Line for the production of crackers (budget option)

Consumers today are becoming more and more picky. The usual beer is eaten not just with dried fish - it is replaced by delicious squid and a wide variety of snacks.

Small crackers with numerous additives to enhance the taste, as well as dried and dried seafood (squid, roach, cod, etc.) have gained popularity in the salty snack market.

According to the results of the latest study, the production of the above products, and even more so banal imports, is quite a profitable business. With the right approach, it does not require very large start-up capital.

Registration and permits

For such a business, it is advisable to open an LLC in order to easily cooperate with wholesale suppliers and large customers. You also need to obtain a barcode from the Chamber of Commerce and Industry, permission from the SES and Rospozhnadzor, and register your brand with Rospatent.

In addition, when launching the plant, it will be necessary to develop technical specifications (TS) for the snack produced.

Completion of documentation can take up to six months and will require about $1,500.

Business registration process

First of all, before carrying out any actions of buying, selling, renting, or concluding contracts, you will need to officially register your activity. The process of obtaining and processing documents for such a business will include the following operations:

• Registration with the federal tax service as an individual entrepreneur or legal entity. The production of crackers can be organized in both one and another form. It is worth choosing based on the planned production volumes, the number of business founders, as well as estimated distribution routes;
• Registration as a tax payer;
• Development of technical documentation for production;
• Obtaining permits from regulatory services (fire inspection, sanitary and epidemiological station, labor safety inspection);
• Opening a current account (for individuals if necessary, for legal entities mandatory);
• In the event that registration is carried out in the form of an LLC, the creation of a charter and an order for the appointment of a general director.

Room

The total area of ​​the room must be at least 150 square meters. Of these, 70-90 sq. m - the workshop itself, the remaining area is allocated for warehouses and administrative premises. Rent will cost approximately 1000-1200 dollars per month , and repairs and preparation of the premises for work will cost another 1000-1500 dollars.

Must be:

• Heating, ventilation, sewerage and water supply;
• Fire safety system and evacuation schemes;
• Electrical network 380 V;
• The height of the ceilings in the workshop is from 3 meters.

Marketing

It is most profitable to sell this type of product through large retail chains and wholesale companies. Create a bright and memorable trademark and packaging design. Don’t immediately aim for a federal scale. Start by conquering the regional market.

Your target audience is students, young people aged 17-30 years. Actively use the Internet, outdoor and print advertising directly at points of sale. The organization of promotions, tastings, promotions, prize draws works flawlessly. But the best advertising move will be the high quality of products and constant updating of the assortment.

Croutons production technology

The technological process can be divided into two large parts - the production of snacks and their packaging.

Production

Manufacturing of the product is divided into stages:

1. The bread is sliced ​​and fried;
2. Cut into strips;
3. The straw is dried thoroughly;
4. Spices and various flavoring additives are added;
5. The product is kept cooled and packaged.

If you bake your own bread, you can save on purchasing raw materials in the future. Then the first step will be baking bread.

Package

Before starting a business, you need to develop a packaging design. It must be bright and eye-catching in order to stand out among many competitors. The packaging itself is made of metallized film , onto which a pattern is applied, according to the created design.
It is best to pack crackers in 50 and 75 g sizes. Packing 100 kg of product will take approximately 5 kg of film.

Features of product sales and advertising

Sales of finished products can be carried out in the following way:

• Wholesale sale of crackers to companies and organizations that will then sell them at retail. This method is convenient in that large volumes can be sold immediately, albeit at a lower price;
• Independent sale on trading platforms (shops, supermarkets, kiosks, cafes);
• Organizing your own sales points.

In order to develop a customer base and advertise your products, you should pay attention to the following methods:

• Develop a name for crackers and a colorful packaging design that will attract the attention of consumers. In this case, it is better to turn to specialists - although such a service will have to pay a certain amount of money (from 10 thousand rubles), such costs are always worth it;
• Order advertising in the media, post information on the Internet;
• Conclude marketing agreements with retail outlets that involve placing your products in a place visible to the buyer (golden shelf);
• Monitor the quality of the product produced very carefully, since any advertising will sooner or later stop working if the product itself is not liked by customers.

Equipment for the production of crackers

The standard set should include the following machines:

• Ovens for frying and drying bread (around $1000);
• Equipment for cutting bread into strips ($1200-1500);
• Oven for roasting snacks (about $1,000);
• Coating machine (up to $800);
• Spice machine (approximately $600);
• Packing machine ($1000-1500).

If you want to immediately receive a finished product, you should purchase a production line. The most inexpensive lines produce about 20-25 kg of product per hour and cost around $3500-5000. Let's also add here a bread baking oven that costs about $3,000.

Buying a line is not always profitable . It often turns out that the productivity of the coating machine and the straw cutting equipment is higher than the productivity of other machines. To avoid downtime, you can purchase each machine separately, based on performance indicators. And also the purchased line can be completed. For optimal operation, you need one or two more semi-automatic packaging machines and several ovens for frying snacks. Production volumes will increase two to three times.

The best manufacturers

A complete line of equipment can be purchased from the following manufacturers:

1. Clextral;
2. Lydia;
3. DG LLC

Among the best manufacturers of industrial bread makers are Russian Trapeza, Magikon, Enkomak. Tornado offers high-quality machines for cutting bread into strips or cubes. And packaging machines should be purchased from the companies Rovema, Ishida, ITP PROMBIOFIT, Lyon.

Additional equipment and tools

In addition to equipment, you need tables, shelving, containers for storing and drying crackers, small things like scales, mugs, and measuring spoons. It is better to purchase tables and shelving used than to look for initially cheap ones. Purchasing equipment will require costs in the region of $1000-1500.

Risks and disadvantages of business

The main disadvantage of organizing food production is the high cost of equipment. The compensating factor is that in the event of a business closure, the machines are quite simply sold at their residual value, and this makes it possible to compensate for up to 50% of capital investments.

The disadvantages of business also include

• unstable quality of flavoring additives from Russian suppliers;
• noticeable seasonality of sales with a drop in profits in the first half of the year;
• high competition from well-known brands;
• a state program for the demolition of stalls and shopping pavilions - key sales points;
• high packaging and advertising costs.

Raw materials for the production of crackers

Snacks are made from wheat or rye bread. In our case, we will need wheat or rye flour. As well as spices, flavorings, oils, flavorings.

To make 100 kg of snacks you will need about 95 kg of flour, 30-40 liters of oil and about 3 kg of spices. It is best to buy flour and butter from domestic brands, but all kinds of additives are from foreign brands.

Among consumers, the most popular flavorings are cheese, meat, seafood, onion and sour cream.

Raw materials and personnel

For the production of crackers, the most common domestic raw materials are used. This is sunflower oil and flour. If croutons are made from previously baked bread, it is better to use dense varieties that have a smooth mesh surface and no voids. Any bread baking company that works in accordance with classical technologies will fulfill such an order with ease and speed.

The number of personnel in production, which should be employed only on the production line, is about 4-5 people per shift and a foreman. In addition to the above, a snack enterprise needs a responsible production manager (controller) and highly qualified chief technologist and mechanics. Under conditions of indirect distribution, the total number of personnel is approximately 20-30 people.

Organization of production

When the equipment is fully equipped, work can be organized in two shifts. In this case, you will need to hire:

• Four workers per line;
• Technologist;
• Mechanics;
• Accountant;
• Manager;
• Purchasing Manager;
• Sales Manager;
• The cleaning lady.

There are 11 people in total. The salary fund will be about five to six thousand dollars a month.

Working in two shifts, up to 300 kg of finished products can be produced in one day.

Relevance of the idea and market assessment

The production of crackers as a business idea has a number of positive aspects:

• high level of demand for this type of product;
• simple manufacturing process, the technology is very easy to master;
• adequate cost of equipment, no specialized room parameters required;
• payback period – from 6 to 18 months.

At the same time, it is necessary to evaluate the market, since competition in this sector is high, both among domestic firms and among imported products. This is the main disadvantage of the business in question.

Sales

Where to sell the finished product?

1. Wholesale companies and retail chains;
2. Crackers by weight can be offered to supermarkets, cafes, and bars.

When starting a business, it is best to focus on the middle segment. That is, for small chains and stores . They can be interested by offering supplies at a fixed price that is acceptable to them. Even if you have to slightly reduce the cost of sales, you will benefit from stable large orders.

It's worth taking care of advertising. The most effective will be outdoor POS advertising (placed directly at the point of sale of the goods). This is an expense item of $700-1000.

Problems and nuances

With certain mistakes, even such a simple production can be completely ruined. Therefore, pitfalls should be taken into account:

• additional costs due to the human factor (theft, shortcomings, malfunctions);
• inspections of SES not only on a district, but also on a regional scale, you must always be prepared for them;
• it is imperative to constantly update the assortment and number of offers in order to attract new customers;
• the packaging should be colorful and attractive in order to stand out from the general palette on store shelves.

If you take into account all the details, the production will pay off as quickly as possible.

Review of popular manufacturers

Bread slicers from Wabama, Gastrorag and Sinmag are rightfully considered high-quality and popular equipment.

Wabama

The Signa Atoma bread slicer from the German company Wabama is designed for large bakeries.

The model, measuring 1,700x620x1,020 mm and weighing 240 kg, is capable of cutting up to 800 loaves with a height of 150-160 mm into pieces 9-12 mm thick in an hour. The cutting speed can be adjusted.

The machine is equipped with Teflon-coated knives, a pressure conveyor, a safety system, functions for blade lubrication and oil level control, a counter for sliced ​​bread slices, and a device for packing bread.

The cost of such equipment is from 90,000 rubles and above.

Bakery owners who purchased bread slicers say:

Svetlana:

“This is very expensive, but high-quality catering equipment. I did not regret purchasing such a bread slicer for my bakery. The pieces of bread turn out smooth and uniform, and there is no need to pack the bread by hand. I'm happy with the purchase.”

Natalia:

“I bought a bread slicer for the dining room. We have a lot of traffic, close to a university and a small factory. We buy bread from a local bakery and cut it ourselves, which makes it cheaper. The thing is, of course, expensive, but it fully justifies its price. We have been using it for a long time, it has never broken or malfunctioned. I recommend it to anyone who has their own bakery or large dining room.”

Gastrorag

Chinese automatic bread slicers BS-HLM-31, manufactured by Gastrorag, allow

quickly cut the bread into slices, cubes or sticks 12 mm thick. Machine dimensions – 800x510x780 mm, weight – 77 kg. The equipment can cut up to 220 loaves per hour.

The cost of bread slicers BS-HLM-31 is 39,000 rubles and more.

Here's what buyers say about the technology:

Catherine:

“This is a great bread slicer at a great price! It's been in our bakery for a long time! The machine fits perfectly into the interior, it is easy to use and easy to clean. I recommend to everyone."

Basil:

“I looked closely at different models of bread slicers for a long time, but settled on a device from Gastrorag. I was attracted by the price and size. The machine works great, thanks to the cooks they save time, the dining room is large, we have to cook a lot. We are very pleased with the purchase.”

Business on crackers: recruitment

Almost everything is standard here. You need a manager, sales and customer service managers, an accountant (you can outsource the work), a mechanic to maintain the operation of the machines, as well as two pairs of workers. The latter will directly control the machines during production.

But that is not all. Even the manager is not the most important figure. The most important person in the workshop is the technologist. It is he who will be responsible for creating new recipes to produce even more fantastic tastes. If you manage to find and lure a good technologist to you, then consider half the success already in your pocket.

Workshop technical equipment

The next thing to do is to find suitable premises for a workshop and buy equipment for the production of crackers. The type of equipment will depend on the planned sales volume of the finished product and available finances. Since this area is popular, there should be no problems finding the necessary devices.

Production line for the production of crackers

The line for the production of crackers consists of the following equipment:

• coating machine,
• bread slicer,
• oven,
• packaging machine.

This is the main list of units. But if you plan to use the same workshop to produce bread for further processing, you will need an additional line - dough mixers, ovens, proofers, dispensers, flour sifters.

The price of equipment for beer crackers varies widely. A decent low-power line can be purchased for 800,000-1,500,000 rubles. Savings are possible with used machines. High-capacity automatic equipment can cost up to 5,000,000 rubles. It just doesn’t make any sense for a novice entrepreneur to purchase this.

The cost of a line for crackers is not the only expense that a production workshop will require. Don't forget about preparing the room. To place the necessary equipment here, you will need an area of ​​at least 80 m2. Food products will be produced here, and therefore the workshop must be re-equipped. In the future, the entrepreneur will be subject to an inspection by the SES and fire inspectors. The enterprise will not open until all requirements of the supervisory authorities are satisfied.

Harm to health of kirieski

Absolutely no one doubts that frequent consumption of artificial foods is harmful, but not everyone knows what exactly the harm is:

1. These crackers contain absolutely no vitamins and microelements, so they do not bring any benefit.
2. The high calorie content of these crackers is primarily achieved through the use of oil in their preparation (not always the best type).
3. Chemical flavoring additives, dye and carcinogens negatively affect the functioning of the gastrointestinal tract. Undoubtedly, satiety comes quickly, but even faster comes a feeling of heaviness in the stomach, heartburn, constipation and other negative consequences.

And as a conclusion from all of the above, the main problem of kirieski lovers is obesity and a sore stomach. Harmful fat compounds are not completely broken down by the body; they are absorbed into the intestinal walls and enter the blood, after which the excess is stored “in reserve.” However, such a “reserve” is not always beneficial.

What diseases can be caused by substances contained in crackers?

Most often, the gastrointestinal tract is affected by frequent consumption of kirieshi, but the cardiovascular system is also at risk. It has been scientifically proven that kirieski lovers have an increased risk of heart attack and stroke, and also lack stable blood pressure. In this case, the liver suffers no less, since it is she who has to make titanic efforts to at least slightly remove all harmful substances from the body.

I think it’s not worth saying that Kirieshki contributes to excess weight, depression and other psychological problems, and is also addictive, since this is elementary.

Why are kirieshki harmful to a growing body?

If you think that the main consumer of kirieski is children and teenagers, who on the way home from school can eat a whole pack of these crackers, or even two. After all, a child cannot realize what is healthy and what is not, so he relies only on taste sensations, as well as the crunch, which is so pleasant to the ear.

However, frequent consumption of such food can slow down the growth of organs and tissues, as well as create an unstable psyche and provoke early gastritis.

Harm of kirieshki for pregnant and lactating mothers

The worst thing for an expectant mother should be the consumption of food products that are created artificially. Since they bring absolutely no benefit to either the expectant mother or her child.

According to some data, they can even provoke complications during childbirth, as well as slow down the baby’s intrauterine development. Don't forget about such troubles as constipation, swelling, heartburn and mood swings, which can only be aggravated by these crackers.

How to choose quality equipment

The main criterion that you should focus on when choosing a bread slicer is the enterprise itself and its size.
For large bakeries and bakeries, it is more advisable to purchase automatic floor-mounted

bread slicers with program control and a set of additional functions, including intelligent slicing, feed speed adjustment, product packaging system, air injection for opening bags, and a compartment for collecting crumbs.

For canteens, restaurants, cafes, food processing plants and bakeries of medium and small sizes, semi-automatic and manual tabletop equipment is perfect. The choice of model will depend on production volumes, traffic and serving requirements.

To prevent bread from sticking to the knives when slicing, preference should be given to models whose knives are coated with Teflon.

In addition to design features, attention should be paid to the appearance of the bread slicer and its manufacturer.

Using paper baking dishes you can make various baked goods: muffins, cupcakes, Easter cakes. Do you need to clean large quantities of fish frequently? Then an electric fish scaler is a godsend for you! Useful information in this article.

Cutting carcasses is very easy with special saws. Read about the varieties of this equipment at https://vkusologia.ru/osnashhenie/elektromexanicheskoe/pily-dlya-myasa-i-kostej.html link.

The process of releasing crackers

The technology for producing crackers is extremely simple - anyone can master it.

The stages are as follows:

• cutting bread (cubes or slices),
• frying the semi-finished product (with or without oil),
• adding spices,
• packaging and packing of finished products.

On average, to produce 10 kg of crackers, it takes about 13-14 kg of fresh bread and 3-4 liters of vegetable oil (if it is provided for in the recipe at all).

Since we are talking about a food enterprise, special attention should be paid to the quality of raw materials - this will affect the final taste of the product. The production of crackers can take place either from purchased bread or from bread made at the same enterprise. The second option, although it will require additional costs, will help to significantly reduce variable costs in the future.

A trial batch of products is sent to an independent laboratory, where the composition of the crackers is checked and their compliance with quality standards. This is the only way to obtain permission from supervisory authorities to conduct activities.

Table with points

10th place - VIATTO ACS-Q31

In tenth place in the ranking is the ACS-Q31 bread slicing machine from the Chinese brand VIATTO. The professional model will easily cut baked goods into even pieces of equal thickness. You just need to place the bread in the loading tray, adjust the guides and turn on the machine.

The cutting method is gravitational. This means that the bread will pass through the frame with knives under its own weight.

You cannot select the slice thickness when ordering a bread slicer. The model is equipped with a 12 mm frame.

IMPORTANT! To maintain the same speed of operation, it is necessary to ensure that there are at least 2-3 loaves in the loading tray at all times.

9th place - PYHL TR350

9th place is occupied by PYHL TR350 - a tabletop, gravity, frame bread slicer. Structurally, it is no different from the model from 10th place: the same 12 mm piece, frame with knives, lack of safety elements and pushers.

It is worth noting the convenient guides in the receiving area, which keep the sliced ​​bread from falling apart.

The bread slicer can cut up to 160 loaves in an hour. Speed ​​largely depends on the agility of the operator.

8th place - Hurakan HKN-PICO12

The Chinese tabletop bread slicer HKN-PICO12 from Hurakan is a gravity model with frame knives. The thickness of the piece cannot be changed. For this model it is 12 mm. Not the most popular size, but close to it. There is also no option to choose a different slice thickness when ordering equipment.

Not intended for slicing fresh bread, as well as products made from rye flour. Cutting should be done only after the products have completely cooled and been kept for 24 hours.

The machine is not equipped with any safety features. Moving knives are exposed and the operator must be extremely careful to avoid injury.

The speed is average - up to 180 loaves per hour.

Rating of dough dividers

7th place - Gastromix SH31

The body of the tabletop bread slicer SH31 from the Chinese brand Gastromix is ​​made of stainless steel. According to the manufacturer, it is able to provide operating speeds of up to 180 loaves per hour. The knives can easily handle even fresh bread. But, like most similar models, it is not capable of slicing rye bread.

The thickness of the slice is set at the factory and is 12 mm.

6th place - PYHL TR12

TR12 from the Chinese manufacturer PYHL is an improved version of the model that took 9th place in the rating. A more powerful machine with a stated productivity of up to 300 loaves per hour. This bread slicer already has some safety features in the form of a closed feed tray, which explains its high operating speed. Now the operator’s hands, even by accident, will not be able to get into the operating area of ​​the knives.

Like TR350, the thickness of the piece remains unchanged and is 12 mm. Unfortunately, the manufacturer did not add anything else interesting: there is no container for collecting crumbs, or a table for packing sliced ​​bread. She can't handle rye bread either.

5th place - SINMAG SM 302

The high-speed frame gravity bread slicer SM 302 from SINMAG (Taiwan) can handle 300 loaves in an hour. I am glad that the manufacturer does not limit customers to one slice thickness: when ordering, you can choose a frame with knives of the required slice thickness from 6 mm to 9 mm and 12 mm. But it’s worth considering that switching from 9 to 12 mm will not be so easy. Most likely you will have to buy another bread slicer with a different size of knives.

The manufacturer promises that the machine can even handle fresh, soft bread.

The security problems are the same as the models above. The operator must be careful with his hands and not push the loaf on top with his fingers.

4th place - Lozamet MKP11.6

The Polish bread-slicing machine MKP11.6 from Lozamet is the only one in this rating equipped with a static knife block, which completely eliminates the possibility of injuries during operation of the equipment. The manufacturer has provided the ability to adjust the cutting speed depending on the size and type of bread. Easily copes with both hard (hard crust, bread with a large grain content) and soft fresh bread.

The crumbs are collected in a special drawer. The thickness of the piece is preset and is 11 mm.

Additionally, you can purchase a trolley on wheels, which is ideal for this model. This will allow equipment to be moved freely around the workshop.

3rd place - Jac Pico 450

This line is deservedly occupied by the Pico 450 model, a compact tabletop bread slicer from the Belgian company Jac. Manufacturers have thought through everything to the smallest detail, which has the best impact on the convenience and safety of operation.

The standard package includes:

• Pusher. You must choose one of three types depending on the average height of the loaf.
• Removable tank for collecting crumbs. Made of lightweight material, with frontal access. Capacity 7 liters.
• Packing table. The sliced ​​bread is placed on a special stainless steel slide, onto which the bag is placed.
• JAC FLAPS system. Provides retention of bread as it exits the bread slicer for easy removal.
• Frame with knives for cutting into slices with a thickness of 9 to 18 mm to choose from.

It is possible to further secure the machine by ordering additional protective covers. The plastic casing will completely cover the working area of ​​the knives. And the emergency switch will prevent the machine from operating when the rear or front cover is open.

The machine is semi-automatic - the cutting cycle is started by pressing the lever.

An important feature for the Russian market is the ability to slice bread with a sticky crumb. For these purposes, special Teflon knives and a pusher with a lubrication system are used, which are purchased separately.

Additionally, you can order a stand on casters, which automatically turns the tabletop bread slicer into a mobile floor-mounted one.

2nd place - AHM-300T

In second place is a tabletop model with a sickle-shaped knife – the Bulgarian bread slicer “AXM-300T”. Used in bakeries, cafes and bakeries to automate the cutting of baked goods into pieces of equal thickness. The slice thickness can be adjusted from 5 to 25 mm.

The bread slicer is equipped with safety elements. The painted steel housing is equipped with two protective screens with limit switches. One covers the bread loading area, the second covers the unloading area of ​​the product already cut into pieces. When both or one of them is opened, the bread slicer will stop automatically. But at the same time, there is no curtain made of metal plates in the unloading area, which does not completely protect the knife.

The speed is decent and depends on the slice thickness set. The manufacturer promises from 85 to 340 loaves per hour.

1st place - ATESY JANISSAR AHM-300A

The bread slicer of the Russian Janissary AHM-300A takes first place. It is ideal for the needs of catering establishments: cafes or canteens. A distinctive feature of models with sickle-shaped knives is the ability to adjust the thickness of the slice, which can vary from 5 to 20 mm.

The manufacturer has taken care of the safety of the operator: the power supply stops as soon as one of the two protective plexiglass covers installed on the bread loading tray and the receiving tray is opened. In addition, a curtain made of metal plates covers the operating area of ​​the knife. No foreign object will be able to get in there.

Suitable for slicing both fresh (soft, but not warm) wheat or rye-wheat bread, as well as day-old bread. The thickness of the pieces does not vary, remaining the same thanks to a special feeding mechanism.

The crescent knife is made of hardened stainless steel. It retains its sharpness for a long time and does not require sharpening.

The body can be made of either stainless or painted steel.

It does its job quickly and, depending on the set slice thickness, can cut from 100 to 300 loaves per hour.

What about the assortment?

In your business plan for the production of crackers, include a list of the types of crackers that you will produce in the future. A qualified technologist will help here, who will think through the recipes and develop a product line.

It is important what kind of bread you will work with in the future.

The following types of crackers can be distinguished:

• from wheat bread,
• from rye bread.

Each product has its own fans, and therefore, focus on each customer by producing all types of crackers.

To impart the final flavor to the crackers, cracker spices are used. According to experts, the most popular flavors are “sour cream and onions,” “bacon,” and “mushrooms.” To get your bearings on the demand for your product in a specific market, do not start producing crackers in all flavors at once - 3-5 will be enough for a start.