How to open a workshop for the production of dumplings? Technology, equipment. How to open a sausage shop - instructions

Sausages made from poultry, liver, brawn, blood, boiled, smoked sausages are products of daily demand. Not only large meat processing plants can produce them. A mini-workshop will do an excellent job of producing such an assortment.

But the official opening of a sausage shop from scratch is associated with certain difficulties: obtaining permits, high competition in the market. It is easier to deal with them if you pay great attention to the quality of the product and its promotion on the market. A workshop should be opened if there are sales channels.

Market analysis

Sausages occupy fourth place in consumption among Russians after dairy products, vegetables and fruits, and bakery products. This market is experiencing constant growth. The development of the market for sausages and meat delicacies is determined by the development of the raw material base and the solvency of the population.

Sausages predominate in the structure of sold products of the meat processing industry, and among them, buyers give preference to cooked types. Surveys of Russian buyers indicate that the taste of the product is most important to them, followed by freshness, composition of raw materials, price and appearance. Therefore, homemade sausages are popular among the population.

Market analysis is necessary to develop a competent strategy for developing your business and determining the optimal range of products. It should be carried out depending on the level and scale of production. If an entrepreneur operates only in his locality, the local market should be analyzed. If you plan to enter regional, national or international markets, you should first analyze them. Market analysis includes studying demand, how it is satisfied, analyzing competitors, risks and opportunities.

Based on the results of the analysis, the range of sausage products and ways to sell them are determined, and a pricing policy is developed to ensure prompt sales of finished products.

Depending on the planned production volumes, a retail or wholesale strategy or a combination of both is developed.

Sausage production as a business should begin with drawing up a business plan. It is necessary for the entrepreneur himself to assess the feasibility of his project and the rational construction of a business model. Investors and lenders will want to familiarize themselves with it if they plan to raise borrowed funds.

A business plan is a document that describes the project idea, business processes and ways to achieve the goal. It analyzes all the strengths and weaknesses of the future business, possible difficulties, problems, and ways to solve them. A business plan answers the question of whether the project is worth investing in. Planning is a management tool for a manager.

The classic version of the business plan structure is as follows:

1. Introductory part.
2. Product Description.
3. Market analysis, planned marketing strategy.
4. Plan for organization and development of production.
5. Organizational plan.
6. Financial plan.
7. Conclusion. Expected result and prospects.

What permits are needed to open a sausage shop in Russia?
Before starting work, you must register as a business entity. To do this, you need to decide on the organizational and legal form of doing business.

In the Russian Federation, an individual conducts business by registering as an individual entrepreneur or organizing an enterprise - a legal entity.

An individual entrepreneur has the right to conduct any business that is not prohibited by law, to engage in economic activities from the moment of registration, confirmation of which is a certificate issued by local government authorities. To conduct licensed activities, you must purchase a license. An individual entrepreneur does not register start-up capital and organizes a business using personal funds or loans. He independently manages the business, receives profit in the form of remuneration, bears full personal responsibility, and is liable for his obligations with all his property.

The individual entrepreneur does not keep accounting records. Tax accounting has been simplified for him; it is necessary to regularly fill out the Book of Income and Expenses. There are no restrictions on cash payments for individual entrepreneurs.

An individual can become a founder of an enterprise - a legal entity, individually or in cooperation with other individuals and legal entities.

By uniting, the founders develop the charter of the future company, form the authorized capital necessary to start operations, and register their enterprise.

They jointly make decisions on development prospects, management of the organization, acquisition of fixed assets, and distribution of profits. Profits can be distributed among the founders in proportion to their participation in the formation of start-up capital or reinvested in the business. The owners of the company are jointly liable for their obligations.

After registering as a business entity, you must:

1. Select a production facility.
2. Obtain permission from Gospozhnadzor.
3. Select and install the necessary equipment, perform a test run.
4. Draw up technological maps for the entire range of sausage products. This should be performed by a professional technologist.
5. Find suppliers, purchase raw materials to produce a trial batch of products.
6. Obtain permission to start work from the sanitary and epidemiological station and veterinary service.
7. Receive quality certificates for the entire range of products.
8. Recruit, train, test staff.
9. Launch the workshop.

According to Russian legislation, consumer goods must be labeled and have a certificate of conformity. The label contains information about the composition of the product. There are two types of certification:

• for compliance with GOST,
• for compliance with the declared declaration.

Obtaining a Gosstandart certificate is beyond the capabilities of a mini-workshop. To do this, you need to have your own laboratory and fulfill many requirements. For a start-up sausage shop to operate, a certificate confirming that the quality of the product meets the declared requirements is sufficient.

To obtain certificates, submit the following documents:

• statement of intent to obtain certificates;
• constituent documents;
• documents confirming the rights to the production premises (lease or sale agreement);
• sanitary passport of the premises issued by the SES;
• list of certified products;
• regulatory and technological documentation for products;
• documents that confirm the quality of raw materials, certificates for raw materials and packaging;
• expert opinions;
• samples of products subject to certification;
• certification agreement.

How to properly set up sausage production

The key to business profitability is its rational organization. Compliance with sausage production technology, hiring qualified personnel, using high-quality raw materials and modern equipment allows us to produce excellent products that are popular among customers.

At the same time, along with ensuring high sales volumes, unnecessary expenses should be avoided and production costs should be reduced.

Should the premises be purchased or can it be rented?

Sanitary standards do not allow the location of a sausage shop in a residential building, premises of former kindergartens, bathhouses, or other public institutions. The minimum area of ​​such a workshop must be at least 50 square meters. m.

Sausage production must be organized so that the flow of raw materials does not intersect with the flow of finished products. This is the requirement of the SES. Therefore, the sausage shop must have the following premises:

• workshop for processing raw materials;
• premises for storing raw materials, with spices and other components stored separately from raw meat;
• dishwashing room;
• production workshop where raw materials are processed;
• thermal shop;
• finished goods warehouse;
• utility room for storing tools and equipment;
• household premises (shower room, bathroom, storage areas for work clothes, cleaning equipment).

In practice, to ensure the availability of all workshops and install equipment, you need a room with an area of ​​100 square meters. meters.

Utilities must be connected to it: water supply, heating, electricity, ventilation and air conditioning systems, waste removal must be organized.

Before starting work on the premises, they receive a sanitary passport and a conclusion from the veterinary service from the SES.

Why you can’t make sausages at home

According to Russian legislation, sausage products can be sold by:

• private households, if there is a surplus of products produced for their family;
• business entities, and each product must have a certificate.

The certificate is awarded to a production workshop that has been able to prove that its sausage is made from high-quality raw materials, according to the stated recipe, under conditions that allow the production of a safe product.

To do this, the SES requirements for the premises, equipment, and utilities must be met. Sausage production is not allowed in residential buildings.

Thus, it will not be possible to organize the production of sausage at home legally, since this contradicts the sanitary standards for the production of sausages and semi-finished meat products. Illegal production is a risky enterprise. It will not last long and threatens with serious fines and legal proceedings.

Purchase of raw materials

Raw materials for sausage products include:

• meat,
• lard,
• eggs or melange,
• cow's milk,
• salt,
• sugar,
• starch,
• soy protein,
• nutmeg,
• various types of pepper, other spices and seasonings,
• sodium nitrite.

Auxiliary materials (milk, sugar, salt, spices and others) are added to the minced meat to improve the taste and smell of sausages; they make the consistency more tender and increase the digestibility of the product.

To form sausages, food casings and twine are used. All types of raw materials, as well as casings and twine, must be of high quality and have confirmation of this - a certificate.

To supply meat, they enter into an agreement with farms. Raw materials must be supplied with accompanying documents, one of which is a veterinarian’s report.

All carcasses must be stamped by the farm's veterinary service, affixed at slaughter.

Equipment for sausage shop

The equipment required for the production of sausages is determined by:

• assortment of sausage products,
• planned production volumes.

The workshop must have:

• freezers for purchased raw materials;
• tables for deboning carcasses and cutting meat;
• industrial electric meat grinder;
• mince mixer;
• sausage cutter for the production of boiled sausages and pates;
• industrial syringe with nozzles for filling casings;
• thermal chamber;
• freezer for finished products;
• smoking equipment if you plan to produce smoked products;
• trays for minced meat;
• frames for hanging sausage loaves.

All devices must have a certificate confirming that they can be used in the food industry.

When purchasing equipment, you should consider its characteristics, not the brand. The degree of automation of technological operations significantly affects productivity. The use of universal machines for sausage production, modern automated lines, and improvement of technical processes reduces costs and improves product quality.

Imported devices are much more expensive than domestic ones, but are often not inferior in reliability. Repair and maintenance of Russian equipment is much cheaper.

When purchasing equipment and any expensive fixed assets, it is advisable to consider several options:

• buying a new one,
• buying a used one,
• use under a lease agreement,
• leasing

Leasing is a long-term lease with the right of subsequent purchase at the residual value.

If funds are limited, it is often more profitable than operating lease or purchasing equipment that is already working.

High-quality production requires qualified employees

Before launching a mini-workshop for the production of boiled-smoked sausages, it is necessary to recruit qualified personnel. In addition to the manager, the workshop requires:

1. A technologist who monitors compliance with technology, compliance with product manufacturing recipes, and the quality of finished sausage products.
2. A deboner or butcher is engaged in cutting carcasses, deboning, and preparing meat.
3. Delivery driver, delivers raw materials and finished products.
4. An accountant, he keeps records, prepares and submits financial and tax reports.
5. Support workers.
6. Purchasing and sales managers. At first, their functions can be performed by the workshop manager.

They are looking for personnel through recruitment agencies, acquaintances, placing recruitment advertisements on the Internet and in print.

If you search through the Employment Center, you can save on taxes charged on the payroll of an employee hired through the employment service.

Recruiting staff is a difficult process that requires patience and a responsible approach. The success of the entire enterprise depends on the competence of the workforce and its professional approach to work.

The relationship between the administration and employees is regulated by the Labor Code of the Russian Federation. The order of the enterprise approves the staffing table. The number of employees depends on the planned production volumes and the shift schedule of the workshop. It should be taken into account that labor legislation establishes working time standards. The employee has the right to annual leave. A daily time sheet is kept for each worker.

The hiring of an employee is approved by order of the manager. It indicates the following data: from what date the employee enters the workplace, for what position, full or part-time, salary.

The order is issued after receiving an application from a future employee with a request to hire. The following must be attached to the application: a certificate from the tax service confirming the assignment of a taxpayer identification number, a copy of the passport, and educational documents.

Employees of food industry and trade enterprises must present a personal health book, which is permission to work. Before starting work, the employee must read the job description and undergo training on labor protection and fire safety.

Technology and process of sausage production in a mini-workshop

Like any production process, the production of sausages must be described, approved and strictly followed. Technological maps are prepared for each product. Regulatory technological documents indicate the types of raw materials, their quantities, describe in detail each operation, their sequence, duration, temperature conditions, humidity.

Raw material cutting

Cutting up carcasses consists of the following processes:

• division into parts
• deboning of meat,
• vein.

For this stage, tables for cutting carcasses are used. The deboning process separates the meat from the bones. It is carried out manually by deboners using special knives, which quickly and conveniently cut meat from the bone.

Trimming is an operation in which cartilage, small bones, and tendons are removed from meat. At this stage, the meat is sorted:

1. High-grade raw materials include muscle tissue without streaks, fat or films.
2. First grade meat contains muscle tissue with no more than 6% of veins, films, and fat.
3. Various inclusions up to 20% are allowed in the composition of second grade meat.

The process of making sausage in a mini-workshop

The general scheme for preparing sausage is as follows:

• grinding of prepared raw materials;
• adding salt, spices;
• maturation;
• re-grinding, mixing with bacon, water, ice;
• stuffing the casings with minced meat (injection);
• mating;
• draft;
• heat treatment: cooking, smoking, roasting;
• cooling, storage.

Premium boiled veal sausage ingredients:

• beef meat (possibly veal) of the highest grade, trimmed 0.25 kg;
• lean, trimmed pork meat 0.3 kg;
• fatty trimmed pork meat 0.15 kg;
• backfat 0.18 kg;
• boiled beef and pork tongues 0.1 kg;
• chicken eggs (possibly melange) 25 g;
• table salt 22 g;
• sodium nitrite 0.06 g;
• sugar, glucose 1.1 g;
• mixture of crushed peppers (black, white) 0.85 g;
• cardamom or nutmeg 0.55 g;
• pistachios, peeled 2 g.

Loaves are formed using shells:

• beef blues (dead ends),
• artificial film pipes with a diameter of 65-120 mm.

Boiled sausages are made from fresh meat, cooled, frozen or chilled. They contain pork, beef, meat of other farm animals, offal, blood, plasma, protein preparations from soy. Spices, wheat flour, starch, melange, and eggs are added to the sausages. The cooking recipe depends on the specific product. Schemes for the production of the popular doctor's sausage are similar to the production of other boiled sausages.

Their production is carried out in the following sequence:

1. The trimmed meat is cut into pieces up to 1 kg, then sent for salting. It is salted in pieces or crushed, kept at a temperature from 0 to +4 ⁰С. Salting time is from 6 to 28 hours depending on the size of the minced meat particles. Lump meat is salted for the longest time, from 48 to 72 hours.
2. Mix lean meat, minced using a 2-6 mm grid, beef, lamb, lean pork, cold water, ice, phosphates, protein stabilizer, soy proteins in gel form. The mass is stirred for 3–5 minutes, then lean pork meat, spices, ascorbic acid, and butter are added if these ingredients are required by the recipe. Then stir the minced meat for another 3-5 minutes. Starch or flour is mixed in 2.5 minutes before the end of processing.
3. Water is added to the minced meat according to the recipe. Ice is used instead of water, partially or completely, to reduce the temperature of the minced meat. Milk is used in doctor's sausage and some premium products.
4. The prepared minced meat is filled into the shells, ensuring a dense filling. From loaves in a natural shell, air is removed by piercing it.
5. After knitting, the loaves are hung on sticks so that they do not touch each other. The sticks are fixed to the frame. To compact the minced meat and dry the shell, the loaves are left for 2 hours at a temperature from 0 to +4 ⁰С.
6. The loaves are fried, then boiled in water or steam in steam chambers. The temperature regime and duration of processing depend on the thickness of the shell and the size of the loaf.
7. After heat treatment, the loaves are kept for 10 minutes under a cold shower, then at a temperature of +8 ⁰C and a humidity of 95%. The temperature inside the loaf should be no more than +15 ⁰С.

Sausages with damaged or contaminated casings are discarded. Control of finished products is carried out according to organoleptic and physico-chemical indicators.

High-grade sausages are stored hanging on a frame for no more than 72 hours at a temperature from 0 to +8 ⁰С, of which no more than 12 hours - at the manufacturer. Air humidity should be maintained at 75 - 85%. Sausages of lower quality (grade 1, 2, 3) are stored in the same conditions for no more than 48 hours.

For transportation, boiled sausages are packaged in 20 kg boxes in cardboard containers or in plastic return boxes with a capacity of 40 kg of sausage. Each unit of container is marked with the following:

• the enterprise and its trademark;
• name, type of sausage;
• date and time of manufacture;
• net and gross weight;
• type of container.

Cooked-smoked products

Ingredients of cervelat, premium boiled-smoked sausage:

• premium trimmed beef meat 0.25 kg;
• Premium quality lean pork meat, trimmed 0.25 kg;
• fatty trimmed pork meat or pork belly 0.5 kg;
• table salt 3.5 g;
• sodium nitrite 0.1 g;
• sugar 2 g;
• ground black or white pepper 1.5 g;
• cardamom (nutmeg) ground 0.3 g.

Sausage loaves are formed using artificial casings with a diameter of 45 mm to 65 mm, lamb sinyuga (dead ends), beef rounds No. 3, 4, 5.

For boiled-smoked sausages, cooled, chilled or frozen meat is used. Pork belly should contain no more than 25% muscle tissue, be of dense consistency, and the bacon should be lightly salted or fresh.

The simplified hardware and technological scheme for the production of boiled-smoked sausages is as follows:

1. After trimming, beef and pork (each type of meat separately) are cut into pieces of 400-600 g and ground in a meat grinder with a 16-25 mm grid.
2. The meat is kept at a temperature from +3 to +4 ⁰С for 48–72 hours. If the meat is salted in pieces, then it is kept for up to 5 days.
3. The semi-finished product is ground again to a particle size in accordance with the specific type of sausage. Lean pork and beef are ground to 2 mm. For lean pork, install a 9 mm grill. Fatty pork, beef lard for Minskaya, Ukrainian, Salami, Cervelat sausages are crushed to a piece size of 5–6 mm.
4. Mix chopped lamb, beef, horse meat, lean pork in a minced meat mixer for 3–6 minutes, add the necessary spices according to the recipe, garlic, nitrite (if not added during salting), add chopped lean and fatty pork in small portions, mix for another 2 minutes , add brisket, bacon, raw lamb fat. Mix in a minced meat mixer for another 3 minutes until there is a homogeneous viscous mass with even distribution of pieces of bacon, fatty pork and brisket.
5. Stuff the mass into the shell. Air trapped in the shell is removed by puncturing.
6. Leaning of loaves for 2 days at a temperature from +5 to +10 ⁰С. Minsk sausage undergoes sedimentation within 4 hours.
7. The loaves undergo primary smoking with smoke from burning sawdust from deciduous trees (beech, alder, oak) for 1–2 hours at a temperature of +75 ⁰C.
8. The smoked sausage is steamed at a temperature of +74 ± 1 ⁰С for 45–90 minutes. Using a higher temperature results in a loose consistency. The operation is stopped when the temperature in the center of the loaf reaches +60 ⁰С.
9. The sausage is cooled for 5–6 hours at temperatures up to +20 ⁰С.
10. Secondary smoking occurs within 24 hours at a temperature of +42 ± 3 ⁰С or within 48 hours at a temperature of +33 ± 2 ⁰С.
11. The sausage is dried in a well-ventilated area with a humidity of 76 ± 2% at a temperature of +11 ± 1 ⁰С for 3–7 days. As a result of drying, it should acquire a dense consistency and moisture content that meets the requirements of the specifications.

Semi-smoked sausage

Ingredients for second grade semi-smoked Polish sausage:

• second grade beef 0.6 kg;
• lean pork 0.25 kg;
• pork belly or fat tail fat 0.15 kg;
• table salt 3 g;
• saltpeter 0.75 g;
• sugar 1 g;
• black pepper 0.5 g;
• fresh garlic, peeled, chopped 0.8 g.

Cooking semi-smoked sausages is carried out in the following sequence:

1. After trimming, the beef and pork are ground in a meat grinder with a 16–25 mm grid.
2. For every 100 kg of minced meat, add 3 kg of salt and 10 g of nitrite.
3. The meat is kept at a temperature from +3 to +4 ⁰С for 48–72 hours.
4. The semi-finished product is ground again to a particle size in accordance with the specific type of sausage.
5. Add the necessary spices according to the recipe, chopped bacon and mix in a mince mixer until a homogeneous mass is formed.
6. Stuff the mass into the shell. Trapped air is removed by puncturing.
7. According to the recipe, the loaves are tied, if necessary.
8. Leaning of loaves for 4 hours at a temperature from +10 to +12 ⁰С.
9. Hang the sausage on the frames at intervals of at least 10 cm for frying. The operation is carried out from 30 to 60 minutes at a temperature from +60 to +90 ⁰С. The sausage turns red and the casing becomes dry. The temperature in the center of the loaf should not exceed +40 ⁰С.
10. The sausage is cooked in water or steam for 40 to 80 minutes at a temperature of +70 to +85 ⁰C. The duration and temperature depend on the shell. The sausage is ready when the temperature inside the loaf reaches +68 ⁰C.
11. Cooling occurs within 3–4 hours indoors at a temperature less than +12 ⁰С or under a cold shower.
12. The sausage is sent to smoking and roasting cabinets, where smoking occurs with hot smoke at a temperature of +35 to +50 ⁰C for 12–14 hours.

Sausage intended for transportation to other populated areas is dried in a well-ventilated area at a temperature of +70 to +85 ⁰C for 2–4 days. Its duration is longer, the longer the product is on the road. Sausage for local sale should not be dried if its moisture content and consistency meet the requirements of the specifications.

Quality control is carried out using organoleptic freshness analysis. It consists of assessing the conformity of appearance, taste, smell, color, consistency with those stated in the regulatory documentation. If the need arises, a chemical and bacteriological analysis is performed.

The shelf life of semi-smoked sausages depends on the temperature and humidity in the warehouse. At temperatures up to +16 ⁰С and humidity 75%, they are stored for up to 10 days in a suspended state. If stored for a longer period of time, the sausage dries out.

Raw smoked products

The difference between the technology for producing raw smoked meat products and other types of preparation is that they are not fried or boiled, but only smoked at a temperature of +25 ⁰C. According to GOST, the production time for raw smoked sausages is up to 40 days. According to the specifications, it is allowed to add starter cultures and food additives that accelerate the ripening of meat. The product is ready in 20 days.

For raw smoked sausages, produced using classical technology in accordance with GOST, premium meat, table salt, bacon, spices and herbs, sodium nitrite, and sugar are used. Sausages are prepared from the meat of any farm animals. According to the technical specifications, the use of low-grade meat, starch, flour, soy preparations, stabilizers, flavors and other additives is allowed.

1. During deboning and trimming, raw meat is cut into pieces of 0.3–0.6 kg and sent for salting.
2. After adding salt according to the recipe, the meat is kept for 5–7 days at a temperature from 0 to +4 ⁰С.
3. The salted meat is ground in a meat grinder or grinder with a hole diameter of 2–4 mm.
4. The chopped raw meat is mixed in a minced meat mixing machine, gradually adding additives, spices, and all ingredients according to the recipe, for 5–10 minutes.
5. Minced meat in a layer of up to 25 cm is left in containers to mature for 2 days at a temperature of +2 ± 2 ⁰С.
6. The shells are tightly filled with minced meat, the loaves are tied, clipped, and hung on frames.
7. The sausage is placed for precipitation in a climate chamber with controlled temperature, humidity, and air speed for a period of 5–7 days. The temperature is maintained from +2 to +4 ⁰С, humidity 87 ± 3%, air speed 0.1 m/s.
8. Smoking takes place on hardwood sawdust for 2-3 days at a temperature of +20 ± 2 ⁰С, humidity 74–80%.
9. Subsequent drying lasts 20–25 days, depending on the diameter of the loaf. The use of starter cultures allows you to reduce the duration of ripening and drying of the product.

Sausage quality control is carried out using the organoleptic method. The shelf life depends on the storage temperature. Raw smoked sausages are stored without loss of quality from 4 months at temperatures from +12 to +15 ⁰С to 9 months at temperatures from -7 to -9 ⁰С.

Dry-cured sausages are classified as deli meats. They are distinguished by their exquisite taste, attractive appearance, structure, and color. They are made without heat treatment from fresh meat of any farm animals, including horse and poultry. The duration of the technological cycle is the longest. Freezing raw materials for such sausages is allowed only once.

In addition to meat, minced meat for dried sausages contains table salt, sodium nitrite, starter cultures, spices, seasonings, food additives, flavor and aroma enhancers; for some sausages, wheat flour and starch are added.

During production, very high demands are placed on compliance with sanitary standards, temperature conditions, and humidity. Their violation threatens the development of pathogenic flora and microbial spoilage of sausages.

The simplified scheme of technological operations is as follows:

1. Chilled meat is salted for 4–7 days.
2. Raw meat is ground to a particle size of 2–6 mm, all ingredients are added according to the recipe, and mixed for 2–7 minutes in a mince mixer or cutter.
3. To ripen, the minced meat is laid out in a layer of 10–15 cm in containers made of food materials and kept for 12–24 hours at a temperature of +2 to +4 ⁰С.
4. Natural or artificial casings are used for stuffing. The filled shells are bandaged or clipped.
5. For precipitation, leave in a chamber at a temperature of +2 to +3⁰С for 3–5 days.
6. Drying is carried out for 30–120 days in chambers with air blowing at temperatures from +10 to +14 ⁰С. The process is stopped when the standard humidity and quality of the sausage are reached.

Finished sausages are checked for quality, packaged and sent for sale. Sausages can be stored for 6–9 months if the temperature is maintained.

Liver sausages

To make liver sausages use:

• pork liver 0.36 kg;
• meat trimmings 0.20 kg;
• pork lung 0.10 kg;
• side bacon 0.10 kg;
• broth, milk 0.20 kg;
• premium wheat flour 40 g;
• table salt 16 g;
• mixture of ground spices (black pepper, allspice, coriander, nutmeg) 5 g.

Liver sausages are made from pork and beef liver, offal, jowls, meat trimmings, and fat. Prepared, cut into pieces of 0.5–0.8 kg, the raw material is boiled. Remove the tendons and bones, chop them, add spices, broth, onions, and salt. The onion is added in chopped form and is sometimes sautéed according to the recipe. Eggs and milk are added to the minced meat for premium sausages. It is mixed until a homogeneous gray mass with a spreadable consistency. To form loaves, pork or beef casings, circles, artificial casings, twine or clips are used. The loaves placed on frames are sent to thermal chambers for cooking. Liver sausages are not fried. The cooked product is cooled to a temperature from 0 to +6 ⁰C in a shower or in ice water and sent for storage.

Liver sausage is stored at temperatures from 0 to +6 ⁰С and humidity 80% for 24–48 hours from the end of the technological process. The shelf life increases if the recipe provides for the addition of preservatives.

Sausages and sardels

Ingredients for premium quality pork sausages:

• lean pork, trimmed 0.930 kg;
• fatty trimmed pork, cheek, bacon trimmings 0.070 kg;
• table salt 25 g;
• sodium nitrite 0.075 g;
• sugar or glucose 2 g;
• ground black and white pepper 1.3 g;
• ground coriander 1.3 g;
• chopped garlic 0.6 g.

To fill with minced meat, use casings:

• pork or beef casings,
• artificial shells with a diameter of 32–44 mm.

The technology for making sausages and sausages is the same as for boiled sausages.

Pros and cons of the sausage business

In general, sausage production is a profitable business with a high capital turnover. Considering that food products are in demand even in economically unstable times, this is a good investment.

The following advantages are obvious:

1. With proper organization, the profitability of the sausage business is about 30%.
2. Low barrier to entry. The business is of interest to both entrepreneurs with minimal capital and large businessmen. Everyone can organize a business according to their scale. Small entrepreneurs have the opportunity to gradually expand.
3. Constant demand for products even in times of crisis.
4. It is possible to organize a business in such a way as to close the entire production cycle from raising animals for meat to selling sausages. This scheme increases profits many times over and allows you to control the quality of raw materials and finished sausages.

This direction has its own difficulties.

The main risks of this business are dependence on high-quality raw materials and a short sales period.

Disadvantages include:

1. High competition, it is difficult to find your niche and place in the market.
2. Opening a sausage shop or retail outlet requires permits. Receiving them is often delayed.
3. Constant control by the SES, veterinary service, Rospotrebnadzor.
4. It is difficult to find a supplier of quality raw materials.
5. The short shelf life necessitates the creation of a system for rapid implementation. Errors in sales organization result in serious losses. Expired products cannot be sold.

Sausage sales opportunities

Competent sales organization is a decisive factor for success in any business. It is sales that revitalize the finances of a commercial enterprise, are the source of the purchase of raw materials, equipment, and further development. Sales channels are thought out in advance, preparatory measures are carried out, and preliminary negotiations are carried out. Sausages have a short shelf life, after which the business suffers serious losses.

Sales routes depend on production volumes and product range. A variety of products and a large number of product positions make retail trade profitable. The advantage of this type of trading is the ability to sell goods at a high price. In order to sell a larger volume, it is advisable to organize a network of retail outlets.

If a workshop produces one type of sausage, it is more profitable to sell in bulk. This increases profits due to turnover and allows you to avoid the costs of organizing and maintaining retail stores.

Your own trading stall

To organize the sale of finished products from a sausage shop, it is advisable to build a network of retail outlets. The sale of cheese, sauces, ketchups and other similar products will increase trade turnover and profitability.

Organizing a retail outlet for selling sausages consists of several stages:

1. Selecting the organizational and legal status of a retail outlet. It can operate as a division of an existing business or as an independent business entity.
2. Searching for suitable premises, drawing up a lease or sale agreement. The stall can be rented or purchased as property. Permission to place it is obtained from the administration of the locality in which trade is planned. It must be located in a busy place at the intersection of pedestrian and car flows, and comply with sanitary standards for the sale of sausages. The retail outlet must have water supply, sewerage, and electrical power sufficient to connect refrigeration equipment. To start trading, you will have to obtain permission from the SES, veterinary and fire services.
3. Installation of commercial equipment. Depending on the volume of trade, financial feasibility and strategic plans, it can be rented, purchased or leased.

To sell sausages you need the following equipment:

1. Refrigerated display cases in which the temperature is maintained no higher than +6 ⁰С. It is optimal to install two display cases, but it must be taken into account that each consumes electricity, for which you will have to pay at prices higher than for the population. For the same reason, it is worth calculating whether it is necessary to sell frozen food. It requires a freezer, which means your monthly energy costs will increase.
2. Refrigerator for storing sausages.
3. Table or cabinet for scales.
4. Scales, you should purchase two of them so as not to interrupt trade in case of breakdown.
5. Different knives are used for sausages and cheese.
6. Cutting boards, at least two. They should also be different for cheese and sausages.
7. Cabinets, shelves for piece goods.

If plans include selling other goods, they make a list of them and look for suppliers. In this case, several candidates should be considered and, in addition to prices, delivery conditions should be analyzed. By selling goods purchased for sale under commission agreements or with deferred payment, they avoid the diversion of financial resources from the circulation for the purchase of goods.

Sales should be analyzed for each product item, items that sell poorly should be removed from the assortment, replacing them with popular items. The sausage loses moisture and its weight decreases. Sausages should be sold quickly, taking into account shelf life.

The revenue of a retail outlet largely depends on the seller. The buyer will definitely come shopping again and will recommend it to friends and neighbors if he was offered a quality product and received attentive service. Proper display of goods in the window is important. An experienced seller can handle this better. Price tags should be positioned so that they are easy to read. In addition to the price, the price tags indicate the name and variety. In a display case with sausages, it is better to install lamps with a warm spectrum of light. This makes the product look more advantageous.

Wholesale

Wholesale sales allow you to make a profit through turnover. Products are sold in large quantities, but the price is lower than retail. Clients are retail stores, trade stalls, supermarkets. They organize such a sales network through direct negotiations with the owners or heads of purchasing departments. First, you need to have product samples and documents, certificates confirming quality.

Profitability - calculation of profitability

Profitability is the level of profitability of a business, expressed as a percentage. It is defined as the ratio of profit, expressed in monetary units, to cost.

This complex indicator expresses the ratio of the profit received to the amount of resources used and characterizes the efficiency of the business.

It is influenced by sales volume, production costs, and, consequently, the range of products sold, labor productivity, and the effectiveness of promoting the product on the market.

The profitability of the sausage business in Russia is on average about 30%.

Advertising - without it it will be difficult to sell sausages

If an entrepreneur is forced to promote a product independently, then a certain strategy should be followed. This will allow the allocated funds to be spent more efficiently.

First of all, you should analyze your potential client. Promotional activities depend on who the consumer is: a supermarket, the sausage department of a grocery store, or a resident of a neighboring house. Specific actions should:

• inform about the product, brand, emphasize distinctive features, positive properties;
• create a positive image;
• convince potential buyers to purchase the product;
• encourage you to make a purchase now;
• remind you to purchase a product;
• reinforce positive past shopping experiences.

The advertising emphasizes the naturalness, freshness of the product, uniqueness (manufactured according to original recipes), and accessibility. The product is accessible to the end consumer when the retail outlet is located near the house, to intermediaries if delivery of the goods to a supermarket or store is organized. Advertising can emphasize adequate pricing policy.

• advertising in the media (television, radio, print media, Internet);
• outdoor (city lights, billboards, in public transport);
• internal (leaflets, business cards, booklets in shopping and business centers, elevators, etc.).

The channel is chosen based on financial capabilities and accessibility to potential buyers. Promotions and sales are informational reasons for organizing promotional events.

It is important to participate in specialized trade shows. Such participation allows you to increase sales, express yourself and your products, evaluate competitors, expand business connections, and conclude new contracts. You should prepare for exhibitions in advance, stock up on promotional materials, and analyze what range of products is appropriate to bring.

Conclusion

In general, the sausage business is a profitable investment. This is a business with high profitability and turnover. Sausages are products that are always in demand. With proper analysis and good organization, the business successfully expands, generates income for the owner, and provides customers with tasty, safe products.

* The calculations use average data for Russia

Sausage is a food product that belongs to sausage products and is minced meat from one or more types of meat, fat and offal with the addition of salt and spices, heat-treated until ready for consumption and packaged in an oblong casing. Sausage is one of the most common types of meat delicacies in our country.

Types of sausages

There are several main types of sausages, which are produced by most modern domestic producers - both small and large. The most common and inexpensive types of sausages include boiled sausages, made from salted minced meat. The most popular variety of this type of sausage in our country is “doctor’s sausage.” As the name implies, cooked sausages are cooked at a temperature of about 80 degrees Celsius. Cheap types of sausages contain, in addition to the meat itself, a large amount of soy. Due to the high water content in boiled sausage, it has a short shelf life.

Cooked-smoked sausages They are first boiled and then smoked. If boiled sausages have a uniform consistency and do not contain a large amount of spices, then boiled-smoked sausages have a more spicy taste and may consist of small pieces of meat. Milk, cream, lard, flour and starch are often used as additives in the preparation of these types of sausages.

Semi-smoked sausages, according to the recipe, they are first fried, then boiled and finally smoked. Semi-smoked sausages are not inferior in taste to boiled-smoked ones. The only difference is that when they are heat treated, the weight loss will be significantly less.

Raw smoked sausages, unlike other sausages, are not subjected to high-temperature heat treatment and contain the largest amount of spices. During the process of cold smoking at a temperature of 20-25 degrees Celsius, the meat is fermented and dehydrated. It takes about a month (up to 40 days) for raw smoked sausages to mature. This period can be reduced by adding an acid that affects the pH level and starting cultures (usually yeast microorganisms).

Dry-cured sausages(for example, salami) are made from minced marinated meat, which is smoked in cold smoke for 3-4 days and then dried at a temperature of 15-18 degrees Celsius.

Finally, there are also liver sausages, which are made from meat by-products and are the cheapest types of sausages on the Russian market.

Prospects for the sausage business in Russia

The Russian sausage market, according to research data, has been actively developing over the past ten years. The annual growth rate is about 7.5-8.0%. First of all, thanks to the stable and constantly increasing demand for meat products. In general, this segment, which has one of the highest turnover rates in the Russian food industry, is assessed by entrepreneurs and investors as promising, which explains the high level of competition in it. The domestic market is dominated by domestically produced products (its share is estimated at 99%). However, after Russia joined the WTO, the share of imports of sausage products increases every year.

The largest domestic sausage production enterprises are mostly located in the following regions: Central Federal District - 38%, Volga Federal District - 19%, Northwestern Federal District - 12%. In terms of production volumes, enterprises in Moscow, the Moscow and Saratov regions are leaders. At the same time, most of them use the capacities at their disposal by an average of 62%.

Despite the high level of competition in the sausage market, it does not lose its attractiveness for new manufacturing companies operating at the regional level. However, in order for a mini-workshop to become successful, several basic rules must be followed. First, you first need to select the segment (product and price) in which you will work. Today, the market for smoked sausages is the most promising, with a share of almost 30%. Secondly, experts advise investing in the development of your own recipes and strict quality control of manufactured products. Thirdly, you should start by searching for distribution channels and establishing relationships with grocery stores and retail chains (including super and hypermarkets).

Opening of a sausage shop

The production of sausages is a highly profitable and fast-paying business, which, however, has certain nuances and difficulties (like any other food production). Most of the difficulties in organizing it are associated with finding suitable premises for a workshop that would comply with all sanitary rules, and obtaining the necessary permits. So, for example, the building of a former kindergarten, residential premises and public institutions (rest homes, bathhouses, etc.) will not be suitable for a sausage shop. Its minimum area should be 50 square meters. meters. However, even for a small production of sausages, producing less than one ton of finished products per day, you will need a premises with an area of ​​at least twice as large - from 100 to 250 square meters. meters. If your production volumes amount to one ton of sausage per day, then the workshop area will be no less than 300 square meters. meters.

The workshop should have a low-temperature chamber for storing raw materials, one refrigeration chamber for ripening minced meat, and a second for finished products. The total area of ​​the workshop is divided into several separate zones: a department for the preparation and processing of raw materials, a raw materials workshop, a workshop for grinding, salting and preparing minced meat, a thermal department, a warehouse for dry bulk products, a room for storing equipment and other materials, a washing room for returnable containers, storage room for sodium nitrate solution, expedition. In addition, it is necessary to provide space for a locker room, shower, kitchen and bathroom, storage space for sanitary clothing and equipment. The main requirement is that during the production of sausages, the finished product should not come into contact with raw materials that have not yet been processed.

If you have not had experience in this area, it is better when choosing a premises for a workshop to seek help from an experienced specialist who can assess it for compliance with all requirements and prepare a plan for production, warehouse and office premises.

With an extremely limited budget, you can purchase a monoblock, which is a turnkey mini-workshop. To install a monoblock, you will need a plot of land with all communications connected. This option is more suitable for rural areas and small production on a functioning farm (for processing your own raw materials). However, as an independent option for a sausage production workshop, it is unprofitable.

At the next stage, when the premises have been found, you need to choose a legal form for your enterprise. This can be either an individual entrepreneur (individual entrepreneur) or an LLC (limited liability company). In addition, you will need to register with the funds (Social Insurance Fund and Pension Fund) and obtain permits to carry out your activities from various services - SES, ROSTEST, Veterinary and Fire Inspectorate. According to the Law on the Protection of Consumer Rights, products that go on sale must have a certificate of conformity and consumer labeling, by which the manufacturer can be identified. Mandatory certification of food products is carried out in one of two forms: according to the documents of the GOST R Certification System and according to the rules for product certification using a declaration statement.

Now, as a rule, large production facilities, which have a fully established production and quality control system and whose workers have the necessary qualifications, undergo GOST R certification. The difficulty lies in the fact that GOST R requires that the enterprise have a production certificate or a quality certificate issued by ROSTEST. Obviously, it is almost impossible or very difficult for a small workshop to fulfill all these requirements.

For the GOST R certification system, it is necessary to submit a number of documents: a production or quality system certificate, a product test report in an accredited laboratory, a hygiene certificate, a veterinary certificate.

Most small businesses prefer to certify their products through a declaration application. To do this, you need to contact the same ROSTEST with a statement guaranteeing that the workshop will produce safe products that comply with regulatory and technical documentation. The following list of documents is attached to the application: copies of constituent documents, lease of production space, a copy of a certificate from the SES on production permission, a list of produced food products indicating regulatory and technical documents, copies of regulatory and technical documentation (NTD) for new types of products agreed with Trade, SES and registered at the All-Russian Scientific Research Institute Standard, a hygienic certificate as a form of approval of technical documentation with the SES, a document on the enterprise’s ability to monitor physical and chemical quality indicators or an agreement with an existing laboratory, certificate documents confirming the safety of raw materials and packaging materials, samples of test products, an agreement on product certification, veterinary certificate.

After checking all the submitted documents, Gosnadzor carries out an inspection of the production with the execution of an act and, if the inspection is successful, issues a certificate of conformity. The latter can be issued for a period of one or three years. For a new small production it is more profitable to obtain a certificate of conformity valid for a year. This time will be enough to finally formulate your assortment and fine-tune all processes. The received certificate, by the way, does not at all exempt you from quarterly inspection control by ROSTEST, SES and Veterinary Inspectorate, which involves a thorough inspection of the premises and analysis of samples of manufactured products, checking their packaging and labeling. If the condition of the selected samples does not comply with established regulatory documents, the products are subject to confiscation, and for the workshop itself this is fraught with serious losses and troubles, including closure.

To make sausages you will need special equipment. The main equipment and inventory include boning tables, knives for cutting carcasses, deboning (separating meat from bones), grinding ingredients, a minced meat mixer, an electric meat grinder (grinder), refrigeration chambers, a cutter for preparing minced meat for boiled sausages and pates, a syringe for stuffing sausages. shells with minced meat, an oven with a smoke generator (it is better to give preference to a universal model, which can be used for drying, cooking, frying and smoking). You should not skimp on equipment, since it is this that determines the productivity of your enterprise. The domestic market offers equipment from both Russian and foreign manufacturers.

When choosing, experts recommend focusing, first of all, on technological indicators, and not on production. Imported cars are much cheaper than domestic ones with similar characteristics, but the latter are almost as reliable as them. An additional advantage of domestic equipment is the lower cost of spare parts and repairs, if necessary. When choosing equipment, pay attention to the material from which it is made. It should be either stainless steel or food grade aluminum.

For comparison, we give approximate prices for basic equipment. Thus, the minimum cost of a refrigeration chamber (a total of 2-3 units will be needed) is from 100 thousand rubles, a grinder - from 60 thousand rubles, a minced meat mixer for 150 liters - from 35 thousand rubles, a cutter - from 100 thousand rubles, a vacuum syringe - from 35 thousand rubles, pneumatic clipper - from 20 thousand rubles, hair cutter - from 68 thousand rubles, band saw - from 20 thousand rubles, heat chamber - from 87 thousand rubles.

It is best to purchase raw materials from domestic suppliers - wholesale companies and farms. Please note: all products you purchase and components of the finished product (even sausage casings and sausage dressing threads) must have certificates confirming their origin and quality. To check the authenticity of the documentation and the quality of the raw materials, you can contact the services of a commodity doctor or a sanitary doctor who understands all the nuances. When purchasing small quantities of meat from farms, medical examination can be carried out during production by concluding an agreement with the veterinary and sanitary laboratory of the regional food market. Specialists from the local laboratory will carry out all the necessary tests and stamp it.

Many manufacturers prefer to purchase raw materials abroad, which entails additional costs for obtaining a special permit to import them into Russia. To obtain such permission, you must submit a written application to the veterinary service of your region (region or republic) at least thirty days before importation, indicating the characteristics of the imported products, the place of their storage, quarantine, processing, purpose of import, and country. It goes without saying that this raw material must have all the necessary documents: a general certificate or a certificate agreed upon with the veterinary service of the exporting country, agreements (treaties, protocols, conventions) between the veterinary services of our country and the exporting state.

To work in production you will need employees. First of all, you cannot do without the help of a technologist who will control the quality of products and prepare recipes for sausages, butchers for deboning meat and cutting carcasses, if you do not plan to purchase already prepared meat, a forwarder, a mechanic, general workers, and an accountant. The functions of managers for the purchase of raw materials and sales of finished products can be taken over for the first time. Modern automated equipment allows significant savings on labor costs. No more than five people will be required to operate one production line. But you shouldn’t skimp on the specialists themselves. Give preference to qualified and experienced workers. Then you will not have to worry about the quality of the products you produce.

However, producing a high-quality and tasty product is only half the battle. It is also necessary to establish its sales. The main sales channels for sausage products are grocery stores, kiosks and stalls, super- and hypermarkets, as well as catering establishments. The most difficult thing is to get on the shelves of super- and hyper-markets, although, for obvious reasons, every manufacturer dreams of this. To do this, you will need to ensure large volumes of supplies, pay for placing your goods on the network, and also agree with an authorized person who is responsible for the assortment of the retail network.

Renting shelf space, for which an agreement is concluded with the network, will cost a decent amount - from 3 to 10 thousand rubles per square meter of display, depending on the type of product. In the case of a new product that is still unknown to the consumer, paying monthly or annually for a shelf may not be profitable. Ideally, it is better to display your product in networks where there is a single fee for joining the network. However, keep in mind that with the latter option, a change in management is possible (which happens quite often in large chains), and proving to the new person in charge that you have already made your single contribution may be problematic and you will have to pay again.

A high entry threshold, the requirement for large volumes and stable supplies, deferred payment (minimum 60 days) - all this makes it much more difficult for small industries to enter the network. In addition, most hyper- and supermarkets, as well as regular retail chains in the “convenience store” format, produce goods under their own brand for the most popular food items. If there is no other option, you can try to offer them to sell your products under their own brand. Keep in mind that if your product does end up on the supermarket shelves, but turns out to be unmarketable, the chain will simply terminate the contract with you.

So, let's calculate our expenses and possible profits. Let's take as an example a mini-workshop with an area of ​​50 square meters. meters (minimum area) with a capacity of 200 kg of sausages per eight-hour shift. Renting such premises will cost from 120-130 thousand rubles per year, depending on the location. To open such a small workshop for the production of sausages, you will need from 550 thousand rubles. This amount includes registration and registration of the enterprise, rental of premises (conditionally ready for operation as a workshop), purchase of equipment, raw materials and wages to employees for the first time. Ideally, the reserve for the first months should, of course, be larger. Experts advise having enough funds for at least six months of uninterrupted operation of the workshop when reaching zero.

Monthly costs include the cost of purchasing raw materials, utilities, rent and wages. However, most likely, you will not need this supply. A sausage shop has a very high profitability, which can reach 30% (however, in fact this figure is rather closer to 25%). The payback period is, under favorable conditions, three months.

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After Russia introduced protective sanctions against the EU, high-quality sausages almost completely disappeared from store shelves. The expected import substitution never happened - the stores were filled with low-quality products from domestic producers, who decided to reduce the cost of production as much as possible by adding vegetable fats and fillers to the sausages. There is an acute shortage of quality meat products on the market. That is why now is the time to open your own mini sausage production workshop and take your place in the sun.

Market analysis

First of all, study the market situation. There may already be a sausage maker in your area. Find out exactly what products he produces, what his price range is, how production is organized. Visit several large stores, find out prices for sausage products, think about where you can deliver the finished products.

Sausage production workshop is a profitable and affordable business

Room

For a small workshop, you need a fairly spacious room that is not combined with a residential building. You should not look for premises in the city center - the outskirts or even a building in a nearby village will suit you.

In the building you will need to place:

1. Refrigeration units for storing incoming raw materials.
2. Special cooling chambers for minced meat and finished products.
3. Separate room for meat processing.
4. Separate room for defrosting raw materials.
5. Separate premises for the production of sausages.
6. Separate room for storing spices.
7. Product heat treatment workshop.
8. Utility room for storing materials and tools.
9. Separate room for washing equipment.
10. Premises for domestic purposes.

Your premises should be quite spacious - usually a mini-workshop occupies approximately 200 m2. Some premises can be combined with each other, but when planning it is better to consult with the local sanitary and epidemiological station so that in the future you do not have to redo the workshop.

Before opening, you will need to draw up a technical specification, indicating the volume of processed products, the range (approximate), make a list of the equipment used and describe the technological process. Then the terms of reference are agreed upon with the SES and the local veterinary service, and only after that can further actions be taken.

What documents are required

First of all, you need to go to the local tax office and register as an individual entrepreneur or LLC. You will also be given the appropriate codes that you can use. Are you interested in:

1. OKVED 15.13, allowing the production of meat products.
2. OKVED 15.13.1, which allows the production of products from meat, offal and blood.
3. OKVED 15.13.9, which allows heat treatment of meat.

Never skimp on raw materials - they must be fresh and have quality certificates

At the same time, registration is taking place with the pension fund, sanitary and epidemiological station and veterinary supervision. At the end, the premises are inspected by fire inspectors.

You will also need to obtain certain certifications. Thus, according to the law, all meat products must receive a quality certificate. There are two options here:

1. If you are going to work on an industrial scale, you will need to go through the GOST certification system. Such certification is usually issued at factories that produce a large number of products.
2. If you plan to work in your city or region, you can certify sausages by application and declaration. You simply draw up a statement in which you indicate that you are going to produce high-quality sausage, which is guaranteed to meet all requirements.

Where to get raw materials

If you are going to produce high-quality sausage, then your raw materials must be high-quality. You need to establish contacts with local farmers who sell wholesale meat in whole carcasses. This is why a sausage production workshop in the village is more preferable than in the city - you can buy the freshest meat right next door.

Read also: How to open a waste processing plant: business plan

You need to find high-quality, certified raw materials that meet all standards. What kind of meat do you need? Any: pork, beef, chicken, lamb, horse meat, etc.

For high-quality sausage, meat from young animals with a low fat content is usually chosen. If necessary, it is better to add fat or lard separately according to the recipe.

Note: Depending on the type of sausage, you will need defrosted, steamed or chilled meat. It is necessary to properly organize delivery and storage so that you always have the necessary raw materials.

To create low-calorie and dietary products, milk, starch, flour, melange, cereals, and soy can be added to minced meat. Additionally, various seasonings are added to the meat: nitrite salt, ascorbic acid, herbs, spices, sugar, phosphates.

The workshop should be divided into several separate rooms

How does the manufacturing process work?

The cooking process consists of several stages:

1. Dismemberment of the carcass. The whole carcass is divided into parts according to the instructions. The beef carcass is cut into eight parts, the pork carcass into five.
2. Boning. At this stage, workers cut the meat from the bones using special knives. The final yield of meat and its quality depend on the quality of work of the deboners.
3. Zhilovka. At this stage, various veins, cartilage and small bones are removed from the meat. After trimming, the meat is sorted depending on quality and fat content.
4. Grinding. The meat is minced using special machines for further processing. Then the minced meat is matured (it is salted with nitrite salt and placed in the refrigerator). Aging meat is necessary to maintain its color, flavor and stickiness.
5. Re-grinding. After the meat has matured, it is ground again and kneaded in a cutter. Also, during repeated grinding, various spices and additives are added to the minced meat.
6. Syringe. Ready-to-use minced meat, which, when mixed, has turned into a uniform emulsion, is syringed into casings of various types and diameters.
7. Dressing. To ensure the strength of the sausage, it is tied with a special twine or a mesh is put on top.
8. Smoking. If smoked sausages are made, they are sent to special chambers in which they are smoked for several hours at a low temperature.
9. Heat treatment. Boiled sausages are steamed or boiled in water at temperatures up to 70 degrees. When the temperature inside reaches 70 degrees, the sausages are removed, dried and stored.

This is how the process of preparing most types of smoked and boiled sausages goes. Dried products are prepared in a special chamber - they dry for about 30-40 days at constant humidity, which avoids hardening and swelling.

List of required equipment

Let's look at what equipment you will need to purchase for the production of sausages. We make calculations for a small workshop producing boiled and smoked products, which are the most popular in our time.

Don’t skimp on equipment – ​​it will quickly pay for itself

You need to purchase:

1. Defroster/defroster - 2,600,000 rubles.
2. Grinder type meat grinder for grinding large pieces of meat - 800,000.
3. Apparatus for dosing and twisting minced meat - 800,000.
4. Special conveyor for boning and trimming work - 650,000.
5. Ice maker - 300,000 rub.
6. Cutter (grinding minced meat and turning it into an emulsion) - 800,000.
7. Chopper for chopping frozen blocks - 500,000.
8. Vacuum syringe for stuffing – 500,000.
9. Vacuum device for packaging finished products - 300,000.
10. Chamber for cooking sausages - 2,500,000.
11. Chamber for smoking sausages - 2,500,000.
12. Chamber for drying sausages - 2,500,000.

Recently, retail chains have been actively developing in Russia; in Moscow alone there are already more than ten of them (“Metro”, “Auchan”, “Kopeyka”, “Seventh Continent”, “Twelve Months”, “Ramstore”, etc.). The product range offered in these stores exceeds thousands, even tens of thousands of domestic and foreign food products.

Nowadays it has become important for retail chains not only to sell, but also to produce products with high added value. Moreover, making a decision to produce products under your own brand is only the beginning of the journey.

WHERE DO WE START?

How to organize and staff a workshop that will expand the range by producing competitive products, while saving nerves, money, and vitality for solving other, more important issues?

You have decided to organize a workshop for the production of semi-finished meat products, semi-finished fish products, fish production, chilled salads or a workshop for the production of cookies, bread and bakery products. What should you start from?

• the equipment of the workshop, which is located within the retail outlet and in a separate room, is practically no different from each other;
• if the production unit is separated (located at some distance) from the distribution network, then it is necessary to think through the system of transportation and sales of products;
• if the production premises are located within the sales area, an established sales system and the absence of transportation costs will undoubtedly lead to higher profitability;
• it is necessary to decide on the initial data, that is, “what to start with”: the raw material base, the availability of certain types of equipment, technologies, and the sales system. In this case, the main starting point is often an established sales system, a well-proven brand, and, less often, equipment and technology (a set of basic knives, slicers, cutting tables is available in every supermarket).

Therefore, at the next stage, the question of organizing a workshop moves to a new level: how to assemble equipment, select an assortment, master technologies, certify products?

Since resolving such issues requires a balanced approach, it is necessary to turn to professionals who will help optimize production and reduce the time spent searching for equipment, technologies, and product certification.

– We are very often approached by specialists who are tasked with organizing a workshop, which is called “without leaving the cash register.” At the initial stage, we determine which group the workshop belongs to. The workshops are divided into several groups: according to production volumes and assortment; by degree of distance from the sales system. A low-power workshop in a small area using only manual labor and the use of simple tools (cutting boards, knives, baths) can produce small batches of, for example, simple salads. In this case, the assortment may be minimal and limited by the capabilities of the equipment and the professionalism of the staff. Workshops with a wider range and high productivity require a significant production area, professional equipment, organization of packaging areas, storage and cooling of finished products. But in both cases, regulatory and technical documentation, certificates for machines and units, products are needed - professionals can also help with this, says Dmitry PETUSHKOV, head of the project team at Space City.

Distance from sales points determines the speed of delivery of products to retail outlets, the use of certain transport containers or equipment for group strapping, and the need to think through a cargo transportation scheme.

The close location of production (for example, on the territory of a retail outlet) allows you to save on delivering products to the consumer, reduce the cost of shipping packaging, and take advantage of an established sales system for finished products.

For example, it is known that the customer has the opportunity to organize a small workshop for the production of salads based on Russian equipment, which will be located on the territory of a shopping center. To organize a workshop with a capacity of 200 kg/shift, a production area of ​​at least 15–30 m2 is required (we have such experience) and 2–4 service personnel.

– At the initial stage, a preliminary design of a workshop for the production of chilled salads should be prepared. It includes: technical specifications and functional and technological flow diagram of production, optimal composition of equipment, specifications, technical data and prices, a brief description of the technical process, a list of basic requirements for engineering support, recommendations for explication of premises, arrangement of equipment indicating power supply points. The salad production technology involves several mandatory stages: acceptance and preparation of raw materials, chopping, preparation of bay, marinade, blanching, salad production, packaging, storage, says Dmitry PETUSHKOV

Since the main equipment affects the quality of the finished product, it is necessary to dwell in more detail on the models that are included in the workshop for the production of salad snacks.

SELECTING MODELS

A logical question arises: which approach to choosing equipment models is considered correct?

– The brands we use to complete the production line are a conscious, informed choice. We have been working in the Russian market for more than 10 years and know what our customers need: first of all, reliability, ease of operation, and the optimal combination of price and quality. For example, the MOK-300 potato peeler is designed for peeling potatoes and other root vegetables by exposure to abrasive-containing cleaning agents. The potato peeler hopper is made of stainless steel and is closed with a lid, which has a built-in loading hatch, which, when opened, spontaneously unloads the peeled product while the disk is rotating. The potato peeler provides adjustment of the duration of the operating cycle through the use of a time relay. The machine operates at many enterprises and has demonstrated high technology and reliability. The GAMMA-5 vegetable cutter is an example of the optimal price-quality ratio. It is designed for slicing and chopping raw and boiled vegetables and fruits into pieces of different geometric shapes; it can be used for preparing minced meat and chopping hard cheeses. The vegetable cutter comes with a large selection of knives, shredders, and grates that allow you to cut into slices, plates, cubes, sticks, and strips. It is possible to equip the machine with a meat grinder attachment. Small overall dimensions and the ability to be installed on any horizontal surface allow the unit to be used in mini-workshops, and the presence of a locking device eliminates the possibility of turning on the chopper while changing attachments, says Ivan NIKOLAEVSKY, leading specialist of the Master of Trade company. – At the client’s request, the workshop is equipped with a medium-temperature refrigerated cabinet ШХ-0.7*, which allows storing raw materials and finished products. We usually include a packaging stage in the production line, where we propose to use an easy-to-use and reliable “hot table” packer! SW-450*. It allows you to package finished products in stretch film and is optimal for use in retail establishments and small industries. The device is made of stainless steel and equipped with a Teflon-coated thermal knife for cutting the film, a heated Teflon-coated table, and a temperature controller that can be adjusted to the film thickness.

Of course, the equipment of the workshop may be somewhat different; models and brands of equipment may vary not only in productivity, but also in other preferences (country of origin, cost, design).

PITCHES OF CERTIFICATION

It is known that the release of a particular finished product for sale is checked for compliance with GOST. But at the moment, the situation has developed that products that seem to be familiar from childhood (remember, semi-finished products were sold in culinary shops?) are not “governed”, that is, GOST or OST have not been developed for them. There are no GOSTs for chilled and Korean salads, beetroot, carrot, cabbage balls, and even more so there is no documentation that allows you to produce products under your own brand.

What to do if you still decide to produce products for which GOST standards have not been developed?

Currently, there are several options for resolving this issue.

In order to produce salads and any other products, the requirements for which are not described in GOST or OST, at the first stage it is necessary to purchase or develop normative and technical documentation (NTD) for the products. You can purchase technical documentation from the developer - for a significant part of food products, the holders of the original documents are industry institutes. But it is difficult to work with them, since the list of technical documentation is limited by the available assortment and the sanitary and hygienic conclusion of the SES obtained “once and for all”.

Some documentation developers are owners of their own brands, but few manufacturers will want to work under someone else's name, unless this is a case of working under a franchise. And it is unlikely that the owners of “exclusive” documents will want to sell the technology and recipe.

The cost of ready-made (current) documentation for chilled salads starts from 30 thousand rubles, the acquisition of documentation for which it is necessary to produce products under the brand increases by an order of magnitude, the development of original recipes and documentation that fully complies with the requirements of Rospotrebnadzor and GOSSTANDART is calculated individually, since depends on the number of recipes.

The developer may be an information agency (IA), which comes up with new recipes and technologies, registers documents, and certifies production.

Why is it preferable to work with a news agency?

Firstly, you can ask questions by phone, fax, e-mail, purchase a copy to study the list of used GOSTs, OSTs, SanPiNs, etc.

Secondly, you can order technical documentation for any type of product, any range (in the case of salads - about 50), under your own brand.

Thirdly, the IA will not only develop the document, but will also receive a sanitary and hygienic conclusion from the SES for the maximum possible period of implementation (in the case of chilled salads it is 7 days), and will receive a GOSSTANDARD catalog sheet.

Few people admit the idea that it is possible to produce high-quality and tasty sausage in a small production facility. Those who know this are looking for a business plan for a sausage shop to open their own business. And they do it right - business profitability sometimes reaches 30%. Let's talk further about how to open a sausage shop.

Choosing a room for a workshop

The first stage of implementing the idea is to search and select a suitable room - with an area of ​​50 square meters. m. In order for the business to run smoothly and without unnecessary costs, it is advisable to immediately find and organize it according to the required standards.

The premises must be classified as non-residential. It is necessary to draw up a technical project for it. It is better to leave the solution to this issue to specialists. In addition, the premises must be renovated in accordance with the requirements of the sanitary station. Their list is voluminous and the standards themselves are quite strict. They provide for the presence of the following premises and areas in production:

• household;
• utility rooms for materials, tools and additional equipment;
• spice storage and mixing warehouse;
• thermal shop;
• raw material processing workshop;
• manufacturing facility;
• defrosting workshop;
• dishwasher compartment;
• cooling chambers for raw materials;
• refrigeration chambers for finished products, ripening of minced meat;
• warehouse of raw materials (dry and bulk).

Not all of these zones can be organized separately; some can be combined, but all these steps must be coordinated with the sanitary-epidemiological station. This permission is obtained on the basis of a technical design and its accurate calculations. The terms of reference indicate:

• equipment used;
• manufacturing technology;
• calculations of the raw materials used;
• assortment of sausages.

After the SES, the documentation must be approved by the veterinary authorities and local administration.

We receive certificates

In order to be able to sell sausage without problems, it must be put through a certification procedure. It is carried out in two ways:

• declaration of products based on the manufacturer’s statement. In it, the manufacturer undertakes the responsibility to produce a high-quality product in accordance with all established requirements. This form is used by mini-workshops for the production of sausage.
• GOST certificates are often issued to large production facilities. To issue this document, you must submit a hygiene certificate, a production and quality system certificate, a veterinary certificate, and a test report.

Specified Requirements

The legal requirements that your products must comply with are set out in the following documents:

• GOST 9793-74 – “Meat products. Methods for determining moisture."
• GOST 7724-77 – “Pork in carcasses and half-carcasses. THAT";
• GOST 4495-87 – “Whole cow's milk powder. THAT";
• GOST 7699-78 – “Potato starch. THAT";
• GOST 1935-55 – “Lamb and goat meat in carcasses”;
• GOST 779-55 – “Beef meat in quarters and half carcasses”;
• GOST 9792-73 – “Sausages and products from beef, pork, lamb and meat of other animals”;
• GOST 52196-2003 – “Cooked sausage products”;

The list of GOSTs is far from exhaustive. But these are the main ones that you need to focus on when starting your own production.

Enterprise registration

There is no fundamental difference in what form of organization you choose to operate a mini-workshop. But most often a legal entity is used, because production volumes are usually considerable, and therefore careful accounting is required.

When registering an enterprise, it is advisable to indicate the following OKVED codes:

• 15.13 – Production of meat and poultry products;
• 15.13.1 – Production of prepared and canned products from meat, meat by-products and animal blood;
• 13.15.9 – Provision of services for heat treatment and other methods of processing meat products.

Types of sausages produced

Before you start producing this type of food product, you need to understand its types. There are these types:

• boiled;
• boiled-smoked;
• semi-smoked;
• raw smoked;
• dry-cured;
• liver.

The latter is the most inexpensive, since it is prepared from other parts of the carcass, the so-called offal. Varenka is a little more expensive, but also inexpensive. It is prepared on the basis of minced meat with soy, cooked at a temperature of about 80 o C, due to which it contains a lot of water. This significantly reduces its shelf life. If you smoke such sausage after cooking, you get boiled-smoked sausage. Whole but small pieces of meat are sometimes added to this type of sausage, and the minced meat is generously seasoned with spices.

Semi-smoked sausages are first fried, boiled, and only then smoked. Raw smoked, as the name suggests, are subjected to so-called cold smoking in their raw form at a temperature of 20-25 o C. Their production process takes about 40 days, so acid is often added to them so that they ripen faster. To make dry-cured sausages, marinated meat is used to make minced meat. The sausages themselves are smoked for 3-4 days, and then dried at a temperature of 15-18 o C.

Raw materials for sausage production

When choosing raw materials for making sausage, you must adhere to the main condition - all meat must undergo certification and veterinary control. To do this, the supplier must be required to provide the appropriate documents for each batch of raw materials.

Most often, pork and beef are used to prepare minced sausage - products made from them are the most popular. But you can use poultry, lamb and other types of meat to diversify the assortment.

The degree of fat content of the meat used depends on the manufacturing technology of a particular type of sausage. More often they take low-fat raw materials. Also in production we use raw materials that vary in temperature:

• defrosted;
• chilled;
• paired

The latter is often used to prepare minced meat for dumplings, as well as sausages and sausages. As already mentioned, according to the standards, they must contain a high percentage of water, and steamed raw materials absorb water well. In addition, the use of such raw materials speeds up and reduces the cost of the manufacturing process - there is no need to defrost the raw materials, it does not lose moisture, as during cooling.

Additives in raw materials

When making regular sausages, animal fats are often added to the minced meat in order to achieve certain taste qualities. When it comes to dietary sausages, the main additives for them are milk and melange. There are also meat and vegetable products in which soy concentrate, cereals, flour, and starch are added to the minced meat.

Almost any sausage contains additives that improve its taste and give it a special aroma. The main ones are:

• sugar;
• nitrite;
• table salt;
• spices;
• spices.

Sometimes phosphates, sodium ascorbate, and glutamate are used. The quantity and types of additives are regulated by recipes approved by regulatory authorities. Additives are used strictly in accordance with established requirements.

We purchase equipment

Before purchasing equipment for the production of sausages, you need to decide what type of products you will specialize in. The production of different types of sausage requires special equipment. By the way, experts recommend choosing domestic equipment. It is much cheaper than imported, and in quality it is not much inferior to it.

Sausage production equipment

№	Name	Purpose	Cost (thousand rubles)
1.	Defroster	Defrosting meat	63
2.	Top	Large and productive meat grinder	455
3.	Vacuum syringe	Filling casings to form pates and sausages	520
4.	Twister	Twisting and dosing of sausages	often comes with a syringe
5.	Conveyor for trimming and deboning meat	Helps to establish the raw material processing process	660
6.	Cart	Transporting raw materials from module to module	2
7.	Ice maker	Produces 100-6000 kg of ice per day	100
8.	Cutter	Second stage of grinding minced meat (80-420 liters)	800
9.	Block cutter	Grinds frozen raw materials before using them in a cutter	120
10.	Hair cutter	Grinding raw materials to specified sizes	90
11.	Clipper	Product packaging in bags	700
12.	Thermal chamber	Heat treatment of sausages	2 710

In total, equipment for sausage production will require about 70 million rubles. Another million must be allocated for its delivery, installation and debugging.

Monoblock option

Today, manufacturers of this type of equipment offer a unique unit - a monoblock, which is a mini-sausage production workshop. It is designed in accordance with all the requirements that the SES service puts forward for production. Its small dimensions allow it to be delivered on a small trawl and installed in any room. This helps solve the problem of finding the right premises, which must comply with food production standards.

In addition, the monoblock can serve fewer employees. Most of its functions are mechanized or automated, so workers only need to monitor several stages of production. Reducing the number of employees means saving on wages and, accordingly, increasing the profitability of the enterprise and its payback period.

Production employees

A small workshop for the production of sausages will require at least 18 employees, for whose salaries it is necessary to allocate at least 230 thousand rubles every month. Monthly salaries will look something like this:

• sales manager – 8 thousand rubles;
• loader – 8 thousand rubles;
• technologist – 16 thousand rubles;
• driver – 8 thousand rubles;
• 10 workers – 100 thousand rubles;
• 2 masters – 20 thousand rubles;
• accountant – 20 thousand rubles;
• director – 50 thousand rubles.

Formation of sales volume

The estimated number of sales is calculated based on the fact that the workshop is located on 50 sq. m, can accommodate machines that produce up to 70 tons of products per month. For example, if a workshop specializes in dairy boiled milk, which retails on average for 300 rubles per kilogram, monthly revenue will be almost 20 million rubles.

Cost of dumplings

To prepare a ton of inexpensive dumplings, you will need approximately 123 thousand rubles worth of raw materials. More precisely, the following ingredients are needed:

• nutmeg – 400 rub.;
• allspice ground pepper – 320 rub.;
• black or white ground pepper – 400 rubles;
• granulated sugar – 30 rubles;
• sodium nitrite - 10 rubles;
• table salt – 300 rubles;
• cow's milk powder (whole) – 3,000 rubles;
• chicken eggs or melange – 4000 rubles;
• trimmed pork – 73,200 rubles;
• trimmed beef – 41,250 rub.

In addition, to form the products you need to purchase casing and twine, which will cost 2-3 rubles per meter.

The cost of production must include utility costs for manufacturing the product. These include:

• electricity – 200 rubles;
• gas – 330 rubles;
• compressed air – 450 rub.;
• cold – 160 rubles;
• steam – 3 rubles;
• water – 250 rub.

This is still no less than 1.4 thousand rubles. In total, it will take at least 224.5 rubles to produce a kilogram of milk sausage.

Fixed costs

The cost item also includes a list of fixed expenses that will have to be calculated every month from revenue. These include:

• Advertising – 450 thousand rubles;
• Utilities – 70 thousand rubles;
• Administrative expenses – 60 thousand rubles;
• Salary – 2,760 thousand rubles;
• Rent of premises – 80 thousand rubles;
• Depreciation of equipment – ​​151 thousand rubles.

Business profitability

Taking into account the difference between the proceeds that are planned to be received and the cost of sausages, the profit from their sale will be approximately 47 million rubles. Accordingly, the enterprise's profitability remains at approximately 25%. Based on this, investments in this kind of business will pay off in about a year and a half if we are talking about the production of dumplings. But besides it, raw smoked and dry-cured sausages are very popular. They should also be included in the range of manufactured products.