How store-bought dumplings are made. What and how are dumplings made from (photo review)

As I said CEO company Sapukhin Maxim Gennadievich: “Our goal is not only to talk about new equipment and the modernization process at the enterprise. Our goal is to talk about food production in general, dispel common myths, and show the modern process of producing semi-finished products.”

After these words, we put on white coats and moved to the workshops.

2. It is imperative to wash your hands before entering production facilities.

A little about the company:

"Siberian Gourmet" occupies a leading position from the Urals to Far East by volume of products sold, in various price categories. Production volume – up to 80 tons of semi-finished products per day, 25,000 tons per year.

Sales volume for the first 6 months of 2011 amounted to 842 million rubles. Every day more than 100,000 people buy the company's semi-finished products.

The company employs 1,198 people. In 2010, Siberian Gourmet took 27th place in the rating of Russian employers prepared by HeadHunter.

And now about production:

Production stages: control of all input raw materials, preparation and quality control of dough and fillings, molding, intermediate molding control, freezing, intermediate freezing control, packaging and control of packaged products (several packs are selected from a batch and checked for compliance with quality standards).

3. The first point of our route is the premises of agroflexes for bulk storage of flour. Flour for the entire production is stored here and is automatically sifted. Flour is supplied to the Dominioni dumpling making line through pipelines, and to other areas in special containers.

4. The Dominioni molding line produces up to 25 tons of products per day. Flour is supplied to the line through a pipeline, which is kneaded into dough by automatic machines. Various dough recipes are entered into the machine’s program, and the operator ensures that the ratio of ingredients is maintained.

5. Automatic trolley distributes dough to all machines. The dough is rolled out into layers, the blank is cut out, the product is shaped (the filling is served and the machine is wrapped in the dough).

6. The operator of this line regularly checks the products for filling.

7. The finished product is sent along a belt to spiral blast freezing chambers. The temperature in the cells is -30 -32.

8. Line hand sculpted produces about 10 tons of dumplings per day. On this line, the blanks are produced automatically; an already cut circle of dough with filling appears in front of the molder. The molder's task is to form the dumpling by hand: sew a seam and connect the ends.

9. Hand-made dumplings are made from less dense dough and more juicy minced meat.
In this area there is increased attention to sanitary standards.

10. After freezer the product is carefully sorted, substandard appearance is selected, and the product meets the standard is packaged.

12. The next stage of the line is a multi-head dispenser, which separates and doses products; it can be used to package 2 types of products at once.

13. After packaging, the products are placed in boxes, then on pallets and sent as quickly as possible for temporary storage in refrigerated chambers. When finished, the product remains at above-zero temperatures for just a few minutes. This is done to save appearance and product quality.

14. Packing tape

15. Temperature in the workshops +13 C

16. The whole process from refrigerator to packaging

17. Right next to the dumplings they make khinkali and cutlets

18. The product goes into the freezer

19. Minced meat used in khinkali

20. Cutlets.

21. Before loading minced meat into the cutlet making machine.

22. Packers

23. After the product is packaged, it is transported to the refrigeration and logistics terminal, which can accommodate 600-700 tons of products; this volume is sold in less than 2 weeks.

24. The terminal supports constant temperature minus 18 degrees. In the loading area there are special entrances for refrigerators, which allow maintaining low temperatures. The close proximity of the terminal and the production site, a comfortable temperature for frozen semi-finished products (products are also transported at a temperature of minus 18 ⁰C) allow us to maintain the quality of the products.

25. Warehouse for 3200 pallets/space

For many, the most interesting thing will be how to make minced meat for semi-finished products? I, too, was most interested in this stage, but in fact I didn’t see anything unusual. Dumplings are made from real meat. I asked a question about plant soy - is it added? I was told that soy is added exclusively to the minced meat that goes into cheap dumplings. All those dumplings that cost more than 150 rubles are made from 100% real minced meat.

Those. If there is soy in dumplings, then only in cheap ones and for the sake of saving the consumer. Therefore, all those who complain that there is no minced meat in dumplings are simply stingy to buy a normal product.

26.

27. In the meat deboning area, meat is cut. Raw materials are purchased mainly from local manufacturers and some from European ones.

28. After separating the meat from the bone, it is sorted into highest, first and second grade. Each type of product uses its own variety of beef and pork.

29. Acceptance of raw meat takes place in the presence of the state veterinary service (from the Veterinary Inspectorate) and a technologist. If the meat does not meet the required level of fatness, it is returned. Meat raw materials are stored at low temperatures in special chambers. According to the technology, raw meat must be stored for at least 24 hours. This is done to “ripen” the meat; it is during this period that it acquires the proper taste.

31. Frozen bacon from European producers is purchased in briquettes. This is done out of necessity, since there is a shortage of raw materials from local producers. This lard, like all raw materials, undergoes thorough laboratory control.

32. Onions that go into minced meat.

33. The next stage of preparing minced meat is mixing the ingredients. The raw meat, chopped on a block cutter to 5 mm, is poured into a minced meat mixer, where it is mixed with onions and spices. After kneading in a minced meat mixer, the minced meat is matured in a special sterile room at low temperature, as required by the recipe.

34. The company has a quality service that monitors product quality at all stages of production. This service includes a quality control department, whose task is to monitor quality at all stages: from the entry of raw materials to the finished product.

To control incoming raw materials, Siberian Gourmet purchased unique equipment beyond the Urals - a fat analyzer. The cost of this equipment is 5 million rubles, manufactured in Germany. The fat content analyzer allows you to determine the percentage of fat content with high accuracy, excluding the influence of the human factor. This point is important, since the fat content of raw meat largely determines the taste. finished products, which the company seeks to standardize.

35. There is also a laboratory where laboratory tests of samples of raw materials and products are carried out at all stages of production. For maximum control, production stages where changes in product quality may occur have been identified. At these stages, samples are taken from each batch of products for laboratory research.

36. All studies are entered into a special electronic database.

37. Without the permission of the laboratory, raw materials and products are not used in production.

I suggest taking a break from dumplings, because I have already shown the entire production process. Let's talk about pancakes :)

38. The Balpe pancake line is French equipment. After kneading, the dough is fed onto a hot drum, where the pancake ribbon is fried on both sides.

39. Endless damn!

40. The pancake belt moves along the conveyor and a special syringe, controlled by a computer, delivers the filling in doses. The amount of filling depends on its density, which is entered into the program and adjusts the operation of the line accordingly.

41. On this moment ham and cheese filling

42. The pancake tape is cut and special devices on the line roll the spring rolls, manual labor It is not used during the cooking, stuffing and folding of pancakes. Irrigation of pancakes with oil also occurs automatically. The baking crust is the same as at home.

43. The line operates for the production of pancakes with 1 type of product for 24 hours, after which it is disassembled, thoroughly washed, and only after that the preparation of products with another type of filling begins

44. After cooking, the pancakes are placed on special carts by employees wearing sterile gloves and sent to a freezing chamber at a temperature of minus 28 - 30 degrees for 1.5 hours.

45. And this is a finished product in packaging

46. An area for baking “Solntsepek” pancakes - special pancakes made from fluffy, soft dough with sweet fillings: cherry, strawberry, chocolate.

47. Pancakes are baked by hand, round shape. For baking, French pancake machines are used - round, flat surfaces heated to the required temperature. The capacity of this production site is up to 700 kg per day.

48. The pancakes are very tasty, I personally appreciated it :)

49. This concludes our excursion. Finally, a photo of the company's security guards :)

Thank you for your attention. I hope it was interesting.

These are digital video cameras that use the IP protocol to transmit a video stream in digital format over an Ethernet network.

As the general director of the company, Maxim Gennadievich Sapukhin, said: “Our goal is not only to talk about new equipment and the modernization process at the enterprise. Our goal is to talk about food production in general, dispel common myths, and show the modern process of producing semi-finished products.”

After these words, we put on white coats and moved to the workshops.

2. It is imperative to wash your hands before entering production facilities.

A little about the company:

“Siberian Gourmet” occupies a leading position from the Urals to the Far East in terms of volumes of products sold, in various price categories. Production volume – up to 80 tons of semi-finished products per day, 25,000 tons per year.

Sales volume for the first 6 months of 2011 amounted to 842 million rubles. Every day more than 100,000 people buy the company's semi-finished products.

The company employs 1,198 people. In 2010, Siberian Gourmet took 27th place in the rating of Russian employers prepared by HeadHunter.

And now about production:

Production stages: control of all input raw materials, preparation and quality control of dough and fillings, molding, intermediate molding control, freezing, intermediate freezing control, packaging and control of packaged products (several packs are selected from a batch and checked for compliance with quality standards).

3. The first point of our route is the premises of agroflexes for bulk storage of flour. Flour for the entire production is stored here and is automatically sifted. Flour is supplied to the Dominioni dumpling making line through pipelines, and to other areas in special containers.

4. The Dominioni molding line produces up to 25 tons of products per day. Flour is supplied to the line through a pipeline, which is kneaded into dough by automatic machines. Various dough recipes are entered into the machine’s program, and the operator ensures that the ratio of ingredients is maintained.

5. An automatic cart distributes dough to all machines. The dough is rolled out into layers, the blank is cut out, the product is shaped (the filling is served and the machine is wrapped in the dough).

6. The operator of this line regularly checks the products for filling.

7. The finished product is sent along a belt to spiral blast freezing chambers. The temperature in the cells is -30 -32.

8. The hand-made dumplings line produces about 10 tons per day. On this line, the blanks are produced automatically; an already cut circle of dough with filling appears in front of the molder. The molder's task is to form the dumpling by hand: sew a seam and connect the ends.

9. Hand-made dumplings are made from less dense dough and more juicy minced meat. In this area there is increased attention to sanitary standards.

10. After the freezer, the product is carefully sorted, those that are substandard by appearance are selected, and the product that meets the standard is packaged.

12. The next stage of the line is a multi-head dispenser, which separates and doses products; it can be used to package 2 types of products at once.

13. After packaging, the products are placed in boxes, then on pallets and sent as quickly as possible for temporary storage in refrigerated chambers. When finished, the product remains at above-zero temperatures for just a few minutes. This is done to preserve the appearance and quality of the product.

14. Packing tape

15. Temperature in the workshops +13 C

16. The whole process from refrigerator to packaging

17. Right next to the dumplings they make khinkali and cutlets

18. The product goes into the freezer

19. Minced meat used in khinkali

20. Cutlets.

21. Before loading minced meat into the cutlet making machine.

22. Packers

23. After the product is packaged, it is transported to the refrigeration and logistics terminal, which can accommodate 600-700 tons of products; this volume is sold in less than 2 weeks.

24. The terminal maintains a constant temperature of minus 18 degrees. In the loading area there are special entrances for refrigerators, which allow maintaining low temperatures. The close proximity of the terminal and the production site, a comfortable temperature for frozen semi-finished products (products are also transported at a temperature of minus 18 ⁰C) allow us to maintain the quality of the products.

25. Warehouse for 3200 pallets/space

For many, the most interesting thing will be how to make minced meat for semi-finished products? I, too, was most interested in this stage, but in fact I didn’t see anything unusual. Dumplings are made from real meat. I asked a question about plant soy - is it added? I was told that soy is added exclusively to the minced meat that goes into cheap dumplings. All those dumplings that cost more than 150 rubles are made from 100% real minced meat.

Those. If there is soy in dumplings, then only in cheap ones and for the sake of saving the consumer. Therefore, all those who complain that there is no minced meat in dumplings are simply stingy to buy a normal product.

27. In the meat deboning area, meat is cut. Raw materials are purchased mainly from local manufacturers and some from European ones.

28. After separating the meat from the bone, it is sorted into the highest, first and second grade. Each type of product uses its own variety of beef and pork.

29. Acceptance of raw meat takes place in the presence of the state veterinary service (from the Veterinary Inspectorate) and a technologist. If the meat does not meet the required level of fatness, it is returned. Raw meat is stored at low temperatures in special chambers. According to the technology, raw meat must be stored for at least 24 hours. This is done to “ripen” the meat; it is during this period that it acquires the proper taste.

31. Frozen bacon from European producers is purchased in briquettes. This is done out of necessity, since there is a shortage of raw materials from local producers. This lard, like all raw materials, undergoes thorough laboratory control.

32. Onions that go into minced meat.

33. The next stage of preparing minced meat is mixing the ingredients. The raw meat, chopped on a block cutter to 5 mm, is poured into a minced meat mixer, where it is mixed with onions and spices. After kneading in a minced meat mixer, the minced meat is matured in a special sterile room at low temperature, as required by the recipe.

34. The enterprise has a quality service that monitors product quality at all stages of production. This service includes a quality control department, whose task is to monitor quality at all stages: from the entry of raw materials to the finished product. To control incoming raw materials, Siberian Gourmet purchased unique equipment beyond the Urals - a fat analyzer. The cost of this equipment is 5 million rubles, manufactured in Germany. The fat content analyzer allows you to determine the percentage of fat content with high accuracy, excluding the influence of the human factor. This point is important, since the fat content of raw meat largely determines the taste of the finished product, which the company strives to standardize.

35. There is also a laboratory where laboratory tests of samples of raw materials and products are carried out at all stages of production. For maximum control, production stages where changes in product quality may occur have been identified. At these stages, samples are taken from each batch of products for laboratory research.

36. All studies are entered into a special electronic database.

37. Without the permission of the laboratory, raw materials and products are not used in production.

I suggest taking a break from dumplings, because I have already shown the entire production process. Let's talk about pancakes :)

38. The Balpe pancake line is French equipment. After kneading, the dough is fed onto a hot drum, where the pancake ribbon is fried on both sides.

39. Endless pancake!

40. The pancake belt moves along the conveyor and a special syringe, controlled by a computer, delivers the filling in doses. The amount of filling depends on its density, which is entered into the program and adjusts the operation of the line accordingly.

41. Currently filled with ham and cheese

42. The pancake tape is cut and special line devices roll the filled pancakes; manual labor is not used in the process of preparing, stuffing and rolling the pancakes. Irrigation of pancakes with oil also occurs automatically. The baking crust is the same as at home.

43. The line operates for the production of pancakes with 1 type of product for 24 hours, after which it is disassembled, thoroughly washed, and only after that the preparation of products with another type of filling begins

44. After cooking, the pancakes are placed on special carts by employees wearing sterile gloves and sent to a freezing chamber at a temperature of minus 28 - 30 degrees for 1.5 hours.

47. Pancakes are baked by hand, round in shape. For baking, French pancake machines are used - round, flat surfaces heated to the required temperature. The capacity of this production site is up to 700 kg per day.

48. Pancakes are very tasty, I personally appreciated this :)

Recently I took part in a press tour to the production site of Siberian Gourmet Semi-Finished Products Plant LLC. The production is quite interesting, mobile and, as it seemed to me, compact. Below is the entire production of dumplings from the stage of creating minced meat, to packaging the finished product and shipment to the warehouse. In addition to dumplings, they showed the production of pancakes, cutlets and khinkali, about this also under the cut.

(Total 49 photos)

As the general director of the company, Maxim Gennadievich Sapukhin, said: “Our goal is not only to talk about new equipment and the modernization process at the enterprise. Our goal is to talk about food production in general, dispel common myths, and show the modern process of producing semi-finished products.”

After these words, we put on white coats and moved to the workshops.

2. It is imperative to wash your hands before entering production facilities.

A little about the company:

“Siberian Gourmet” occupies a leading position from the Urals to the Far East in terms of volumes of products sold, in various price categories. Production volume – up to 80 tons of semi-finished products per day, 25,000 tons per year.

Sales volume for the first 6 months of 2011 amounted to 842 million rubles. Every day more than 100,000 people buy the company's semi-finished products.

The company employs 1,198 people. In 2010, Siberian Gourmet took 27th place in the rating of Russian employers prepared by HeadHunter.

And now about production:

Production stages: control of all input raw materials, preparation and quality control of dough and fillings, molding, intermediate molding control, freezing, intermediate freezing control, packaging and control of packaged products (several packs are selected from a batch and checked for compliance with quality standards).

3. The first point of our route is the premises of agroflexes for bulk storage of flour. Flour for the entire production is stored here and is automatically sifted. Flour is supplied to the Dominioni dumpling making line through pipelines, and to other areas in special containers.

4. The Dominioni molding line produces up to 25 tons of products per day. Flour is supplied to the line through a pipeline, which is kneaded into dough by automatic machines. Various dough recipes are entered into the machine’s program, and the operator ensures that the ratio of ingredients is maintained.

5. An automatic cart distributes dough to all machines. The dough is rolled out into layers, the blank is cut out, the product is shaped (the filling is served and the machine is wrapped in the dough).

6. The operator of this line regularly checks the products for filling.

7. The finished product is sent along a belt to spiral blast freezing chambers. The temperature in the cells is -30 -32.

8. The hand-made dumplings line produces about 10 tons per day. On this line, the blanks are produced automatically; an already cut circle of dough with filling appears in front of the molder. The molder's task is to form the dumpling by hand: sew a seam and connect the ends.

9. Hand-made dumplings are made from less dense dough and more juicy minced meat. In this area there is increased attention to sanitary standards.

10. After the freezer, the product is carefully sorted, those that are substandard by appearance are selected, and the product that meets the standard is packaged.

12. The next stage of the line is a multi-head dispenser, which separates and doses products; it can be used to package 2 types of products at once.

13. After packaging, the products are placed in boxes, then on pallets and sent as quickly as possible for temporary storage in refrigerated chambers. When finished, the product remains at above-zero temperatures for just a few minutes. This is done to preserve the appearance and quality of the product.

14. Packing tape

15. Temperature in the workshops +13 C

16. The whole process from refrigerator to packaging

17. Right next to the dumplings they make khinkali and cutlets

18. The product goes into the freezer

19. Minced meat used in khinkali

20. Cutlets.

21. Before loading minced meat into the cutlet making machine.

22. Packers

23. After the product is packaged, it is transported to the refrigeration and logistics terminal, which can accommodate 600-700 tons of products; this volume is sold in less than 2 weeks.

24. The terminal maintains a constant temperature of minus 18 degrees. In the loading area there are special entrances for refrigerators, which allow maintaining low temperatures. The close proximity of the terminal and the production site, a comfortable temperature for frozen semi-finished products (products are also transported at a temperature of minus 18 ⁰C) allow us to maintain the quality of the products.

25. Warehouse for 3200 pallets/space

For many, the most interesting thing will be how to make minced meat for semi-finished products? I, too, was most interested in this stage, but in fact I didn’t see anything unusual. Dumplings are made from real meat. I asked a question about plant soy - is it added? I was told that soy is added exclusively to the minced meat that goes into cheap dumplings. All those dumplings that cost more than 150 rubles are made from 100% real minced meat.

Those. If there is soy in dumplings, then only in cheap ones and for the sake of saving the consumer. Therefore, all those who complain that there is no minced meat in dumplings are simply stingy to buy a normal product.

27. In the meat deboning area, meat is cut. Raw materials are purchased mainly from local manufacturers and some from European ones.

28. After separating the meat from the bone, it is sorted into the highest, first and second grade. Each type of product uses its own variety of beef and pork.

29. Acceptance of raw meat takes place in the presence of the state veterinary service (from the Veterinary Inspectorate) and a technologist. If the meat does not meet the required level of fatness, it is returned. Raw meat is stored at low temperatures in special chambers. According to the technology, raw meat must be stored for at least 24 hours. This is done to “ripen” the meat; it is during this period that it acquires the proper taste.

31. Frozen bacon from European producers is purchased in briquettes. This is done out of necessity, since there is a shortage of raw materials from local producers. This lard, like all raw materials, undergoes thorough laboratory control.

32. Onions that go into minced meat.

33. The next stage of preparing minced meat is mixing the ingredients. The raw meat, chopped on a block cutter to 5 mm, is poured into a minced meat mixer, where it is mixed with onions and spices. After kneading in a minced meat mixer, the minced meat is matured in a special sterile room at low temperature, as required by the recipe.

34. The enterprise has a quality service that monitors product quality at all stages of production. This service includes a quality control department, whose task is to monitor quality at all stages: from the entry of raw materials to the finished product. To control incoming raw materials, Siberian Gourmet purchased unique equipment beyond the Urals - a fat analyzer. The cost of this equipment is 5 million rubles, manufactured in Germany. The fat content analyzer allows you to determine the percentage of fat content with high accuracy, excluding the influence of the human factor. This point is important, since the fat content of raw meat largely determines the taste of the finished product, which the company strives to standardize.

35. There is also a laboratory where laboratory tests of samples of raw materials and products are carried out at all stages of production. For maximum control, production stages where changes in product quality may occur have been identified. At these stages, samples are taken from each batch of products for laboratory research.

36. All studies are entered into a special electronic database.

37. Without the permission of the laboratory, raw materials and products are not used in production.

I suggest taking a break from dumplings, because I have already shown the entire production process. Let's talk about pancakes

38. The Balpe pancake line is French equipment. After kneading, the dough is fed onto a hot drum, where the pancake ribbon is fried on both sides.

39. Endless pancake!

40. The pancake belt moves along the conveyor and a special syringe, controlled by a computer, delivers the filling in doses. The amount of filling depends on its density, which is entered into the program and adjusts the operation of the line accordingly.

41. Currently filled with ham and cheese

42. The pancake tape is cut and special line devices roll the filled pancakes; manual labor is not used in the process of preparing, stuffing and rolling the pancakes. Irrigation of pancakes with oil also occurs automatically. The baking crust is the same as at home.

43. The line operates for the production of pancakes with 1 type of product for 24 hours, after which it is disassembled, thoroughly washed, and only after that the preparation of products with another type of filling begins

44. After cooking, the pancakes are placed on special carts by employees wearing sterile gloves and sent to a freezing chamber at a temperature of minus 28 - 30 degrees for 1.5 hours.

45. And this is a finished product in packaging

46. ​​Area for baking “Solntsepek” pancakes - special pancakes made from fluffy, soft dough with sweet fillings: cherry, strawberry, chocolate.

47. Pancakes are baked by hand, round in shape. For baking, French pancake machines are used - round, flat surfaces heated to the required temperature. The capacity of this production site is up to 700 kg per day.

48. Pancakes are very tasty, I personally appreciated this

49. This concludes our excursion. Finally, a photo of the company's security guards

Recently I took part in a press tour to the production site of Siberian Gourmet Semi-Finished Products Plant LLC. The production is quite interesting, mobile and, as it seemed to me, compact. Below is the entire production of dumplings from the stage of creating minced meat, to packaging the finished product and shipment to the warehouse. In addition to dumplings, they showed the production of pancakes, cutlets and khinkali, about this also under the cut.

As the general director of the company, Maxim Gennadievich Sapukhin, said: “Our goal is not only to talk about new equipment and the modernization process at the enterprise. Our goal is to talk about food production in general, dispel common myths, and show the modern process of producing semi-finished products.”

After these words, we put on white coats and moved to the workshops.

2. It is imperative to wash your hands before entering production facilities.

A little about the company:

“Siberian Gourmet” occupies a leading position from the Urals to the Far East in terms of volumes of products sold, in various price categories. Production volume - up to 80 tons of semi-finished products per day, 25,000 tons per year.

Sales volume for the first 6 months of 2011 amounted to 842 million rubles. Every day more than 100,000 people buy the company's semi-finished products.

The company employs 1,198 people. In 2010, Siberian Gourmet took 27th place in the rating of Russian employers prepared by HeadHunter.

And now about production:

Production stages: control of all input raw materials, preparation and quality control of dough and fillings, molding, intermediate molding control, freezing, intermediate freezing control, packaging and control of packaged products (several packs are selected from a batch and checked for compliance with quality standards).

3. The first point of our route is the premises of agroflexes for bulk storage of flour. Flour for the entire production is stored here and is automatically sifted. Flour is supplied to the Dominioni dumpling making line through pipelines, and to other areas in special containers.

4. The Dominioni molding line produces up to 25 tons of products per day. Flour is supplied to the line through a pipeline, which is kneaded into dough by automatic machines. Various dough recipes are entered into the machine’s program, and the operator ensures that the ratio of ingredients is maintained.

5. An automatic cart distributes dough to all machines. The dough is rolled out into layers, the blank is cut out, the product is shaped (the filling is served and the machine is wrapped in the dough).

6. The operator of this line regularly checks the products for filling.

7. The finished product is sent along a belt to spiral blast freezing chambers. The temperature in the cells is -30 -32.

8. The hand-made dumplings line produces about 10 tons per day. On this line, the blanks are produced automatically; an already cut out circle of dough with filling appears in front of the molder. The molder's task is to form the dumpling by hand: sew a seam and connect the ends.

9. Hand-made dumplings are made from less dense dough and more juicy minced meat.
In this area there is increased attention to sanitary standards.

10. After the freezer, the product is carefully sorted, those that are substandard by appearance are selected, and the product that meets the standard is packaged.

12. The next stage of the line is a multi-head dispenser, which separates and doses products; it can be used to package 2 types of products at once.

13. After packaging, the products are placed in boxes, then on pallets and sent as quickly as possible for temporary storage in refrigerated chambers. When finished, the product remains at above-zero temperatures for just a few minutes. This is done to preserve the appearance and quality of the product.

14. Packing tape

15. Temperature in the workshops +13 C

16. The whole process from refrigerator to packaging

17. Right next to the dumplings they make khinkali and cutlets

18. The product goes into the freezer

19. Minced meat used in khinkali

20. Cutlets.

21. Before loading minced meat into the cutlet making machine.

22. Packers

23. After the product is packaged, it is transported to the refrigeration and logistics terminal, which can accommodate 600-700 tons of products; this volume is sold in less than 2 weeks.

24. The terminal maintains a constant temperature of minus 18 degrees. In the loading area there are special entrances for refrigerators, which allow maintaining low temperatures. The close proximity of the terminal and the production site, a comfortable temperature for frozen semi-finished products (products are also transported at a temperature of minus 18 ⁰C) allow us to maintain the quality of the products.

25. Warehouse for 3200 pallets/space

For many, the most interesting thing will be how to make minced meat for semi-finished products? I, too, was most interested in this stage, but in fact I didn’t see anything unusual. Dumplings are made from real meat. I asked a question about plant soy - is it added? I was told that soy is added exclusively to the minced meat that goes into cheap dumplings. All those dumplings that cost more than 150 rubles are made from 100% real minced meat.

Those. If there is soy in dumplings, then only in cheap ones and for the sake of saving the consumer. Therefore, all those who complain that there is no minced meat in dumplings are simply stingy to buy a normal product.

26.

27. In the meat deboning area, meat is cut. Raw materials are purchased mainly from local manufacturers and some from European ones.

28. After separating the meat from the bone, it is sorted into highest, first and second grade. Each type of product uses its own variety of beef and pork.

29. Acceptance of raw meat takes place in the presence of the state veterinary service (from the Veterinary Inspectorate) and a technologist. If the meat does not meet the required level of fatness, it is returned. Raw meat is stored at low temperatures in special chambers. According to the technology, raw meat must be stored for at least 24 hours. This is done to “ripen” the meat; it is during this period that it acquires the proper taste.

31. Frozen bacon from European producers is purchased in briquettes. This is done out of necessity, since there is a shortage of raw materials from local producers. This lard, like all raw materials, undergoes thorough laboratory control.

32. Onions that go into minced meat.

33. The next stage of preparing minced meat is mixing the ingredients. The raw meat, chopped on a block cutter to 5 mm, is poured into a minced meat mixer, where it is mixed with onions and spices. After kneading in a minced meat mixer, the minced meat is matured in a special sterile room at low temperature, as required by the recipe.

34. The company has a quality service that monitors product quality at all stages of production. This service includes a quality control department, whose task is to monitor quality at all stages: from the entry of raw materials to the finished product.

To control incoming raw materials, Siberian Gourmet purchased unique equipment beyond the Urals - a fat analyzer. The cost of this equipment is 5 million rubles, manufactured in Germany. The fat content analyzer allows you to determine the percentage of fat content with high accuracy, excluding the influence of the human factor. This point is important, since the fat content of raw meat largely determines the taste of the finished product, which the company strives to standardize.

35. There is also a laboratory where laboratory tests of samples of raw materials and products are carried out at all stages of production. For maximum control, production stages where changes in product quality may occur have been identified. At these stages, samples are taken from each batch of products for laboratory research.

36. All studies are entered into a special electronic database.

37. Without the permission of the laboratory, raw materials and products are not used in production.

I suggest taking a break from dumplings, because I have already shown the entire production process. Let's talk about pancakes :)

38. The Balpe pancake line is French equipment. After kneading, the dough is fed onto a hot drum, where the pancake ribbon is fried on both sides.

39. Endless damn!

40. The pancake belt moves along the conveyor and a special syringe, controlled by a computer, delivers the filling in doses. The amount of filling depends on its density, which is entered into the program and adjusts the operation of the line accordingly.

41. Currently filled with ham and cheese

42. The pancake tape is cut and special line devices roll the filled pancakes; manual labor is not used in the process of preparing, stuffing and folding the pancakes. Irrigation of pancakes with oil also occurs automatically. The baking crust is the same as at home.

43. The line operates for the production of pancakes with 1 type of product for 24 hours, after which it is disassembled, thoroughly washed, and only after that the preparation of products with another type of filling begins

44. After cooking, the pancakes are placed on special carts by employees wearing sterile gloves and sent to a freezing chamber at a temperature of minus 28 - 30 degrees for 1.5 hours.

45. And this is a finished product in packaging

46. An area for baking “Solntsepek” pancakes - special pancakes made from fluffy, soft dough with sweet fillings: cherry, strawberry, chocolate.

47. The pancakes are baked by hand and are round in shape. For baking, French pancake machines are used - round, flat surfaces heated to the required temperature. The capacity of this production site is up to 700 kg per day.

48. The pancakes are very tasty, I personally appreciated it :)

49. This concludes our excursion. Finally, a photo of the company's security guards :)

Thank you for your attention. I hope it was interesting.

Recently I took part in a press tour to a semi-finished products plant. The production is quite interesting, mobile and, as it seemed to me, compact. The report shows the entire production of dumplings from the stage of creating minced meat, to packaging the finished product and shipment to the warehouse. In addition to dumplings, they showed the production of pancakes, cutlets and khinkali.

As the general director of the company, Maxim Gennadievich Sapukhin, said: “Our goal is not only to talk about new equipment and the modernization process at the enterprise. Our goal is to talk about food production in general, dispel common myths, and show the modern process of producing semi-finished products.”

After these words, we put on white coats and moved to the workshops.

2. It is imperative to wash your hands before entering the production workshops.

A little about the company:

“Siberian Gourmet” occupies a leading position from the Urals to the Far East in terms of volumes of products sold, in various price categories. Production volume – up to 80 tons of semi-finished products per day, 25,000 tons per year.

Sales volume for the first 6 months of 2011 amounted to 842 million rubles. Every day more than 100,000 people buy the company's semi-finished products.

The company employs 1,198 people. In 2010, Siberian Gourmet took 27th place in the rating of Russian employers prepared by HeadHunter.

And now about production:

Production stages: control of all input raw materials, preparation and quality control of dough and fillings, molding, intermediate molding control, freezing, intermediate freezing control, packaging and control of packaged products (several packs are selected from a batch and checked for compliance with quality standards).

3. The first point of our route is the premises of agroflexes for bulk storage of flour. Flour for the entire production is stored here and is automatically sifted. Flour is supplied to the Dominioni dumpling making line through pipelines, and to other areas in special containers.

4. The molding line produces up to 25 tons of products per day. Flour is supplied to the line through a pipeline, which is kneaded into dough by automatic machines. Various dough recipes are entered into the machine’s program, and the operator ensures that the ratio of ingredients is maintained.

5. An automatic cart distributes dough to all machines. The dough is rolled out into layers, the blank is cut out, the product is shaped (the filling is served and the machine is wrapped in the dough).

6. The operator of this line regularly checks the products for filling.

7. The finished product is sent along a belt to spiral blast freezing chambers. The temperature in the cells is -30 -32.

8. The hand-made dumplings line produces about 10 tons per day. On this line, the blanks are produced automatically; an already cut circle of dough with filling appears in front of the molder. The molder's task is to form the dumpling by hand: sew a seam and connect the ends.

9. Hand-made dumplings are made from less dense dough and more juicy minced meat.
In this area there is increased attention to sanitary standards.

10. After the freezer, the product is carefully sorted, those that are substandard by appearance are selected, and the product that meets the standard is packaged.

12. The next stage of the line is a multi-head dispenser, which separates and doses products; it can be used to package 2 types of products at once.

13. After packaging, the products are placed in boxes, then on pallets and sent as quickly as possible for temporary storage in refrigerated chambers. When finished, the product remains at above-zero temperatures for just a few minutes. This is done to preserve the appearance and quality of the product.

14. Packing tape

15. Temperature in the workshops +13 C

16. The whole process from refrigerator to packaging

17. Right next to the dumplings they make khinkali and cutlets

18. The product goes into the freezer

19. Minced meat used in khinkali

20. Cutlets.

21. Before loading minced meat into the cutlet making machine.

22. Packers

23. After the product is packaged, it is transported to the refrigeration and logistics terminal, which can accommodate 600-700 tons of products; this volume is sold in less than 2 weeks.

24. The terminal maintains a constant temperature of minus 18 degrees. In the loading area there are special entrances for refrigerators, which allow maintaining low temperatures. The close proximity of the terminal and the production site, a comfortable temperature for frozen semi-finished products (products are also transported at a temperature of minus 18 ⁰C) allow us to maintain the quality of the products.

25. Warehouse for 3200 pallets/space

For many, the most interesting thing will be how to make minced meat for semi-finished products? I, too, was most interested in this stage, but in fact I didn’t see anything unusual. Dumplings are made from real meat. I asked a question about plant soy - is it added? I was told that soy is added exclusively to the minced meat that goes into cheap dumplings. All those dumplings that cost more than 150 rubles are made from 100% real minced meat.

Those. If there is soy in dumplings, then only in cheap ones and for the sake of saving the consumer. Therefore, all those who complain that there is no minced meat in dumplings are simply stingy to buy a normal product.

27. In the meat deboning area, meat is cut. Raw materials are purchased mainly from local manufacturers and some from European ones.

28. After separating the meat from the bone, it is sorted into the highest, first and second grade. Each type of product uses its own variety of beef and pork.

29. Acceptance of raw meat takes place in the presence of the state veterinary service (from the Veterinary Inspectorate) and a technologist. If the meat does not meet the required level of fatness, it is returned. Raw meat is stored at low temperatures in special chambers. According to the technology, raw meat must be stored for at least 24 hours. This is done to “ripen” the meat; it is during this period that it acquires the proper taste.

31. Frozen bacon from European producers is purchased in briquettes. This is done out of necessity, since there is a shortage of raw materials from local producers. This lard, like all raw materials, undergoes thorough laboratory control.

32. Onions that go into minced meat.

33. The next stage of preparing minced meat is mixing the ingredients. The raw meat, chopped on a block cutter to 5 mm, is poured into a minced meat mixer, where it is mixed with onions and spices. After kneading in a minced meat mixer, the minced meat is matured in a special sterile room at low temperature, as required by the recipe.

34. The enterprise has a quality service that monitors product quality at all stages of production. This service includes a quality control department, whose task is to monitor quality at all stages: from the entry of raw materials to the finished product.

To control incoming raw materials, Siberian Gourmet purchased unique equipment beyond the Urals - a fat analyzer. The cost of this equipment is 5 million rubles, manufactured in Germany. The fat content analyzer allows you to determine the percentage of fat content with high accuracy, excluding the influence of the human factor. This point is important, since the fat content of raw meat largely determines the taste of the finished product, which the company strives to standardize.

35. There is also a laboratory where laboratory tests of samples of raw materials and products are carried out at all stages of production. For maximum control, production stages where changes in product quality may occur have been identified. At these stages, samples are taken from each batch of products for laboratory research.

36. All studies are entered into a special electronic database.

37. Without the permission of the laboratory, raw materials and products are not used in production.

I suggest taking a break from dumplings, because I have already shown the entire production process. Let's talk about pancakes :)

38 The Balpe pancake line is French equipment. After kneading, the dough is fed onto a hot drum, where the pancake ribbon is fried on both sides.

39. Endless pancake!

40. The pancake belt moves along the conveyor and a special syringe, controlled by a computer, delivers the filling in doses. The amount of filling depends on its density, which is entered into the program and adjusts the operation of the line accordingly.

41. Currently filled with ham and cheese

42. The pancake tape is cut and special line devices roll the filled pancakes; manual labor is not used in the process of preparing, stuffing and rolling the pancakes. Irrigation of pancakes with oil also occurs automatically. The baking crust is the same as at home.

43. The line operates for the production of pancakes with 1 type of product for 24 hours, after which it is disassembled, thoroughly washed, and only after that the preparation of products with another type of filling begins

44. After cooking, the pancakes are placed on special carts by employees wearing sterile gloves and sent to a freezing chamber at a temperature of minus 28 - 30 degrees for 1.5 hours.

45. And this is a finished product in packaging

46. ​​Area for baking “Solntsepek” pancakes - special pancakes made from fluffy, soft dough with sweet fillings: cherry, strawberry, chocolate.

47. Pancakes are baked by hand, round in shape. For baking, French pancake machines are used - round, flat surfaces heated to the required temperature. The capacity of this production site is up to 700 kg per day.

48. Pancakes are very tasty, I personally appreciated this :)

49.This concludes our excursion. Finally, a photo of the company's security guards :)