Line for the production of wheat flour. Own flour business

The domestic market has extensive raw material resources for the production of wheat flour, rye and other grain crops. The flour-grinding industry is characterized by deep specificity. The effectiveness of its functioning by 50% depends on the literacy of the organization and implementation technological stages preparation and processing of grain.

Flour production technology

The manufacturing process in flour factories is fully mechanized. The initial stage of preparing the grain fraction for processing is purification and conditioning. from weed impurities are performed in separation, trier and duaspirator apparatus; removal of mineral impurities - in stone-separating; grain is washed in special washing units and moistened in silos. If necessary, the grain mass additionally undergoes a series of these treatments.

The maximum level of purification of the grain mass from weed and oil impurities can be achieved using air-sieve separation apparatus (they remove most of the impurities of all fractions), stone separators (clean from stone-like fractions), trieres (separate grains of the main mass from grains of ballast crops), magnetic separators (remove metal impurities), etc.

The next step in the technology of flour production is the cleaning of the surface of grain shells from contamination. This operation depending on the technical equipment of the enterprise, they are carried out in a dry or wet way. The first of them involves the use of a scrubber, the main working body of which is a whip drum located in a steel or abrasive cylinder. As a result of impacts, friction and interaction with each other, the grains are cleaned of all kinds of contaminants, flaky shells, adherent soil. To remove dusty weedy fractions, the scrubbers are equipped with aspirators.

The wet method of grain cleaning, unlike the previous one, is characterized by high efficiency. It provides for the use of washing units with a water consumption of 2 m3/t. The complexity of its use lies in the need for mandatory cleaning of sewage before draining into the sewer. Therefore, wet peeling of grain was chosen as an alternative to it, in which the volume of wastewater is significantly reduced, and qualitative indicators don't miss anything.

Ensuring the stability of grain quality parameters helps to reduce the frequency of adjustments of grain processing machines. To this end, in the production of flour, a grinding product of mixing is formed and thermal hydrotreatment of the grain is performed before grinding. A competent combination of grain mass components with different moisture content, gluten levels, endosperm, cost, determines the production of flour with the expected yield, predictable properties and acceptable cost. Batch planning contributes not only to increasing the productivity of grinding grains, but also helps to prevent the rejection of low-value grain, during the processing of which it is unrealistic to find flour with suitable properties, and rational use of glassy wheat grain.

Thermal hydrotreatment of grain in order to increase the level of endosperm extraction in the grinding process and reduce energy consumption should be performed before the formation of the grinding mixture, since heterogeneous grain is not uniformly transformed during it.

The flour production process involves grinding the endosperm and grain hulls. The latter, having a high resistance to grinding, are crushed worse than the endosperm, and the more contrasting the difference in their strength qualities, the better the upcoming separation. In dried grains, the level of such a difference is lower than in raw grains, as a result, it should be moistened before grinding. Wetting underlies the thermal hydrotreatment of grain. Three methods of humidification are used: cold, hot and the most demanded - accelerated conditioning. Its feature is the moistening of the grains and their subsequent dampening in the bunkers.

When moistened, water is actively impregnated into the grain. Initially, it is concentrated in the outer shells. Getting into the endosperm, it reduces its strength, increasing supercritical pressure due to the growth of the moisture gradient. Since the moisture content of the outer and inner layers of the endosperm differs, they swell inhomogeneously, which provokes a tense property of the raw material.

In addition, the starch and protein components also swell differently. As a result, when the force increases to critical parameters, microcracks appear in the endosperm, which are capillaries through which water enters the grain with the action of wedging, destructive forces accumulate and the endosperm is weakened. For graduation this process time is needed. With an increase in the level of humidity due to the swelling of cellulose and fiber, the shells are plasticized, and their fragility decreases.

As a result, such a stage in wheat flour production technology as accelerated conditioning provides an intensification of the separation of the structural and mechanical features of the outer shells and endosperm, which simplifies the implementation of varietal grinding and reduces the degree of fragmentation of the shells. The final step in preparing the grain mass for grinding is auxiliary moistening and dampening before grinding for half an hour. During this time, water enters the endosperm, is fixed in the shells, which contributes to the enhancement of their plasticization.

The technological scheme of flour production provides for the grinding of grain into flour, consisting of direct grinding or crushing, as well as sieving the grinding results. Grinding is carried out on rolling equipment with a corrugated, rough or even surface. Following the roller apparatus, a sifter is placed, consisting of a set of different-sized sieves mounted one below the other, to sort the grinding results by particle size. Flour making equipment such as sieving roller form torn or grinding system. The first of them with corrugated rollers is used for grinding the grain mass into grits. The grinding system with smooth rollers is used for making flour.

In the flour production scheme, the main operation is grinding (single and repeated). With a single flour is formed in one pass through the grinding equipment. The quality characteristics of such flour are low.

Modern mills for the production of flour provide for a repeated method of grinding with multiple passage of grain or crushed elements through the crushing and grinding apparatus. Distinguish between simple and complex grinding of this category. With a simple one, only single-grade flour is produced. Crushing is carried out on 3-4 systems. With complex varietal grinding, the grain mass is passed through torn apparatuses, sorting units for grinding fractions and their enrichment, and then grinding grains on different grinding systems. At the initial stage, they try to produce a minimum of flour fraction on tattered machines. The result of grinding is sorted by size and density, enriched in sieves. In total, with complex grinding, about two dozen flour flows of various qualities are produced. Then they are combined into 1-3 varieties in accordance with the varietal grinding.

Preparation of flour for production consists in sorting different batches, sieving them and magnetic cleaning. Different batches differ in baking qualities, as a result of which, before delivery for sale, separate batches of the same grade are mixed on flour mixers. So, low gluten flour is added to strong flour, etc. The volume of components in the finished mixture is predetermined on the basis of laboratory tests.

In the work of the flour mill, a significant yield of by-products is obtained, many of which are sent to the production of fodder flour. Categories of such products are regulated by regulations. In order to avoid self-sorting of the finished fodder meal, it is sometimes granulated on DG press machines. For this purpose, special binding components are introduced into the resulting product. According to Rosstat, the supply of the livestock industry with flour milling waste is 118%, with fodder flour - 96%.

Since ancient times, flour has been the basis of the human diet. From flour products, our body receives the nutrients necessary for human life. They contain vitamins and valuable minerals such as phosphorus, magnesium and potassium. These nutrients are essential for the normal functioning of the human brain.

In modern production of flour products is fully automated. For the production of flour, various equipment and manufacturing technologies are used.

Flour is a powdered product obtained by crushing cereals.

It is classified according to several criteria: by species, types and varieties.

The species is determined by the grain used.

The type is determined in accordance with the intended purpose.

The variety is determined by the amount of product obtained from 100 grams of cereals. The more it is obtained at the output, the lower the grade.

Interesting fact! One grain yields about 20 milligrams of flour. It takes about 10,000 of these grains to make one loaf of bread.

IN modern production The most popular types of flour are:

wheat;
rye;
oatmeal;
rice;
barley;
buckwheat;
corn.

It has the highest popularity in the production of flour products. It has a high calorie content. Contains all the nutrients necessary for life. It is used for the manufacture of bakery and products.

Contains essential amino acids, vitamins and trace elements. It is used for the production of nutrient mixtures, bakery and culinary products. It is often mixed with wheat for special nutritional benefits.

oatmeal

It is high in carbohydrates and nutrients. Technology lean manufacturing allows you to save a rich composition of vitamins A, B and E.

Used for the manufacture of culinary pastries. Used as a food additive to various types of flour products.

Rice

Contains a high amount of starch. Rich in vitamins and beneficial trace elements. Has dietary properties.

It is used for the manufacture of infant formulas and dietary products. Used to prepare various sauces, breading meat and fish dishes.

barley

Contains quite a large number of trace elements. Normalizes the work of the digestive tract. Removes harmful substances and toxins from the body. Widely used as a nutritional supplement for various types of food.

Buckwheat

Differs in its useful dietary properties. Easily digested and absorbed by the human body. Contains nutrients and amino acids. It is used for cooking various cereals and culinary pastries.

corn

It has unique taste, nutritional and healing qualities. The composition of corn grain includes all the substances necessary for the life of the body.

Cornmeal is made from yellow and white corn. Corn is rich in starch, iron, carotene and vitamins PP, E, D, B1.

IN Food Industry There are three main types of flour:

Bakery. Used for production bakery products and yeast dough.
Macaroni. Widely used for the production of pasta and spaghetti.
Confectionery. Used for production confectionery and baking.

Flour grade

In modern food production the following varieties are regulated:

Extra (grain) - 10–25%.
The highest grade (bakery) - 25–50%.
First grade (universal) - 25-70%.
Second grade (butter) - 70-85%.
Wallpaper - 95% or more.

Flour normalizes metabolism, regulates digestion, removes toxins, strengthens muscles, prevents diathesis and dysbacteriosis.

An adult needs from 300 to 500 grams of bread per day. With heavy physical exertion, this rate increases to 700 grams. For children and adolescents, the daily dose of bread consumption is 150-400 grams.

Production equipment

For the production of flour, the following equipment is used:

equipment for preparing grain for crushing;
mill complex;
packing unit.

Flour production equipment is supplied in sets ready for production immediately after installation and commissioning.

Main Suppliers production equipment are factories MILLTECH from Turkey, SKIOLD in Denmark, JSC "Penzmash" in Russia.

Transportation and preparation of raw materials

Grain is brought in railway wagons. Railway tracks go directly to the territory of the mill.

Flour transportation is possible by all means of transport

Grain wagons are different from conventional freight wagons. They have a conical shape and several hatches at the bottom.

The locomotive brings the wagons to the section of the tracks, which is located above the receiving bunker equipment. The hatches open and the contents are poured into the bunker. From the bunker, along the underground conveyor, the grain is transferred to the top floor of the elevator and placed in a storage tank.

Then a sample of each batch of raw materials is sent to the laboratory for testing. Laboratory workers investigate and determine the possibility of using grain for the production of flour.

The studied samples are checked for the presence of grain pests. To do this, use equipment that has two sieves with different cell diameters. Microparticles during sieving pass through the sieve and fall in the form of sediment on the pallet.

Then the studied samples are checked for contamination with impurities of other crops. After finishing laboratory research, a batch of grain is sent to the mill plant.

A modern mill complex is a powerful equipment several floors high.

The grain begins its journey from the very top of the production structure and is transferred from floor to floor, passing through all stages of production. From the starting point to the finished product, the manufacturing process goes through all the floors from top to bottom.

Raw materials enter the elevator equipment from different fields and have different characteristics. To produce flour of the required quality, grain from different batches is mixed in the required proportion.

Main stages of production

The production process is carried out in 5 stages:

peeling grains;
purification of grains from impurities;
washing and moistening of grain;
finished product packaging.

Peeling grains

Raw materials are cleaned from volatile impurities and husks strong current air. Shredded shells are transferred to another workshop for the production of bran.

Purification of grains from impurities

At this stage, various impurities are selected and removed by thermal hydrotreatment. Under the action of air flow and vibration, impurities are lifted up and removed from the cycle.

With the help of washing equipment, grains are cleaned from dust and dirt. The seeds are then moistened by sprinkling with water to facilitate separation of the kernels from the shells. Moistened grain mass is left to rest for several days and then sent for grinding.

Grinding

Moistened raw materials are crushed at the mill complex with the help of special equipment- roller machines. Crushed grains are repeatedly screened by scattering machines until a homogeneous powdery mass is obtained. The finished product is sent to the packaging shop.

Before packing the goods, the laboratory staff takes a sample of the received batch for analysis. According to the results of the analysis, the flour is assigned a grade.

The following indicators are subject to verification:

the amount of gluten;
gluten quality;
ash content of gluten.

Gluten is a mixture of protein products that make up cereals. Gluten is obtained by sifting flour and washing out protein substances with water. It is a highly plastic viscous mass of gray color.

To determine the amount of gluten, knead the dough. The resulting dough is soaked in water. After 15–20 minutes, all starch is washed out of the dough. The resulting dry residue is gluten. Its weight and elasticity are the result of a test.

The ash content is determined by burning the product in a kiln and weighing the remaining ash. The lower this indicator, the higher its grade.

According to the new rules, a vitamin-mineral mixture is added to the flour of the highest and first grades. Therefore, the products are not only natural and fresh, but also enriched with vitamins.

Finished product packaging

With the help of a filling machine, the finished product is placed in bags. The weight of one bag is 50 kg. The bag is sewn up and sent to the finished product storage area.

Ensuring high yields of cereal crops and application modern technologies production allows Russia to occupy a leading position in the world grain market.

In this material:

The flour production business should be based on real calculations made taking into account the state of affairs in a particular region, after analyzing the market situation. The document helps to clearly plan both investments at the start and the expected profit, assess the profitability of the business and its feasibility.

Flour is a product that any housewife can find. On an industrial scale, this raw material is in demand at bakeries and private bakeries; it is used for the manufacture of pasta and breading. Despite relatively high competition, the need for flour is inexhaustible, which means that the business of its production is economically profitable.

Features of the flour milling business

When deciding for yourself on what scale flour production will be organized, you need to understand that modern high-performance equipment allows you to ensure a high yield of the final product, organize the supply of large lots to factories and other interested objects. But at the same time, a small flour mill requires less start-up costs and allows you to manage with a minimum number of workers.

Not being seasonal, the flour production business depends on fluctuations in exchange rates, reliability of raw material suppliers, and crops in specific regions.

What raw material is flour made from?

Along with the traditionally habitual wheat flour of the highest, first and second grade, grains of other cereals can be used in production - rye, barley, oats, corn, spelled, rice, as well as from buckwheat, soybeans, peas.

Flour from different types raw materials differ in taste and energy indicators, different in calorie content and chemical composition.

Flour is divided depending on the purpose:

bakery;
confectionery;
pasta.

Depending on grind:

thin;
coarse (whole grain).

Flour production technology

During the production process, the grain goes through several stages of processing and processing until the finished product is obtained.

Input control of raw materials. At this stage, the quality of the grain, its compliance with the norms and requirements of technological documentation is assessed.
Preparation and cleaning of grain.
Peeling and grinding of raw materials (separation of films).
Grinding (crushing) of grains.
Sifting flour, separating unground grains.
Packing of finished products.

Organizational plan of the enterprise

Production registration

To register a private business, it is necessary to draw up documents for an individual entrepreneur or LLC. If you do not plan to work with legal entities, then IP is enough.

For registration, you will need an application to the tax office to obtain a TIN, an application, a photocopy of your passport and a receipt for payment of state duty.

To register an LLC, you need a Charter, a decision to establish a company, an order to appoint a head, information about the authorized capital and a personal account number.

OKVED code 2 - 10.6 - "Production of products of the flour-grinding industry, starch and starch-containing products."
To obtain a license required for grain processing, you need to submit quality documents for raw materials (from the supplier) to Rospotrebnadzor, technological documentation for machinery and equipment, process flow diagrams, health and safety instructions.

Room search

The room for the equipment of the flour mill must comply with the norms of sanitary and hygienic documents, be equipped with ventilation, have water supply, sewerage, and electrical supply.

Before installing the equipment and starting work, the shop is treated against rodents.

In addition to the main premises for the workshop, warehouses for grain and finished products - flour, utility rooms will be required.

The production room should be located next to a convenient road junction or road to facilitate the transport of grain and the removal of flour.

Purchase of equipment

The flour mill requires:

devices for preliminary processing and preparation of grain;
flour mill;
equipment for filling and packing.

But in addition to the three main positions, as a rule, additional machines are required for the formation of grinding batches and their storage, devices for separating impurities, grinding grains, separators for separating fractions, flour milling machines. rolling machines, sorting sieve machines, brush, whip machines.

The price of machines for the flour mill is directly related to their productivity. Some entrepreneurs prefer to buy used equipment. It is much cheaper than a new one, but often it is either obsolete or not under warranty, unlike a new one.

The domestic manufacturer offers prices lower than those of foreign competitors.

Formation of staff

The staff of a private flour mill is small: 2 workers who have been trained on the spot or have experience in similar work, a technologist (shop foreman), a laboratory assistant providing input control grain and finished flour, room cleaner, storekeeper (1 or 2).

Gradually, gaining momentum and increasing production, you will have to hire an accountant, a purchasing and sales manager.

Advertising and search for flour distribution channels

To establish sales, it is necessary to negotiate and conclude agreements with organizations dealing with flour: bakeries, confectioneries, baking shops, as well as agriculture (if the plans include the production of compound feed).

In addition to working directly, you can attract intermediaries, expanding the horizons of sales. Best Advertising– quality products, positive reviews partners. You can release any amount of printing products, but at the initial stage it is important to personally negotiate and offer free samples.

Project financial indicators

Investments and current expenses

rent for 3 months - 100 thousand rubles;
purchase and installation of equipment - 1.5 million rubles;
advertising expenses, paperwork - 80 thousand rubles;
purchase of grain to start work - 200 thousand rubles.

Current expenses include:

rent, communal payments- 100 thousand rubles;
salary, taxes - 150 thousand rubles.

In some cases, shipping costs must be taken into account.

Income and expected profit, profitability assessment

Statistics say that the profitability of the flour milling business is approximately 20-22%. It will be possible to recoup the costs and start working in profit in 12-18 months with work shift at 12 o'clock without stops and days off.

The greater the power and productivity of the machines, the more products can be obtained per shift. Warehouses for raw materials and finished products should be designed to store a ten-day supply.

The flour-grinding business is interesting and relevant, having selected a set of necessary equipment in a good price / quality ratio, it is possible to organize a profitable production with relatively little bloodshed.

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Alexander Savkov's company has a loud name - "Ochakovsky Food Ingredients Plant", but the scale is not suitable. Compact mill, industrial mixer and filling machine, that's all the equipment. True, it occupies a small part of the floor rented at one of the enterprises of the Moscow industrial zone. An already purchased German unit will be installed on the free area. “We will grow up,” says the owner. “In terms of flour, our capabilities were realized by seventy percent, and by additives - only by ten percent.”

Flour and food additives are not original products. Nevertheless, the revenue of Savkov's company is growing by an average of 30% per year and this year is likely to exceed 110 million rubles. OKPI produces limited demand flour - barley, corn, rice and mixtures of flavoring and functional additives for various products. Moreover, in such batches that other manufacturers will not undertake. Savkov's approach is to seek profit in small things. There was no other choice: at the time of the creation of the business, all of its capital was reduced to managerial experience, and $100,000 had to be borrowed to start.

“I like production,” the entrepreneur, who graduated from Tomsk Polytechnic University, explains without a hint of posturing. After receiving an engineering degree, he moved to Moscow in 2000. He was hired by the Fisonik company, which invested in energy-saving technologies. Its founders also considered non-core projects, and Savkov ventured to put forward ideas from himself. Only on the sixth attempt did he achieve agreement. Mosobltara sold equipment for the manufacture of glassine - impregnated cardboard. Since glassine is used in roofing, Savkov suggested resuming production in order to sell the material. construction companies. Shamil Iskhakov, co-owner of Fisonik, gave him $40,000.

The current miller recalls that already in the third month he was haunted by one thought - to bring the matter to mind, sell it and no longer take on such projects. As production director, Savkov received $400 a month, counting on a share in the profits in the future. The desire to “go out beautifully” helped to cope with a bunch of problems. Within a year, the investment paid off, and the parchment shop was sold for $80,000. Savkov was paid a bonus of $12,000. Encouraged by the fact that everything was successful, he agreed to the boss’s proposal to participate in the competition for projects for the resuscitation of the Pirkenhammer Czech porcelain factory, which was bought by Iskhakov. The tender was conducted by PricewaterhouseCoopers. Savkov admits that he had a trump card - knowledge of investor sentiment. As a result, his project was approved - economical: all viable equipment is restored and concentrated in one workshop. The author agreed to minimum wage- €800. But he could gain unique experience and understanding of all the processes of organizing complex production. “I personally made about 2,500 plates,” the entrepreneur boasts. Having revived, in 2004 the plant produced up to 50,000 items per month. And then Savkov's work permit in the Czech Republic was canceled when he tried to get a visa for his pregnant wife at the embassy.

Alexander did not protest, judging that he was now able to find Good work in Moscow. And he was hired as a director of production at Rosgame with a salary of $6,000. Gambling market grew rapidly, Rosgame shareholders expanded production slot machines. “Alexander was distinguished by his initiative and willingness to take on a large amount of tasks,” notes Evgeny Matveychuk, a former shareholder of Rosgame (now the owner of the Kooker’s cafe chain). “He controlled everything so clearly that we could be calm about the state of affairs.” Savkov was promoted to executive, and then CEO. If in 2004 Rosgame sold equipment for $27 million, then in 2006 - for $55 million. The company has a network of 40 "R-clubs". It all ended when a law was passed in December 2006 banning gambling clubs. The enterprise was closed, the equipment was sold out.

Savkov had to look for work again. Having been interviewed at Mars and Formula Cinema, he chose the least status option - the position executive director in a company created by his acquaintance at Khladokombinat No. 7 (G. F. Ai Rus - production of ingredients for soft ice cream). According to Alexander, in a young growing business, he hoped to achieve more than as one of the managers in major project.

One day a customer purchasing powdered sugar, asked if they could supply him with rice flour as well. Savkov studied the issue and found that such a product in the Moscow region is constantly being produced by a single enterprise. It is unprofitable for large mills to make small batches of rare types of flour, although there is a sales market - confectionery companies, manufacturers of snacks and ready-made breakfasts, meat processors (flour with a high starch content is added to sausages and sausages). The average profitability of wheat flour production is 5-7%, rice flour - 20-25%. Savkov convinced the owner of GEF I Rus to buy the mill, and when he did not agree on a share in the project with him, he decided to create his own company.

Just at that moment, a potential investor appeared - Roman Cherepanov, co-owner of the Nova Leasing and Olymp Engineering companies, a classmate of Savkov's wife. Together with his partner Dmitry Zemlyakov, he agreed to provide $100,000 in exchange for a 50% stake in the project. “As friendly help,” Cherepanov explains.

In February 2008, Savkov established OOO Ochakiv Food Ingredients, ordered a mill, and found premises. In the summer, the company started working. “When we already had clients, I talked with the manager of one mill,” says Alexander. “He said that we can make up to 5 tons of flour a day, and heard: the laboratory level, we make 200–300 tons.” But already in 2009, OKPI's revenue amounted to about 30 million rubles. Savkov agreed to produce batches of even 500 kg and with weekly deliveries - so that the client did not have to order and buy out large volumes.

Where there is flour, there are food additives - flavors, emulsifiers, stabilizers, etc. And the market is wider - both dairy enterprises and canned food producers need additives. What you need: find out the needs, order mixture recipes from food institutes, purchase additional equipment. With additives more cost-effective than flour, the business began to grow faster. In 2012, OKPI sold products for 90 million rubles, flour brought in less than a third of the proceeds.

Compared to the market leaders, this is quite a bit. The revenue of the PTI group of companies - the largest manufacturer of food additives - in 2012 exceeded 3 billion rubles (they do not comment on the activities of a small competitor). Nevertheless, OKPI products are purchased by such giants as Cherkizovo and Mikoyanovsky Meat Processing Plant. Large customers account for about half of the revenue. “We take only a few items and in small volumes, but we are satisfied with the combination of price, quality and service,” says Alexander Kostikov, a representative of Cherkizovo. - OKPI is a mobile company, promptly responds to requests.

Back in 2011, Savkov bought out investors' shares by taking out a bank loan (according to Cherepanov, he invested for a year or two and left the project because this business he is not interested). There is now enough profit and short-term loans for development. When OKPI capacities are loaded, what will happen next? "Let's master new market. Here, we are studying the prospects, - Alexander points to a pile of nutrition bars on his desk. - We want to create a tablet with a complete set of proteins, carbohydrates and amino acids. It's time to make products for end users."

Flour is a commodity that is incredibly in demand on grocery market any country. Bread, rolls are baked from it, pasta is obtained from it and pancakes, dumplings, chebureks and dumplings are prepared.

Also obtained from flour for various kinds domestic animals and birds. A flour business should not be started with a mill for the production of flour, but with an assessment of the potential market for demand for this product. It is necessary to take into account how big the influence of grain processing giants in the region chosen for business is. You also need to take into account your own financial opportunities, as well as the presence of a market for flour products.

If you buy equipment for the production of flour and it will be idle from time to time, you will need to spend on commissioning and cleaning the working bodies from old scree. Certainly, interesting option- This is the use of those mills that worked in a not very long time. But they will require re-equipment to new quality standards, which may require considerable costs. For example, if you buy an old mill with a capacity of 100 kilograms or more per hour, then you should not expect a high quality product. Especially if you do not take into account the quality of the supplied grain and its preparation before feeding it to the mill. The quality of the goods becomes noticeably higher with a decrease in the productivity of the mill unit.

On the other hand, if you use an inefficient mill in your work, it will turn out to be unprofitable to supply small batches to large bakeries. At the same time, the flour production business will give a small profit. It’s better then to master your own bread baking for local residents, thereby avoiding unnecessary costs for transporting goods and making a profit from the sale of the finished product. But the production of high quality baking flour will also place high demands on the equipment.

AND domestic producers, and foreign entrepreneurs are guided by high productivity, estimated at up to one and a half tons of grain processing per hour. Some large enterprises are capable of producing up to 100 tons of product per day at their complexes. Moreover, the yield of premium goods is at least 55% of the total yield. But in the domestic market there are quite different opinions. You can often hear that mill complexes with a capacity of up to 100 kg give sufficient profitability. at one o'clock.

Our business valuation:

Starting investment 2,000,000 rubles.

Market saturation is average.

The complexity of starting a business is 5/10.

Technological features of flour milling

Whole flour is obtained by simple crushing of grain, while there is no need to isolate in technological process some special fractions from the total resulting mass. Such a process is simple in principle and does not require any complex devices in addition to the grain crusher. Beneficial here are hammer crushers to receive feed.

Varietal grinding is carried out by the method of repeated grinding of raw materials for the production of flour. Separation into intermediate stages occurs mainly by sieving through calibrated sieves or using rotary sieving cabinets. Each variety differs from others in the size of the dispersed elements of its fraction.

A more thorough grinding of the flour mass is carried out using special roller machines. Rollers in modern machines have replaced such old methods of production as grinding grains between millstones. But millstones are becoming a thing of the past, although as the surface of the millstones wears out, rubbing them against one another, the quality of the goods only improves.

So, flour is what passes through the smallest sieves. But the rest of the fractions are called, depending on their size, grains (small, medium, large) and dunst (soft or hard). The technology of production of wheat flour, which has a high saturation of the germ and fibrous structures with nutritional value, deserves special attention.

The technological scheme of flour production includes several stages:

grain cleaning from various impurities;
cleaning the surface layer of grain;
hydrothermal grain processing;
grinding grain on rollers according to the stages of readiness;
stage-by-stage sorting of the crushed fraction;
division of flour into varietal categories using sieves.

Bran obtained in the production of wheat flour is also divided into two types according to the diameter of its particles. The division boundary is a dimensional criterion of 0.8 mm.

Wheat flour production difficult process requiring the use of various equipment and significant energy costs. This explains the high price of a product made from premium wheat.

Flour production on Chinese equipment

In order to start flour production closely and on a grand scale, it is enough to open a flour production plant in Russia. A typical Chinese mini-mill uses a high-performance rougher, one sifter, and one stone selection machine. On the rolling floor, there are two 6FY-35 flour grinding machines, drum separators and a flour air filtration network.

Specifications of mini factory from China:

two mills for grinding grain are capable of producing 10 tons of flour per day;
the flour product is divided into grades: first, second and standard grade;
the dimensions of the room for the mini-factory (WxDxH) are 4x7x3.5 meters;
the total consumed electrical power of the equipment is 25 kW.

Mini-production of flour involves placing it in a tempering tank at the final stage. But by force large sizes this product will cost much less if it is made on site. The cost of shipping a large item will be unreasonably high. All installations and adjustments of the equipment of the mini-factory from China can be carried out with the help of a Chinese engineer, specially ordered for the commissioning period of the equipment. But domestic specialists are also able to mount all equipment according to ready-made drawings, perform all its adjustments.

Types of adjustments:

The mill without raw material load is put into operation 30 minutes before the start of the shift. Then it is completely stopped, and the main components are checked for excessive heating, vibration, and the condition of the V-belts. A mill machine without loading can work for an arbitrarily long time without harm to its mechanisms.
After starting the mill in the operating mode, its loading with grain must be increased gradually until the optimal operating modes are reached. If the mill is loaded abruptly, then automatic shutdowns of electric motors are possible, which will create additional labor costs for preparing for a new start-up.
The specified flour grade will be provided not only with the initial settings of the equipment, but also with constant monitoring of the output of finished products. If production suddenly increases, this means that its quality will be reduced.

Equipment List of China Flour Production Line:

flour-grinding machine (mill) - 2 pcs.;
fans - 3 pcs.;
sieve for sorting flour - 1 pc.;
drum unit for screening - 2 pcs.;
combined machine for selection of stones, peeling and sifting - 1 pc.;
wheat washer - 1 pc.;
air sluice -4 pcs.;
weight platform - 1 pc.;
portable sewing machine for sewing bags with finished products- 1 PC.

Before starting the supply of equipment from China, it is necessary to complete the design of the plant. This will make it possible to put the mini-plant into operation in a timely manner and obtain a consistently high quality of grain grinding products. The manufacturer who supplied the equipment in accordance with the provided project guarantees the uninterrupted operation of the mini-factory for one year, minimum costs electricity, the minimum number of operating personnel and service support. If we take into account that the price of equipment for the production of flour from China is much lower than from domestic or European manufacturers, then it is difficult to wish for a better business.

Advantages of Chinese flour mills:

high productivity of the flour production shop;
ease of placement in a small production area;
very low operating costs of the equipment;
lack of increased vibration and noise during operation;
long service life with high reliability of the working units of the equipment;
ease of adjustment and repair of machines for the production of flour;
increased safety of machine operation;
the possibility of placing mills with additional equipment in almost any room;
low price.

Suppliers of flour-grinding equipment from China deliver mini-mills for the production of flour and related equipment to complete the mini-mill within a strictly specified time frame.

Business plan for a flour mill

It would not be a mistake to say that every day every person eats culinary products in which flour is present to one degree or another. The need for flour is only increasing every year. For a product with in great demand the attention of businessmen is quite natural and promising. Activities related to the production of flour are simply doomed to success and profit. But the initial stage of this business, like any other, is the preparation of a flour production business plan. To guarantee success and profit, everything needs to be well thought out and worked out.

Initial cereal crops from which flour is produced:

wheat;
barley;
corn;
oats.

Such a list is needed to analyze the raw material base in the city where it is planned to organize a flour-grinding business. If some types of raw materials are in short supply in a given place, then the production of flour can be established from its other types. Of course, the technology for making flour from wheat grains will differ significantly from grinding corn or oats. This article addresses Special attention on the use of wheat grain for the flour-grinding business. A businessman who has identified wheat as the main raw material for production can begin to plan a production line with necessary equipment, and a room that is suitable for organizing production.

It is very profitable to engage in the production of flour for the reasons that in Russia there is no shortage of raw materials for this business. Grain base of the Russian Federation - the most important industry Agriculture, and representatives of this production are also looking for markets for wheat at a suitable price for them. And it is completely wrong to think that the flour and grain business is seasonal. Sale of bread, flour products and various pasta is carried out all year round with about the same intensity.

Of course, during periods economic crises the demand for all products falls, and the profits of producers fall with it. But after any recession comes a new growth in demand in the grocery market, which allows you to compensate for the losses incurred by businessmen at the time of the crisis. If you are conscientious and receive only a high quality product, conquering the sales market will not present a problem, and the number of trade customers will only increase.

The main buyers and customers of flour products are bakeries. It is very important that in the warehouse of the flour mini-factory there are always goods of all grades, from the first, second to the highest. Carefully observing fluctuations in demand for flour products, the manufacturer will be able to regulate the sale of flour of a particular variety, in accordance with his own profit. By selling different grades of flour, he can constantly maintain his business in a state of profitability and profitability.

The plan for the development of flour production should also take into account the rigidity of competition in the market for the sale of goods. There is hardly any business without problems and difficulties. Considerable competition also exists in the flour market. There are plenty of manufacturers of this product and everyone is looking for ways to sell their own products. But healthy competition is the engine of product quality.

We list the places where flour can be successfully sold:

livestock complexes;
private subsidiary farms in the countryside;
factories for;
bakeries and bakeries.

It would be nice to have your own point of sale on the market. This makes it possible to increase sales and the number of “own” customers. It is good if it is possible to conclude long-term contracts for the sale of flour with large trade enterprises, shops or bases. In any case, if we approach the matter with full seriousness, if we update obsolete equipment in a timely manner and improve the quality of flour, then the company's customer base will only increase.

The Net Economy in Numbers

The choice of premises for production, its disinfection and cleaning, the installation of a ventilation system and anti-insecticide measures are an important part of the cost of starting a business. In addition, such production will require a lot of permits from various supervisory organizations. There will be no big mistake if for all of the above you need to plan expenses in the amount of up to 300,000 rubles.

If 100 kilograms of a high-quality product are produced per hour of operation of flour production plants, then raw materials in the first purchase batch will require at least 200,000 rubles.

A large sum of 100,000 rubles will be required for the installation and commissioning of the plant's equipment. To this must be added the cost of the equipment of the mini-factory itself at 1,500,000 rubles. It turns out that initially you will have to invest at least 2,000,000 rubles. But after a month of operation of the enterprise, a profit of 200,000 rubles will be received from the sale of goods. It turns out that in a year of work, the enterprise can recoup all costs and reach a profitable mode of operation.

But only with a conscientious attitude to production, only without reducing technological requirements and avoiding unreasonable economic measures, it will be possible to consistently obtain high-quality flour and maintain our trade contracts with partners. And there will definitely come a time when the scale of production will not be enough to satisfy all existing orders. Then you have to think about expanding the business. And this will give a new level of profit and success.