Kvass production technology. Production process: How kvass is made Kvass production technology
Characteristics of kvass
Preparation of kvass bread and dry kvass
Preparation of kvass wort concentrate
Production of KKS from freshly sprouted rye malt and unmalted raw materials
Production of KKS from dry malts and unmalted raw materials
Preparation of kvass concentrate
Making sugar syrup
Cooking color
PRODUCTION OF KVASS, SOFT AND LOW ALCOHOLIC DRINKS
KVASS PRODUCTION
Characteristics of kvass
Bread kvass is one of the common drinks with a pleasant aroma of freshly baked rye bread and a sour-sweet taste. It contains various products of alcoholic and lactic acid fermentation, which give it a refreshing effect and a specific sour taste. The nutritional value of 1 dm 3 of kvass is 1000-1170 kJ (240-280 kcal).
Rye malt, rye flour, barley malt, sugar and other products are used as raw materials for the production of bread kvass. The main stages of its production include: obtaining rye malt, making kvass wort, fermenting kvass wort and blending kvass.
Previously, kvass wort was prepared using infusion and rational methods, which are now rarely used.
The infusion method consisted in extracting soluble substances from crushed kvass loaves by steeping in hot water two or three times. And according to a rational method, kvass wort was obtained by preliminary steaming under excess pressure for 2 hours of crushed rye fermented malt and rye flour. The steamed mass was placed in a mash vat, barley malt was added to it, and the mixture was saccharified according to a certain technological regime. The resulting wort was separated from the undissolved grain mass (thick) by filtration.
Currently, kvass wort is prepared mainly from kvass wort concentrate, kvass concentrates, enriched kvass wort concentrate, okroshechny kvass extract, which are obtained in specialized factories from fermented and unfermented rye malt, barley malt with the addition of flour, corn, barley.
When fermenting kvass wort, a combined culture of yeast and lactic acid bacteria is used. Yeast causes alcoholic fermentation, and bacteria cause lactic acid fermentation. Lactic acid bacteria convert about half of the sugar into lactic acid, the rest of the sugar into carbon dioxide, acetic acid and ethyl alcohol. The combined action of microorganisms is based on their different metabolism, and different requirements for the nutrient medium, as well as different reproduction rates. As a result of changes in environmental conditions, the course of fermentation changes, which is characteristic of these microorganisms when they develop separately. For example, in the first half of the fermentation process, where a combined culture is used, as a result of the vital activity of lactic acid bacteria, lactic acid accumulates and the acidity of the medium increases, which contributes to the reproduction of yeast. In the second half of the fermentation process, a further increase in acidity inhibits the vital activity of the yeast, and they begin to die. The autolysis products of these yeasts serve as food for lactic acid bacteria. In the presence of lactic acid bacteria, kvass yeast accumulates in the fermented medium up to 0.04% ethyl acetate, which improves the taste and aroma of kvass, as well as increases the stability of kvass during storage.
Fermented kvass is blended (mixed in certain proportions) with the necessary components, including sugar, thoroughly mixed and poured.
Preparation of kvass bread and dry kvass
Kvass bread and dry kvass are semi-finished products in the production of bread kvass.
Kvass bread is baked from a mixture of rye and barley malt, rye flour and water (without yeast or sourdough). For 1 ton of kvass bread, 477 kg of rye malt, 77 kg of barley malt and 185 kg of rye flour are consumed. Rye and barley malt are ground before use.
Leavened bread is prepared as follows. Rye flour is stirred in boiling water in a ratio of 1: 1.5 and kept for 1 hour to gelatinize the starch. During this time, the temperature of the mixture drops to 70 ° C. At the same time, crushed barley malt is rubbed in another container in hot water at a temperature of 70 ° C in a ratio of 1: 3 and incubated for 1 hour. The malt suspension is mixed with flour brewing and placed in a proving chamber for 2 hours, where the temperature is about 65 ° C. After that, crushed rye malt is added to the mixture, mixed and kept in a proofing chamber for another 1 hour to continue the saccharification of starch.
The finished dough is placed in molds and baked for 13 first 3 hours at a baking temperature of 160-180 ° C, then it is gradually lowered to 140 ° C, and at the end of baking - to 90 ° C. The unloaded I ovens weighing 2-3.5 kg are knocked out of the molds, placed on trolleys and sent to the cooling chamber.
When baking bread, the following processes take place. At a temperature of about 75 ° C, enzymes begin to break down in the bread and denature proteins, dextrins are formed from starch. With an increase in temperature to 100-110 ° C, reactions of melanoidin formation occur intensively. At temperatures close to 150 above, dextrins and sugars caramelize. As a result, kvass bread acquires a dark brown crust, a sweet and sour taste, and a malt-bready smell. Their humidity is not more than 40%. Kvass wort is prepared from freshly baked bread.
You can store breads for no more than 4-5 days (they begin to mold), therefore, for long-term storage, they are cut into chunks and dried for 10-12 hours at a temperature of 50 to 90 ° C to a humidity of 8%. Then the chunks are crushed and the so-called dry kvass is obtained. When dried, in comparison with kvass bread, its aroma is somewhat lost.
Preparation of kvass wort concentrate
Kvass wort concentrate (KKS) is a so-called bread extract, a semi-finished product for the production of kvass. By appearance KKS viscous thick liquid dark Brown color, sweet and sour in taste, with a slightly pronounced bitterness and aroma characteristic of rye bread. KKS is completely soluble in water, opalescence of its solution is allowed. The dry matter content in the concentrate is 68-72%, the acidity is 16-40 cm 3 1 n NaOH solution per 100 g of concentrate. The presence of preservatives and mechanical impurities is not allowed.
Currently, kvass wort concentrate is prepared in two ways:
1) from freshly sprouted rye malt and rye flour;
2) from dry malts (rye and barley) and unmalted raw materials.
KKS technology according to method 1 consists of cleaning and sorting rye, soaking and germinating it, crushing grain products, preparing mash, separating it, clarifying the wort, concentrating the wort, heat treatment of the concentrate and bottling the finished product. According to method 2, the preparation of CCS begins with crushing malts, unmalted raw materials, and then - operations similar to method 1.
In the production of CCS from unmalted raw materials, the following are used: rye, rye flour, corn, barley, flour and corn grits. They are stored separately in a dry and clean warehouse, free from grain and other pests. The storage of other raw materials or materials with odors in the warehouse is not permitted.
Bags with flour and cereals are stacked on wooden grates for storage. In warehouses with dry wooden floors, it is allowed to lay bags on the floor: in the warm season - in stacks of three bags in width; in cold seasons, stacks can be stacked in a width of five bags. The width of the aisles between the stacks must be at least 0.5 m.
The stacking height of the stacks depends on the permissible load on the floors, as well as on the moisture content of the raw materials and the air temperature in the warehouse. The recommended number of rows in a stack is shown in table 28.
Stacks in which the temperature is increased must be disassembled, and the raw materials must be transferred to production.
Dry rye malt is stored as described in chapter 6.
Enzyme preparations are stored in a tightly closed container in a dry room at a temperature not exceeding 20 ° C.
Chemical substances for the preparation of disinfectants, they are stored in a special closed room.
Production of KKS from freshly sprouted rye malt and unmalted raw materials
The scheme for the production of KKS from freshly sprouted rye malt and unmalted raw materials includes cleaning, sorting and weighing rye, preparing freshly sprouted rye malt, crushing grain raw materials, preparing mash, filtering the mash, concentrating the wort, heat treatment of the concentrate and filling the finished concentrate.
A feature of the production of CCS according to this method is that the technological process begins with the preparation of rye malt, that is, rye is the initial raw material. The main advantages of the method are the elimination of the stages of fermentation, drying and drying of malt, which allows you to preserve and effectively use all of its enzyme complexes. The process of melanoidin formation, which forms the fullness of taste, aroma and color of the kvass wort concentrate, occurs in more short time at the final stage of its production during heat treatment and with less loss of dry matter.
When producing 1 ton of kvass wort concentrate using this technology, the approximate consumption of rye is 1340 kg, of which 670 kg (50%) is used for the preparation of malt. The rest of the rye flour is used as unmalted raw material. The consumption of the enzyme preparation of cytolytic and amylolytic action depends on its activity and is approximately 0.02-0.2% of the mass of grain raw materials in the mash.
An instrumental and technological scheme for the production of kvass wort concentrate from freshly sprouted malt using an enzyme preparation is shown in Fig. 82.
Rice. 82. Technological scheme for the preparation of kvass wort concentrate from freshly sprouted malt using enzyme preparations
According to this scheme, freshly sprouted noria 1 malt is fed into a crusher 2 and ground together with water. The crushed mass with a screw conveyor 3 is loaded into a mash apparatus 4 equipped with a mixer and a heater. Preliminarily, water at a temperature of 45 ° C is taken into the mash apparatus and, during continuous operation of the mixer, an enzyme preparation is first introduced from the collection 5, then crushed rye malt in the form of malt milk and rye flour. The total hydronic module is (1: 3.5) - (1: 4). In this case, the wort has 14-16% dry matter and the pH is maintained in the range of 5-5.5.
Rye flour is preliminarily boiled in a predzator apparatus for 30-40 minutes. In the absence of a pre-cutting apparatus at the factory, flour can be used without boiling.
Mashing of grain raw materials is carried out in a mash machine 4 sequentially with the following parameters:
Temperature, ° С 40 52 63 70 72
Duration
pauses, min 60-90 60-90 30-35 30-35 30-35
The rise in the temperature of the mash is carried out at a rate of no more than GS per minute.
The completeness of saccharification is determined by a sample with iodine. When a yellow spot with a brown tint appears when the iodine solution is added to the mash, the saccharification is stopped.
At the end of saccharification, the mash for coagulation of proteins is boiled for 15-20 minutes and transferred to the collector 6, where compressed air is supplied through a bubbler to prevent sedimentation of solid grain particles. Then the mash goes to a two-stage clarification. According to one of the schemes, coarse filtration is carried out in a centrifuge 7, after which the wort is sent to the collector-coagulator 8 for a 30-minute boiling and precipitation of proteins. The first wort from the collection 8 of the hearth is the separator 14 for fine clarification and is collected in the collection 13 in.
The slurry separated during centrifugation in the separator 7 is transferred to the collector 15, where it is mixed with water, then the mixture is pumped into the mash apparatus 4 to extract the remaining extractive substances and again sent through the collector 6 to the centrifuge. Kvass thick after the second washing is transferred to the collection 16, from where it is sent to feed the cattle.
The filtrate obtained after the second extraction (second wort) is sent through the collector-coagulator 8 and the separator 14 to the collector 13, where it is mixed with the first wort and a wort with a content of 9-12% of dry substances is obtained. This wort is pumped into a supply collector 9, from where it enters the vacuum apparatus 10 for thickening. Concentration by evaporation is carried out under vacuum created by a vacuum pump 12, at a temperature of about 55 ° C to a dry matter content of 68-72%. The resulting hot concentrate of kvass wort is sent to the collection 11, from where it is poured into cans, flasks, barrels, road and rail tanks.
KKS production from dry malts and unmalted raw materials
Raw materials used. According to this method, the kvass wort concentrate is prepared from pre-boiled rye, corn flour and dry malts - fermented rye, unfermented rye or barley according to the scheme.
Raw materials are laid in the following percentage of extractives: fermented rye malt - 32 to 42%; malt barley or rye unfermented malt - 12-15%; corn flour (crushed corn) or rye flour (crushed rye) 43-56%, crushed barley - 20-25%.
Rye and corn flour can be used separately or as a mixture. It is allowed to use barley flour or crushed barley up to 25% by weight of raw materials.
The ratio between malt barley malt and unfermented rye malt, as well as between the listed types of unmalted raw materials, may vary. If unfermented rye malt is used, a partial replacement of fermented rye malt with unmalted grain products is allowed. In this case, the total amount of rye malt should be at least 32% of the extractives of all raw materials.
When producing kvass wort concentrate using this technology, the consumption of grain products per 1 ton of CCS is approximately 1240-1280 kg -
Crushing of grain products. Before crushing, all raw materials are passed through a magnetic separator, weighed and ground. becoming grinding (in%) should be as follows (table. 29).
It is allowed to change the degree of grinding of grain products, depending on the quality of the raw materials and equipment used at a particular enterprise.
Mashing. Unmalted raw materials are not prepared for the effects of malt enzymes and enzyme preparations, therefore they are subjected to heat treatment. To do this, the drawer is filled with water at a temperature of 15-25 ° C and, with continuous stirring, the entire calculated amount of unmalted raw materials (hydromodule 1: 4) is introduced into it and, for liquefaction, diastatic malt (unfermented barley or rye) in the amount of 10% of its setting. Full or partial replacement of malt with enzyme preparations is allowed.
The resulting slurry of unmalted raw materials is pumped into a pre-mixing apparatus, heated with stirring at a rate of GS per minute to a temperature of 70 ° C and kept at this temperature for 20-30 minutes. Then the liquefied mass for starch gelatinization is boiled for 30 minutes or pumped through a continuous cooking apparatus ("Lager") at a steam pressure of 0.3-0.4 MPa in it. The boiled mass is sent to the mash machine, where the distribution of fermented rye malt and the remaining part of barley or rye unfermented malt with a temperature of 45-47 ° C is preliminarily served and enzyme preparations are added in the form of aqueous solutions.
Flushing water from the pre-dispensing apparatus and the "Lager" apparatus is also directed to the mash apparatus. The mass is thoroughly mixed, obtaining the final ratio of grain products and water in a mash machine of about 1: 4.
Duration 60-70 30-60 60-90 30-40 30-40 Before saccharification pause, min
Mash separation.
The separation and clarification of the mash is carried out in one stage - when using filtration devices or filter presses, or in two stages - when using a centrifuge and a filter press, or a centrifuge and a separator, or a filtration apparatus and a separator.
The shot is washed to a mass fraction of dry substances in the wash water of 0.9%. The last rinse water should be used to prepare the next mash.
When dividing the mash on filtration devices and filter presses, it is recommended to bring it to a boil in order to shorten the filtration time and increase the degree of use of extractives. At the same time, as a result of additional extraction of starch and gelatinization, the mash again acquires a blue color with iodine. Therefore, the kvass wort, after filtration, must be subjected to additional saccharification with an enzyme preparation at the optimum temperature for its action in a separate collection or directly in a vacuum evaporator.
The parameters of the mash separation mode are adjusted depending on the equipment used, the type of raw materials used and its quality indicators. Below we give possible options carrying out the process of separation and clarification of the mash.
Separation of the mash in one stage in the filtration apparatus is carried out as follows. The filtration apparatus is filled with water at a temperature of 80-82 ° C to a level 2-3 cm higher than the sieves, after which, with continuous stirring, the saccharified mash is pumped into it, kept at rest for 30-60 minutes and its filtration begins.
The first portion of the cloudy wort is returned to the filtration apparatus, and the clear wort is sent to the collection of the clarified wort. At the same time, the top layer of the clear wort is removed with a decanter and is also pumped into the collection of the clarified wort. The leavened grains are washed with water at a temperature of 75-80 ° C. To do this, after draining the first transparent wort, water is taken into the filtration apparatus, the ripper is turned on and the upper layer of the settled grains is thoroughly loosened. The ripper is turned off, the mash is left alone for 30-60 minutes and the filtration is continued with decantation of the liquid after the spent grain has settled. For a more complete extraction of extractive substances, the process of washing the leavened grains is repeated 2 or 3 times.
When filtering on a filter press, belting, diagonal filter or other material is used as the basis of the filtering partition.
Clarification of the mash on the filter press is carried out in accordance with the instructions for its operation. After separating the first wort on a filter press, it is recommended to wash the leavened grains hot water temperature 70-100 ° C. The remnants of the wort and rinsing water are squeezed out with compressed air or water and the leavened grains are discharged into the collector.
When separating the mash in two stages, the following options are possible: separation in a centrifuge, then in a frame filter press; in a centrifuge -> a separator; filtration apparatus -> separator.
According to the centrifuge -> frame filter press, the mash is preliminarily clarified in a centrifuge, which ensures the separation of large particles of leavened grains. The incompletely clarified wort from the centrifuge is sent to the filter press, and the leavened grains from the centrifuge are collected in a collector, washed with hot water at a temperature of 70-90 ° C and centrifuged again. The number of washings of kvass spent grains with hot water is determined by the yield of extractives.
When separating the mash in a centrifuge and a separator, the centrifuge is used to separate the coarse fraction of kvass spent grains, and the final clarification of the kvass wort is performed on the separator.
In the scheme of the filtration apparatus - "separator, a filtration apparatus is used to separate the bulk of the leavened grains, and the final clarification of the wort is carried out on the separator.
Boiling the wort. When using dry malts for the purpose of coagulation of protein substances, stabilization chemical composition and sterilization of the wort, it is recommended to boil it in a wort machine for 1-1.5 hours, after which the mass fraction of dry substances in the finished wort should be at least 10-14%.
Then the wort is fed into separators or hydrocyclone apparatuses, where protein substances coagulated during boiling are separated. It is advisable to add protein sludge containing 80-85% complete wort to the mash while boiling the unmalted part in order to reduce extract loss.
The clarified wort enters the collection, from which it is sent to thickening by evaporation.
Concentration of kvass wort. The clarified wort with a mass fraction of dry substances of 10-14% is thickened in film tubular and film rotary vacuum apparatus in two stages. At the first stage, the wort is evaporated to a mass fraction of solids of 43-47% in two tubular film apparatus in sequence: in the first apparatus - up to 22-26%, in the second - up to 43-47%. Kvass wort is served centrifugal pump into the distribution device of the film tubular apparatus located in the upper part of the heating chamber, and it flows down with a thin film along the surface of the pipes, thickening to a predetermined concentration.
At the second stage of concentration, the kvass wort is thickened in a rotary film apparatus with hinged blades. In this apparatus, the wort through the feed pipes enters the rotor blades, where, under the action of centrifugal force, the wort is pressed against the inner surface of the body, being distributed over it in the form of a thin film. As the solution flows from one row of blades to another, the wort heats up and the moisture evaporates.
In the second stage, to prevent burning, the wort thickening temperature should be 50-60 ° C. The process is stopped after reaching the mass fraction of dry substances of 68-76% and heat treatment of the resulting kvass wort concentrate is carried out. The finished kvass wort is transferred to heat treatment.
For the concentration of kvass wort, evaporators of various types (VV-25, VV-50, VNIIKP-2, etc.) are also used, guided by the recommendations for their operation.
Heat treatment of kvass wort concentrate. Heat treatment of the obtained concentrated kvass wort containing 68-76% of dry substances is carried out in order to accumulate the products of the melanoidin reaction, which give it the aroma characteristic of rye bread and the necessary color. Simultaneously, during heat treatment, the finished product is sterilized and its viscosity decreases.
Heat treatment of kvass wort concentrate is carried out either directly in evaporators (if their design allows it), or in special devices with a stirrer designed for increased pressure.
To carry out heat treatment, the CCF is kept at a temperature of 110-112 ° C at a pressure of 0.14-0.16 MPa (but not higher than the allowable for this type of apparatus) and constant stirring for no more than 30 minutes.
In the specific conditions of the plant, depending on the type of apparatus used for heat treatment, the pressure, temperature and duration of the process can be specified. In this case, the required duration of heat treatment is set depending on the temperature or pressure reached in the reactor and is determined by the quality indicators of the finished cooled CCS. Heating of the CCS to the required temperature is carried out with steam entering the steam jacket. Heating of the CCS with steam through a bubbler is allowed, while heat treatment can be carried out without additional stirring.
After the end of the heat treatment, the steam is turned off, the obtained CCF is cooled in a heat exchanger to a temperature of no more than 5, weighed, and sent to storage tanks or directly for filling.
Filling, storage and transportation of KKS. Large batches of kvass wort concentrate are poured into road and railroad cisterns, which are washed, disinfected and sent to the consumer before filling. KKS is poured into glass and metal cans at a temperature not lower than 50 ° C and sealed on an automatic machine. The sealed cans are fed into an autoclave, where the product is sterilized at a temperature of 100 ° C in the mode specified in Table 30.
Table 30
The guaranteed shelf life of the kvass wort concentrate after sterilization at a temperature of 2-12 ° C is 8 months.
Preparation of kvass concentrate
Concentrate preparation methods. Kvass concentrates are prepared from the kvass wort concentrate, for which it is blended (mixed) with sugar syrup, food acids, other ingredients. The most widespread are concentrates: kvass, Russian and Moscow kvass.
Kvass concentrates are prepared by blending the kvass wort concentrate with the necessary ingredients in closed enameled or stainless steel blenders equipped with a stirrer, steam jacket or bubbler for heating and mixing the product.
The kvass wort concentrate and water are added to the blender while the mixer is running to the calculated volume of the final product minus the volume of sugar syrup, heated to 77-83 ° C and kept for 25-35 minutes for pasteurization. Then add sugar syrup, lactic or citric acid, mix for 20-30 minutes and transfer hot to bottling.
The consumption of raw materials for their preparation is indicated in table 31.
The concentration of dry substances in the kvass concentrates given in the table is 70%.
Kvass extract for Russian okroshka is prepared in the same way. When preparing it, CCS is blended with horseradish, salt, parsley, and 65.5% of the substances in the finished extract.
Table 31
Note: a - the amount of acid introduced with the CCS.
Kvass concentrate can be prepared in another way. Fermented and unfermented rye dry malt is ground. served in a mash machine with half the estimated amount of hot water at a temperature of 54-56 ° C in a ratio of 1: 5, stirred for 10-15 minutes, add ground barley malt, melt for 1 hour. Bring in the remaining water at a temperature of 75-80 ° C, stirred for 10-15 minutes, infused for 1 hour, then cooled to 10-15 ° C and left for 10-12 hours to settle. Then the wort is decanted into a cooking apparatus with a dry matter concentration of 11%. In a cooking apparatus, the wort is heated to 50-60 ° C, sugar is added to it, heated to a boil and boiled for 30 minutes. By the end of boiling, add color and lactic acid. The boiling of the kvass concentrate is completed when the mass fraction of dry substances reaches 57% and it is pumped through a sieve filter into a measuring tank for storage for no more than 24 hours.
After decantation of the first wort, the kvass grounds are poured with water at a temperature of 60-80 ° C, the mixture is stirred and left alone for 1 hour for infusion and clarification. The resulting wort of the second withdrawal with a dry matter concentration of 8% is decanted and transferred to the cooking apparatus, where it is also thickened to 57%.
Then the kvass concentrates obtained from the wort of the first and second withdrawals are mixed and transferred to bottling with a mass fraction of dry substances of 57% of the mass.
Technological scheme for the preparation of kvass. In fig. 83 shows a technological scheme of kvass prepared from kvass wort concentrate (KKS) by the fermentation method. According to this scheme, the kvass wort concentrate, delivered to the plant in tank trucks 1, is pumped by pump 2 through the measuring tank 4 into the collector 3. When the KCS arrives in the barrels 5, they are placed on the pallet 6, rinsed with hot water, and the concentrate is pumped through the pump 7 through the measuring tank 4 into the collector 3 for storage.
Liquid sugar, delivered in tank trucks 11, by pump 2 through a heat exchanger 12 and a measuring tank 14 is fed into collectors 13 equipped with bactericidal lamps 15.
When granulated sugar, packed in 16 bags, arrives at the factory, they are removed from the car onto pallets 18 and transported to the warehouse by a forklift 19. As required, sugar is weighed on a scale 19, loaded with elevator 20 into hopper 21 and fed into a syrup cooker 22, where water is previously poured. The finished sugar syrup is pumped by a pump 24 through a trap filter 23 and a heat exchanger 25 into a collection container 17 for storage.
To prepare kvass wort by pump 2, KKS is pumped through a measuring tank 4 into a collector 8, where it is diluted with hot water to a certain concentration and with a pump 9 through a heat exchanger 10
sent to the fermentation apparatus 27. Here from the collection 17 serves the estimated amount of sugar syrup, from the collection 52 - water, and from the device 43 - combined yeast and lactic acid starter culture.
A pure culture of yeast is prepared in apparatuses 41 and 40, and a pure culture of lactic acid bacteria - in apparatuses 46 and 45. From these apparatuses, pure cultures of yeast and lactic acid bacteria are pumped by pumps 39 and 44 into apparatus 43 and then by pump 42 into a fermentation apparatus 27 for fermentation ...
The fermented kvass wort is cooled down, the settled yeast is removed into the collection vessel 26, and the calculated amount of sugar syrup and color is added to the fermentation apparatus 27. Kohler is prepared in Rice. 83. Apparatus and technological scheme for the production of bread kvass
apparatus 38 and discharged into the collector 37, where it is mixed with a calculated amount of water and pump 36 is fed into apparatus 27.
The kvass blend is thoroughly mixed and sent for filling into the tank trucks 28 previously washed at the washing plant 29 or into isobaric filling machines 31, on which the kvass is poured into barrels. Empty drums are delivered to the enterprise by vehicles 35, removed from them and stacked 34, and then sent for inspection and washing on machines 33. Clean drums are rinsed on syringes 32 and dropped for filling.
The water used for technological needs from the intermediate collector 47 is directed to the sand filter 48, where it is clarified, and through the collector 49 is pumped to the ceramic candle filters 51 for fine filtration. Filtered water enters the collection 52.
This scheme is intended for making kvass from kvass wort concentrate. When using kvass rye bread or dry kvass, the scheme additionally includes an infusion apparatus with a decanter for removing kvass wort from the lees of kvass grounds and a collection of kvass grounds. The leavened herb is then sold for livestock feed.
Making sugar syrup
When obtaining bread kvass, sugar syrup is used, a concentrated aqueous solution of granulated sugar, containing 60-65% of dry matter. It is prepared in syrup boilers.
Such an apparatus (Fig. 84) is a closed cylindrical vessel 4 with a spherical bottom 13 and a flat lid. It is made of sheet steel or copper, and the inside is covered with a food-grade tin half. The second spherical bottom 12 forms a steam jacket equipped with a gas outlet 15, a pressure gauge and a safety valve. Steam under a pressure of 0.3 MPa enters the jacket through the nozzle 5, the condensate is discharged through the nozzle 11. The apparatus is equipped with an anchor stirrer 7 with a drive 2. Water is fed into the apparatus through the nozzle 1, the secondary steam is discharged through the pipe 3. The finished syrup is discharged through the nozzle 9 connected with the outlet valve 8, the handwheel 14 and the screw device 10 for controlling the valve 8. The apparatus is mounted on three supports 6. Frequencies Fig. 84. Syrup cooker stirrer rotation 47 min 1.
Sugar syrup is prepared using hot and cold methods. When preparing syrup in a hot way, water is poured into the syrup machine and heated to a boil. Then sugar is gradually introduced with continuous heating and stirring. After dissolution, the syrup is brought to a boil, the foam formed on the surface is removed (when the syrup is boiled in open apparatus). Foam removal is imperative, since when bottling drinks, foam impairs their taste and causes opalescence. Sugar contaminants are also removed along with the foam. The syrup is boiled with stirring for 30 minutes to kill mucus-forming bacteria, longer boiling may lead to deterioration. Boiling is stopped when the mass fraction of dry substances in the syrup reaches 60-65%. Hot syrup is filtered in cartridge or other filters. White flannel, greatcoat cloth, belting, silk and nylon cloth are used as filtering materials. The use of bag filters is allowed. Trap strainers are often used. Then the sugar syrup is cooled to 10-20 ° C in plate or counter-flow tubular heat exchangers. The content of dry substances is determined in the syrup and sent to storage in enameled or aluminum collectors equipped with measuring instruments. Further, the syrup is used to prepare blended syrups.
Sugar syrup can also be prepared cold. To do this, sugar is dissolved in water at a temperature of 60-70 ° C, filtered and cooled.
The consumption of granulated sugar for the preparation of 100 dm 3 of 65% syrup is as follows.
The mass of 100 dm 3 of 65% syrup with a density of 1.319 kg / dm 3 is equal to 131.9 kg. It contains (131.9-65) - 00 = 85.73 kg of sugar and (131.9-35) - ^ -100 = 46.17 kg of water.
With a moisture content of standard granulated sugar 0.14%, its consumption per 100 dm 3 of syrup will be 85.73+ (85.73-0.14) -100 = 85.85 kg and water consumption (taking into account 10% evaporation when boiling syrup ) 46.17+ + (46.17.10) -100 = 50.8kg.
Cooking color
Kohler is a crystalline sugar caramelized at a high temperature. To prepare the color, a color-coder is used (Fig. 85), which consists of two cylinders 3 and 4, a crucible 2 is located inside the body. The apparatus is heated by an electric heater 1. With two semi-axes 8, the apparatus rests on the frame racks. With the help of gears 6 and 7, handles 5, it can be turned. The mass in the apparatus is stirred with a portable stirrer. An exhaust hood is installed above the device. Appliances fitted with lids are fitted with a chimney.
The capacity of the apparatus should be 4 times the volume of the sugar melted in it.
To prepare the color scheme, 1-2% of water is poured into the pre-heated apparatus based on the weight of the loaded sugar, and when the mixer is running, sugar is uniformly fed. The mixture is gradually heated with stirring to 160-165 ° C, the sugar begins to melt and acquires a dark brown color. Then the heating is stopped and, with stirring, hot water with a temperature of 75-90 ° C (about 8% by weight of sugar) is carefully added, the heating is turned on and the mixture is kept at a temperature of 180-200 ° C until a drop of the resulting mass applied to the glass is not will spread. The finished color is diluted with water and transferred to a collection tank, where, while the mixer is running, water is added at a temperature of 60-65 ° C to obtain a dry matter concentration in the color of 68-72%.
When boiling the color, it must not be allowed to char, it must completely dissolve in water. The color output is 105% by weight of sugar. The loss of sugar in the preparation of the color is 28-30%.
Color coders are installed in a separate room or in an isolated place in the syrup-brewing department. When preparing a color scheme, service personnel must work in aprons, gloves and glasses. The duration of one cycle when preparing a color is 3-4 hours
Preparation of a mixed starter culture of yeast and lactic acid bacteria
For the preparation of starter cultures, yeast of races M, 131-K, C-2, bakery and wine yeast, lactic acid bacteria of races 11 and 13 are used. The starter culture is prepared directly at the plant according to the scheme shown in Fig. 86.
The yeast dilution of a pure culture for starter culture should contain yeast of at least 40 million cells in 1 cm 3, the acidity of the dilution of lactic acid bacteria is 6.8-7 cm 3 of a hydroxyl solution at a concentration of 1 mol / dm 3 per 100 cm 3 of the medium.
Rice. 86. Breeding scheme for pure cultures of yeast and lactic acid bacteria
Maintenance of pure cultures, their breeding and preparation of the combined starter culture is carried out by the microbiologist of the enterprise laboratory.
Preserve pure cultures of yeast and lactic acid bacteria in the laboratory. Yeast is stored in the form of colonies on a mowed wort at a temperature of 6-7 ° C and subcultured 1-2 times a month. A pure culture of bacteria is maintained on wort with the addition of up to 10 g of sugar per 100 cm 3 of wort. After keeping the culture in a thermostat for 2 days at 20 ° C, a little sterile chalk is added to it and shaken daily for better neutralization. The culture is subcultured every 10 days. The preparation of the breeding of yeast and lactic acid bacteria is a few passages with an increase in the kvass wort and the number of microorganisms in the laboratory, then in the department of pure cultures and in production (see Fig. 86).
The wiring is prepared in two ways: separate cultivation of pure cultures of yeast and lactic acid bacteria (method A is the most preferable) and mixed cultivation of cultures of microorganisms (method B). The diagram shows the volume of reseeding for a plant with a capacity of 10 thousand dal of kvass per day. With a higher productivity of factories, it is necessary to increase or decrease the volume of wiring, starting from the II laboratory stage. Laboratory stages I-III are common to both methods. They are carried out by a microbiologist in the laboratory. The subsequent stages are already performed by the fermentation department operator in the apparatus of the pure cultures department.
In the laboratory, they work on sterile wort with a mass fraction of dry substances of 8%. For this, the wort is sterilized in an autoclave at 0.5 MPa for 15-20 minutes. In the department of pure culture, wort, boiled for 10-15 minutes, is used, the temperature of which is not higher than 30 ° C. To obtain a mixed sourdough, a production wort is used.
Breeding a pure culture of yeast in the laboratory. To carry out work in the laboratory, based on a productivity of 10 thousand dal of kvass per day, you must have: test tubes with 10 cm 3 of sterile wort; a flask with a capacity of 0.5 dm 3 with 250 cm 3 of sterile wort; a flask with a capacity of 3 dm 3 with 1.75 dm 3 of sterile wort. With a higher productivity of the plant, the volumes of yeast and lactic acid bacteria in the laboratory (at stage III) can reach 10 or 20 dm 3. In this case, it is necessary to use several glass flasks made of heat-resistant glass to sterilize the wort and prepare the wort, their number should provide the total capacity (10 or 20 dm 3).
The optimum temperature for growing yeast at all stages is 25-30 ° C, and the duration of growing at each laboratory stage is 24 hours.
A complete loop of inoculum is taken from a test tube with the original yeast culture on oblique agar, inoculated into a test tube with 10 cm 3 of wort (stage I) and grown for 24 hours in a thermostat.
The yeast wort is completely transferred from the test tube into a flask with 250 cm 3 of wort (stage II), mixed with light rotary movements, avoiding wetting of the cork, and kept at the optimum temperature for 24 hours.
The dilution of a pure culture of yeast grown in a flask (stage III) is transferred to the compartment of pure cultures. In this case, the flask should be covered with a sterile paper cap and tightly tied with twine. To avoid mechanical damage, the flask is placed in a wooden box with two handles and covered with plastic wrap.
Breeding a pure culture of lactic acid bacteria in the laboratory. To carry out work in the laboratory, you must have: two flasks with a capacity of 0.5 dm 3 with 250 cm 3 of sterile wort in each: a flask with a capacity of 3 dm 3 with 1.5 dm 3 of sterile wort and a flask for 5 DM 3 with 2 dm 3 of sterile wort. The optimum temperature for growing lactic acid bacteria is 28-30 ° C.
The contents of three ampoules of lactic acid bacteria of race 11 are transferred into one of the flasks with 250 cm 3 of wort, and the contents of three ampoules of bacteria of race 13 are transferred into another flask with 250 cm 3 of wort (stage I). The culture is grown for 24 hours.
The contents of two flasks (stage I) are completely transferred into a flask with 1 5 dm 3 of wort (stage II), mixed and grown for 24 hours. wort (stage III), mixed and grown for 24 hours and the grown wort is transferred in compliance with the rules of sterility in the department of pure cultures.
Breeding of pure cultures of microorganisms in the department of pure cultures according to method A. A feature of method A is the separate cultivation of bacteria and yeast to the stage of mixed starter culture (stage VI) The duration of growing yeast (at stages IV and V) is different, namely 24 hours and 48 hours, respectively ... Therefore, for the daily transfer of yeast and bacteria cultures to production, it is necessary to cultivate bacteria (stage V) in two containers of equal volume, in which the cultivation process is phase-shifted by 24 hours.
Breeding pure yeast cultures. The yeast wiring grown in the laboratory (2 dm 3), subject to the rules of sterility, is diluted 10 times (up to 20 dm 3). Yeast is grown for 24 hours to a concentration of 40 million cells in 1 cm 3. Then 18 dm 3 is transferred to the container for the preparation of the starter culture. In subsequent cycles of preparation of yeast wort in this container, a detachable method is used: 18 dm 3 of wort is added to the remaining 2 dm 3 and cultivation is carried out for 24 hours. from a new test tube.
Breeding a pure culture of lactic acid bacteria. To 4 dm 3 of a lactic acid bacteria distribution grown in the laboratory, 36 dm 3 of wort is added (dilution by 10 times) and bacteria are grown for 48 hours until the acidity accumulates 6.8-7 cm 3 of 1 n sodium hydroxide solution per 100 cm 3 of the medium.
At stage V according to method A, two containers are used for diluting lactic acid bacteria, the cycle in which is shifted by 24 hours. First, 40 dm 3 of the dilution is transferred to one of the containers (stage IV), diluted with wort 10 times (volume 400 dm 3). After 24 hours of cultivation, 40 ° Dm 3 is taken away and transferred as inoculum to the second container, the wort is added to both containers to a volume of 400 dm 3 and the contents of the first container are transferred after 24 hours, and the second after 48 hours. spreading, add wort to 400 dm 3 and grow the culture for 48 hours, thus alternating up to 7 cycles.
According to method B, in stage V, a premixed wiring is obtained.
Preparing a premixed wiring. In a container for premixed wiring, 40 dm 3 of a pure culture of bacteria are transferred, wort is added to 580 dm 3 and grown for 24 hours. , 8-7 cm 3. The total duration of the cultivation of the culture is 48 hours.
Approximately 90% of the dilution is sent to the workshop in the apparatus for the preparation of mixed sourdough, and the remaining 10% (60 dm 3) is again poured with wort up to 600 dm 3. After 48 hours, fresh wiring is used in production. Such a detachable-topping process can be carried out for no more than 7 cycles (48 hours each), after which the wiring is replaced with fresh cultures of yeast and lactic acid bacteria (stages I-III).
With the joint cultivation of yeast and lactic acid bacteria, it is ensured that the acidity does not exceed 6.8-7 cm 3. All operations are carried out at 25-30 ° C. If the need for wiring decreases, then the container in which the detachable-topping process is carried out is cooled to 6 ° C.
Mixed starter preparation. In the container for the mixed starter culture is transferred: according to method A, the distribution of lactic acid bacteria 360 dm 3 and yeast 18 dm 3, and according to the method B 540 dm 3 of the pre-mixed distribution. Diluted 10 times according to method A and 7 times according to method B with industrial wort with the addition of sugar syrup (25% of the norm for kvass). The total volume will be equal to 4000 dm 3.
After 6 hours, the starter is sent to the fermentation apparatus, where its volume is 4% of the total volume of the fermented wort.
Since the duration of obtaining a mixed starter culture (6 hours) and a fermentation cycle in apparatus (12-18 hours) is shorter than the preparation time of a pre-mixed starter culture (48 hours), it is advisable to carry out a weaning-topping process directly in the device for mixed starter culture before the end of its preparation. To do this, leave half of the wiring in it and add it to the full volume with wort with sugar syrup. Half of the mixed starter culture is transferred to fermentors, where it is 2% of their volume. After 8-10 hours, the fermentation apparatus is added to its full capacity and fermentation is carried out until the required acidity is accumulated.
Every 2 cycles, the contents of the apparatus of the mixed starter culture are transferred to the fermentation apparatus, where its amount is 4% of the volume
In the apparatus for mixed starter culture after its release, the ready-made pre-mixed wiring is transferred from the department of pure cultures, and the cycle of preparation of the starter culture is repeated again.
In small enterprises where there are no devices for breeding true crops, glass bottles with a capacity of 20 dm 3 can be used. For breeding yeast and lactic acid bacteria. It is necessary to have two small vessels, and the capacity of the vessel for yeast should be 2 times less than for bacteria.
In a high-performance enterprise, it is necessary to have two devices for breeding pure cultures: one for breeding yeast, the other for lactic acid bacteria. Before starting work, all containers of the apparatus are washed with hot water with brushes, and sterilized with a stream of steam for 1 hour a day for three days. At the end of sterilization, the valves with a supply of sterile air are kept open in the sterilizer and the fermentation apparatus.
After cooling, the sterilizer is filled with hot wort and sterilized for 1 hour, periodically stirring with sterile compressed air. Then the wort is cooled to 25-30 ° C and transferred to one of the fermentation cylinders, 8-12 dm 3 of a pure culture of microorganisms is introduced there from the Carlsberg flask.
If the apparatus has two fermentation cylinders, then a mixture of bacteria of races 11 and 13 is propagated in one, and kvass yeast in the other. If there are three cylinders, then each of them is seeded with one culture.
Dilution of dry kvass yeast. For the production of 1000 dal of kvass, wort is prepared with a mass fraction of dry substances of 8%, boiled for 10 minutes and cooled in a closed vessel to 26-30 ° C.
In a bottle with a capacity of 20 dm 3, thoroughly washed with 2-3% sodium carbonate solution, add 100 g of dry yeast and 5 dm 3 of the prepared wort. The bottle is closed with a cotton stopper, the contents are stirred for 10-20 minutes and left for 18 hours for fermentation, then another 15 dm 3 of wort is poured, kept for 8-12 hours, 15 dm 3 of the fermented wort are taken and put into a vat with a lid with a capacity of 100 dm 3 ... 15 dm 3 of wort is added to the bottle again and left for 12-16 hours before intensive fermentation begins. The process is repeated 5-6 times. At all stages, topping up is carried out only in the stage of active fermentation.
The leaven in a chink is added with 85 dm 3 of kvass wort, brought with sugar syrup to a concentration of 6%, and left for 18-20 hours until intensive fermentation, after which it is transferred to a production apparatus with a capacity of 1000 dal and fermented for 12 hours. disinfected and used for the next batch of yeast.
Dilution of lactic acid bacteria from dried cultures is carried out in a bottle with a capacity of 20 dm 3, where 100 g of bacteria are added, 5 dm 3 of boiled and cooled wort, closed with a sterile cotton plug and left for 24 hours. After fermentation, 15 dm 3 of wort (boiled and cooled) is added and leave for 24 hours.
Then the bacteria spread is transferred to the production apparatus. filled with wort at the rate of 5-6 dm 3 per 1000 dal. At the same time, yeast culture prepared as described above is served there.
A bottle of 20 dm 3 after each weaning of the starter culture is topped up with boiled 8% wort to the original volume. After 6-7 days, the wiring is updated.
Breeding of pressed baker's yeast. Yeast at the rate of 15 g per 10 dal of wort is placed in a container, mixing with water in a ratio of 2: 1, 40% lactic acid is added at the rate of 40 cm 3 per 1 kg of pressed yeast and the pH of the yeast dilution is set to 2.7-2, nine. The suspension is kept for 3 hours, a five-fold volume of wort, pasteurized or boiled and cooled to 20-30 ° C with a concentration of 8% DM, is added. After that, the yeast suspension is mixed with wort, kept for fermentation for 2-3 hours at a temperature of 20-30 ° C and put into fermentation tanks.
For the preparation of the wort, KKS is diluted in water to a DM concentration of 3-3.2% or unboiled kvass wort of the same concentration is used, sugar syrup is added up to 8% DM.
Kvass preparation methods
Making kvass wort
At the factories of soft drinks, kvass wort is obtained by diluting the kvass wort concentrate in water or by infusion from kvass rye loaves or from dry kvass.
The preparation of the wort by the infusion method consists in extracting soluble substances from kvass loaves or dry kvass with hot water and separating the undissolved mass (kvass grounds). Kvass bread is crushed on crushers and infused in apparatus.
The infusion apparatus (Fig. 87) is a cylindrical vessel 1 with a lid 2. Inside the apparatus is equipped with a coil 5, a paddle stirrer 4 and a decanter 6 for removing the wort from the leaven. A steam jacket is preferred instead of a coil or bubbler.
The infusion apparatus is filled with hot water (80-90 ° C) in such a volume to obtain the first wort in the amount of 1/3 of the given volume of the produced kvass, and with stirring according to Fig. 87. The infusion apparatus gives the whole mass of crushed kvass or dry kvass, which should be consumed according to the recipe for the volume of finished kvass. The mixture is stirred for about 30 minutes and then infused for 1.5-2 hours. The settled first kvass wort is pumped through a decanter into a fermentation-blender, cooling it before that in a heat exchanger to 25-30 ° C.
The residue remaining in the apparatus is poured with hot water (60-70 ° C) in an amount equal to the volume of the first wort, stirred for 20 minutes, infused for 1.5 hours and the decantate is passed through a heat exchanger, cooling the resulting second wort to 25-30 ° C. The second wort is combined with the first wort.
For the third bay, water is taken so that it is enough to bring the total volume of kvass wort to the specified one. The mixture of water and grounds is stirred for 20 minutes and infused for 1 hour. Cooled to 25-30 ° C, the third wort is added to the first two.
To obtain wort for okroshechny kvass, rye flour is steamed with boiling water in a ratio of 1:10, mixed, cooled to 55 ° C, chopped barley and rye malt is added to water heated to 70-73 ° C. Next, insist as described above. Mass fraction of dry matter in the wort supplied for fermentation is 1.3%. The total wort output should be equal to the volume of the prepared kvass.
When preparing the wort from the kvass wort concentrate, first, water at a temperature of 30-35 ° C is poured into the fermentation and blending apparatus and the kvass wort concentrate is dissolved in it to the mass fraction of dry matter 1.4% (for bread kvass) and up to 1% for okroshechny kvass. CCS is fed into the fermentation-blender in parts: 2/3 is spent on obtaining kvass wort, and 1/3 is added during blending, which improves the aroma.
For the preparation of the wort intended for fermentation in TsKBA, diluted pasteurized kvass wort concentrate (KKS) or enriched kvass wort concentrate (KOKS) are used, and then sugar syrup, combined yeast and lactic acid sourdough or rejuvenated yeast.
Before dilution, KKS or KOKS is pasteurized by subjecting it to heat treatment at 75-80 ° C for 30-35 minutes. You can pasteurize in the specified mode and diluted kvass wort concentrate. After pasteurization, it is cooled to 26-30 ° C and pumped to the Central Design Bureau.
It is allowed to feed the entire calculated amount of KKC or KOKS for fermentation without further blending of kvass with concentrate.
Diluted kvass wort concentrate with a dry matter content of 1.4% (when filling 70% of the calculated amount of concentrate), or 2.2% (when using the entire amount of the concentrate in full) is pumped to TsKBA.
The preparation of kvass using barley malt is possible both at enterprises producing kvass and at breweries, with the replacement of half of the CCS with unhopped beer wort. In case of insufficient color of kvass, part of the sugar is replaced with color.
Fermentation of leavened wort
Fermentation of kvass wort is carried out in fermentation-blending or fermenting apparatus.
The fermentation-blender (Fig. 88) is a cylindrical vessel 7 with a conical bottom, a spherical lid, sealed with a hatch 12, and supports 2. To control the temperature of the wort, the apparatus is equipped with a jacket 6. In the lower conical part, a yeast separator 3 with a valve 1 is installed. For mixing the wort during fermentation and blending, there is a propeller stirrer 4.
The apparatus is also equipped with fittings 8 and 13 for venting air from the apparatus and jacket, fittings 16 and 5 for inlet and outlet of cooling brine, nozzle 9 for supplying wort and nozzle 14 for injecting syrup, thermometer 10, manometer-17 rum 15, compensator 17, a test cock 18, a drain nipple 19 and a nipple 11 for entering a sensor for automatic determination of the liquid level. The body of the device is covered with a layer of heat-insulating material.
The apparatus is produced with a capacity of 100 and 500 dal and a capacity of 150 and 700 dal / day, respectively.
The fermenter (fig. 89) is a cylindrical tank 1 with a hermetically sealed lid. It is equipped with a cooling coil 2, a decanter 3 for removing the fermented wort from the yeast sediment and a nozzle 4 for draining the wash water with a pipe for removing C0 2.
First, kvass wort and 1/4 of the sugar (in the form of sugar syrup) of its total amount specified in the recipe are fed into the fermentation-blending or brokering apparatus. The dry matter content in the wort for palatine kvass should be at least 2.5%, and for okroshechny kvass - 1.6%. After that, a combined starter culture from pure cultures of yeast and lactic acid bacteria (2-4% by volume of wort) or a dilution obtained from dried, technically pure cultures (0.8% yeast and 0.06% lactic acid bacteria to the volume of wort) is carried into the wort. ... Fermentation is carried out at a temperature of 25-28 ° C until the content of dry substances in the wort is reduced by 1% by weight, and the acidity is at least 2 cm 3 of an alkali solution with a concentration of 1 mol / dm 3 per 100 cm 3 of kvass. During fermentation, the temperature is regulated, preventing its rise.
For a more complete saccharification of carbohydrates and, as a result, to accelerate fermentation, after adding sugar syrup, add ground barley malt (5 g per 1 dm 3 of wort). Malt should have a low saccharification time - no more than 10 minutes.
To increase stability, the fermented wort (kvass) at the end of fermentation is carefully separated from the yeast, for which it is cooled in a fermentation-blender to 5-7 ° C. In this case, the yeast is deposited in a dense layer in the yeast separator, and the kvass is carefully pumped into the blender or blended directly in the fermentation and blender without touching the yeast sediment.
It is not allowed to blend kvass in the fermentation apparatus.
During the fermentation of kvass wort, part of the nutrients is spent on the growth of yeast cells and lactic acid bacteria, and the bulk under the action of enzymes is converted into new products: sugars, ethyl alcohol, organic acids, including lactic acid, carbon dioxide, etc. Reduced temperature wort promotes dissolution of CO2 and saturation of kvass with it.
When working with insufficient accumulation of lactic acid in kvass in the finished wort, even before adding sugar to it, it is allowed to introduce 4% (by volume) of the combined starter culture or dilution of dried cultures (0.5% yeast and 1.5% lactic acid bacteria) and insert product for 6 hours to accumulate lactic acid at 30-32 C. Then add 1/4 of the sugar from the recipe (in the form of sugar syrup) and ferment at 30-32 ° C until the DM content decreases by 1% by weight. With insufficient accumulation of alcohol in the previous fermentation cycles using this raw material, yeast is introduced into the wort how many hours earlier than lactic acid bacteria. Fermentation is carried out at 28-30 ° C until the DM content decreases by 1% of the mass.
In the production of bread kvass, in addition to fermenting and blending and fermenting apparatus, cylinder-container fermenting apparatus TsKBA are used (Fig. 90). TsKBA is a more advanced apparatus, which is a cylindrical vessel 1 with a spherical lid, equipped with jackets: 2 on the cylindrical and 4 on the conical parts of the body for cooling fermenting wort and kvass. A yeast separator and a horizontally located mixer are mounted in the lower part of the apparatus. The apparatus has a pipeline 3 for removing carbon dioxide and supplying a washing solution and a chamber 5 for introducing a combined starter culture and outputting finished kvass. The device is installed on annular supports 6.
The devices are manufactured with a working capacity of 9.4 and 25 m 3. The prepared diluted kvass wort concentration, having a temperature of 26-3 ° C, is pumped over the prepared TsKBA with the gas valve 3 open. WITH. To prevent foaming and to simplify operation, filling the TsKBA with kvass wort is carried out from below. Then, while stirring with a centrifugal pump "on oneself", 25% of the sugar prescribed by the recipe is introduced into the CKBA in the form of a filtered syrup with a dry matter concentration of 60-65%.
After thorough mixing, a sample is taken to determine the physicochemical indicator of the wort before the start of fermentation - the mass fraction of dry substances, temperature - and the air valve is closed. The pressure in the CKBA during fermentation is regulated with a sheet piling device, it should not exceed 0.065 MPa.
In order to reduce the terms of employment and increase the turnover of TsKBA, it is recommended to prepare the wort in separate collectors, where it is thoroughly mixed and brought to the required density.
Fermentation is carried out at a temperature of 26-30 ° C until the mass fraction of dry substances in the wort decreases by 1 g in 100 g of fermented wort and the acidity is at least 2 cm 3 of a sodium hydroxide solution with a concentration of 1 mol / dm 3, consumed for titration of 100 cm 3 of the wort ... During fermentation, it is necessary to control the temperature of the kvass wort, not allowing it to rise.
Fermentation is carried out with periodic stirring with a centrifugal pump (every 2 hours) for 30 minutes.
Blending and bottling of kvass
Blending of fermented kvass wort. The remaining 3/4 of the sugar and color are added to the fermented kvass wort, which is in the fermentation-blending or blending apparatus. If the wort was prepared using 70% of the CCC of the recipe, then add the remaining 30%. The resulting mixture, called a blend, is thoroughly mixed by blowing carbon dioxide through it, the quality of kvass is checked for compliance with the requirements of the standard, and it is sent for bottling.
If the kvass wort is fermented in fermentors, the kvass is blended in a blending apparatus, which is a container covered with enamel or made of corrosion-resistant steel, which has thermal insulation and is equipped with a stirrer, a bubbler for mixing the blend with carbon dioxide.
When blending kvass in TsKBA after fermentation, which is determined by a decrease in the content of dry substances and an increase in acidity in kvass, both shirts of the TsKBA and a plate refrigerator (if the unit is equipped with it) are connected to cooling, through which the fermented kvass is pumped with a pump. At the same time, Yeast is deposited in the lower conical part of the CKBA. The yeast sediment is discharged from the bottom, while opening the air valve. The end of the drainage of the yeast is determined visually through a sight glass or a drain funnel. Kvass is cooled to a temperature of 5-7 ° C.
After draining the yeast, kvass is blended by adding the remaining 75% of the calculated amount of sugar in the form of syrup and 30% of KKS or KOKS. After that, the contents of the CKBA are thoroughly mixed with a pump.
With a decrease in consumer demand, in order to prevent the possibility of over-fermentation of kvass and, as a result, to reduce the content of dry substances in it, it is recommended to cool the kvass to 4-6 ° C.
The amount of sugar syrup (in dm 3) added to kvass is calculated by the formula
X = [K (a-a 1)] / a 2,
where K is the volume of blended kvass, dm 3; a, a, a 2, - the content of dry substances in 1 dm 3, respectively, of finished kvass, original kvass wort, sugar syrup, g.
Example. It is necessary to calculate how much 65% sugar syrup (a 2) should be fed into the fermentation and blender for 2000 dm 3 of bread kvass, if the dry matter content in the fermented kvass wort is 1.4% (a,), and after blending in their finished kvass should be at least 5.8% (a).
According to the testimony of the sugar meter, we find the dry matter content in 1 dm 3 of kvass, g: a = 59.22; a, = 14.05; a 2 = 855.61. Substituting these data into the equation, we get
x = /855.61 = 105.6.
Therefore, 105.6 dm 3 of sugar syrup should be added to the wort.
During blending, ascorbic acid, calcium chloride, potassium phosphate, table salt (sodium chloride), etc. are introduced into bread kvass prepared for workers in hot shops.
Filling of kvass into barrels and tank trucks. Ready kvass is cooled to 12 ° C and poured at a special station with several fittings. The containers are usually filled open way through rubber hoses, which leads to the loss of carbon dioxide and kvass. Therefore, kvass should be poured under isobaric conditions (pa pressure) according to the scheme shown in Fig. 91.
To do this, the auto-thermo tank 2 is sealed and, when bottling, is connected to the upper part of the fermentation and blending apparatus 1. The pressure is equalized through the fitting 3 and the kvass is poured under excess pressure. The thermo tank 2 is equipped with a safety valve 4, a sight glass 5 to determine the completeness of the tank filling and a pressure gauge 6.
Kvass fermented in TsKBA is bottled after the laboratory has checked the compliance of quality indicators with the established requirements. When bottling, open the air valve, valve and valves on the filling communication and transfer the kvass to the collection tanks installed at the filling station or directly into prepared tank trucks. The temperature of kvass when bottling should not exceed 12 ° C. The auto-thermocisterns are released into the trading network hermetically sealed with hatches sealed by the trading network. Loss of extractives. When preparing kvass wort sugar syrup, fermenting wort, blending and pouring kvass, when pumping products, some of the extractive substances are lost.
For example, when kvass wort is prepared by the infusion method, then 20-24% of extractives leave the kvass thick, therefore it is more economical to prepare it from the concentrate. When sugar syrup is boiled down, up to 1% of sugar is lost (with removable foam or when pumping into a container). In a fermentation-blender, the loss of wort with yeast is much less than in a fermentation apparatus. About 0.3% of the wort is lost on wetting the walls of tanks and pipelines. When bottled by the open method, they lose up to 2%, and by the isobaric method, about 0.8% of kvass.
In the finished kvass, lactic acid and alcoholic fermentation do not stop, since it contains small amounts of yeast, lactic acid bacteria and carbohydrates. Therefore, during storage, there is a decrease in the content of DM. In 100 cm 3 of the finished product, the dry matter content is 5.7 g, which, according to the indications of the sugar meter, corresponds to 5.6% (taking into account the distortion of the results due to the alcohol content).
Below is the content of alcohol and dry matter in the finished kvass (bread and for okroshka), produced from the enterprise (table 32) and located in the trade network (table 33).
Table 32
Production of bottled kvass and drinks from grain raw materials
Both kvass obtained without fermentation and fermentation kvass after pretreatment are poured into bottles.
Without fermentation, kvass is made Moskovsky, Russian, Aromatny, Mint, Honey and kvass with horseradish. The most widespread are Russian and Moscow kvass, which differ only in the recipe ratio of components and the content of dry substances. These kvass are obtained both from the kvass wort concentrate and from the concentrates of the Russian and Moscow kvass. The second method is preferable, since it is simpler, and the products of different batches are more uniform in quality.
Cooking bath syrup, for example, for Russian kvass from KKS, consists of diluting the latter cold water in a ratio of 1: 2 (kvass wort), settling for 10-12 hours, decantation and filtration, preparation of a 50% citric acid solution (lactic acid for Moscow kvass). Then the clarified kvass wort is mixed sequentially with sugar syrup and acid solution, filtered and the bath syrup is cooled to 10 ° C.
To make kvass, Honey blend is prepared both cold and hot. When cold, sugar syrup, kvass wort concentrate, honey, citric acid solution are blended. When hot, water, sugar are added to the syrup cooker, the syrup is boiled for 30 minutes, the kvass wort concentrate and honey are added, transferred and cooled in the collection unit to 10 ° C. The blend is filtered and served for bottling.
For the preparation of Mint kvass and kvass with horseradish, KKS is diluted with water in a ratio of 1: 0.9 and 1: 0.7, respectively. For Mint kvass, diluted KKS is blended with sugar syrup, citric acid, diluted honey and peppermint infusion. And for kvass with horseradish, it is blended with sugar syrup, citric acid and grated horseradish. Kulazh are allowed to settle for 2-3 hours to remove air bubbles.
In the blended syrup, the dry matter content is determined and its dose per bottle (D, cm 3) is calculated using the formula
D = WBD / B 2 D 2, where B is the useful capacity of the bottle, cm 3; B, B 2 - the content of dry substances, respectively, in the finished kvass and blended syrup,%; D 1, D 2 - the density of the finished kvass and blended syrup, respectively, g / cm 3.
The finished blend with a temperature of 8-10 ° C is fed into a dosing apparatus, from where it is poured into bottles in a certain amount, filled with carbonated water on a filling machine, sealed, mixed with a mixer, the quality of the drink is checked on an illuminated screen, a label is pasted and the bottles are automatically placed in boxes.
Kvass quality
Increasing the persistence of kvass. To increase the biological stability, kvass, poured into bottles, is pasteurized in tunnel, in-Uzhny pasteurizers or, previously, in a stream. Stability of pasteurized kvass is 3 months. for Moscow and Russian and 1 month. for Mint and kvass with horseradish.
For tunnel pasteurizer
Option I
Temperature, ° С 40 -> 60 -> 65 - 70 -> 60 -> 40 -> 30 -> 12
Exposure time, min 7 -> 7 -> 44 -> 7-> 7-> 7- "6
Option II
Temperature, 9 C. 40 -> 60 - »70 -> 60 -> 40 -> 30 -> 15
Holding time, min 6 - "6 -> 24 -> 6 -> 6 -> 6 -> 6
For immersion pasteurizer Temperature, ° С 45 -> 65 -> 45 - »35 -> 25 -> 10
Holding time, min 15 -> 35 -> 10 -> 10 -> 10 -> 10
The volume of gas space in bottles intended for pasteurization must be at least 20 cm 3 for bottles with a capacity of 0.5 dm 3 and 14 cm 3 for bottles with a capacity of 0.33 dm 3.
Recently, a technology has been proposed for stable bread kvass obtained by fermentation and subsequent blending not with sugar, but with a sweetener. After that, the kvass is treated with beer clarifiers, which have recently become widespread, which leads to a sharp decrease in yeast cells in it, filtered on a diatomaceous earth or depressurizing filter and pasteurized.
Vices of bread kvass. According to its composition, bread kvass is a favorable environment for the development of microorganisms that cause spoilage. Therefore, a strict sanitary regime in production, compliance with the rules of personal hygiene by workers, bacterial purity of raw materials, equipment, indoor air are necessary to ensure the bacterial purity of kvass.
For bread kvass, the following defects are characteristic: acetic acid sourness, mold, mycoderma (wild yeast), E. coli contamination, mucus.
With acetic acid souring, the acidity of kvass sharply increases and the content of dry substances decreases during the fermentation process,
The taste is impaired. The causative agent of this fermentation is acetic acid bacteria, which oxidize ethyl alcohol to acetic acid. During their development, a thin visible film is formed on the surface of kvass. Poor cleaning of equipment, a large volume of gas space in the bottle and a leaky closure contribute to the growth of bacteria. A characteristic sign of the development of acetic acid bacteria is the appearance of a fruit fly in production facilities, which transfers bacteria to open containers with kvass and wort. The optimum temperature for their growth is 30-34 ° С.
Molds are filamentous microscopic fungi. Molds develop on the walls of the premises, on the surface of barrels, hoses of apparatus, where there are remnants of wort, on grain, malt, and leavened bread! To prevent their appearance in the production premises, they maintain constant cleanliness, and the surfaces of the equipment are treated with chlorine solutions. Anoxic conditions and heat treatment are detrimental to microscopic fungi.
Wild yeast is widely distributed in the air, on the surface of grains, fruits, berries. During their development, they form a white folded film on the surface, worsen the taste of kvass. In conditions of closed fermentation, wild yeast dies. Wild yeast decomposes ethyl alcohol and organic acids to carbon dioxide and water; they do not cause alcoholic fermentation. Pure cultures of commercial yeast should not contain more than 0.5% wild yeast.
E. coli can get into kvass with water, as well as from service personnel who do not observe personal hygiene. For bread kvass prepared on pure cultures, in 1 cm 3, and in 0.1 cm 3 fermented with baker's yeast, the presence of bacteria of the E. coli group BGKP (coliforms) is not allowed. Pathogenic microorganisms should not be in a volume of 25 cm 3.
Slime of kvass occurs as a result of the development of mucus-forming bacteria (leukonostok and potato bacillus). Leukonostok belongs to the group of cocci, gets into kvass with sugar syrup. Under favorable conditions, this microorganism develops in granulated sugar. Consuming sugar, it produces a slimy substance - dextran, which makes kvass viscous, stretching. At the same time, the sweetness is sharply reduced. Such kvass is not suitable for use. In the presence of 0.7-1% acid in the medium or when boiling for at least minutes, the leukonostok dies.
Potato stick, like leukonostok, is a spore-forming microorganism that licks kvass. To prevent contamination of bread kvass with mucus-forming microorganisms, sugar syrup must be boiled for at least 30 minutes and strictly observe the sanitary regime of production. When signs of kvass mucking appear, all containers and equipment where such kvass was located are disinfected with a solution of bleach or antiformin, steamed with live steam.
Assortment of kvass. The non-alcoholic industry produces drinks prepared by the fermentation method (bread kvass, kvass for okroshka, Dneprovsky kvass, bread kvass for hot shops, Russia, Kvass real, Kvass Pobeditel, Okroshechny, Ochakovsky with horseradish, My family, Epic with honey, Khutorskaya) and on bottled carbonated drinks (kvass Russian, Moscow, Lithuanian, aromatic with horseradish, mint; drinks on bread
raw materials Health, Autumn, Ostankino, etc.).
Of the numerous types of kvass obtained by the fermentation method, the factories produce bread kvass and Moskovsky, which have the following quality indicators:
Khlebny Moskovsky Content of dry matter in 100 g of kvass when leaving the factory, g, not less than 5.4-5.8 7.3
Acidity 100 cm 3 of kvass,
cm 3 1 N NaOH solution 2-4 3
carbon,% mass. 0.3-0.4 Not less than 0.3
With the use of KKS and malt extract, drinks are produced on grain raw materials. For example, the Health drink contains sugar, malt extract, citric and ascorbic acids, and color. The drink Autumn contains corn syrup, CCS, color, infusions of tea, oranges, lemons, as well as citric acid and vanillin. Drinks are prepared by blending the ingredients.
Bread kvass, okroshechny, Dneprovsky and bread kvass for hot workshops are opaque drinks, during settling, a precipitate is formed from yeast and particles of raw bread.
Bottled kvass is also opaque, brown in color, sweet and sour in taste. Their aroma depends on the raw materials and additives used.
All types of kvass are sweet and sour in taste, brown in color, have a pronounced aroma of rye bread, and are saturated with carbon dioxide.
In this material:
Kvass is a delicious refreshing drink made from natural ingredients. It does not contain GMOs and preservatives, and therefore it is becoming more and more popular. According to marketing research, sales of kvass are growing by 8-10% annually, so the idea of opening their own mini-enterprise for the production of a drink is of interest to investors. Those who want to make money from this should first develop a business plan for the production of kvass.
The advantages of our own production
The business of making kvass has a number of advantages:
- relatively small amounts of investment in the discovery;
- high demand for the product, especially in the summer;
- maximum benefit - the cost of the drink is 8–10 times less than the selling price;
- low competition in this niche;
- ease of doing business;
- quick launch of a mini-enterprise.
Company description
The goal of the project is to open a small workshop for the production of various types of kvass. The enterprise will be located in a rented area outside the city. In summer, the production process is organized in 2 shifts - from 8.00 to 17.00 and from 20.00 to 5.00. In winter, the workshop works in 1 shift. Weekends are Saturday and Sunday.
The mission of the company is to meet the growing demand of the local population for natural products. The assortment of the produced kvass:
- bread classic;
- okroshechny;
- berry;
- ginger.
An LLC with one founder was chosen as the organizational form. This will allow you to cooperate with organizations - cafes, shops and supermarkets, to sell products in bulk. The selected taxation system is the simplified tax system with a deduction rate of 6% of the amount of income.
Drink making technology
For the preparation of kvass, special equipment is used. The beverage production process takes place in several stages:
- Purification and boiling of water.
- Preparation of wort from water, purchased kvass briquettes with added sugar and yeast.
- Fermentation. This process takes 10-12 hours.
- Filtration of kvass and filling into hermetically sealed containers.
- Ripening of the drink - the container with kvass is placed in a cool place for 4 hours.
- Enrichment with carbon dioxide.
Attention! The drink prepared by this method is stored no longer than 4 days at a temperature of + 5 ... + 7 degrees. To increase the shelf life by 2 times, you can subject it to clarification at the final stage of the technological process.
Analysis of the market and competition in the production of kvass
Before embarking on a project, it is necessary to thoroughly research the local market. The company's competitors are large producers of kvass. It is important to find out:
- what products they offer;
- what technology of making a drink is used;
- whether preservatives are added to the product;
- how the sales channels of competing firms are established;
- at what price they sell the product.
Analyzing this data will help you develop your own "chips" and stand out from the competition. You can fight them by offering the consumer a natural product that does not contain genetically modified additives, dyes and preservatives. However, in this case, the shelf life of the drink will be reduced to 5 days. In this regard, it will be necessary to carry out serious work to find distribution channels for the entire volume of products. Otherwise, the company will incur losses.
How to start a business: a step-by-step guide
The organizational plan of the enterprise includes several stages of work. The first step towards achieving this goal is the legalization of the business. Next, you have to find a room for a production line, purchase equipment, hire workers, find suppliers of raw materials. The products will have to be certified.
Registration of activities and certification of products
To be able to cooperate with legal entities, you will have to open an LLC. If there is only one founder, the entrepreneur will have access to a simplified taxation system with a deduction rate of 6% of the amount of income. To register an LLC, you must go to the tax office and write an application in the form of P11001. Bring documents with you:
- passport and copy;
- TIN and a copy;
- a receipt for payment of the state duty (4000 rubles);
- LLC Charter;
- LLC establishment protocol;
- a letter of guarantee from the owner of the premises and a lease agreement.
After submitting the documents (no later than 30 days), you must write an application for the application of the simplified tax system with the selected tax rate. Also, the entrepreneur needs to choose from the classifier the OKVED code, which allows him to engage in activities for the production and sale of kvass - 15.98.2.
You will have to obtain a certificate of conformity from the Customs Union. The costs for certification of the product will amount to 25-40 thousand rubles. The document is issued for a period of 3 years.
Premises
An area of up to 100 m2 located on the outskirts of the city or outside of it is suitable for placing a production line. Ideal if it is a former canteen. The main requirements for the arrangement:
- availability of a water supply system with the possibility of installing filtering equipment;
- good ventilation;
- sewerage;
- serviceable electrical wiring with a power of up to 5 kW and with an alternating voltage of 220 V;
- separate area for storing kegs;
- the floor and walls are tiled with tiles or other easily washable material;
- convenient access roads and a site for loading and unloading goods.
The minimum set of equipment for a medium-sized enterprise will cost a businessman 400-500 thousand rubles. It is better to buy a complete turnkey production line. It includes units:
- fermentation chambers;
- keg washing machine;
- dispensers for raw materials;
- containers for water;
- water filtration system;
- mixers;
- cooling equipment;
- bottle filling and rolling line;
- oak barrel for wort storage;
- industrial refrigerator;
- stock of kegs.
The search for suppliers of raw materials should be approached with all seriousness, because the taste of the finished product depends on the quality of the ingredients. The main components from which kvass is prepared are:
- barley malt;
- Rye flour;
- special kvass briquettes;
- sugar;
- water.
To prepare 100 liters of a drink, 5 kg of sugar, 300 g of dry briquettes, about 300 liters of purified boiled water are used. 600-700 rubles are spent on the purchase of ingredients to obtain such a volume of kvass.
Staff
Together with the business organizer, the staff includes 14 employees:
- Deputy Director;
- 2 production technologists;
- sales manager;
- accountant;
- Foreman;
- 4 workers per production line;
- 2 loaders.
The main requirements for personnel are experience in the production of soft drinks, no criminal record, understanding of the technological process, knowledge of regulatory documents, decency.
Advertising and marketing, search for sales channels
Product promotion starts with creating your own brand. We'll have to come up with a catchy name, a slogan for the company and develop a label design for kvass. Effective methods advertising:
- creation of videos for demonstration on TV;
- local radio advertisements;
- holding meetings with the owners of supermarket chains in order to conclude supply contracts.
Your products should be positioned as unique, environmentally friendly, natural. Consumers are more and more interested in healthy image life, in the choice of food and drink, they are guided by the desire to get benefits. This should be taken into account when developing commercials.
How much can you earn on the production of kvass?
To find out how profitable the business of making kvass is, you need to make calculations by comparing the estimated income with the expenses of the enterprise.
Investment in the project
Shop opening costs include:
- registration and certification costs - 44,000;
- purchase of equipment - 500,000;
- purchase of raw materials for the first time - 10,000;
- advertising - 50,000;
- arrangement of the premises - 50,000.
Total: 654,000 rubles.
Running costs
Monthly maintenance costs include:
- premises rental costs - 40,000;
- Payroll - 260,000;
- advertising - 30,000;
- transportation costs - 10,000;
- raw materials - 170,000;
- tax deductions - 6% of the company's income.
Total: 510,000 rubles plus taxes.
Income and profit calculation
The enterprise produces 1,000 liters of kvass per day, and 24,000 liters per month. The wholesale selling price of 1 liter of the drink is 35 rubles. The average monthly revenue is easy to calculate - 24,000 x 35 = 840,000 rubles. To calculate the net profit of the workshop, you need to subtract monthly expenses and tax deductions from this amount. Let's make calculations:
- 840,000 x 0.06 = 50,400 - tax;
- 840,000 - 510,000 - 50,400 = 279,600 rubles - the company's net profit for the month, provided that production is fully loaded.
The investment payback period will be 6-8 months, depending on the number of orders. In the first quarter, the workshop will not work on full power... During this period, it is important to actively search for sales channels.
Kvass production is a great business idea. Its main advantages are ease of implementation, high profitability and low investment volume. However, a well-designed marketing strategy plays a huge role in achieving success.
Kvass is a drink that is familiar to us from childhood, despite the fact that it is a consequence of the fermentation of grain raw materials, and which gives us such a desired coolness in summer heat... For the first time, this drink appeared in a person's life a long time ago and has not lost its popularity since then. But at the same time, since then, kvass has become a product of mass consumption.
For its production, products such as malt (obtained from wheat or barley) can be used, in some cases they are used. In addition, if desired, some other ingredients are added to it, such as honey or wax, in some cases a mixture of some herbs. It is believed that kvass as a drink is a purely Slavic traditional drink.
Apparatus for the production of kvass - equipment
Even for kvass at home, you will need appropriate equipment, in particular a container for fermenting wort, in most cases an ordinary glass jar is used for this at home. But on a scale of industrial production, special fermentors, devices for crushing grain, for blending kvass and much more are used. In this case, it is necessary to cancel that, depending on the amount of drink produced, the volumes of the devices will also depend.
It is also worth noting that during the production of kvass it is very important to get a drink of a sufficiently high quality, which cannot be achieved without the use of high-quality raw materials, as well as devices that could help achieve the desired result. The correct selection of equipment for kvass is especially very important from the first days of the production's existence, although it should be borne in mind that it is not always possible to arrange this. And also during the modernization of the business to increase its scale.
Scroll:
- Beverage making machine;
- Keg washing;
- Fermentation tanks;
- Mixing tank (circulation + mixer);
- Capacity for prepared water 120l. (float + squeegees);
- Water treatment system. (3-stage purification + UV filtration);
- Cold hopping machine;
- Sip washing;
- Dispenser for raw materials;
- Mixer for raw materials;
- Reducer with heating functions;
- Measuring instruments;
- Suction heads of fitting A (G / S / H / M / U / D).
The minimum price for the purchase or collection of a mini-plant with a capacity of 10,000 liters per day is from 250,000 rubles.
Kvass production technology + video how they do it
Today, such a drink as kvass is produced according to the technologies of carbonated and non-alcoholic drinks. And its main ingredient is the so-called kvass wort concentrate. In addition, it includes, of course, water.
What the process looks like:
- Water preparation... To make naturally fermented kvass, you need drinking water suitable for sanitary and hygienic standards SanpiNa 2.1.4.1074-01 and / or TI 10-5031536-73-90. The water must be sterile, therefore it must be disinfected by boiling or passing through a special disinfecting filter with UV radiation.
- Wort preparation... To obtain kvass wort by the infusion method, use special kvass briquettes based on rye flour and sugar beet. The briquettes are filled with boiling water (30 liters of water for 4 kg of briquettes). Sugar and wort concentrate are added to the fermentation vessel, according to the recipe. Then it is poured warm water(about 35 ° C) and a pre-diluted yeast mixture.
- Fermentation process... After adding the yeast mixture, the wort is thoroughly mixed, the fermentation apparatus is tightly closed. The temperature (about 30 ° C) and the fermentation time (at least 12 hours) are set.
- Ripening process... The fermented liquid is filtered through filters, poured into plastic food barrels, kegs or PET bottles for its further maturation. Kvass is placed in a dark room, where it is kept at room temperature for 4 hours.
- Cooling process... After maturation of kvass and saturation of the drink with carbon dioxide, the container is placed in the refrigerator. Further, such naturally fermented kvass is sold together with the container in which it matured.
Since the wort concentrate is the main ingredient for kvass, the main focus is on its production. It is made from barley or wheat malts that are mash with water. But in addition to malts, corn or rye flour can be used. It should be noted that any production for the production of kvass has its own recipe for its production. For example, some enterprises may use freshly sprouted fermented rye malt. At small-scale enterprises, so-called leavened rye crispbreads are most often used. In addition, dry bread kvass and much more can also be used. All this depends on the scale of production and the desire of the manufacturer to supply a high quality non-alcoholic drink to the market.
And for this, it is imperative to follow the sequence of each stage of kvass production. So one of the first stages is to obtain the wort, for the manufacture of which the above ingredients are used, which must be infused for a certain amount of time. The next stage is the fermentation of the kvass wort. To do this, the kvass wort must be pumped into a special apparatus and, depending on the recipe, add a certain amount of sugar (at this stage it is 25% of the total amount of required sugar). For a more thorough mixing, it is added in the form of a sugar syrup. Next, kvass is blended. In its process, the remaining 75% of sugar is added, in addition, it is necessary to add kvass wort concentrate, as well as, if necessary, color. After thorough mixing, the kvass product is transferred to the bottling stage. Ordinary plastic bottles, tank trucks or barrels can be used as containers. It should be remembered that the temperature should not exceed 12 degrees Celsius.
Video how kvass is made:
It should be noted that in addition to real kvass, you can also see so-called kvass drinks on the shelves, which practically have nothing to do with real kvass, except for the name. Since they consist of soda, various sweeteners and flavoring agents. Most of the time they are sold in plastic bottles.
According to experts, the production of kvass can become a promising business for an entrepreneur, since the final product is in high demand among consumers (especially during the season). Competition in this niche is quite high, since several large enterprises and dozens of small workshops for the production and bottling of this delicious drink are successfully operating in Russia. But by offering the end customer a quality product, you can quickly gain their trust. And the variability of technology allows you to buy equipment for the production of kvass for various purposes and functionality.
Kvass is a traditional Russian drink obtained by alcohol and lactic acid fermentation of wort. The ethyl alcohol content in the final product should not exceed 1.2%.
Our business valuation:
Initial investments - from 300,000 rubles.
Market saturation is high.
The complexity of starting a business is 6/10.
So, the idea is formed. It's time to start implementing the project. What does an entrepreneur need to highlight when drawing up a business plan for the production of kvass?
Prospects for the direction and possible problems in doing business
Every year the amount of kvass consumption is growing, which is confirmed by statistical data. And this is even taking into account the fact that every year new enterprises specializing in the production of the drink appear on the market. And this cannot but have a positive effect on the prospects of this direction. The production and sale of kvass as a business, subject to competent planning and a well-thought-out marketing policy, can become a highly profitable business that brings high incomes to an entrepreneur.
Beginning entrepreneurs should hardly be afraid of high competition, since large factories mainly produce so-called kvass drinks, and not a natural product. A small-capacity workshop can be focused on the production of a "live" drink, which consumers love so much. And it is the quality of the products, in this case, that it is advisable to use as a publicity stunt.
The only drawback that can cloud the whole picture is seasonality. The manufactured product is in great demand only in the spring-summer period, but in winter the mini-plant for the production of kvass will sell a much smaller amount of finished products, which, of course, will affect profits.
What assortment to offer to consumers?
With the assortment that will be further supplied to retail outlets, you need to decide right away. It is on this that both the technological instruction and the manufacturing process itself will depend.
It would seem that kvass is kvass. But the technology of kvass production allows introducing various additives into the recipe, designed to make the final product unique in comparison with others that are abundant on store shelves. And here many options are possible. Today, having developed the appropriate recipe and correctly adjusted the technological process, it is possible to produce different types of kvass:
- bread,
- pear,
- citric,
- cranberry.
"Standard" bread kvass is more popular. Therefore, the main stake should be made on this particular type of drink. And in the future, as the brand's popularity grows, it will be possible to expand the product line.
The most popular container for kvass among buyers is PET bottles. As for their volume, it is better to pour the drink in containers of 2 liters.
Business options
Mini installation for the production of kvass
The production of bread kvass can be adjusted in several ways. And in order to choose the right one, you should carefully monitor the market and weigh your financial capabilities. What development paths are possible here?
- Homemade beverage production.
- Industrial beverage production.
Both options are quite "working" and with well-functioning distribution channels will be able to bring the entrepreneur a decent income. But making a drink at home, using simple equipment, you will not be able to enter a large consumer market, the maximum that is possible is to sell the product to neighbors and friends. But the industrial production of kvass, through the use of high-tech equipment, is able to satisfy any consumer's needs.
When organizing an industrial enterprise, it is not at all necessary to invest large funds. It may be a small workshop that sells kvass on the local market.
Raw materials and technology for making kvass
To implement a smooth process, it is necessary to establish constant purchases of raw materials in the workshop. It is better to conclude contracts with suppliers for the wholesale supply of components - this is cheaper.
You will need the following raw materials for kvass:
- leavened bread,
- yeast,
- sugar,
- purified water.
To reduce the cost of the process, many entrepreneurs use semi-finished products - kvass powders and concentrates. It is worth deciding which components to choose based on the planned assortment and cost plans for obtaining the finished drink.
Technological scheme for the manufacture of kvass
The technological scheme for producing kvass is simple, and can be described as follows:
- Water preparation (filtration and boiling).
- Wort production (mixing all ingredients).
- Wort fermentation (12 hours at a temperature of ≈30 ˚C).
- Pouring a drink.
- Fermentation of kvass (4 hours at room temperature).
- Cooling kvass.
Even a beginner in this business will be able to master the production of live kvass. But for the development of recipes and specifications, as well as for the commissioning of the line, it is better to invite an experienced technologist.
Technical equipment of the workshop
Even a mini production of kvass will require a certain set of equipment in the workshop. And this direction is also good because the widest choice of devices allows you to launch an enterprise even with minimal funds, since suppliers offer the widest range of prices.
A standard kvass production line is completed as follows:
- Water treatment system.
- Dosing machine with scales.
- Fermenter.
- Fermentation tank.
The specific number of items will depend on the planned production volumes of the drink. For example, a mini-workshop at first can function with only a few containers for fermentation and maturation of the product.
The minimum price of equipment for the production of kvass, which has to be spent on equipping a small-capacity workshop, is ≈500,000 rubles. If we talk about a large-scale plant, much more money will be required - up to 5,000,000 rubles. And to save money, you can order devices from China, or, alternatively, buy a supported line.
Sales options for kvass
You should think over the options for selling the finished product at the stage of developing a business plan. This will help to establish cooperation with regular customers as soon as possible and will not allow the equipment to be idle.
Kvass can be sold in the following ways:
- wholesale deliveries to retail outlets,
- directly to customers through our own retail outlets.
Having chosen the second option, it is better to prepare for spending, since it will require the purchase of special equipment for bottling the drink (kegs with taps, taps, refrigerators) and renting a passage. But it can be a great solution for a budding entrepreneur, since you don't have to waste time looking for “profitable” clients. And after all, not every chain of large stores will take kvass of a little-known brand for sale.
The profitability of the planned business
The production of kvass by fermentation will require an investment of at least 1,500,000 rubles from an entrepreneur. This will include expenses for the purchase and commissioning of equipment, registration of the enterprise and registration of the brand, preparation for the operation of the premises, and raw materials supply. Capital investments can be reduced to 300,000 rubles if you plan a home production of the drink.
The business promises to be profitable, which is proved by some economic calculations. Kvass on lactobacilli stands on wholesale market≈35 rubles / liter At the same time, its cost is 15-20 rubles / liter. And, if you sell 200 l / day (which is quite realistic even with 1 small-volume fermentation plant), you can have a monthly revenue of up to 250,000 rubles. And we are talking about a small shop - revenues will triple if we start full-scale production.
Kvass(cf. Russian. ferment) is a traditional Russian drink with a volume fraction of ethyl alcohol not exceeding 1.2%, made as a result of unfinished alcoholic and lactic acid fermentation of wort.
Kvass is easily prepared both industrially and at home. To make yeast kvass at home, yeast, crackers (or better, kvass wort) and sugar are usually used. To give the drink special shades of taste, berries, mint, hops, apples, pears, raisins and other products are also often added to kvass. A separate group of non-cereal kvass (raw materials for which are beets, sea buckthorn, etc.) are used mainly in cooking and folk medicine... The medicinal and dietary properties of such kvass were studied and described by B.V. Bolotov.
Kvass is prepared from various types of flour and bread, water and malt and is a product of lactic acid and partly alcoholic fermentation of sugary substances formed from starch contained in the starting materials. Rye, barley, wheat, buckwheat and oat flour are used; they take both rye and wheat bread; malt is mostly rye and barley. Sometimes kvass is made without adding malt. The most common is grain kvass.
For the preparation of non-alcoholic kvass, almost any plant product is used, filled with water and left for a day (for example, for rare kvass - grated radish).
The essence of the traditional methods of making kvass is as follows: a mixture of malt, rye, wheat or some other flour, taken in certain proportions that are different for different varieties of kvass, are poured into a wooden tub and brewed with boiling water; when brewing, they usually take about 1/10 of the total amount of water that has to be used for kvass. The resulting thick doughy mass (mash) is stirred with a paddle until a sweet taste appears in it; after that, the mash is transferred to cast iron and the latter are placed in a Russian, pre-heated, oven for a day. After this time, the cast irons are removed from the oven and the mash is transferred into large vats, then diluted with water, left to stand for 2-3 hours and the settled liquid, upon adding yeast (no more than 1% of all starting materials), is poured into prepared barrels. Fermented rye bread is sometimes used instead of yeast. Barrels with kvass are placed on a glacier or in a basement, generally in a room with a low temperature.
There are a huge number of recipes for making kvass. The difference between them lies both in the quantities and grades of the starting materials, and in the details of the preparation technique itself; for example, both cold and hot water is used to brew the mash; the residence time of the mash in the oven and the wort in the vats in different ways is different. Some varieties of bread kvass are flavored with sugar, hops, mint, raisins, molasses, honey, vorain (honey residues obtained as a by-product of candle wax from honeycombs), and so on before being poured into barrels.
Technology of production (preparation) of bread kvass
Bread kvass production technology consists of:
Making white sugar syrup,
- preparation of wort,
- preparation of starter cultures of microorganisms,
- fermentation of wort,
- blending of kvass.
The guaranteed shelf life of bread kvass is 2 days at a temperature not exceeding 12 ° C.
With a variety of methods for preparing bread kvass, the essence of the chemical changes occurring in this process is in general as follows. As already mentioned, a mixture of flour and malt with water, the so-called mash, is kept for a long time at a moderately high temperature in the oven, as a result of which the starch contained in flour or bread, under the influence of the unorganized enzyme diastase, which is in the malt, turns into sugar at this time. and dextrin. With the subsequent dilution of the dough with water in vats and after the addition of yeast, the formed sugar and other soluble parts of flour and malt are fermented under the influence of mainly two types of organized enzymes: alcohol-fermenting fungus and lactic acid fermentation bacillus, which results in the formation of alcohol and lactic acid. Since the mash is not boiled, the wort is kept for a long time at a low temperature and the cooling is slow, this gives all the conditions for the souring of the wort, that is, for the development of lactic acid fermentation; despite the addition of yeast, alcoholic fermentation in the wort occurs only to a weak degree, since the alcohol-fermenting fungus does not withstand the above-described conditions for preparing the wort, in which lactic acid fermentation is predominant and proceeds so vigorously that it prevents the strong development of alcoholic fermentation.
According to a recognized expert in the field of beer and soft drinks based on bread, Corresponding Member of the Russian Academy of Sciences Y. Sviridyuk, this is exactly what kvass differs from beer - the starting materials for both drinks are the same, but the method of preparation is different: when making beer, everything is directed in order to prevent the occurrence of acidic fermentation, for which the mash is heated to more high temperature and it cools down as quickly as possible, so that alcoholic fermentation in beer is predominant, while making kvass is the exact opposite.
In addition to these substances, lactic acid and alcohol, other by-products arise during fermentation, such as: carbon dioxide, acetic acid, formic acid, etc., then mannitol, dextrin, esters of acids with alcohol, and other substances that give kvass its peculiar taste. After pouring kvass into barrels and bottles, fermentation does not stop in it. The formation of lactic acid occurs most vigorously during the first 4-5 days, and then acetic acid fermentation occurs; subsequently, the more the percentage of lactic acid in kvass increases, the slower lactic acid fermentation occurs and acetic acid fermentation comes to the fore. The higher the room temperature of barrels with kvass, the faster acetic acid develops.
When preparing kvass, hygiene standards must be observed: barrels and vats must be thoroughly steamed, boiled water should be taken to dilute the wort - otherwise, along with the formation of lactic acid, butyric acid fermentation occurs, and such kvass, when consumed, produces and enhances the development of butyric acid in the intestine and can serve cause of serious digestive disorders. The storage of kvass should be furnished with the best possible conditions - a clean, well-ventilated room, clean barrels. Rationally prepared and carefully preserved kvass can remain unchanged for 2-3 months. With careless storage in kvass, decomposition processes soon begin; acetic acid fermentation comes to the fore, and kvass acquires an unpleasant sour taste. Sometimes kvass acquires the properties of stretching in threads, which depends on the formation of a special gummy substance; often kvass is covered with mold fungi. In such kvass, Dr. Georgievsky found a fatty acid of a higher order, reminiscent of nylon in smell.
