple in execution, in design and reliable in operation. On fig. 2.1 shows diagrams of typical tops with normal and forced supply of raw materials to the cutting mechanism. The top consists of a bed 1, a drive 8, a loading neck 6, a receiving 5 and a working 3 cylinders, a cutting (knife) mechanism 4 and devices for supplying raw materials to it - a worm 2 in tops with a normal supply of raw materials, as well as a worm 2 and auger 7 in tops with forced feed. Meat through the boot

Rice. 2.1. Schemes of tops with the usual (a) and forced supply of raw materials to the working cylinder (b):

/ - bed; 2-screw working (chernyak); 3- working cylinder; 4 - cutting mechanism; .5 - receiving cylinder; 6 - loading neck; 7- feed auger; 8-drive

the neck enters the receiving cylinder, from where it is fed by a worm (or a screw and a worm) into the working cylinder. Under the action of pressure due to a decrease in the pitch of the worm turns, the meat is pushed through the sequentially assembled knives and grates, and exits the top in a crushed form. Inside the working chamber there are ribs that guide the movement of the meat, preventing it from being crushed.

Forced supply of raw materials to the working part of the machine provides a constant loading of the cutting mechanism (at the level of a given productivity) and high specific productivity. The specific energy consumption for grinding is reduced compared to manual or gravity feed. However, the design of the top with forced feeding is more complicated, therefore, its cost increases, so that the forced supply of meat gives a positive effect only with a high productivity of the tops. The longer the working auger (worm), the less meat is forced back into the loading part and the higher the productivity of the top: with a large number of turns, a kind of labyrinth is formed, which reduces the possibility of forcemeat from the pressure zone to the loading zone.

The most important part of the top is the cutting mechanism. It can be flat or conical. The most common are tops with a flat cutting mechanism, which is recruited from knives and grates (as for meat grinders). Usually the grate is fixed and the knife rotates. Flat cutting mechanisms are simpler in execution and more convenient to use - it is easier to adjust the degree of pressing of the grates and knives, on which the efficiency of meat chopping depends. Conical cutting mechanisms are more difficult to implement, but they reduce the energy consumption for mincing meat.

Rice. 2.2. Schemes of assembly of the cutting mechanism of the top:

a - for fine grinding; b - for coarse grinding: / - receiving grate; 2- double-sided knife; 3 - large lattice; 4 - small lattice; 5-receiving ring is narrow; 6 - wide receiving ring; 7- clamping nut

The performance of the top and the specific energy consumption can be adjusted by completing the cutting mechanism, which can be assembled from 1-6 cutting planes. With fine and medium grinding of meat, more cutting planes are installed. Typical options for the set and assembly scheme of knives and gratings of the cutting mechanism of the top are shown in fig. 2.2.

With coarse grinding of raw materials, the cutting mechanism is assembled in the following sequence: a one-sided receiving knife is put on the finger of the working auger, then a grate, which is motionlessly fixed in the working cylinder with a key. The knife rotates together with the working speck, the sharpened blades of the knife are adjacent to the grate. Grid and knife surfaces are ground for a tighter fit, which improves cutting conditions.

The cutting mechanism must be assembled so that the grinding is coarser at first, then finer. This ensures less energy consumption, and, accordingly, the ground product heats up less. In a knife mechanism with four cutting planes, a receiving grate, a double-sided knife, a large grate with holes of a larger diameter, for example 16 or 25 mm, a second double-sided knife, a fine grate and a pressure ring are put on the finger of the working auger. Knives and grills are moderately tightened with a clamping nut.

The performance of the top is determined throughput cutting mechanism, which, in turn, depends on the diameters of the grid and the holes in it. Lattice diameter is a characteristic by which tops are distinguished (for example, a top with a 120 mm diameter lattice, or a 120 mm top). Grids with diameters of 82, 120, 160, 220 mm are adopted in domestic-produced tops, 100, 130, 160, 200 and 300 mm in foreign ones. Lattices are made with holes with diameters of 2, 3, 4, 6, 8, 12, 16, 20, 25 mm (sometimes 5, 9 and 13 mm).

The performance of the cutting mechanism depends on the number of feathers on the knives. The most common are cruciform knives, i.e. with four feathers. With an increase in the number of feathers on the knife, the productivity of the top increases, if the degree of use of the grate is not reduced (knife feathers do not cover too much area of the grate).

The performance of the top is regulated by changing the frequency of rotation of the knives. The higher the cutting speed, the lower the cutting force and the better the cut quality, but at the same time, the temperature in the contact zone of the cutting part of the tool with the product increases significantly. In addition, with an increase in the cutting speed, the specific pressure sharply increases on the contact surface of the knife and the grate, which provides more favorable conditions for cutting hard connective tissue.

With improper assembly of the cutting mechanism of the top, uneven surface of the gratings, poor sharpening of knives and gratings, gaps form in the cutting plane. When the top is working, pieces of meat, or rather connective tissue, are hammered into them, which leads to the “scrolling” of the knife without cutting and heating the minced meat due to friction.

Proper operation of the cutting mechanism is ensured when the knives and grids are tightly tightened. To do this, the flywheel nut is tightened with a wrench to failure, and then released by about a third of a turn. The flywheel nut should not be tightened too much, since cutting the meat on the top should not be accompanied by large compressive forces, which can lead to the release of a liquid fraction from the minced meat.

Fatty meat on the top is poorly crushed, frayed, slowly passes, especially if its temperature is high. In this case, it is better to use a cutter.

During the operation of the top, meat and fat serve as a lubricant for the cutting mechanism, auger and cylinder. In this regard, it is not recommended to turn on the top before loading.

A malfunction in the operation of the top is determined by the degree of meat grinding. With the correct assembly of the cutting mechanism and good sharpening of knives and grates, the minced meat fills all the holes in the grate, flows out smoothly, evenly and does not noticeably heat up. In the event of a malfunctioning top, blunt knives and grates, some of the holes remain unfilled, the minced meat jet can be intermittent, zigzag.

The resulting minced meat is sent for the manufacture of semi-finished products or cooling. It would not be superfluous to recall that during grinding, meat is usually significantly inoculated with microorganisms and deteriorates noticeably faster during storage. Therefore, it is impossible to keep minced meat in the semi-finished products workshop - it must immediately be placed in the refrigerator.

3. COMPOSITION

Minced meat can be used to form natural chopped semi-finished products, which include products made from one meat, i.e. without the addition of non-meat components, and chopped semi-finished products, the recipe of which includes, in addition to meat, other products - breadcrumbs, bread, vegetables, eggs, vegetable and milk proteins, etc.

Natural semi-finished products from minced meat are produced relatively rarely for technological reasons, in particular, because of the poor cohesion of minced meat and the possible disintegration of the product during cooking, as well as for economic reasons. Other components used in the manufacture of chopped semi-finished products are usually cheaper than meat, and due to this, the cost of the final product and its wholesale price are reduced, or the manufacturer's profit is significantly increased if the price is left unchanged (which, unfortunately, is practiced more often).

To obtain a well-coupled minced meat structure, white bread, potatoes, soy or milk protein, rice are added to the meat. breadcrumbs.

When adding wheat bread soaked in milk or water to minced meat, chopped semi-finished products retain their shape well. During their culinary processing, the bread not only binds the secreted meat juice, but also increases in volume, so that the product turns out to be juicy and lush. However, at the same time, the taste of bread is noticeably manifested in the cooked semi-finished product, which the consumer does not always like, especially if he has not forgotten the taste of “public catering” cutlets.

Potatoes, especially raw ones, also stabilize the structure of minced meat well and, unlike bread, do not interrupt the taste of meat. But due to the rapid browning of the potatoes semi-finished meat it is necessary to immediately cook or freeze (in the frozen state, the potato does not darken) or use sulphated potatoes. Semi-finished products with boiled potatoes do not darken, but their taste is somewhat worse.

Relatively recently, soy and milk proteins began to be used in the production of chopped semi-finished products. Due to the neutral taste, good binding capacity and relatively low cost, their use can only be welcomed, unless, of course, the amount of hydrated protein is excessive (no more than 10-15% of the mass of the semi-finished product).

When breadcrumbs are added, the minced meat structure is noticeably compacted, and it remains after cooking. Therefore, the stuffing stuffing of dumplings, prepared with the addition of breadcrumbs, retains its shape even if the test shell is broken during the cooking of dumplings.

Often used rice does not significantly affect the structure of raw minced meat, but it retains the meat juice released when heated, significantly improving the taste of the finished product. This is especially evident in the manufacture of cabbage rolls: without rice, minced meat will be dry and tough.

Rice. 3.1. Scheme of a meat mixer with spiral blades:

1 - bed; 2 - electric motor; 3-drive; 4 - capacity; 5-kneading spirals; 6 - lattice cover; 7 - covers for unloading minced meat

The minced meat is finally prepared in mixers, where the raw materials are laid according to the recipe. Usually, open intermittent mixers with mechanized unloading or manual overturning of the bowl are used. The main working mechanisms of the mixer are blades, spirals or screws. Meat mixers with spiral augers and product unloading through a special side hatch with a lock are convenient in operation (Fig. 3.1). The mixer consists of a container 4, inside which two kneading spirals 5 rotate counter-rotating. The rotation of the spirals is carried out from the electric motor 2 through the drive 3. The minced meat is unloaded when the kneading spirals rotate through the cover 7.

Raw materials are loaded into the meat mixer in the following sequence: meat, hydrated protein or bread soaked in milk, onions, eggs or melange, spices. Minced meat is mixed until a homogeneous mass is formed, usually within 4-6 minutes. The prepared minced meat is immediately sent to the molding of the semi-finished product. Even a short exposure of minced meat is undesirable due to a possible increase in bacterial contamination.

4. FORMING CHOPD SEMI-FINISHED PRODUCTS

From the prepared minced meat, they form: cutlets in the form of an oval-shaped cake 2-2.5 cm thick; meatballs in the form of cakes of a rounded flattened shape 1.5-2 cm thick; schnitzels in the form of flat-oval flat cakes 1-1.5 cm thick; other products, the form of which is specified in the regulatory and technical documentation.

Forming cutlets, even with small production volumes, can be carried out on a machine that is simple in design and, therefore, reliable in operation. The car consists of the case on which the minced meat bunker, the rotating table and the dumping disk are placed. The ejector disc rotates 5.3 times faster than the table. Minced meat is loaded into the bunker. Blades, obliquely placed on a vertical shaft, forcemeat is fed to the bunker channel. Through the channel, the stuffing fills the next of the five nests of the continuously rotating table. The volume of the channel is regulated by a piston. The piston rod ends with a roller sliding along a fixed guide. The volume of minced meat in the nest is regulated by the piston stroke by means of a two-arm lever through a restrictive disk. When the table moves, the piston rod roller slides along the guide, raising the piston to the table surface. In the upper position of the piston, the dosed portion of minced meat is dumped by the disc.

Table pistons consist of a piston with a rod, a glass and a cover. Between the cover and the glass, a spring is put on the piston rod, returning the piston to its original position.

5. PACKAGING AND PACKAGING

Chopped semi-finished products are packed manually in bags made of polymer film or on trays made of polymer materials. Semi-finished products are usually placed in the package, the appearance of which is not decisive for the consumer - sets for broth, soup, jelly, etc. d, semi-finished products are not packaged, since in order to bring the exact mass to almost every package, small pieces must be added - makeweights. This is both time consuming and degrades the appearance of the product. On the electronic scales automatically accurately determine the mass of the product and stick on the package (or issue) a label indicating the mass, price per 1 kg (100 g) and the cost of the semi-finished product.

Chopped semi-finished products packaged in trays retain their shape well, and outwardly such packaging looks modern and attractive. It is better to stack semi-finished products on the tray tightly, one to the other - then the packaging retains its shape well. Trays with semi-finished products are then placed in a plastic film bag or wrapped in a plastic film. Packages and film can be printed in color.

Often, chopped semi-finished products packed in film or trays will be placed in rectangular cardboard boxes, which are more convenient to put in boxes, i.e. shipping containers. Due to the denser packing, they take up less space per unit volume of the refrigerator. In addition, during transportation and loading operations in the distribution network, the packaging film is often damaged, and the buyer refuses to take such goods. AT cardboard box polymer packaging is not damaged, but the consumer does not see the product and therefore is more willing to buy semi-finished products in transparent packaging. Although products from well-known manufacturers are better bought if they are packed in cardboard boxes.

As already noted, the packaging of chopped semi-finished products in trays and bags is done manually. Some solutions and techniques allow increasing labor productivity in packaging operations. In particular, with a large volume of production, it is advisable to install a system of conveyors through which semi-finished products are delivered from the place of cutting and molding to the packaging area. With a large number of semi-finished products of the same name, they can be delivered by a separate conveyor to the place of packaging. In this case, the number of conveyor lines is equal to the number of assortment names of semi-finished products, not counting the general and connecting conveyors.

A simple option for organizing the packaging of chopped semi-finished products is shown in fig. 12. Poultry carcasses arriving along the conveyor / are dumped onto the distribution conveyor 2, from where they go to the conveyor 3. Workers take the carcasses from it, cut them, lay them on the substrates and transfer them to the conveyor 4. Thanks to the organization of the flow scheme, labor productivity increases markedly.

With small volumes of production of chopped semi-finished products, the flow in the organization of workplaces for cutting, packing and packaging is also essential.

When choosing equipment for packaging semi-finished products, one should proceed from the required productivity and packaging method (under vacuum, thermal packaging, in bags with subsequent sealing by heat sealing or adhesive tape).

It is not recommended to seal packages with metal clips due to the frequent tearing of the film during the application of the clip or during the subsequent transportation of semi-finished products.

For large production volumes, continuous machines are usually chosen, arranged according to the non-contact packaging method (Fig. 5.1). In the machine for packaging semi-finished products in shrink films, the vacuum chamber is replaced by a shrink tunnel. The substrate with semi-finished products is placed on the lower film between the stops of the conveyor, which moves synchronously with the lower film. The distance between the two stops determines the length of the packet. On top of the product is covered with another film. Longitudinal seams are formed continuously with the help of heating elements, to which the films are pressed by PTFE rollers.

Cooling Shrinkage Transverse, longitudinal Infeed of packaging Welding and cutting of packaging material

Rice. 5.1. Scheme of a machine for packaging products in a contactless way

Film broaching is carried out by a transverse welding mechanism consisting of two conveyors: upper and lower. On the top there are silicone rubber pads, on the bottom there are two heating elements, between which there is a knife for cutting bags. Films with embedded product and welded longitudinal seams are clamped between the upper cushions and lower heaters and moved by a transverse welding mechanism. At the same time, the transverse seam of the package is formed by thermal impulse welding. Then the package is cut off by a knife, which is pulled out of the groove while moving along the stationary copier. The modes of welding of the longitudinal seam and thermal pulse welding of the transverse seam can be changed using voltage regulators and electronic time relays. The welding voltage of both types of seam is controlled by a voltmeter.

Packing on machines in a bagless way is characterized by high performance labor. All operations, from laying the substrates on the conveyor to the release of the packaged product, are performed automatically. On separate machines, automatic weighing, printing of a check and sticking it on the packaging are carried out. The productivity of the machine is from 1000 packages per hour, respectively, and the cost of such equipment is high.

On the domestic market, you can purchase continuous machines with a bagless packaging method only of foreign production. Batch equipment with a capacity of up to 300 packages per hour with non-packaged and packaged packaging methods of domestic and foreign production can be freely purchased. For semi-finished products, for example, lines with thermal tunnels for block packaging in shrink film, packaging semi-automatic machines and thermal tunnels, vacuum packaging machines can be used.

Of course, for the operation of packaging semi-finished products under vacuum or in shrink film, even in a small production, significant investments are required. It is possible to produce semi-finished products on substrates with sealing in bags of film by heat sealing or adhesive tape (this, by the way, is done in most small enterprises) and do without investment. However, under the conditions modern market The appearance of the package is of great importance and should not be neglected. The cost of more advanced packaging is well justified, although such packaging requires a special shrink or self-adhesive shrink film. Small enterprises successfully use machines for wrapping products in shrink film on a heated plane (the so-called "hot table").

Of the vacuum packaging machines, two-chamber ones are more often used: while vacuuming is taking place in one chamber, the other is being prepared for work.

Literature

1. Gushchin V.V., Technology of semi-finished products from meat, Moscow, 2002

2. Gabrielyans N.A., Kozlov A.P., Commodity research of meat and fish products, Moscow 1986

Characteristics of the organization structure of the plant

The organizational structure of the Remit Meat Processing Plant LLC is linear. Management within the structure of the enterprise is decentralized. The division of rights and responsibilities is divided between different bodies governing technical developments, purchase of raw materials and materials, production, marketing, etc. Also on the territory of the enterprise there are three workshops for the production of products:

sausage shop;

workshop for the production of semi-finished products;

raw-smoked products shop;

as well as a transport and raw material shop.

The organizational structure of the workshops is the same type in all workshops and is linear. In each workshop there is directly the head of the workshop, in his subordination are: technologist, chief mechanical engineer, shift foreman and workers.

All finished products are stored in the finished product warehouse.

The organizational structure of the Remit Meat Processing Plant LLC is shown in Fig. one:

Rice. one.

Description of the technological scheme for the production of chopped semi-finished products

Fig.2

Following the technological scheme presented in fig. 2 is the process of production of chopped semi-finished products. MPZ presents to the buyer 8 types of cutlets: Kyiv, fire, homemade, kebab, chicken, peasant, steak, Moscow. Chopped semi-finished products are made from beef, pork, chicken.

Meat raw materials. Beef enters the workshop in the form of minced meat, minced on a top, the diameter of the grate is 25 mm. Pork enters the workshop in half-carcasses, after which it is cut, deboned, trimmed. Deboning is carried out by a differentiated method, when each worker debons a certain part of the carcass, this happens on stationary and conveyor tables. The defrosted meat is supplied to the deboning, with a temperature in the thickness of the muscles of 1 - + 4 ° С. The permissible content of meat on the bones after deboning is up to 8%. After that, the meat is ready for the trimming process: removal of fat, tendons, cartilage, connective tissue films, large blood vessels, as well as blood clots and small bones from deboned meat. The zhilovschik performs the operation of dividing the meat into grades depending on the content of adipose and connective tissues.

Meat raw materials after trimming are crushed on tops of various systems with a lattice hole diameter of 3-6 mm. In the body of the top there is a working chamber for processing the product, which is a fixed hollow cylinder, inside which there are ribs that prevent the product (meat) from turning relative to the screw. To advance the product in the working chamber, feed it to the knives and push it through the knife grates, a rotating auger with a pitch of turns decreasing towards unloading is used.

For the manufacture of chopped semi-finished products, it is allowed to use frozen meat blocks without preliminary defrosting with grinding, which is located in the adjacent shop for s / c products. After grinding meat blocks in the form of meal on a block cutter with a lattice hole diameter of 20-25 mm or pieces of 10 x 3 x 3 mm in size, they are sent directly to a top with a hole diameter of 3-6 mm.

When compiling minced semi-finished products, protein preparations, vegetable or cereal components, bread, water, salt and all spices are weighed, according to the recipe, in a separate room specially designated for this. Weighed raw materials and spices are loaded into intermittent meat mixers and mixing is carried out to produce minced meat for cutlets. In the mixer, all the components of minced meat are thoroughly mixed for 3 minutes.

The prepared minced meat is molded on the AK2M-40 machine, the weight of each cutlet is 100g.

Next, the finished product is packed into trays, if the recipe requires, then some cutlets and steaks are evenly sprinkled with breadcrumbs. Chilled semi-finished products on trays-liners are placed in wooden, metal or polymeric boxes or in container-equipment (containers). Frozen chopped semi-finished products are packed in two pieces in bags of polymeric materials approved by the Russian health authorities for contact with food products. Packages with frozen semi-finished products are placed in corrugated cardboard boxes.

Chopped semi-finished products intended for sale in a chilled form, after molding and laying on trays-liners and packing in boxes or container-equipment, are sent to the cooling chamber. Cooling is carried out at a temperature from 0 to 4°С until the temperature inside the semi-finished product reaches no higher than 4±4 0С, inside the minced meat briquette - 2±2°С. Chopped semi-finished products such as cutlets (cutlets, meatballs, rump steak, beef steak), intended for sale in frozen form, are placed in one row on frames, shelves or mesh containers after molding and sent to a freezer or quick freezer. In the chambers, semi-finished products are frozen at an air temperature not higher than -18 ° C.

When the finished product leaves the workshop for sale, the labeler weighs it, labels the boxes and sends it to the logistics department.

Chopped semi-finished products with manufacturing defects (deformed, with deviations from weight) with non-expired sales periods without signs of spoilage are used in the manufacture of semi-finished products of the appropriate assortment in an amount of not more than 3% of the mass of cooked minced meat with the permission of the veterinary and sanitary supervision. In this case, in the manufacture of minced semi-finished products, the amount of bread and breading contained in the semi-finished products sent for processing should be taken into account.

The shelf life, transportation and sale of chilled chopped semi-finished products at a temperature of 2 to 6 ° C is no more than 12 hours from the end of the technological process, including at the manufacturing plant - no more than 6 hours. Frozen chopped semi-finished products are stored at a temperature not higher than - 10 °C, depending on the species, from 10 to 20 days.

An approximate layout of the semi-finished products workshop is shown in Fig. 3, where: