A flour mill as a business: is it possible to count on large orders? Method for the production of wheat flour and wheat flour obtained by this method (options)

Flour is a necessary raw material for the production of bread and pasta, animal feed, as well as fast food. In addition, flour is also one of the main ingredients in the preparation of pies, pancakes and other homemade food.

Flour can be made from crops such as barley, rice, oats, corn, but it is wheat flour that is most in demand today. Flour products traditionally occupy a significant part of the diet in Russia, and practically regardless of social status and income.
The demand for flour products depends little on the economic situation in the country. Of course, during periods of crisis, the demand for expensive cakes and pastries decreases, but the demand for pasta and the bread remains high enough anyway. It should be noted that the global Russian market flour belongs to Russian enterprises, which is a consequence of the fact that Russia has the necessary raw material base.

  • Bread factories;
  • Confectionery;
  • Workshops producing flour products;
  • bakeries;
  • Restaurants, cafes, pizzerias;
  • Private farms.

Technological process

Flour-grinding production technology involves the following steps:

  1. Grain cleaning, preparation and quality control;
  2. Peeling of raw materials;
  3. Splitting up;
  4. Screening;
  5. Packing.

Raw material

The quality of flour directly depends on the quality of raw materials, therefore, for the successful development of the enterprise, it is necessary to initially select suitable grain suppliers.

It is also necessary to take into account that different types of wheat are used to produce different types of flour suitable for certain purposes. In particular, pasta is made from durum wheat flour, and bread is baked from flour. soft varieties grains.

When choosing raw materials, it is worth focusing on the generally accepted classification, according to which grain is divided into 5 categories:

  • I - red grain;
  • II - solid;
  • III - white grain.
  • IV - red grain;
  • V - white grain.

If you need to make pasta flour, then you need to purchase raw materials of type II, and if baking flour - I or IV.

Equipment

To organize the work of a flour mill, it is necessary to purchase:

  • farm mill;
  • Cleaning equipment, preparation of raw materials for grinding;
  • platform scales;
  • Bag sewing machine.

The cost of Russian flour-grinding equipment is lower than that of imported ones. The price of a farm mill with a capacity of up to 200 kg / h is 500-600 thousand rubles, with a capacity of up to 380 kg / h - about 1 million rubles.

The cost of a grain cleaning and preparation unit with a capacity of up to 1200 kg / h fluctuates around 700 thousand rubles. It is needed to clean the grain from various impurities, as well as to moisten it.

Minimum cost production equipment to equip a small flour mill will amount to 1.5 million rubles. including delivery and installation.

Modern flour-grinding equipment is quite compact in size, so it is not advisable to rent a large production area, but the enterprise needs to allocate premises for a warehouse of raw materials and products. The storage capacity of raw materials must ensure the operation production line for 1.5 weeks, and the capacity of the flour warehouse - for 1 week. Statistics show that with such a capacity, the equipment can operate at maximum efficiency.

Staff

To organize the work of a flour mill, its staff must have:

  • Manager - 1 person;
  • Worker - 2 people;
  • Storekeeper - 1 person;
  • Cleaning lady - 1 person

Initially, accounting functions can be performed either by a manager or an organization specializing in accounting services. When expanding the business, it will be necessary to hire a full-time accountant as the manager will spend much more time solving problems with suppliers and customers, and employees of the accounting organization may not be able to cope with the volumes.

Costs and payback

To organize a flour-grinding business, approximately 2.01 million rubles are needed, which will be distributed as follows:

  1. Repair of premises and purchase of furniture - 150 thousand rubles;
  2. Purchase of equipment, including installation - 1.5 million rubles;
  3. Purchase of raw materials - 300 thousand rubles;
  4. Registration of an enterprise - 10 thousand rubles;
  5. Other expenses - 50 thousand rubles.

Monthly expenses:

  1. Wages of employees - 150 thousand rubles;
  2. Premises rental - 70 thousand rubles;
  3. Security - 5 thousand rubles;

Total: 225 thousand rubles.

With an average output of finished flour in the amount of 150 kg / hour, approximately 1800 kg of flour will be produced in one twelve-hour shift. Consequently, the estimated production volume for the month will be 54 thousand kg. With the wholesale cost of flour 16 rubles. for 1 kg, the monthly income will be approximately 850 thousand rubles. Excluding monthly expenses and the cost of purchasing raw materials, the estimated profit will be 80-100 thousand rubles.

The approximate payback period for the initial costs of starting a flour production business will be 1.5-2 years.

Opening a flour mill is most advisable in those places where grain is initially produced, otherwise, starting a business will require a larger amount of capital investment. The fact is that in this case you will have to purchase vehicle for the transport of raw materials. This will negatively affect the payback period and due to the introduction of a driver's vacancy and the cost of maintaining a car.

Probably not worth it once again talk about how popular flour products are among various segments of the population. Each of us goes to the store every day and buys baked goods, cookies and other things. The main component in the production of the above products is flour. Flour is obtained by grinding grains of various varieties.

But today we will not talk about the technology of making delicious cookies or bakery products. In this article, we will look at how to open your own flour production. Given the size of the fields in our country, the cultivation of grain crops is very popular, and the grain itself is in great demand. And if there is a high demand, then you can make good money on it.

General information

As mentioned at the beginning of the article, flour can be made from different grains, for example: corn, oats, rice, barley, wheat, and so on. Such an abundance of cereal crops gives us the right to choose. Let's say your area has some problems with the supply of wheat, which means that something else can be used instead. But you should consider that the production will be slightly different.

In order not to miscalculate with the equipment, first decide on the cereal crop that you will process, and after that already buy a production line. Russia and Ukraine have their own raw material base, so it will be easier for us to buy grain, because there are no foreign competitors within our countries.

But you must understand that such a business cannot be considered seasonal in any way, because people buy pasta, bread with buns and various cookies at any time of the year. Of course, you may face some difficulties during the economic crisis, in particular for expensive products in the form of baked goods, but this is still not a good reason to shut down your business. Get ready for the fact that the production of flour is considered a very complex and responsible technological process, which requires constant monitoring at all stages of production.

If you were able to make a product High Quality, then believe me, there will be no end to buyers. The first and main buyer is bakeries. But before you own a flour mill, you should know that flour comes in many varieties. You probably paid attention when you bought flour in the market, as they write on the price tags “Highest grade”, “First grade” and “Second grade”. Here you should make all three grades at your plant. When there is a bright streak, you can easily sell “highest grade” flour, but when hard times come, the first and second grade will be used.

Purchase of equipment

To open your business, you need the appropriate flour production equipment. If we open a factory, then we will need our own elevator, which will supply flour. by the most best solution is to use a chain conveyor. We also need a unit responsible for the preliminary preparation and cleaning of raw materials before grinding. In this unit, the grain will be cleaned of harmful impurities by 85-95%, after which it will be sent for varietal grinding.

In addition, you can buy a PTMA-4 machine that can process more than 1,000 kilograms of grain per hour. Its cost ranges from 500-800 thousand rubles. I would also like to mention the main equipment in the production of flour - the F1 farm mill. Its price varies between 400-600 thousand rubles. This mill makes it easy to get flour of all three varieties. Its productivity is about half a ton of grain per hour. The dimensions of the mill are relatively modest, respectively, you will not need additional industrial premises.

But the above equipment is not all. You will also need air and sieve separators. With the help of air separators, all kinds of third-party inclusions are removed due to air flows. Also, do not be stingy with the purchase of industrial platform scales. To date, they can be purchased in thousands for 60 rubles.

It is desirable, but not necessary, to have a machine in your arsenal that will sew bags of flour in automatic mode. The cost of such a useful unit is in the region of 25-30 thousand rubles. If you open a large production various types and varieties of flour, it would also be nice to have an automatic packing unit behind your soul that does not need human intervention in manufacturing process.


Preparing raw materials for grinding

Modern equipment allows for the preparation of grain in a fully automatic mode. There are three stages in the processing of cereal crops before subsequent grinding:

  • Preparation for grinding;
  • Directly grinding into flour;
  • Product packaging.

How well the grain was prepared, how high quality the final product will turn out. The preparation process begins with the formation of a batch for grinding. In fact, this is a simple selection of grain that will be processed in the first batch. After that, the raw material must be cleaned of various impurities by dry and wet surface treatments. Now let's take a closer look at each step.

To obtain premium flour that will go to bakeries, it is necessary to correctly form a batch for grinding. It is very simple to do this: you need to mix grains of different quality, which allows you to get stable properties of the grain. After that, purification from various impurities begins. There are plenty of technologies that allow you to make high-quality cleaning. For example, on an air sieve, all light inclusions can be removed. With the help of a sieve separator, both large and medium inclusions can be removed. To obtain high-quality flour, brush machines are used that remove grooves, dust and dirt from the surface of the grain.


Flour production scheme

Modern flour production technology, as well as modern equipment, make it possible to obtain goods of relatively high quality from almost any grain. Most best option– use a farm mill F1 with high productivity. You can of course use any analogue with the same characteristics. First, the flour goes from the elevator to the flour factory, after which it is loaded into the silos. The silos are equipped with gravity pipes, which I pass grain of different grades through themselves by gravity. Thus, a grinding batch is formed.

All grain flows in the pipes undergo a degree of purification, and if necessary, heating. The last stage involves moving the grain from the magnetic separator to hydroprocessing. Next, the grain is sent to the silos for tempering, where it must lie for a certain time before it goes further to the scourer. The next step is grain moistening and short-term conditioning. After that, the grain is fed for weighing, and then crushed in a torn system.

Here is just the most interesting process. The essence of the technology for processing grain into flour is that a high-quality product cannot be obtained in one pass. After the first stage, you will have small, large particles and flour. The second stage is for reprocessing and enrichment. After that, the resulting fraction is sent to grinding machines, where the product of the desired fraction is already formed. At this stage, quality control is carried out. At the final stage, the flour is fed into the magnetic separator and sent for packaging.


How to get fishmeal?

The production of fishmeal with a similar technology has a number of advantages. These types of flour are high in useful substances. Feed fish meal contains about 60% protein, which is several times higher than the concentration of protein contained in grass meal. As you already understood, fish flour is made from fish and fish waste. When obtaining flour from fish, close attention is paid to the removal of fat and drying of raw materials. by the most the best way removal of moisture from raw materials is a vacuum.

The production of fishmeal consists of several simple steps. First you need to boil the raw materials, and then remove the fat. Why is it better to use a vacuum? The fact is that after vacuum processing, all useful substances, trace elements, vitamins, proteins, etc. will remain in the raw materials. The drying time is 190-200 minutes, but this figure is relative, since different fish have different fat content.


How to get meat and bone meal?

The production of meat and bone meal is based on the processing of the bones of dead or unfit for human consumption animals. These animals can be small or large. cattle. Bone meal can be added to pet food as a vitamin supplement, because meat and bone meal is high in phosphorus. I would like to mention one significant disadvantage in the production of meat and bone meal - raw materials must undergo a thorough check of sanitary and veterinary services before it reaches you for processing. But the technology for obtaining this flour is very simple. The bones are first crushed and then dried and boiled. After that, a special pump grinds everything to a homogeneous consistency.

After obtaining a homogeneous mass, the bones are sent to a centrifuge to remove fat and moisture. Next, the raw material must be dried again and sent to the crusher, where it is finally crushed. The cost of equipment for such production will cost you relatively little - only 500-800 thousand rubles, we mean a complete production line.

Everything is changing - technology, raw materials, engineering. The only thing that everyone always needs is food.

Flour, as the basis of the agricultural industry, will never be at a loss, because everyone needs to eat. That is why the production of flour as a business project is seen as a solution with good prospects.

Here are the minimum requirements:

  • Elevator for moving raw materials.
  • Workshop equipment (an example is PTMA-4, which can process a ton of raw materials in an hour);
  • Optional equipment:
    • Air and sieve separators;
    • Bag sewing equipment;
    • Packing machine.
  • Warehouses.

Business idea - flour production, details in this video:

Registration and promotion

Business registration is carried out in the Federal Tax Service at the place of residence. Depending on the scale, you can choose one of two forms of doing business: LLC and IP. Despite the scale of the LLC, for a start it will still be more reasonable to choose an individual entrepreneur.

The advantages of sole proprietorship over LLC are as follows:

  • Simplified taxation;
  • Tens of times less fines;
  • Ease of bookkeeping.

But if the enterprise is large, it may be better to pay attention to LLC - legal entity it is easier to work with large volumes of products and it is easier to control many workers.

Bread products are made from spring or winter red grain wheat, pasta products are made from spring durum wheat. Confectionery flour is produced with a reduced protein content.


Flour production is a profitable and promising business.

Production takes place in stages.

  • Stage 1. Purchase of grain. Ideally, one supplier of quality grain is needed.
  • Stage 2. Equipment preparation.
  • Stage 3. Preparation of grain for processing. At this stage, the grain is cleaned of impurities, the grinding mixture is compiled, and conditioning takes place. Air conditioning is hot (about 50 degrees) and cold. Rye grain is processed only by cold method.
  • Stage 4. After cleaning and sterilization of the grain, it goes to quality control. If harmful impurities and foreign particles exceed the norm, it is sent for reprocessing.
  • Stage 5 Grinding and preparation for storage. First, the grain is crushed, then it is sieved. Grain is crushed on roller machines. After passing through each machine, the ground grain is sieved through sieves of different sizes. Grinding can be single and repeated. The most high-quality flour is obtained after several grindings with a pass through a torn system.

The figures are quite impressive, but the turnover is not comparable.

Sales of products

So, the main question is who needs flour? The demand for it is very high. Companies that buy it can be divided into several categories.

  • Bakeries. They usually require large volumes of production, but if you can establish sales, you can say that everything is already arranged. Bread is always in demand, it has a more or less stable price, and if you establish relations with a large company, it's time to think about gradually expanding production. However, many factories also work with small producers if their products are of high quality and competitive in a fairly large food market.
  • Bakeries and confectioneries. More suitable for small deliveries of high-end products. They require fresh and well-refined flour, the cost of which is somewhat more expensive than simpler products. A large bakery or pastry chain can buy large volumes of flour, and if you manage to reach several such companies, the prospects for expansion will become clear.

Mini-factory for the production of flour.
  • Outlets. They need flour as it is to be realized. Flour is taken by shops, it is profitable to sell it to wholesalers. You can consider the option of self-selling flour with delivery. In this case, you will need to additionally attend to the purchase of a truck.
  • Catering establishments. All kinds of cooking, canteens, cafes, restaurants. It is quite obvious that they need flour for cooking. Even with small production volumes, you will most likely have to look for several such buyers. But many restaurants high level will buy rare, well-refined flour at very good prices.
  • If you are a novice businessman, do not rush to build your "business empire". At first, small amounts are enough. Once you get a feel for the market and find your niche, it becomes both easier and harder at the same time. But only after that it will be possible to expand your enterprise.
  • There is no need to open an LLC if a very large production is not planned at the start. It is easier and faster to open a sole proprietorship, it requires much less investment, it is easier to get rid of it if something goes wrong with the business.
  • A good supplier is almost half the success. The other "almost half" is a constant and reliable distribution channel. Look for a financial partner you can trust.
  • Workers should be treated with respect. Select smart staff. Better - on your own, because at the start a good personnel officer may not be affordable.

And the main advice - love your job, invest in it not only money, but also your soul and work.

The organization of the storage process is an important factor that ensures the preservation of the quality of the finished product.

Flour is stored at mills, warehouses and bases of the Ministry of Procurement, sometimes at bases, warehouses and trade and public catering enterprises.

Flour can be stored in a variety of ways.

Storage in bags (textile containers) is one of the oldest and most common ways. With this method of storage, bags of flour are stacked carload-wise in stacks, the height will be 6-8 rows. This is how flour is folded in the warm season, and in the cold season, the laying is somewhat different: the bags are arranged in 12-14 rows with a well, a tee or a five. Flour is stored in boxes, on racks or in pallets, which is packaged in bags and boxes.

Also, the method of bulk storage of flour is now very popular. Specially equipped large-capacity silos, as well as mills and bakeries, are suitable for this type of flour storage.

The shelf life of flour varies. So wheat flour, which is not enriched with dry wheat gluten, can be stored for 12 months. Soy flour can also be stored for 12 months, but on condition that the humidity is not more than 60%. And the flour that is enriched is stored for no more than 12 months, and the shelf life of the component with which it is enriched must be taken into account.

Also worth mentioning is one important point: the flour that has just come out of production will have an elevated temperature, approximately 40-42 o C. In order for its temperature to return to normal and catch up with the temperature environment, and also in order for the flour to improve its baking properties, it goes through a process such as resting. It takes quite a bit of time, about 5 or 10 days.

The properties and quality of flour are affected by biochemical and chemical processes. In order for them to be normal, it is necessary to monitor humidity, ventilation and temperature. All these parameters must be within certain limits.

In order for the flour to be well preserved, it must have a minimum temperature between 0°C and 15°C. But, nevertheless, during the storage of flour, in any case, a change in its moisture content will occur. This is due to the fact that it is extremely hygroscopic.

In addition to hygroscopicity, which affects the fact that the flour actively absorbs moisture, there is another property. Condensation of water vapor is very actively collected on the surface of the flour. This can happen when chilled flour is ventilated with air that is warm and sufficiently moist. If the moisture content of the flour is more than 15%, and it will be stored where relative humidity increased, the product will deteriorate. It may begin to mold, cake, and so on. Therefore, to prevent the flour from spoiling, it is better to store it at a temperature of 5 to 15 ° C. But if it is stored for a sufficiently long period, then the temperature can be much lower. Different temperatures of flour and air, as well as its heat capacity and thermal conductivity, affect the rate at which the temperature of the flour itself changes. The longest time to maintain the original temperature, even though the temperature difference between air and flour can vary significantly, will be the one that is stacked.

The ambient temperature will most affect those layers of flour that are outer. And, for example, in silos, the temperature of the entire mass of the product can change quite quickly.

When the temperature and humidity of flour change, certain biochemical and physico-chemical processes occur. These processes include maturation and aging. And if the conditions are not very favorable, then the flour begins to deteriorate, that is, it can begin to mold, cake, go rancid, and various pests can start in it.

On the example of high-quality wheat flour, the process of its maturation is best seen, which has a strong effect on the properties that gluten has, as well as on its color. So, for example, gluten can become more elastic, but less extensible.

Flour is weak and strong. And if the ripening process has a positive effect on weak flour - its properties improve, then this very ripening process has a rather negative effect on strong flour, or it does not affect it at all. Regarding rye flour: the ripening process has practically no significant effect on it. And this applies to absolutely all varieties. The same applies to wheat flour. Of course, it is worth saying that the process of maturation, that is, its essence, has not yet been fully studied. It is known that this process is activated when a sufficient amount of unsaturated free fatty acids is accumulated. To speed up the maturation process of flour, it must be enriched with air at a temperature of 15-25°C. It is also suggested that the ripening process is closely related to oxidative processes, which, in turn, affect the compaction of gluten particles.

When there is a change in the properties of gluten, then simultaneously with this process there is a change in its color. Flour may turn white, or it may become acidic. Acidity increases due to hydrolytic processes, that is, phytin is split, as well as phosphatides. Moreover, when phytin is cleaved, inositol-phosphoric acid is formed, and when phosphatides are cleaved, free fatty acids are formed. The color changes due to the fact that carotenoids are decolorized and oxidized, all this happens under the action of lipoxygenase. However, the idea that the acidity of flour can only increase due to the accumulation of free fatty acids is very doubtful and requires a number of experiments to verify and confirm it.

storage long time packaged flour, humidity and temperature regime. After all high humidity and fever can lead to the fact that an irreversible aging process of flour will begin. This will affect the fact that proteins will be less capable of swelling, their digestibility and solubility will also decrease, and if this process is long, then in the end it will not even be possible to obtain dough from such flour and it will only be suitable for technical purposes.

A fairly common occurrence in wheat flour (most often of the 2nd grade), oatmeal and corn flour is rancidity, in other words, among the types of spoilage, this is the most common. But rye flour almost never goes rancid.

Flour goes rancid for one reason only: the fat and fatty acids contained in it can be broken down and oxidized. All these processes occur under the action of certain enzymes. Or, light, heat, air and oxygen can also affect oxidation and breakdown, that is, it does not occur under the influence of enzymes.

Dry flour will go rancid most quickly, that is, the one whose humidity is lowered, as well as packaged flour stored in small batches in a room where the temperature is quite high.

Flour can also develop acid-forming bacteria that cause the flour to sour. However, this phenomenon is observed quite rarely. In order for the flour to sour, it must contain a lot of starch and sugar, and it must also be initially moist.

A complex process, which is caused by the respiration of the product, is the self-heating of flour and the self-heating of grain. This phenomenon causes the accumulation of heat and moisture in the product, which leads to the development of various microorganisms that decompose flour substances and contribute to the release of moisture, carbon dioxide and heat. This can cause the flour to smell musty, change flavor, and start to clump. Also, flour can darken, which is caused by the formation of melanin. And, of course, such flour is completely unsuitable for baking bread from it or using it for other food purposes.

Also, flour that has undergone mold may become unusable. In this case, she will have bad smell and a taste that flour does not have. In general, the molding process itself is sometimes outwardly completely invisible. But if this process has begun, then it will lead to the fact that different kinds molds that will decompose fats and carbohydrates. Due to the mold, organic acids will accumulate, as well as water-soluble substances, and in sufficient in large numbers. The process of molding may be simultaneously accompanied by the process of self-heating, or may not be accompanied. But in order to avoid such a nuisance, it is necessary to observe certain rules: good ventilation, low humidity and optimum temperature.

Why is it not recommended to store flour in a room where humidity is high? Because the surface of the flour is very hygroscopic and easily absorbs gaseous, vaporous substances and water. It is precisely because of its properties that it is also not recommended to store flour where there are odors that it can absorb.

Butterfly caterpillars, beetles and their larvae can also cause flour to go bad. It is worth saying that these pests are one of the most common causes of flour spoilage. If we talk about bread mites, then they, as a rule, affect those layers of flour that are adjacent to the burlap, but they damage the grain many times more often.

It is worth noting that most often such beetles as the small flour beetle breed in flour. These pests love heat, they are very prolific. With their waste products, they pollute the flour and give it a very unpleasant odor. The red flour beetle, the Mauritanian goat, and the large flour beetle are also very common.

Mill and flour moths, as well as grain moths, are those butterflies that most often infect flour.

Flour becomes infected with pests quickly and easily. To do this, it is only necessary to store it in warehouses that are already infected. However, it also happens that infection of initially pure flour can also occur in decontaminated warehouses. Moreover, the infection can be quite strong. This is due to the fact that sometimes the methods that are used to detect pests are ineffective, since they take into account only the visible forms of pests. At the same time, for example, eggs cannot always be seen, as they are small and white color. By sifting the flour, mobile pests are removed, but the eggs remain in the flour. Also, flour can be infested with pests if the mill where it was produced was infected.

Flour that is contaminated cannot be sold. Methods for disinfecting flour are completely different. Processing can be mechanical, chemical or physical.

However, it must be borne in mind that the above methods of pest control are sometimes ineffective, and sometimes even impossible. So, for example, on commercial enterprise it is impossible to process flour with the help of gassing. If, nevertheless, contaminated flour was found on sale, then it must be withdrawn from trade and taken to special bakery bases. And those rooms in which flour was stored must be cleaned and disinfected.

Quite a lot of problems arise with the storage of fortified flour. This is due to the fact that synthetic and natural vitamins contained in flour have different storage properties. And one more important point: the lower the temperature of the flour, the better the vitamins will be preserved.

All of the above allows us to conclude that flour must be stored in rooms that are clean, odorless, well ventilated and, of course, not infested with pests. And the humidity of the air must be no more than 75%, and the temperature - no more than 25 ° C.

It is hardly necessary to talk once again about the popularity of flour products. Almost all of us buy bread, rolls, cookies and other similar products daily. For all this there is a basis - flour. This product of grinding wheat and other crops is in demand always and everywhere.

Let's talk about how to fix own production flour. This is exactly the kind of business that, with the proper approach, can bring significant profits. But in the early stages, you will have to work almost all day.

Some general information

As noted above, flour can be made from various cereals such as barley, rice, oats, corn, etc. This gives us a wide choice, so if there is a problem with the supply of wheat in your area, you can use other grain. At the same time, one should not forget that production will differ slightly depending on the type of raw material selected.

For this simple reason, it is recommended to first decide on the cereals, and only then purchase the production line. It is safe to say that Russia has its own raw material base, therefore most of products are made here. This suggests that it will be a little easier for you to start, since there will be no competition from foreign companies.

This business can hardly be classified as seasonal. This is due to the fact that bread and pasta are well bought, both in winter and in summer. Of course, during a crisis, the consumption of expensive products, such as baked goods, decreases, but this is not at all a reason to stop your business. Flour production is complex technological process requiring quality control at all stages of production.

If you can make a quality product at the exit, then you will have plenty of buyers. First of all, these are bakeries. But you, as the future owner of a flour factory, should know that it happens different quality. There is a first, second and highest grade. It is desirable that you can produce several. AT better times you will successfully sell products of the highest grade, and in heavy products - the second. Let's talk about what the production line consists of, and at the same time consider the process itself.

Purchase of the necessary equipment

Of course, it is unlikely that we will be able to produce something without the availability of appropriate technology. Since it is planned to produce large batches, first of all we will need an elevator through which we will supply flour. It is best to use a chain conveyor. You can not do without the unit for pre-training and purification of raw materials for grinding. The grain will be cleaned of harmful impurities by about 80-95%, after which it will go to varietal grinding.

You can buy a PTMA-4 machine that can process more than a ton of grain per hour. The cost of such a unit is approximately 500-600 thousand rubles. It is impossible not to say about the main equipment - the mill. You can use an F1 farm mill worth 400-450 thousand rubles. This is a high-performance unit that will allow you to get flour of the highest, first and second grade. Processes approximately 500 kilograms of grain per hour. Such a mill is small in size, so additional organization of the industrial premises is not required.

But it is worth saying that the process of flour production does not end with the above equipment. You will need to purchase sieve as well as air separators. The latter remove third-party inclusions using air currents. You will also need platform industrial scales. Today they can be bought for about 30-40 thousand rubles.

It is advisable to acquire a machine that will automatically sew up bags of products. The price of such a unit ranges from 15 to 20 thousand rubles. By the way, the production of vitamin flour, as well as any other, especially when it comes to large batches, should include an automatic filling machine that does not require human intervention.

Preparing grain for grinding

Thanks to modern equipment, the preparation and the actual processing are carried out fully automatically. There are several stages of grain processing before grinding:

  • Preparation for grinding.
  • Grinding into flour.
  • Package.

The quality depends on how well the first stage is performed. finished product. The process begins with the formation of a grinding party. In fact, this is the selection of grain that will be processed in a given batch. Then the raw material is cleaned of impurities by wet and dry surface treatment. Let's look at each stage in more detail.

To obtain a product with optimal baking characteristics, it is necessary to form a grinding batch. This is done quite simply: grain of different quality is mixed, thus it is possible to achieve stable properties of raw materials. The next step is to remove impurities. Here you can use different technologies. Air sieves can remove light inclusions. The principle of operation is extremely simple. Air flow supplied certain power, which is not enough to remove the grain. As for sieve separators, they are needed to remove large and medium inclusions.

It is worth noting that the beard and groove of the grain have a decent amount of dust and dirt that was not removed during the primary processing. For this simple reason, raw materials for the production of flour are processed in a dry way in scouring and brushing machines, which work on the principle of abrasion of grain and removal of all inclusions from the surface. Often this is quite enough to obtain high-quality flour.

Technological scheme of flour production

Modern equipment, as well as proven technologies, make it possible to produce high-quality goods from grain. To do this, we will use a high-performance mill, for example, a farm mill F1, or any other with similar technical characteristics. First of all, the flour is fed from the elevator to the flour mill, and then it is loaded into silos. The latter have gravity pipes through which grain of different grades is passed, thereby forming a grinding batch.

Each flow of grain going through the pipe is cleaned and, if necessary, heated (in the cold season). On the last step raw material from magnetic separators goes to hydroprocessing. The prepared grain is sent for softening to silos, where it stays for some time before entering the scouring machine. After that, the raw material is slightly moistened and sent for a short-term softening. After some time, the grain is fed to a weighing device, and then for grinding in a torn system.

This is where the most interesting thing happens. The fact is that the flour production technology is such that it is impossible to obtain a high-quality product in one stage. Therefore, at the first stage, large and small particles, as well as flour, are obtained. And on the second, the particles are re-processed, after which they are enriched and subjected to grinding. Further, in whipping machines, the product of the required fraction is obtained, where, in fact, quality control is carried out. Then the flour enters the magnetic separator and is sent along the conveyor for further packaging. That, in principle, is all about the technological scheme.

Coniferous flour: production and features

Tree greens contain a variety of amino acids that are essential for normal functioning organism. Vitamin flour is mostly given to livestock or poultry as a dietary supplement. This is due not only to the low cost of the product, but also large quantity it contains carbohydrates (up to 80%) and protein (6-10%). Let's see what are the features of manufacturing such a product.

Everything is somewhat simpler here, due to not so tight control. If you want to establish the production of such a product, you can use a mobile unit, which is mounted on a tractor sledge, or a stationary, more expensive and productive one. But in any case, the principle is the same. The coniferous foot falls into a special bunker, where it is separated from the branch. Then comes drying and grinding to a given fraction.

After that, the raw material enters the hopper-cyclone, where, in fact, it turns into flour. It is worth paying attention to the fact that the wood foot must be thoroughly dried. For this, there is a special dryer, the coolant temperature of which reaches 300 degrees. The production of wood flour and coniferous flour is carried out in almost the same way. Even the temperature and final moisture content of the raw materials are at the same level.

It is worth noting that it is better to collect the foot for manufacturing in the autumn-winter period. This is due to the high content of useful substances, for example, carotene, amino acids, etc. Do not forget that you need to store coniferous flour a little differently than rye or wheat flour, since it is necessary to control the carotene content. When stored in paper or plastic bags for two months, the carotene level should not fall by more than 20%. In principle, the production of grass flour is good where agricultural land is highly developed. With that figured out, let's move on.

About fishmeal

As noted above, fodder varieties of flour are distinguished by the fact that they have a high content of nutrients and can be made from relatively inexpensive raw materials. Feed fishmeal contains up to 60% protein, which is several times more than if we talk about grass meal. As you can see, it is made from fish or waste. Most attention is paid to drying with simultaneous removal of fat. It is worth noting that it is more preferable to apply a vacuum during the removal of excess moisture.

The production of fishmeal takes place in several simple steps. At the first raw material is boiled. On the second, it is dried and crushed at a given temperature. The last step is to remove the fat. The advantage of vacuum processing is that all useful nutrients such as proteins, vitamins and trace elements. As a rule, drying lasts about 200 minutes, but this depends on the fat content of the raw material. The higher the percentage, the longer the heat treatment lasts. Almost always try to remove as much fat as possible. This is because given element, more precisely, its large inclusion in the composition of flour, significantly reduces the shelf life of the product.

Bone meal: advantages and features of production

The raw materials for meat and bone meal are the bones of dead and unfit for human consumption animals. It can be large and small cattle. The resulting product is used as a vitamin supplement for food for cats, dogs, livestock or poultry. Such a product is extremely rich in phosphorus. It is worth noting that the production of meat and bone meal is often difficult due to the fact that raw materials undergo a thorough analysis of sanitary and veterinary services. In general, the manufacturing process of the finished product is very simple. The bones are first crushed, then they enter the drying and cooking unit. Then a special pump grinds the raw material to a homogeneous mass.

Only then do the bones enter the centrifuge to remove moisture and fat. The raw material is re-dried, after which it is sent to the crusher for final grinding. In general, the production of bone meal is quite simple, and the equipment will cost about 500-600 thousand rubles, meaning a complete production line. But then again, it hardly makes sense to organize such a business in the center of Moscow. It is better to choose a place where with sales finished products there won't be any problems.

A little more about the equipment and its characteristics

Let's talk about how the finished production line should look like. Since we have already discussed the necessary equipment for the production of flour, now we will consider only the sequence of installation and some features of the line. In order to perceive information a little easier, let's divide the equipment into 3 groups:

  • initial complex;
  • central complex;
  • final complex.

The first includes equipment for the preparation and processing of grain. Silos are installed here, transporting devices, most often these are belt or chain conveyors. Next are machines for removing impurities from grain, and immediately after them are devices for hydrothermal surface treatment (grooves and beards) from dirt and dust. Sometimes there are also units for the mechanical processing of raw materials. At the very end of the complex there is a device for dosing and quality control of the product.

Since the production of wheat flour is a complex and responsible process, the most expensive equipment is in the central line, which is often called the main one. As a rule, these are about 3-5 (depending on performance) torn machines. Each has magnetic separators and roller machines, as well as sieve machines. The complex necessarily contains whip and brush machines, which are necessary for processing large particles of grain.

The final piece of equipment is the simplest. It contains aggregates for flour weighing, dosing and mixing. Special large containers are also installed for storing finished products. Packing machines are sometimes not installed. In this case, it is necessary to hire several workers who will be responsible for the final packaging and packaging of flour. In principle, for 20-30 thousand rubles, you can put an automatic machine that will sew up the bags.

A few important points

It is worth noting that as an aspiring entrepreneur, many difficulties will await you. First, they are competitors. Today it is not so easy to promote your product. This is due to the fact that there are a lot of manufacturers, and everyone is trying to sell their product. Do not forget that among the main distribution channels are:

  • local and regional bakeries;
  • private confectionery shops;
  • factories for the production of pasta;
  • agricultural land owners.

As practice shows, it is best to open your own point in the market. This is due to the fact that flour of different varieties is well bought both for preparing various dishes and for adding to livestock and poultry. You can still conclude several agreements with grocery stores, but this will take a lot of effort.

It should also be noted that the production different types flour requires modern equipment. Despite the fact that the principle of manufacturing the product is approximately the same, the production line will be slightly different.

For example, the production of high-quality rye flour requires equipment worth 1-1.3 million rubles, and a herbal-based product can be made by spending half as much. This suggests that you need to start with one thing. If you want to make premium, first and second grade flour for sale to confectioneries and bakeries, then buy the appropriate line. In a year or two, when the line pays off, expand your own plant.

A little about the initial costs and other important details

You will spend most of your time searching for industrial premises. It is best if there is a warehouse right there, from where you can carry out wholesale sales. Buyers especially appreciate a product that just rolled off the assembly line, believe me, this is true. The room must be carefully prepared: clean, remove moisture, install forced ventilation to exclude the possibility of insects. After that, you can safely register your business. All this will take you about 200-300 thousand rubles. The initial batch of raw materials with a plant capacity of 85-90 kg / hour of flour will amount to 200 thousand rubles.

Since the equipment production line quite complicated, it is not possible to install it yourself, so installation and commissioning works will cost an additional 100,000 rubles. Well, the equipment itself, as noted above, is about 1-1.3 million rubles. As a result, the initial investment will amount to 1.7-1.8 million rubles. At this rate, for a month you will have a net revenue of 200,000 rubles. Under favorable conditions, you will get a profit in a year and will be able to gradually expand production.

So we talked about how flour is produced different quality, purpose and cost. At first glance, everything may seem very complicated, but when it comes down to it, you will realize that this is not entirely true. All equipment is almost fully automated, so you don't need many employees.

The most important thing is not to save and not to abuse. Each stage of production must be controlled, because only in this way you can get something suitable. Well, you don’t have to worry too much about sales, because good product in any case, find a buyer. Conclude several lucrative contracts and become a reliable flour supplier. Over time, the fame of the quality of your product will spread to all bakeries and confectioneries of the city, after which there will be no end to buyers. We will have to significantly increase the range and quantity of products produced.

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