Pasta has long become a familiar and popular type of side dish in our country. The main advantages of pasta are the speed of preparation and affordability. In addition, not without the participation of manufacturers of these flour products, the “image” of pasta is gradually changing. If earlier they were considered not the most healthy food and were not recommended for people who are on a diet, now they are gradually acquiring the status of a healthy product, thanks to the fashion for Italian cuisine. Demand for pasta especially increases during economic crises, when consumers stock up on products with a long shelf life.

The pasta business was considered very profitable just a few years ago. The organization of the "pasta shop" requires several thousand dollars (a relatively small amount for a manufacturing enterprise). The technology for making pasta is relatively simple. The payback period of such a business is short, and the profitability is high (about 30% in normal times and up to 80% in "hard times"). Therefore, there is nothing surprising in the fact that every year the number of players in this market increases two to three times. It is all the more surprising that this soon led to a crisis of overproduction (about 30% of domestic production capacity quickly became redundant), which is due to the fact that pasta production volumes exceeded their consumption.

Experts distinguish the following price segments in the pasta market:

economy class (lower price segment). This group includes weight pasta category "B". Their share is over a third of the market (about 350 thousand tons).
middle price segment. This group includes packaged pasta group "B". The market share of these products is about 25% (200 thousand tons). Such pasta is packaged in packages weighing from 400 grams to one kilogram.
"medium plus". This group includes category A pasta, which is made from durum wheat. Products of this category occupy about 35% of the market share of pasta (300 thousand tons). It is these pasta, for the most part, that are packaged in polypropylene bags weighing up to one kilogram and sold under various brands.
premium segment. This includes category “A” pasta, mainly from Italian producers (or Russian, but “masquerading” as Western ones in terms of name and packaging design). The products of this group have a small market share - about 5% (45 thousand tons). The cost of a half-kilogram pack of premium pasta starts from 55 rubles.

In the pasta market, as well as in the food industry in general, the majority of consumers (from 70 to 80% according to various sources) prefer middle-class products. At the same time, consumers in this segment, as a rule, do not have pronounced brand preferences. On the other hand, if the ratio of price and quality of a particular product suits buyers, then they willingly show loyalty to this brand, continuing to buy its products in the future. During crises, mainly mid-price and premium segments suffer. However, it is the production of Group A pasta, which is made from durum wheat using imported equipment and raw materials, that is considered the most promising direction among entrepreneurs. If the lower and mid-price segments have been filled for a long time and the competition there is too high, then expensive pasta domestic production(including the new brand) may well compete with Western products not only in quality but, more importantly, in price. Until recently, this segment was dominated by imported pasta, but recently the volume of their supplies has noticeably decreased. The second most attractive segment is low-quality pasta made from soft wheat varieties. In just two years, their market share increased from 40 to 55%. True, since 2011 the pace of development of this segment has somewhat decreased, but it still accounts for most of the sales. According to analysts, there are currently less than 200 players in the pasta market, including small producers.

Let us consider in more detail the main trends in the development of the industry. An excessively large selection of various pasta products has led to the fact that manufacturers are gradually moving from price to non-price competition, creating their own federal-level brands. This tendency is inherent in more civilized market relations. The assortment of producers consists mainly of pasta products of the middle price segment (costing from 35 to 125 rubles per pack). The development of the pasta industry directly depends on the suppliers of raw materials. Since flour is the main component for the production of pasta, the cost of the finished product depends entirely on pricing policy flour mills. This is especially critical for products in the mid-price segment. For this reason, large producers, hoping to receive guarantees of timely supplies of raw materials of adequate quality, are beginning to create grain holdings. These mergers can significantly increase the profitability of production - up to 5% by optimizing logistics processes and reducing the likelihood of supply disruptions. On the other hand, it is obvious that these measures are not suitable for medium-sized and, especially, small-scale industries, and it is in these segments that the competition is the highest. Under such conditions, analysts are sure, in a few years only about five largest manufacturers will remain in the industry. But so far, the pasta business has not lost its attractiveness for small companies. The average consumption of regular pasta in our country reaches over 7 kg per capita per year. At the same time, for instant noodles and vermicelli, this figure is almost 8 kg per person per year.

Pasta is a dried unleavened dough made from specially ground wheat flour and water, which is shaped into tubes, ribbons, threads or other shapes, and dried to a residual moisture content of 13%. Some pasta, due to low humidity, can be stored under appropriate conditions for a year without losing most of its consumer properties. Varieties of pasta depend on their composition, calorie content and nutritional value. Pasta of each grade, depending on the standard, can be one of four types: tubular, figured, thread-like and ribbon-like. Moreover, each of these types has its own subtypes and types, depending on the length, width and diameter of the product. Instant pasta, which stands out in a separate group, has a porous structure and various enrichment additives in its composition, so that they do not require cooking. The main flour raw materials used in pasta production are flour and water. The most suitable raw materials for the production of pasta are durum wheat flour (durum) for pasta, high-grade durum wheat flour, soft vitreous wheat flour, baking wheat flour and premium flour (semolina) selected during baking grinding. In this case, the flour must be necessarily cleaned of metal impurities and, in some cases, can be additionally enriched with vitamins (for this, heat-resistant water-soluble vitamins B1, B2, PP are used). The moisture content of the flour used should not exceed 15.5%, and the gluten content in it should not be lower than 28%. Pasta made from baking flour the highest grade, as a rule, have a light cream color, and products made from flour of the first grade have a dark cream color with a gray tint. Drinking water, which is used to prepare the dough, must also meet certain requirements, be epidemically safe, harmless in chemical composition and have a pleasant taste.

In addition to the main raw materials - flour and water, various additional components are used in the production of pasta to improve the taste and quality of products: chicken eggs, egg melange, egg powder, dairy products (whole dry or skimmed cow's milk), vegetable products (concentrated tomato juices and pastes, natural juices with carrot and beet pulp). In addition, in the production of pasta, food colors can be used - certified synthetic (for example, tartazine) or natural (for example, beta-carotene). Both tartazine and beta-carotene give the products a pleasant yellowish color.

As improvers, surfactants are used that improve the quality of pasta, preventing them from sticking together during drying and helping to better retain their original shape during cooking. In the manufacture of pasta for dietary and baby food they may contain vegetable and fruit puree, iron glycerophosphate, etc. Pasta of group "A" is made from durum wheat flour (durum) or premium flour of increased dispersion from durum wheat, products of group "B" - from soft flour vitreous wheat, group "B" - from baking wheat flour.

Pasta of each grade is divided according to the standard into four main types, depending on its shape: tubular, figured, thread-like, ribbon-like. Moreover, each of the types is divided into subtypes, depending on the length, diameter and width (pasta, feathers, horns). Macaroni are long tubes with a straight cut. Their length can vary from 15 cm to 30 cm (short pasta) and from 30 cm (long pasta). In this case, pasta of the latter type can be double bent or single. Depending on the diameter, pasta is divided into straws (4 mm), special (4.1-5.5 mm), ordinary (5.6-7 mm) and amateur (over 7 mm). Feathers are pasta in the form of tubes with an oblique cut. The length of the feathers from an acute angle to a blunt one can be from 3 to 10 cm. The types of such pasta depend on their diameter (special, ordinary and amateur) and the shape of the section (round, square, embossed, etc.). Horns are called pasta in the form of short curved tubes with a straight cut. Their length along the outer curve is from 1.5 to 10 cm. Depending on the diameter, there are straw horns, special, ordinary and amateur. Thread-like products include vermicelli, which can have a different cross-sectional shape: round, square, ellipsoidal, etc. Vermicelli is divided into the following types depending on the size of the section: gossamer (0.8 mm), thin (1.2 mm), ordinary (1.5 mm), amateur (3 mm). Ribbon-shaped pasta is also called noodles. Noodles can be smooth or corrugated with straight, paw-shaped or wavy edges of various lengths (long - from 20 cm and short - from 2 cm). Figured products are produced in the form of shells, letters, ribbons, stars, gears, etc.

The recipe for pasta dough depends on the quality of the flour used, the type of pasta, how it is dried, and other factors. When compiling the recipe, it indicates the amount and temperature of flour and water, the humidity and temperature of the dough, the dosage of additives, if any. Pasta production technology has some nuances. For example, there are two ways to store flour in warehouses manufacturing enterprises- tare, in which flour is stored directly in bags, and bulk method, in which flour is poured into a bunker (silo). The bulk method of transportation and storage of flour raw materials is considered to be better, since its use minimizes the amount of manual labor and additional losses of flour associated with its dispersion or residues in bags. In addition, the costs for the production of packaging (sewing bags) are reduced. Before the flour goes to production, it is carefully sieved to separate metal-magnetic impurities from it, heated to 10 degrees Celsius, samples from different batches are mixed to improve quality indicators. Then, a predetermined portion of flour is loaded into the dough mixer hopper, and then gradually introduced into it drinking water(sometimes water is pre-mixed with additives), in accordance with the recipe. Then the dough is kneaded for 8-10 minutes, with the help of an auger it is fed to the matrix and forced through its holes. Products emerging from the matrix are blown with air from the built-in fan. Products are automatically cut into predetermined segments, laid out on a tray, which is placed on the rack of the table of the press machine for pre-drying. The final drying is carried out in a drying cabinet, where thirty trays are placed. Each such tray allows you to lay up to two kilograms of pasta. Pasta is dried for 50-60 minutes ( exact time depends on the type of product) until their moisture content reaches 19%. The pasta is then packaged in cardboard packaging where they are dried naturally at a temperature of 25 degrees in a ventilated room. When the moisture of the products reaches 13% (it takes at least four hours), they can be sent for packaging. But before that, they undergo an examination, where their appearance, taste and smell. Controllers check products for substandard (broken and deformed pasta), crumbs, evaluate the moisture content of products, their acidity, digestibility, the absence of barn pests and metal impurities, strength. Macaroni from batches that have passed the examination are packed in polypropylene bags using special filling and packaging machines.

To organize the production of pasta, special lines will be required. You can purchase both a semi-automatic line with a capacity of about 100 kg of products per hour (about 500-700 thousand rubles), and fully automatic equipment with a capacity of about 500 kg of products per hour and cost from 375 thousand euros. The required set of equipment includes a press, a flour sifter and a drying line. Large capacity lines are usually equipped with conveyors and a stabilizer bunker. The presses are supplied with special dies (the exact set depends on your assortment). One matrix for the production of products of one type will cost 3-5 thousand rubles. It is enough for 500-2000 working hours, depending on the line load. In addition, you will need equipment for packaging finished products. Depending on your budget, you can choose semi-automatic, automatic equipment or a whole line (the latter option is suitable for large production volumes). As mentioned above, before packaging, finished products are aged for several hours in cardboard boxes. This stage can be significantly reduced by using special equipment operating on the hydrothermal technology of pasta production. Such equipment cools the pasta and allows you to immediately proceed to their packaging. In addition to the lines, you will need shelving for storing dies and finished products, trolleys for transporting raw materials, a device for sharpening die knives (optional, but desirable) and a sink.

The minimum starting capital for the organization of the production of pasta of low and medium price ranges from 950 thousand rubles (calculation of equipment manufacturers and suppliers). This amount includes the purchase of a production line, registration legal entity, rent of industrial and warehouse premises. The payback period at such expenses and the availability of sales channels for finished products does not exceed 1.5 years. But it is worth considering the fact that the business for the production and sale of pasta is subject to the seasonality factor. Thus, the greatest demand for pasta is observed in winter months, and in the summer - the season of fresh fruits and vegetables - there is a rapid decline in sales.

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Pasta production as a business

Pasta is in demand and easy as a side dish for lunch or dinner among different segments of the population. Fashion for Italian cuisine has made pasta popular among wealthy people. Pasta is recognized as a healthy product that is easy to prepare. Their price is not too high, so all segments of the population buy pasta. They have a long shelf life, so some people stock up on them for future use.

The annual consumption of pasta per capita is 7 kg, and instant noodles are consumed up to 8 kg per year per person. Therefore, the payback period of this business is about 30%, and during periods of crisis (when people switch to cheap products), the profitability of the pasta business reaches 80%. You can recoup the entire enterprise in about 1.5 years. Agree, the figure is not very big.

For the production of pasta, unleavened dough is kneaded with wheat flour of various grindings and water, sometimes the recipe contains various additives to improve quality, taste and color. After kneading the dough, the pasta is molded and subsequently dried to a residual moisture content of 13%.

Pasta differ in calorie content, nutritional value and, in fact, the composition, which is described above. To give the pasta a certain taste, chicken eggs, egg powder or melange, skim milk and other dairy products are added to them.

All pasta can be of four types:
- tubular;
- filamentous;
- ribbon-like;
- curly.

Each of the species is divided into even more subspecies. This division depends on their width, length and diameter.

Instant noodles also belong to pasta and are placed in a separate group. In order for the noodles not to be boiled, but simply steamed in boiling water, it contains additional additives.

To make a pasta recipe, you need to consider the amount and temperature of water and flour, the temperature and humidity of the dough, as well as the types of additives and their amounts.

pasta production technology

The pasta production technology is very simple. In order for the recipe to take the form of pasta, you need to sift the flour: get rid of lumps and impurities, and then perform a magnetic cleaning to remove possible metal parts that may be contained in it.

Next, the dough is kneaded: a little water is added to a large amount of flour. At first, this mass is lumpy, after further pressing the dough turns into a homogeneous mass. Next, the dough is continuously kneaded, and all the other ingredients that are contained in your recipe are added to it. After that, the dough is compacted and shaped. The dough is compacted in order to get rid of air bubbles, and after molding, the pasta takes on its appearance and is sent to the matrix.

Next, raw pasta is cut and dried well. The quality of drying depends on the shelf life and taste properties of this product. Now it remains only to pack the finished products and send them to the warehouse for further sale.

According to price characteristics, pasta is divided into four classes:

Now you are thinking which of the price segments should you take? That's right, and the following information will prompt you to solve this problem. Categories of middle classes are more popular among the population: up to 80%. But they don't single out any brand in particular. Only in rare cases is it a great honor for buyers to choose a particular brand.

The same part, along with the premium class, suffers during crises, as people switch to a cheaper option. But premium-class pasta is considered a promising direction, since domestic competition in this sector is low.

Imported manufacturers can be ousted not only by quality, but mainly by the price of finished products. If you do not want to produce expensive pasta that requires foreign equipment and expensive raw materials, you can, on the contrary, go into the low price sector and produce class B pasta from soft wheat varieties, as their consumption has increased significantly in recent years. But remember that the first three classes are oversaturated with manufacturers, so it will be much more difficult to break through among them.

You should also take into account that the cost of your products directly depends on the cost of flour on the market, since this particular product is fundamental. Therefore, it is best to enter into long-term contracts for the supply of flour so that the cost of your finished products is more or less stable and you do not increase the cost of purchasing raw materials. Thanks to this, you can increase your profitability by 5%. If you decide to open the production of middle-class pasta, then you will need to spend 26 thousand rubles on raw materials every month.

To open a pasta business, you need a lot of space to fit everything. necessary equipment, and give an additional 90 square meters for a warehouse where flour and finished products will be stored. By the way, at this stage of the organization, you must choose the method of storing flour in tare or bulk.

The first is that the flour is stored in separate bags, and in the second case, the flour is poured into one large container.

The second method is the most preferable, since the loss of raw materials in this case is less and you do not need to spend money on containers, that is, bags. The cost of rent and utilities will be 18 thousand rubles a month.

Don't forget about the legal side of this case. In addition to the standard documents on opening a new enterprise, you need to obtain a production permit from the sanitary and epidemiological service for the production of food products.

Equipment for the production of pasta

Now you need to think about what equipment for the production of pasta you need to purchase, since the bulk of the capital will go exactly to this issue. If you will produce expensive pasta, then you simply need foreign equipment. Italian manufacturers are the best. For other types, domestic cars will be enough, which are much cheaper and no worse than foreign ones. When buying equipment, also consider the cost of further maintenance and repair. "Our" cars are much faster and cheaper to fix, and there should be no problems with new parts.

To create a production line, you will need a flour sifter, a pasta press, a drying cabinet, and a filling and packaging machine. To purchase equipment, you will need 3-3.5 million rubles. Domestic equipment can produce up to 500 pasta molds, some lines reach a capacity of up to 100 kilograms per hour.

You will also need certain personnel. Two employees who will maintain the pasta production line, a technologist, a driver and a manager. You will need 67 thousand rubles a month for their salary.

It is easier and more profitable to sell products to wholesale buyers who will subsequently sell your product at retail. In addition, you can try to conclude agreements with large supermarkets, which will buy pasta no less than wholesalers. Also sell your goods to restaurants and canteens. Win tenders to provide pasta products public institutions(schools, kindergartens, boarding schools, orphanages, nursing homes, etc.).

Pasta is a universal product that is bought by people of all age categories and all financial status. They are in great demand, so this business has the right to life. To start such a profitable and interesting business, you will need 460 thousand rubles for the production of medium and premium pasta and from 800 thousand rubles for the production of expensive varieties of pasta.

Do not be afraid to start a new business, besides such a useful and profitable one.

Interesting video about pasta production:

Pasta production: 5 product advantages + classification + 7 process steps + market analysis + raw material selection + 3 flour suppliers + equipment recommendations + 3 dealer firms + 6 recruitment methods + 5 types of advertising + marketing + income and expense calculation.

Pasta is especially popular in Italy and East Asia. However, among the Slavs, this type of side dish is in demand due to its long shelf life and availability.

Therefore, the production of pasta is a business idea, the implementation of which will bring a good income. In addition, with relatively small investments, this type of small business quickly pays off.

Benefits of Pasta

Pasta or pasta is a food product from a series of culinary semi-finished products, which is produced from special flour of the highest grades (usually wheat) with water and a high protein content.

The origin of pasta dates back to the 4th century BC. The origin of the pasta industry in Russia is celebrated in 1797, when the Odessa pasta factory was opened. Their earlier production was carried out thanks to horsepower and water mills.
With the advent of technology, the production of pasta was simplified on the basis of steam units. By 1913, there were about 30 thousand pasta enterprises throughout the country. By 2013, this number increased to 950 thousand pasta factories, and production volumes increased 40 times.

As in Soviet times, today pasta is not in short supply, but this product is the basis of many dishes used in East Asian, European, even vegetarian and, of course, Italian cuisine.

Therefore, their production will not be unprofitable, and the supply, which is formed from such factors as the availability of substitutes and compliments (substitutes and complementary goods), the level of technology, production capabilities, resource provision, consumer and inflation expectations, and price, will only increase demand.

Those. it is beneficial for a person who wishes to start the production of pasta products to implement this idea.

Also, the demand for pasta is determined by the advantages of products, including:

long-term storage;
trouble-free transportability;
ease and efficiency of cooking;
unique nutritional value;
fast digestibility.

Variety of pasta.

These food products can be made in different shapes, colors. So, it is possible to establish the production of semi-finished pasta in the form of feathers, shells, threads, rings, etc.

In general, pasta is classified into:

State standards define a separate classification:

The cooking method determines the following class of semi-finished pasta:

egg or fresh
dry.

In accordance with the degree of readiness, there are ordinary pasta and products “by the tooth”.

Where does the production of pasta food begin?

Before opening an enterprise for the production of pasta, it is necessary to research the industry, analyze competitors, and the consumer market.

Even with the naked eye, you can see that pasta products are found in all grocery supermarkets and other retail stores. outlets. However, this does not yet mean that the market is oversaturated with pasta food products.

If a balance is maintained between price and quality, each product is worn by its buyer. To get a good income, the best solution would be the production of products of medium and budget price categories.

We will touch on the market analysis in more detail in the next section, and now we will briefly consider step by step how to establish the production of pasta:

Let's pay attention to each stage.

No. 1. Analyzing the pasta market.

In the production of pasta, an analysis of the consumer market is carried out. This will allow you to properly plan production and marketing activities, rationally allocate production resources, select the best periods for implementation advertising campaign.

Marketers based on the results of research conducted in 2010-2016. found out that there was a rush for pasta products, therefore, the production growth rates were also high. Demand for products depended on seasonality and decreased in January.

The dynamics of both production and consumption of pasta products is also affected by the state of income Russian citizens. When the material situation of the population worsens, products are bought up better.

According to statistics, the determining factor when buying pasta is price.

It is followed by:

quality,
variety,
manufacturer,
packaging appeal,
recommendations from friends.

35% falls on the budget segment, medium-priced pasta is purchased in the amount of 30%, and only 5% is allocated to the premium class.

Due to the saturation of the market in 2016, the production of pasta is reduced by 5%. However, since 2015, export volumes have been increasing. And on Russian market import substitution takes place.

As a result, expensive foreign brands fade into the background, and more affordable domestic pasta comes to the fore.

An important aspect is the geography of production. Most of all pasta is produced in the Central Federal District. It produces more than 100 tons of pasta products in 1 quarter.

It is not advisable to open production in the Ural Federal District, Volga Federal District. Instead, you should pay attention to such districts: Crimean, Far Eastern, Siberian, Ural, etc.

In the analysis, the future manufacturer must take into account the competitive environment.

The main market players are:

Limak (Lipetsk region),
Rolton (Moscow region),
MAREVEN FOOD CENTRAL (Moscow region),
Extra M (Moscow),
Makfa (Chelyabinsk region), etc.

And do not forget about competitors at the regional level.

Some of the companies mentioned above are going to make changes in the production process and assortment, stopping the production of unprofitable pasta products and introducing new products.

According to experts' forecasts, there is a real prospect of production profitability. The development of the pasta industry is expected in the coming years, and this will be influenced by economic processes.

An increase in investment activity, consumer demand, intensification of production, and entry into the international sales market are also expected. Besides, Russian government intends to contribute to the development of the country's agro-industrial complex with the help of various activities and state funding.

No. 2. Where is the pasta factory located?

Requirements for the premises are standard:

availability of electricity, water supply, sewerage;
the ventilation and heating systems must be in good working order;
the building must be spacious, the minimum area is 400 sq. m.

Of these 400 "squares", half of the space will be occupied by the production of pasta, 100 sq.m. necessary for storage and utility rooms.

The characteristics of the building should provide the possibility of convenient placement of equipment, safety of work. In the warehouse, you need to install enough racks for storing pasta. If large volumes of production are planned, it is better to automate the warehouse.

When raw materials enter the warehouse, it is desirable that there be an incoming quality control, during which samples are taken and analyzed. If the parameters do not meet the standards, the raw materials are not accepted and must be returned to the suppliers.

In a warehouse, an employee uses a reader (terminal) to quickly find an order. You will also need a loader that will deliver pasta to the overpass. They also allocate space for the office of the manager and the chief accountant, the head.

We also need an office for QC (organization of incoming quality control, control carried out during production and after it). It is equipped with special equipment and consumables.

A workshop located outside the city is cheaper. But here it is important to provide vehicles with easy access, because raw materials will be supplied to the enterprise, and finished pasta products will be shipped from it.

One of the main parameters of the building microclimate is dryness. If the relative humidity causes dampness, the quality of the pasta will decrease.

The presence of odors is another factor that should not be present in the room, because. pasta products are sensitive not only to moisture, but also to the absorption of odorous substances present in the air.

The building should have high ceilings to allow for multi-storey storage. Due to this, you can rent or buy a room of a smaller area. It is recommended to equip the room with equipment to maintain the microclimate at the required level, bird repellers, insecticidal lamps, rodent traps.

Number 3. What raw material to take for the production of pasta?

In the recipe, the main components are high-quality flour and pure water.

Pasta will meet high quality indicators if they meet the requirements:

large size,
color (at least 50-60% whiteness),
gluten (within 30-40%).

Such types of flour have significant differences from baking flour: wheat flour is characterized by a grainy structure. Products made as a result of grinding durum wheat are sold at the highest price, as a rule, they are tinted with tomato, spinach, dill, and beetroot juices.

They are not as high in calories as they say and are highly digestible, have more gluten but less starch content, smooth surface, even cream/gold color.

The production of such pasta products is characterized by high cost, therefore, such a product is presented on the market in small quantities.

Most often on the shelves of shops there are products made from summer varieties of wheat. The Russian market is occupied by 85% of this pasta products, as opposed to 15% of durum wheat products. It is less useful, sold at a low price.

Some in the production add flour enriched with egg additives, vitamin groups E, H, B and P (thiamine, riboflavin, PP), dairy components, calcium, iron.

To increase the content of trace elements in pasta, the addition of 25% dry gluten, 3% wheat germ, 10% bran is observed. At the same time, pasta does not lose its usual taste.

Other additives in the production of semi-finished pasta are:

buckwheat (increases iron content by 5 times, magnesium by 8 times, water-soluble vitamins B by 2 times, potassium by 2 times);
rice, peas, soybeans (increases the content of vegetable protein by 30%);
wheat groats (triples the fiber content);
corn (improves taste, makes pasta yellow, improves cooking properties);
Jerusalem artichoke (enriches with calcium, inulin);
vegetables, fruits (gives taste and colors products).

Among the suppliers who have earned the trust of many manufacturers, we highlight:

You can also find a list of suitable organizations on the website. https://www.zerno-product.ru/catalog-1-1-0-1.html

No. 4. The flow of the production process of pasta.

The following production phases are distinguished:

Raw material preparation,
Creating a test
Forming (giving products a certain size and shape),
Drying, packing and packing.

The "rudiment" of production is the sifting of flour. Then the raw material in an airless space through the conveyor enters the hermetic vacuum batcher and the dough mixing machine (press).

At this stage, dough is produced by mixing flour with warm water (proportion 2:1). During kneading, air must be completely removed, otherwise bubbles will appear in the future pasta product. After 20-30 minutes, a homogeneous mass is obtained.

Upon completion, under a pressure of 90-150 bar, it enters the formation. A machine with dies and cutting mechanisms sets the desired shape and size of pasta.

The molding process can take place in 2 ways: pressing and stamping. If classical pressing takes place, the shape of the product is created by the hole of the die. When matrices are equipped with inserts, pasta products are tubular in shape.

solid round sections give filamentous products. Slotted holes allow you to make pasta in the form of ribbons, different figures. In the production of noodles, a different technology is used. The machine cuts the thinly rolled dough into long strips.

More pasta curly products are made using stamping equipment. The form does not affect the value and composition, only the aesthetic perception, the speed of assimilation of food changes.

Next, the pasta is dried in an oven for 2-5 hours, keeping a clear shape of the finished products. Drying is one of the most important production processes. The temperature at which moisture evaporates from the dough (84-110°C) affects the quality of the pasta.

The drying cabinet is divided into 4 zones, in each of which for 60 minutes. Products are subjected to the following steps in the order listed:

fast drying
stabilization (when moisture flows from the center of the product to the edges),
short drying again.

The final action at this stage of production is additional stabilization. Dried to a moisture content of 12-13% and already cooled, the products leave the machine and are inspected for compliance with size, color, shape, thickness.

After that, moving along the vibrating conveyor, the pasta product ends up in the storage bin. There is a separate tank for each form of pasta. There they are until the moment of packaging.

Storage silos have discharge belts that send pasta to a vibrating screen that screens out dust and defective products, from where it is transferred to a multihead weigher.

This is the apparatus involved in the last stage of production - packaging. It is equipped with blades and dispenser. When the pasta product gains a certain mass, it is dumped into the package, after which it enters the manual control of the correctness of the labeling, the integrity of the container.

If pasta is produced in small sizes, they are packaged in bags, while large pasta is placed in a cardboard substrate.

No. 5. What to buy equipment for the production of pasta?

The production of pasta products is carried out by several machines, which are purchased separately or as a set.

Schematically, the traditional apparatus that manufactures products looks like this:

If the budget allows, it is better to purchase an automated line.

typographic(like booklets, business cards, brochures);
audiovisual(express information, short videos on the Internet);
outdoor (ads on transport, electronic scoreboards, company signs, staff clothing, showcases);
direct mail (mailing letters).

The listed methods of positioning and increasing sales are characterized by good level perception, mass coverage, flexibility, high effect. However, they also have disadvantages: some are labor-intensive, such as with print advertising. Others are worth a lot.

It is worth noting that the advertising campaign should not stop even when it seems to you that it no longer makes sense and pasta sales are going up. This may be a short-term phenomenon, and advertising is also needed to perform a reminder and strengthening function.

Determining the market, you need to rely on its characteristics (development trends, economic and geographical indicators, capacity, structure) and type. Thanks to market segmentation, you will be able to identify free niches, determine the group of consumers for whom production will be designed, and gain competitive advantages.

When segmenting the market, use the priority features for production, since there is no universal formula.

Consider the following factors:

economic variables (income of the population, etc.),
socio-demographic (living conditions, personality variables),
geographical,
psychological (perception of a new product).

Sales channels for pasta can be:

Production of pasta.

Equipment for the production of pasta.
Advantages and disadvantages of a business idea.

No. 8. Calculation of preliminary expenses and possible income.

To find out the amount of capital investment required for the production of products, all costs should be calculated. On average, the total costs for the purchase of new domestic equipment (in parts) will amount to about 275 thousand rubles.

Costs for labor force will result in 100-150 thousand rubles. + tax from 45 thousand rubles. You also need to take into account the costs of preparing the premises for production - 60 thousand rubles. For the manufacture of 1 kg of pasta, about 960-1000 gr. flour.

If you produce 4730 kg of pasta per month (215 kg per day with 22 working days), and take the average price of flour (14 rubles per 1 kg), it turns out that the cost of raw materials will be: 4730 * 14 \u003d 66220 rubles.

In addition, there are the following items of expenditure:

paperwork - from 50 thousand rubles;
rental of premises - from 100 thousand rubles;
communal payments- from 50 thousand rubles.
transportation costs - from 20 thousand rubles;
purchase of packaging - from 6 thousand rubles;
advertising expenses - from 30 thousand rubles;
unforeseen and situational costs - from 15 thousand rubles.

Total the minimum capital investment in the production of pasta products is 86,7220 rubles.

Now let's calculate the projected income:

1 kg of products at retail costs about 40 rubles,
if we subtract VAT, the revenue from 1 package of pasta will be: 40 - 20% \u003d 32 rubles;
the total income from the sale of all pasta produced in a month will be: 4730 * 32 = 151360 rubles;
the value of the net income after taxation = 151360 - 15% = 128656 rubles;
find out the profitability of production = (151360/457220) * 100% = 33%.

Investments in business in a good situation will pay off in 7-8 months.

The rate of return is in the range of 8-25%. Our value exceeds the normal level by 8 points. This allows us to conclude that it is profitable to engage in the production of pasta products.

Pasta production- not the most profitable business idea, but with the right approach to the organization of the process, a good advertising campaign, high quality products and an affordable price, you can significantly improve your financial condition and at the same time satisfy the needs of customers.

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Pasta is perhaps the most familiar product on the table in almost every family. This is due to the fact that pasta is inexpensive, and even the poorest segments of the population can afford it. Yes, and with certain culinary skills, this product can be cooked really tasty.

Now, when our society is going through not the best financial times, many are trying to save on expensive products, giving preference to budget ones. And here again pasta comes to the fore. How to open your own pasta production - more on that later.

Industry Research

Pasta is now sold in almost any grocery store, be it a large supermarket or a stall near the subway. Nevertheless, it is impossible to say that the market is oversaturated with pasta. As a rule, the products of each manufacturer find their buyer. Both expensive pasta and cheap budget pasta are actively bought. In order not to be left out of demand, you need to properly maintain the balance "price - quality". People who buy the cheapest pasta don't expect high quality. And those who pay a high price for the goods want to get high-quality products.

To get the most financial return from your business, bet on mid-range and low-end products. Pasta at an average price and with an average quality, as a rule, is bought by consumers most often - about 60% of buyers prefer it. Pasta of the budget category occupies about 30% of the market. Elite pasta highest quality have a price three or even four times higher than other types of these products. As a rule, such goods are imported from abroad. It is not very profitable to produce luxury pasta in large quantities, since people who have the opportunity and want to pay a high price for such a product are more likely to give preference to foreign brands than domestic ones.

How to organize pasta production

Registering an enterprise

It is best to register a pasta enterprise as an LLC. When submitting documentation, you will need to indicate the type of activity according to the OKVED system (general classifier of types economic activity). Specify "Production food products, including drinks”, and further subsection “Production of pasta”.

To start production, you will also need permits from the sanitary-epidemiological, fire and environmental service, as well as sanitary books for each employee.

We select a room

For such a business, you will need a fairly spacious room - from 300 square meters. Moreover, about 200 of them will be used directly for production, and 100 for the placement of warehouses and utility rooms. Also set aside some space for the office of executives and managers. The premises can be located anywhere, even on the outskirts of the city, though generally outside the city. This will allow you to save a lot on the cost of renting a room. However, make sure that there is easy access to the plant for vehicles. You will need to deliver raw materials and export finished products.

The room must be fairly dry. Any dampness can significantly reduce the quality of manufactured products - pasta is very sensitive to moisture. There should not be any extraneous odors either, otherwise the product will absorb them, which will also not add quality to it, but only reduce it.

We study production technology

The steps for making pasta are as follows:

1. Preparation of raw materials. For the preparation of pasta, flour of the highest grade from durum wheat is used. Flour must be thoroughly cleaned. This is done using a magnet, which extracts various metal impurities. Refined flour undergoes heat treatment (heated to a temperature of at least 10°C and no more than 15°C) and mixed with warm water in a ratio of 2:1.

2. Dough kneading. Next, flour with water is kneaded using special equipment (dough mixer). If any additives are used (dyes, egg yolk, flavors, flavor enhancers), they are also added to the dough at this stage.

3. Pressing. Next, the dough must go through a pressing procedure so that the mass is compacted. The dough should become homogeneous and very plastic. For pasta various forms(shells, tubules, curls, horns, spaghetti) the dough must be passed through the appropriate molding equipment. The dough is pressed through the holes in the matrix, as a result of which we get pasta strips, which are cut into separate small elements - pasta using the same equipment. So that they do not stick together, during the cutting process, the device must release cold air streams onto them.

4. Drying. Finished products are dried at high temperatures. This makes it possible to preserve the appearance of pasta, prevent their deformation, and also destroy bacteria and harmful microorganisms that could get on the surface of the products. The product is then cooled down again to approximately room temperature. It is impossible to pack warm products in containers, otherwise the packaging will begin to fog up, which will adversely affect the quality of pasta.

5. Quality control. Finished products are inspected for defective and deformed parts, which are removed from the batch.

6. Packing. Products that have passed quality control are packed in portions in containers. Most often these are polymer bags or carton boxes. Then batches of finished products are formed and sent to the warehouse, and then to the buyers.

Please note that the packaging must contain information about the manufacturer, product composition, date of manufacture and expiration date.

We buy equipment

For the production of pasta, you will need several devices that can be purchased individually or as a whole set. If you have a fairly wide budget, purchase imported equipment (Italian is especially appreciated). It is more expensive than domestic, but will last you longer. However, domestically produced equipment is also quite acceptable for use. If the enterprise is not at all large, then feel free to take "our" equipment - you will save money, and you will not lose product quality. Most importantly, before making a final purchase decision, read specifications equipment from different manufacturers and feedback on its work from the owners.

If you purchase the entire set of equipment at once, the manufacturer will deliver it to your territory and help with the correct installation and configuration. If you decide to buy each device separately, be prepared for the fact that you may have to deal with all the technical issues yourself.

So, what is needed for making pasta? There are six main units: a flour sifting machine, a dough kneading machine, a pasta press, molding machines, a cabinet for drying finished products and a product packaging machine for subsequent sale. When buying new equipment, you will receive a warranty from the manufacturer and will be able to use the services technical support during the warranty period. If you want to save money - buy used equipment, now it is not a problem to find it. However, no matter how the seller praises such equipment, you can never be completely sure of its quality and good performance over a long period.

As for storage facilities, they should be equipped with special racks for convenient storage of finished products.

Recruiting staff

If we are talking about a small pasta factory, then a large staff of staff will not be required for it. It will be enough to have such employees: production chief (manager), technologist, warehouse manager, driver, adjuster, accountant, two workers, sales manager. The entire process of making pasta is automated, so it requires minimal human involvement in the production process. Accounting can be handled by the owner of the production or an outsourcing company.

To avoid various problems associated with insufficient staff experience, recruit employees who have worked for at least three years in the field of food production. Select a technologist with special care, because the entire technological process of production will depend on him, and this, in fact, is the most important thing.

Choosing markets

The pasta factory does not need to look for the end consumer and win his trust. Good or bad - decide for yourself. your potential clients will become grocery stores, supermarkets, establishments Catering(restaurants, cafes, canteens), catering companies, wholesale dealers. Be prepared for the fact that at first your products will be purchased with caution and in small quantities. It all depends on you: if you demonstrate the excellent quality of products, then trust and loyalty to you will only grow stronger.

Take part in tenders to provide products to state institutions - schools, hospitals, children's camps, etc. If you are lucky and you win, you will receive a constant and profitable sales of products. At the factory, you can open a company store where you will sell products with the slogan "from the manufacturer."

Pasta business plan

To open a pasta factory, you need to consider the following cost items:

Purchase of equipment: from 5 thousand dollars.
Measures to prepare the premises (repair, ventilation, etc.): from 1 thousand dollars.
Acquisition of furniture, arrangement of workplaces: from 1 thousand dollars.
Transportation costs: from 2 thousand dollars.
Advertising campaign: from $500.
Salary fund: about 2 thousand dollars a month.
Room rental: from 1.5 thousand dollars per month.

The business plan should also include such costs as the purchase of raw materials, utility bills, and the manufacture of branded packaging. The average payback of such an enterprise is 15-18 months.

And this is how the process of pasta production at factories looks like.

The pasta business is currently a profitable investment. The demand for these products is constant, according to a sociological survey, 40% of Russians eat pasta three times a week. When organizing activities, not only an automated pasta line is important - production is a more complex process, it includes the preparation of premises, the selection of qualified personnel, the selection of suppliers of high-quality raw materials, and effective marketing activities.

What you need to know about pasta

Classic pasta is made from two main ingredients - flour and water. Depending on the quality of the flour, there are varieties of pasta:

Basic ingredients for pasta

"A" - durum wheat;
"B" - soft flour (made from crushed wheat);
"B" - baking flour.

Products differ in shape:

long - from 14 cm;
short curly - up to 14 cm;
small soup products;
baking sheets.

To expand the range of pasta products, the company can improve the recipe by introducing new ingredients - eggs, mineral and vitamin supplements, new types of flour.

Organization of production

How to open a pasta production line? To begin with, you need to take care of production facilities. The workshop where the line will be located must be dry, heated, with a good ventilation system, all engineering communications are connected. Production area must be at least 100 m 2, it is necessary to provide a room for an office and household rooms, as well as a warehouse for raw materials and finished products. If not own premises, it would be advisable to rent rather than purchase a new one, the monthly fee will be 15 thousand rubles, utility bills - 15 thousand rubles.

To maintain the line, two workers and a chief technologist will be needed, in addition, a loader, storekeeper, manager and driver will be needed. With a small volume of production, vacancies can be combined. The monthly wage fund, when working 22 days in one shift, will amount to 60 thousand rubles.

According to the main recipe for classic pasta, flour of the highest or first grade will be required, depending on the class of products. The consumption rates of raw materials per 1 kg of finished products are 0.950 kg. The wholesale price of flour is 12 rubles per kilogram, respectively, the cost of production will be 11.40 rubles, excluding the cost of water. It is advisable to use purified water, to do this, install industrial filters, then the cost of water will be included in utilities.

Equipment for the production of

Main component technological process is automatic line for the production of pasta. The cost of acquiring it makes up a large proportion of all investments. Both domestic and foreign manufacturers are represented on the Russian market. Italian equipment (Realpast) is in the greatest demand, but it is also the most expensive, cheaper analogue - Chinese-made lines (Milltech). Domestic ones are in no way inferior to foreign competitors, the Makiz line of the Ural Machine-Building Plant has proven itself perfectly.

Components of Makiz Pasta Mini Line:

flour sifter

press machine;
conveyor dryer;
pneumatic conveyor;
stabilizer-cooler;
storage hopper;
bag holder.

A flour sifter is necessary to remove impurities, foreign bodies and metal particles that have accidentally entered. Characteristics:

The press machine is used to make dough. Equipped with an evacuated hopper for mixing ingredients, thanks to which air bubbles are removed from the mass, this further improves the taste and structural qualities of finished products. Characteristics:

power - 14 kW;
productivity - 240 kg / h;
electricity - 380 V;
dimensions - 1860 * 1950 * 750 mm;
weight - 550 kg.

Pneumatic conveyor is a device for transferring products from a press machine to a conveyor dryer, an integral mechanism of a pasta production line.

Mini Pasta Production Line

The conveyor dryer carries out high-temperature drying of products. This unit has automated system control, which maintains the required humidity, temperature, controls the residence time of products in the dryer. Characteristics:

power -84 kW;
electricity - 380 V;
productivity - 200 kg / h;
dimensions - 1500 * 1300 * 6400 mm.

The storage bunker is designed for the collection and temporary storage of finished products, its volume is 1000 kg.

The bag holder is part of the packing mechanism - it packs products in paper bags, unloading the storage hopper.

The price of the line for the production of Makiz pasta is 350 thousand rubles.

Economic benefits of production

Payback is the main issue in deciding on the organization of production, since any entrepreneur is interested in making a profit. Net profit is obtained by subtracting the cost of production and fixed costs from gross revenue.

Cost calculation: 100 kg of finished products per day, 22 working days per month, the cost of raw materials for 1 kg is 11.40 rubles. 11.40*100*22 = 25080 rubles

Fixed costs:

rent - 15,000;
utilities - 15,000;
transport costs -12,000;
packaging - 4000;
salary - 60,000;
raw materials -25080 rubles.

The total cost of production is 131,080 rubles.

Gross revenue: the price of 1 kg of pasta is 32 rubles, per month it turns out 72 * 100 * 22 = 158,400 rubles.

Profit - 158,400 - 131,080 \u003d 27,320 rubles.

It will take one year to fully pay back the cost of the pasta production line. And if you organize work in two shifts, then the desired results can be achieved in six months.

Pasta business plan. Pasta machine in home food production