The production of sugar cookies is an attractive investment. Despite enough high level competition in the industry, there is a steady increase in demand, on average by 8-10% annually. When organizing production, it is necessary to come up with an original recipe in order to stand out from competitors. An automated cookie production line provides opportunities for improvisation with shape, additives, and filling. If the production of bakery or confectionery products has already been organized, the production of cookies will diversify the assortment, and it will also be possible to save on some production mechanisms.

Where to start?

Before starting activities, you should consider some organizational issues:

• what types of cookies will be produced;
• study manufacturing technology;
• select equipment;
• select premises for a workshop;
• work out options for selling products;
• make preliminary calculations of production costs and profitability.

To begin with, it would be advisable to produce well-known types of cookies, the main advantage being high quality products. With high competition in the industry, consumers can be attracted either by low cost or quality.

It is ideal, of course, to combine these two indicators, but in no case should you reduce the price at the expense of quality. Using one technological line for the production of cookies, you can produce various types of cookies:

• sugar;
• biscuits;
• crackers;
• lingering.

The assortment can be diversified with different shapes, sizes, fillings, and additives. It is necessary to study the market, competitors’ products and choose new types of cookies or traditional ones, but in new interpretations.

Cookie making technology

Regardless of what types of cookies you choose and what their recipe is, the manufacturing technology is approximately the same and includes the following steps:

The preparatory stage consists of weighing all the necessary ingredients according to the recipe and immersing them in the bowl of a dough mixing machine. The sequence of adding raw materials is determined by the manufacturing technology of each type of cookie.

There are two main types of dough - sand-removal and sand-jigging. Removable butter dough contains more sugar and fat, and turns out plastic. The main ingredients (flour, sugar, vegetable oil, water) are mixed for 10 minutes, then added egg powder, condensed milk, vanillin, according to the recipe and knead for another 15 minutes.

At the next stage, the dough is divided into portioned pieces for further rolling and shaping. If filling is provided, the next step is to add it.

Cookie forming machine

Then the pieces are sent to the oven for baking, this process usually lasts 10-15 minutes. The finished cookies are cooled, glazed if necessary and sent to the packaging line.

Shortbread dough is prepared using a different technology - at the initial stage, margarine and sugar are mixed, the remaining ingredients are gradually added, and flour is added last. The mass turns out to be liquid, like sour cream; it is mixed in a mixer at high speed to saturate it with oxygen. The formation of blanks from such dough is carried out using syringes or pastry bags. To diversify the assortment, various shaped nozzles are used. The line for the production of sugar cookies has a special depositing machine, its functions include various product configurations and filling possibilities. At the next stage, the blanks are sent to the oven at a temperature of 220 o C and the production process is completed. Finished products are cooled and packaged.

Production equipment

The following equipment is used to carry out the cookie manufacturing process:

• flour sifting device;
• dough mixing machine or mixer;
• bake;
• packaging machine.

The flour sifting unit is designed to remove impurities and metal particles from the composition, as well as fill the flour with oxygen. Specifications:

• power – 1.1 kW;
• voltage – 380 V;
• productivity – 1250 kg/h;
• Hopper capacity – 120 kg;
• weight – 293 kg;
• cost – 50,000 rubles.

A dough mixing machine with a Z-shaped attachment is designed to combine all the ingredients into a homogeneous mass. Specifications:

The dough depositing machine, as part of a cookie production line, is used in the production of such types of cookies as: chicken, oatmeal, eclairs, sticks, biscuit. Specifications:

The baking installation consists of several baking modules, a feeding and receiving table, an exhaust system and a control panel. The baking modules are connected to each other by a moving conveyor that looks like a tunnel. Specifications:

The packaging mechanism is used when finished products are packaged in shrink polyethylene film. Specifications:

• power – 5.5 kW;
• voltage – 220 V;
• operating speed – 5 m/min;
• dimensions – 12000*750*630 mm;
• cost – 120,000 rubles.

With this configuration, you can buy a line for the production of cookies for 1,660,000 rubles. Additionally, you will need scales for raw materials, a sink, baking sheets, a thermometer, and knives, which will increase the cost of the line by about 100,000 rubles.

Production premises

Cookie making workshop

When preparing the premises, you should take into account the total length of the production line, as well as additional equipment - sinks, tables, refrigerators. A workshop of less than 100 m2 will be cramped; in addition, a warehouse for raw materials and finished products, an office space, and household rooms should be prepared. In the production workshop, it is necessary to ensure sanitary and hygienic conditions that meet all the requirements for safe production. To service an automated mini-line for the production of cookies, you will need three-phase sockets with a voltage of 380 and 220 V, water supply, sewerage, and ventilation. The workshop must be heated; it is better to use an air conditioning system.

Financial production plan

To organize activities for the production of cookies, capital investments will be required in equipment, preparation of premises, and purchase of vehicles.

• price of the cookie production line – 1,750,000 rubles;
• preparation of the premises - 100,000 rubles;
• transportation costs – 100,000 rubles;
• total – 1,950,000 rubles.

It is planned to produce 80 tons of cookies per month.

Product cost:

• raw materials – 2,400,000 rubles;
• salary – 100,000 rubles;
• rent and utility bills – 80,000 rubles;
• other organizational expenses – 50,000 rubles;
• total – 2,630,000 rubles.

The selling price of 1 ton of cookies is 40,000 rubles.
Revenue for the month will be 80 * 40,000 = 3,200,000 rubles.
Profit – 3,200,000 – 2,630,000 = 570,000 rubles.

If one third of the profit is attributed to covering capital investments, then the payback period will be 11 months. That's enough high rate, but in order to reach it, it is necessary to properly organize the sales of products, enter into agreements in advance with large wholesale companies and private distributors.

Video: Cookie production

Organize cookie production as a business

Whether it's the production of oatmeal cookies or the production shortbread cookies, in any case, the business will bring a significant share of profit. The cookies themselves are a ready-made brand. It does not need to be advertised so that all customers know about it (but this does not apply to newly opened stores selling flour products). Now there are many types of cookies, and every time more and more new options are invented. This means that, having opened such a business, there is little chance of being left without buyers.

Types of cookies

There are three main types of cookies:

• sugar,
• lingering (aka dry),
• butter (it can be shortbread, oatmeal, puff pastry or whipped).

The main difference between them is the method of preparation and consistency of the dough.

1) Production of sugar cookies

First, the dough is kneaded in kneading machines. At least ten are used for its manufacture. various types raw materials. All of them are mixed continuously, that is, they are dosed into the machine in the same ratio. Sugar dough is swelling and brittle. It also has an easy-to-tear consistency.

2) Production of hard biscuits

The dough is not as swollen and brittle as sugar dough. Contains less fat and sugar (almost two times). In addition to all this, long-dough dough differs from sugar dough in special properties. To obtain elastic-elastic dough, you need to create necessary conditions, characteristic of fairly complete swelling.

3) Production of butter cookies

This dough contains greatest number fat, sugar, egg products. Cookies are characterized by a large selection of shapes and sizes.

Cookies as a business - its features

The main advantages of the cookie production business are its prospects, the demand for the product (according to research, every second consumer buys at least one pack of cookies in one trip to the store), long shelf life.

The most promising areas are:

• "nuts"
• fortune cookies,
• biscuits,
• biscuits,
• children's.

One of the disadvantages is competition. But here you can find a plus. Long-established companies, by and large, use old equipment and focus on already “boring” types of cookies, while a new company has a chance to hook and attract customers with something new and unusual. If you use high-quality equipment and advertising, then you can have no doubt about your success.

If you initially invest several million rubles (3-4) in the business, monthly revenue may well amount to a million rubles, while the net profit is 100,000 rubles, taking into account the payback period of 2.5 years.

What do you need to get started?

Before you search for raw materials, prepare documents, rent and hire employees, you need to understand the cookie production scheme. It looks like this.

• preparing ingredients (straining milk, softening fats, sifting flour);
• kneading dough;
• making the filling;
• cutting dough;
• baking cookies;
• removing the finished cookies;
• cooling;
• packaging;
• packaging.

Subsequently, new technologies for the production of cookies can be introduced. You should not make too many products if the technology is not yet sufficiently proven. To get started, a few batches will be enough. If the product sells well, then new technology can be entered definitively.

Where to get raw materials?

Suppliers will help with the supply of raw materials. You can find them in various ways:

• ask friends
• find on the Internet,
• contact popular wholesale companies directly.

The most popular and fastest way is to search on the Internet. You should focus on those suppliers who are located within the same city. It is necessary to evaluate it and agree on an adequate cost.

There are also specialized resources where you can find not only the suppliers themselves, but also get a lot of valuable advice on this topic from knowledgeable people. In any case, choosing a supplier and quality raw materials is a responsible step, since further success in production depends on it.

Equipment and premises required for production?

Equipment for the production of cookies must be of high quality and modern. The following must be available:

• dough mixing machine,
• filling mixing machine,
• pastry oven,
• thermo sealer,
• conveyors,
• dough divider,
• syringe filler,
• bake,
• emulsifier,
• glazing machine,
• packaging machine,
• mixers.

As for the premises, it will not be limited to just the workshop. You will need to equip a warehouse, a garage for cars supplying products, your own office, and separate rooms for staff. You can pay attention to catering establishments. Location doesn't matter.

Required employees and their positions

It is difficult to manage all the work on your own, so you will need department heads who will monitor a specific area themselves. You will need an employee responsible for the removal of products. His subordination will include loaders, drivers, and sectors for receiving and sending containers. You should definitely hire accountants, managers, storekeepers, technologists and operating personnel.

Each hired employee must be trained and a contract is concluded with him. The main point is a medical examination. Every six months, all workers are required to undergo a medical examination and only after a positive result can they be allowed to work.

Licenses, permits and other requirements

It is necessary to obtain all licenses and make sure that the premises comply with all standards in advance. First you need to contact two services:

• sanitary and epidemiological supervision
• Rospotrebnadzor.

The premises must have water pipes, all types of electricity, and sewerage. If all this is not observed, then the sanitary services will not allow the enterprise to survive for long.

Product Buyers

It is advisable to think through options for marketing cookies at the stage when the idea is born. It’s great if at the time of launching your production you already have an agreement with one or even several chain stores. After all, they are the intermediate buyers.

That is, the main sales channel is small retail grocery stores. Don't go to big stores. For beginning entrepreneurs, this is not the best option because manufacturers often have to reduce the purchase price in order to get on the shelves of large stores. Hypermarkets are famous for their lowest prices. Based on this, the ideal option is small chain stores.

The final buyers of products are people. And to make them interested in buying, you need to create and produce something unusual and appetizing.

How to attract clients?

In order for stores to want to buy cookies, you need to come up with something original. For example, focus on product packaging. It was noted that large cities are characterized by large sales of packaged cookies, while loose cookies, on the contrary, sell better in the regions.

To increase sales, you need to pay attention to the following points:

1) Technical capabilities of the forming machine.

It should be aimed at producing a wide range of cookies. And to achieve this, it must quickly move from one mode to another.

2) The quality of the stove.

What's worse than burnt cookies? It is necessary to take a responsible approach to choosing a stove, as it is the key to the success of the product.

3) Reducing costs for both materials and raw materials.

This also includes optimization of product formulations.

4) Well-established relationships with sanitation stations.

Observing a number of requirements will help you avoid unnecessary costs and problems: correct placement of all equipment, layout of the premises, competent organization of storage of materials and raw materials. The absence of problems with regulatory authorities will create a good reputation.

5) Good choice of supplier.

To avoid problems with supplies, it is necessary to focus on long-term cooperation. This will fully contribute to the uninterrupted production and increase in sales of cookies.

Cookie production is one of the most delicious, profitable, sought-after and promising areas in business. There are no people in the world who would not buy it. Even those people who have health problems also do not have to refuse to purchase them, since diabetic cookies are produced.

On the one hand, it may be difficult to beat competitors, but on the other hand, you can always come up with something new or borrow an unusual foreign idea.

Something supernatural must happen for people to stop buying sweets, including cookies. The business will be profitable if you find distribution channels, arrange the production of relatively large batches using modern equipment and in compliance with the recipe.

According to statistics, flour confectionery products are firmly included in the group of products that are in constant demand among Russian consumers. Competition in this market segment can be considered moderate.

Basically, the market is occupied by small artisanal workshops with low productivity and high production costs. Based on these facts, the biscuit production business using modern equipment seems very promising. Let's consider a business plan for organizing the production of cookies with a capacity of up to 4 tons per shift.

Production technology

A detailed presentation of the cookie production technology is not included in our plans, so we will limit ourselves to listing its main stages:

• Preparation of raw materials and components.
• Kneading the dough.
• Cookie molding.
• Baking cookies.
• Cooling the cookies.
• Package.

Organization of product sales

The sale of food products with a short shelf life is characterized by territorial binding. In addition, high transport costs due to the low cost of the goods make transporting them over long distances economically unjustified.

Large and medium-sized cities have always had a lot of confectionery factories and cookie production workshops, so the emergence of another workshop producing inexpensive, high-quality loose cookies will in no way prevent it from becoming a sales leader in this segment.

Imports are poorly represented here (no more than 10-15%), which is explained by the specifics of the products.

Sales can be organized through:

• Wholesalers specializing in food products.
• Grocery chains at the regional and federal levels.

Production premises

The total area of ​​the premises required for the production of cookies must be at least 250 square meters. m with a ceiling height of 3.2 m. The areas should include:

• Technological premises.
• Warehouse premises.
• Household premises and sanitary facilities for staff.
• The premises for production and other purposes must comply with SanPiN 2.3.4.551-96, with provision of water supply and sewerage, 380 V electricity supply, convenient transport access.

Staff

Let's consider the work of a workshop in one shift. We will present the number of personnel, professions and positions, official salaries or salaries of each and the monthly salary fund in total. The total number of personnel will be 15 people. Of these:

• Manager – 1 person. salary 35 thousand rubles, total: 35 thousand rubles.
• Production technologist – 1 person. salary 30 thousand rubles, total: 30 thousand rubles.
• Head of Sales Service – 1 person. salary 30 thousand rubles, total: 30 thousand rubles.
• Storekeeper – 1 person. salary 20 thousand rubles, total: 20 thousand rubles.
• Head of the workshop – 1 person. salary 25 thousand rubles, total: 25 thousand rubles.
• Workers – 6 people. salary 15 thousand rubles, total: 90 thousand rubles.
• Loaders – 4 people. salary 12 thousand rubles, total: 48 thousand rubles.

Total: 15 people, monthly salary fund 278 thousand rubles.

Capital Cost Sheet

Capital costs will include the cost of purchasing technological equipment for the production of cookies and the costs of its delivery, commissioning and commissioning, as well as working capital - costs of raw materials and some other costs.

There is currently no shortage of equipment. We have chosen an automatic biscuit production line with a capacity of up to 450 kg per hour, made in China.

Capital costs will be:

• Automatic line for the production of cookies - 13.5 million rubles;
• Transportation costs for delivery of the line – 1.35 million rubles;
• Installation and commissioning of the line – 1.0 million rubles;
• Turnover expenses (raw materials, advertising, etc.) – 3.5 million rubles.

Total: 19.35 million rubles.

Revenue from a biscuit production plant

The calculation of revenue will be made based on the conditions of the workshop working in one shift, the presence of a technological break and a lunch break, and a monthly workload of 22 shifts.

Based on the productivity of the equipment and the data provided, the monthly volume of cookies produced will be 79.2 tons. The cost of 1 ton of cookies wholesale starts from 42 thousand rubles. With a monthly output of 79.2 tons, the sales volume for the month will be 3,326,400 rubles.

Product cost calculation

To produce 1 ton of cookies, 1,200 kg of raw materials (flour, sugar, margarine, milk, etc.) are required. The daily consumption of raw materials is 4.28 tons, and at a cost of 17,700 rubles. per ton, the shift cost will be 75,827 rubles, respectively, for 22 shifts - 1,668,190 rubles.

Electricity costs per shift will be 9,492 rubles, for 22 shifts 284,760 rubles. The total cost of production will be: per shift - 85,319 rubles, per month - 1,952,950 rubles.

Total expenses for the month

• Salary – 278,000 rubles.
• Rental of premises – 200,000 rubles.
• Advertising expenses – 50,000 rubles.
• Transport costs – 100,000 rubles.
• Utility costs – 10,000 rubles.
• Accounting costs (outsourcing) – 25,000 rubles.
• Other expenses – 35,000 rubles.

Total: 698,000 rub.

• Profit calculation
• Sales – RUB 3,326,400.
• Cost – 1,852,950 rubles.
• Profit (gross) – RUB 1,373,450.
• Costs – 698,000 rubles.
• Profit (before tax) – RUB 675,450.
• Tax (15%) – RUB 101,318.
• Profit (net) – RUB 574,133.
• Profitability – 17.3%

Payback

Capital investments amount to 19,350,000 rubles, net profit – 574,133 rubles. per month. The ratio of these values ​​will give a payback period of about 34 months. The payback period can be significantly reduced by organizing the work of the workshop in 2-3 shifts.

Organizational and legal form of business. Taxation

The most common is individual entrepreneurship (IP) with a simplified taxation system (“income minus expenses”). The tax return under this system is submitted once a year in April.
List of taxes to be paid:

• Income tax – 15%
• – 32%
• Income tax – 13%

Your competitiveness

The most important component of your success. Do not expect to have a successful business if you are going to produce a “gray” standard range. If you set yourself the task of not only staying in the market, but also occupying your niche in it with the prospect of development, then the quality of the product should itself provide a competitive advantage.

And the point is not necessarily to expand the range: on the contrary, it can be reduced. Your products should be different from what is offered in stores in your city. And it can only differ for the better. This is the only key to your success!

Achieve better taste and quality. Every separate species your cookies must be better than anything already offered. That's the only way! Otherwise, there is no point in starting such a business.

Free-Photos/Pixabay

Cookies are small, baked from dough. Various grains are sometimes added to cookie dough; cookies are usually shaped in the form of circles, squares, stars, tubes; Sometimes cookies are made with filling (, raisins, cream) or the filling is placed between two cookies.

The production of cookies is an investment-attractive business for a number of reasons: low cost of finished products, stable demand at any time of the year and the ability to constantly make a profit. To assess the effectiveness of investments, it is necessary to study the production process and estimate the costs of purchasing equipment.

How to set up the process

To organize the baking of cookies, knowledge of the technological cycle and production features is not enough. The ultimate goal can be achieved by adhering to the business opening plan:

1. Determine the assortment based on consumer preferences.
2. Study the features of making cookies, decide on a list of equipment, and calculate the main costs.
3. Rent (buy) premises.
4. Register an enterprise.
5. Hire staff.
6. Set up the production line.
7. Organize sales.

Launching a production line will require the greatest material and moral investments, but choosing necessary equipment impossible without first selecting an assortment.

Definition of assortment

Cookies belong to flour confectionery products. According to GOST R 53041-2008, it can be of different shapes, with or without filling, but one of the prerequisites is a moisture content of no more than 16%. The main types of cookies are reflected in GOST 24901-2014 “Cookies. General technical conditions". This includes:

• Sugar is a confectionery product characterized by a fragile structure, flat shape and friability. The mass fraction of sugar in it should not exceed 27%, and the fat content can reach 2-30%. Sugar cookies must be dry, with a moisture content of no more than 10%. At the discretion of the manufacturer, you can add fillings to it, cover it with glaze and give it intricate shapes.
• Butter - unlike sugar, can be voluminous. It is more humid (up to 15.5% moisture), contains at least 30% products: sugar, fat, eggs and milk (or their substitutes).
• Oatmeal - contains from 14% oatmeal, flakes.
• Lingering. Its peculiarity is the layered structure and the presence of through punctures. The fat content of the product reaches 2-28%, and sugar - no more than 20%.

If we refer to GOST R53041-2008, we can distinguish 3 more types of cookies:

• Sandwiched - 2 or more of any of the above, held together by a filling, trim or glaze.
• Cracker - unsweetened (up to 10% sugar) dry biscuits (moisture no more than 7%).
• Biscuits are layered cookies with through punctures. Moisture - no more than 11%.

Each type of product has GOST indicators, which means that the proportions of ingredients used in production must be under strict control.

At first glance, the range is limited, but in fact it can be diversified by producing cookies of different shapes, adding inclusions and fillings.

Additives can be small or large. Small - finely ground dried fruits and nuts, dry cream, yogurt powder, ground coffee and others. Large additives - whole or split in half nut kernels, raisins, candied fruits, coconut flakes or waffles. The list of additives is determined by the manufacturer’s imagination.

The recipes according to which cookies will be made are drawn up in technological maps, which will require approval by SanPiN. The standard routing contains the following data:

• name of the enterprise;
• card number;
• name of the cookie;
• gross and net consumption rates;
• yield of the finished product;
• source of prescription;
• description of the technology of preparation, decoration;
• at the discretion of the technologist - instructions nutritional value 100 g cookies.

Having determined the assortment, choosing for yourself priority areas production, it is necessary to make cost calculations in accordance with the upcoming types of work.

However, first of all, it is necessary to legalize the business in order to receive income for legally.

Registration of an enterprise

To organize the production of cookies you need or. If you plan to open a chain of bakeries, then it is better to choose an LLC. Documents are submitted to tax office. One of important points- selection of the OKVED code under which the type of activity is encrypted. For the production of cookies the following code is suitable:

• 10.72 - “Production of crackers, cookies and other cracked bakery products... for long-term storage.”

Along with registration, you should choose a taxation system. The best option is the simplified tax system or UTII.

To operate, you must obtain a number of permits from the SES and the Ministry of Emergency Situations, taking into account the requirements for the location of production facilities. Working conditions should be clarified with Rospotrebnadzor. Key points - renting premises that are not basement; carrying out repairs to allow disinfection; provide access to running water and communications; maintain optimal temperature and humidity levels in the room.

When renting, you should take into account the size of the production capacity, but first, decide what equipment is needed for the production of cookies.

Cookie production technology and equipment

To put it simply, the cookie production process consists of several successive steps:

Briefly about each of the processes.

Preparation of raw materials

All ingredients for making cookies must be removed from the container. Solid fats are cleared of plaque. Liquid ingredients are strained. Bulk - flour, sugar, cocoa, coffee and other components required according to the recipe are sifted. It is difficult to do such work manually, so in the production of cookies I use a flour sifting machine. It is a unit consisting of a reservoir for pouring ingredients and a spiral system for transferring into a sifting system. From the machine, the flour immediately goes into a separate tank or dough mixing machine. The advantage of using a sifter:

• obtaining flour without lumps;
• saturation of the component with oxygen;
• removal of third-party inclusions;
• catching metal particles with a built-in magnet.

The most commonly used flour sifters are:

• VOSKHOD PVG-600M - vibration type, capable of sifting up to 600 kg of flour per hour. Cost - up to 25 thousand rubles.
• PENZMASH MPM-800M - vibration type with a productivity of up to 500 kg/h. Installation cost - up to 86 thousand rubles.
• DANLER XL-2000 is a powerful auger unit that sifts up to 2000 kg/h. Cost - up to 163 thousand rubles.

Attention is also paid to the preparation of additives and spices.

After sifting, you can proceed to the next step.

Kneading the dough

The dough preparation technology involves preparing an emulsion from ingredients: eggs, flour and milk-containing products, water, fats and sugar. Afterwards, flour, starch, and baking powder are poured in.

The properties of the dough depend on the quality of the flour and the physical state of the fats. Flour with large particles produces a looser, crumbly dough. It is recommended to administer fats in the form of an emulsion. By enveloping the flour particles, they give the dough greater plasticity.

Each type of dough has its own characteristics, which affects the ability to produce cookies of a given shape.

Sugar dough is sweet, which slows down the process of gluten formation. If you use low-gluten flour when making sugar cookies, the dough will be pliable and less brittle. The consistency allows you to apply a design to the surface.

Long dough is also prepared using flour containing a low percentage of gluten. If you take durum flour, the product will turn out hard and quickly deform. Ideally, cookies made from hard dough retain their shape for a long time, “spring”, that is, they restore their original appearance after light pressure.

Butter cookies come in several types, and their production is a more labor-intensive process. Cookies are prepared from butter dough:

• Sand-excavation. To prepare the dough, beat the butter separately (up to 8 minutes), beat the eggs with water, and then emulsify. Flour is poured in.
• Shortbread cookies are fattier and moister. To produce it, first prepare a whipped mixture of butter and sugar (up to 15 minutes) at increasing speeds, then add the remaining components, and finally flour.
• Whipped butter is whipped with powdered sugar, and after 15 minutes. the remaining ingredients are added.

Product quality control is of particular importance in the production of crackers. They require premium flour with a gluten content of at least 30%, and hard water with a salt content of about 15°F. Using soft water will negatively affect the quality of the dough: it will become soft, sticky, and difficult to mold. The cracker must be layered, and for this purpose fats with a melting point of 36°C are used. The production of crackers is complicated by the stages of production.

At the first stage, the dough is prepared using yeast. Fermentation lasts up to 10 hours, and the degree of readiness is determined by measuring the acidity of the dough. On the second stage, mixing is carried out using chemical disintegrants, which lasts about an hour. The technologist controls the humidity level and temperature of the raw materials. To reduce the duration of the process, many manufacturers use catalysts for oxidation processes, in particular the drug amylorizin. With it, the fermentation process is reduced by 8-9 hours.

As an analysis of dough manufacturing technology shows, for kneading you need to purchase:

• Planetary mixer. With its help you can knead dough with a liquid consistency, whip creams and fillings.
• Dough mixing machine - allows you to knead large volumes of homogeneous mass for making cookies in a matter of minutes. Buying a machine allows you to automate production, since it is controlled by software.

Approximate cost of mixers:

• RTK 20 - up to 50 thousand rubles. Equipped with a speed switch and shutdown sensor. Can be used to prepare custard, biscuit and shortcrust pastry. Mixer capacity - 20 l.
• GL-SM5.7GR Gemlux - up to 8.5 thousand rubles. More economical, but also less spacious model. The mixer can operate at 6 speeds and its capacity is up to 5 liters.

Dough mixing machines:

• YS-W70H-3C GRC is a machine that can knead 70 kg of dough within an hour. You can load up to 12 kg of dough into the machine at a time. The cost of the unit is 65 thousand rubles.
• TMS-20NN-1C Abat - High-quality steel dough mixer with a removable bowl. The unit kneads 60 kg of dough per hour; you can load up to 12 kg of baked goods or up to 4 kg of hard dough at a time. The cost of the unit is up to 80 thousand rubles.

After kneading, the dough is rolled between the rollers of a dough rolling machine.

Leveling and aging

Pumping allows all dough components to be evenly distributed in the formation. Excess air comes out of the mass. The stretched dough is subjected to repeated pumping. According to the technological cycle, the stretch dough must rest. As a result, it will turn out to be a crispy, finely porous cookie.

The cost of a dough rolling machine or “belt conveyor for removing dough pieces” is 100-350 thousand rubles. For example, the Italian model MK600A Mac.Pan will cost 348 thousand rubles. It can roll out layers of 0-38 mm and is equipped with anti-stick scrapers.

Product molding

To give the dough a given shape, various cuttings and stamps are used. With their help, a design is applied to the cookies, they are given a different shape, and the edge of the product is processed. The cost of such installations is from 10 thousand rubles.

Bakery

Perhaps the most important unit in the production of cookies is the oven, but without following the baking technology, nothing will come of it.

Bringing the cookies to readiness is divided into 3 stages. First, high humidity is created in the oven, and the temperature is maintained at 150-160°C. Then the temperature is increased to approximately 250°C, denaturation of proteins occurs, and the cookies rapidly lose moisture. After the product is ready, the temperature is slowly reduced.

The multi-step process requires the use of reliable equipment to control temperature and humidity levels. To bake cookies, it is necessary to install a system of baking modules, which is a tunnel with a conveyor that supplies the semi-finished product for baking. The cost of installation, for example, MGP-12, reaches 100 thousand rubles. You can get by with bakery cabinets that have several compartments for loading products. Popular models:

• Voskhod HPE-500 costing up to 45 thousand rubles;
• Kocateq GU6 at a price of up to 126 thousand rubles.

Example of oatmeal cookie production:

Packaging of the finished product

The liver must be provided with appropriate storage conditions, strictly controlling air humidity and temperature. Ensures the safety of confectionery products and gives them a presentable appearance. appearance high quality packaging. To do this, you need to purchase a packaging machine. Its cost is about 120 thousand rubles.

In general, the purchase of equipment that ensures the process of making cookies will cost around 800 thousand rubles. However, these are the costs of basic production facilities. This does not include other expenses that will become a component of the cost of the finished product.

Additional equipment

It is necessary to install a powerful ventilation and air conditioning system and humidity level sensors in the production workshop. The dough and its main ingredients require compliance with storage conditions.

The following should be placed in the hall:

• refrigeration units for storing ingredients and fillings;
• tables for preparing products for loading onto the production line;
• kitchen utensils.

The cost of equipping the premises with auxiliary equipment will be 100-150 thousand rubles.

Other costs for the cookie manufacturer

Purchasing equipment is one of the main tasks for organizing a business. In addition, it is necessary to find the right premises, qualified personnel and a sales market.

Renting premises

When searching for production space, you should take into account the length of the production line. You can carry out calculations yourself, based on the parameters of the selected capacities, or seek the help of professionals.

The optimal workshop area is from 100 m2. In addition to the production premises, there must be a warehouse for raw materials and finished products; office space for an accountant and production technologist.

The premises must have sewerage, excellent ventilation and a centralized water supply line.

You need to pay attention to the wiring. Most industrial equipment runs on three-phase outlets. Their absence is not critical, but replacing and upgrading wiring will result in additional costs.

It will take up to 150 thousand rubles to prepare the premises for work. The price includes equipping the premises with washable finishing materials, cosmetic repairs, elimination of defects.

Rent of premises will average from 80 thousand rubles. per month. Additional payment for utilities - up to 40 thousand rubles. per month.

Recruitment

Food production workers must be professionals, have an excellent knowledge of technological maps, and work to improve taste qualities products.

A prerequisite is availability health book and regular medical examinations according to the established schedule.

A budget of at least 160 thousand rubles should be allocated for remuneration of personnel (2 operators, technologist, accountant, cleaner).

Raw materials

It is better to look for suppliers of raw materials close to production. After checking the certificates and personally monitoring the quality of raw materials, you can enter into supply agreements. Monthly expenses for the purchase of the main components of cookies depend on the volume of planned production.

On average, the enterprise produces up to 60 tons of cookies per month, and the costs are about 1.8 million rubles. Considering that 1 ton of cookies costs about 38,000 rubles, the income will be 2,280,000 rubles, and the profit will be 480 thousand rubles, which covers the current expenses of the enterprise.

When planning activities, it is necessary to draw up detailed cost estimates according to technological maps, identify reserves for cost reduction and find a permanent sales market.

In this material:

Making cookies is a good idea for starting your own business. Cookies are traditionally one of the most popular products on the Russian confectionery market. It is significantly ahead in terms of consumption of such product groups as gingerbread, cakes, and pastries. This fact allows such a business to guarantee stable demand and profit.

Before deciding to invest in a particular business, you need to carry out marketing analysis market and draw up a business plan.

Russian cookie market

On average, each Russian consumes about 4.5 kg of cookies. This means that every year the residents of our country eat 645-750 tons of cookies. Moreover, most of the demand comes from residents of large cities. According to the results of the research, it was possible to identify a pattern: the smaller the city, the less cookies they consume.

Annual market growth is quite moderate and amounts to about 5-7%, but there are opportunities for new manufacturers to enter.

Competition in the market is average. Local producers play a decisive role in the market. This is due to the fact that cookies have a limited shelf life, which makes it impractical to transport them over long distances. Plus, due to logistics costs, the cost of cookies in other regions may become uncompetitive with local producers.

The problem in the industry is the use of obsolete Soviet-era equipment. Organizing production on modern equipment will allow you to save on costs and occupy a significant market share.

There are many varieties of cookies. Marketing research will help you determine the optimal assortment. After all, demand characteristics may differ depending on the region. A balanced assortment that meets customer requirements is one of the components of success.

According to Workline Group research, the largest volume of demand is for sugar and oatmeal cookies. They account for about 18.3 and 18.6% of the sales structure. The leaders in terms of consumption include crackers, dry cookies (like “Maria”), and kurabiye (with jam). According to research, Russian consumers are very conservative, and the structure of demand remains virtually unchanged since Soviet times.

But this does not mean that you just need to start producing the most popular type of cookies and this automatically guarantees success. This statement is erroneous, since you will have to compete with recognized industry leaders (a novice entrepreneur may simply not have enough funds for this). Even the Russian giants of the confectionery business admit that they cannot do without innovation in this area and regularly update their assortment.

A beginning manufacturer needs to find its own unique unfilled niche in the market, which would allow it to compare favorably with its competitors. For example, you can focus your business on producing healthy cookies (for example, enriched with vitamins), fitness cookies (low-calorie), or environmentally friendly cookies (no dyes with natural ingredients).

Organization of cookie production

Equipment for the production of cookies requires special attention. IN this business In the plan, the calculations are based on a production line from the Cityline company. It allows you to produce up to 450 kg of products in a fully automatic mode (from kneading dough to baking and cooling).

The cost of this line, which ensures the production of cookies, will be 13.5 million rubles. Another 10% (1.35 million rubles) will need to be spent on its delivery to the place. Installation of the line will cost 1 million rubles. We must not forget about the need to replenish working capital (for the purchase of raw materials, etc.) in the amount of 3.5 million rubles. The amount of capital costs will be 19.5 million rubles. .

The production of cookies will require a premises of 200 m². When choosing it, you should pay attention to the presence of a sewerage and water supply system, 380 V electricity, ceilings from 3.5 m, as well as convenient access for vehicles. The average cost of renting 1 m² of industrial use with similar characteristics will be 200 thousand rubles. per month.

To operate the production workshop, a total of 14 people will be required. These include the director, technologist, head of the sales department, production manager, storekeeper, 5 workers, 4 loaders. At the same time, accounting and logistics departments should be outsourced. The monthly salary fund will be 263 thousand rubles.

The production of cookies on this line per month will be 79.2 tons (per day - 3.6 tons). This is the minimum value indicated under the condition of working 22 shifts with breaks for lunch and maintenance required by law. By organizing work in several shifts, production volume can be increased.

With a wholesale price of a ton of cookies of 42 thousand rubles. the monthly revenue of the enterprise will be 3.326 million rubles. (42000*79.2)

Now you need to estimate the cost of production. The main components of the cost of cookies will be flour, sugar, milk, margarine, and electricity. Replacement raw materials will cost 72.83 thousand rubles, electricity - another 9.5 thousand rubles. To produce 79.2 tons of cookies, you will need to spend 1953 thousand rubles.

In addition to rent (200 thousand rubles) and salaries (263 thousand rubles), the following monthly expenses will arise:

• advertising expenses (50 thousand rubles);
• transport (100 thousand rubles);
• accounting services (25 thousand rubles);
• utility bills (10 thousand rubles);
• other costs (50 thousand rubles).

The monthly expenses will be 698 thousand rubles.

Cookie production plan indicators

Based on the above, here are the basic indicators of a business plan for a cookie production workshop:

• initial costs - 19,500 thousand rubles;
• revenue - 3,326.4 thousand rubles;
• cost price - 1,952.9 thousand rubles;
• gross profit - 1373.5 thousand rubles;
• monthly total expenses - 698 thousand rubles;
• profit before tax - 675.45 thousand rubles;
• tax (USN-15%) - 101.38 thousand rubles;

Net profit will be 574.13 thousand rubles, and return on sales will be 17.26%.

Taking into account capital investments of 19.5 million rubles. cookie production will pay for itself in 34 months, which is a pretty good result.

This calculation is based on the assumption that investments in production will be made at own funds. When using bank loans, the payback period will increase due to the need to ensure payments on bank interest.

Setting up a cookie business

It is better to formalize production in the form of an LLC. This will make it easier to attract borrowed funds and allow you to count on help from investors in the future. Banks and investors treat individual entrepreneurs with distrust.

The choice of taxation form depends on the organization of sales policy. The given amount of revenue will allow the company to apply the simplified tax system (according to the current tax legislation, the limit for its application is 79.74 million rubles).

But if an enterprise plans to supply products to large wholesalers, who then distribute it to stores in the region, then it often operates on a general basis and requires invoices with allocated VAT from its suppliers. Therefore, the use of simplification in this case will be unjustified and will lead to the loss of business partners.

If the enterprise has its own logistics system and it supplies directly to retail outlets, bypassing intermediaries, then it will be possible to apply a simplification. As a rule, small stores operate on the simplified tax system or UTII; they do not need invoices and VAT. The use of the simplified tax system will reduce tax burden, since companies are exempt from VAT and pay a single tax at a rate of 6 or 15%, which is lower than the profit tax on OSNO of 20%. In relation to simplifiers there are preferential rates in the area salary taxes(monthly contributions to the Pension Fund and Social Insurance Fund).

Since the production of cookies has a fairly high expenditure component, it is better to choose the mode with the “income minus expenses” object. The rate on it is 15%, but in many regions benefits are applied to manufacturing companies. Paying 6% on revenue in the goods production industry is usually unprofitable.

The presence of an automated line and outsourcing of non-core services (accounting and logistics) will make the enterprise more cost-effective.

Order a business plan

	Investments: Investments 2,700,000 - 3,500,000 ₽ We are a team of professionals with more than 10 years of experience in the food market. During this time, we have implemented more than 40 regional and federal projects in 15 different concepts. In 2017, we launched the “Bakery No. 21” project and now we manage a network of cafe-bakeries, which we want to expand, because we believe that our product is a new level in the world...
	Investments: Investments 1,400,000 - 2,000,000 ₽ My name is Sergey Rogachev, I am the founder of Bulki House. I launched my first bakery on December 7, 2016. Now there are already 24 of them, of which 14 are franchised. This growth is due to our advantages and job features, which we will teach you. Description of the franchise We offer to open your own bakery and start earning from 250 thousand per month. The Bulki House franchise is a well-functioning model...
	Investments: Investments 200,000 - 500,000 rubles. Mini-bakery “Jan Khachapuryan” is one of the franchising projects of the Rus Investment company. Since 1985, our company has been producing equipment for bakeries (tandoors) and is the owner of two brands: the bakery chain “Bread from the Tandoor” and the oriental cooking “Kibir Tandoor”. While developing the Tandoor Bread bakery franchise, it became obvious to us that the market lacks a mini-bakery that would…
	Investments: Investments 1,500,000 - 2,400,000 rubles. "Bretzel" produces bread for modern society according to traditional ancient recipes, using only natural ingredients. We strive to return tasty, natural and healthy bread, improving the quality of everyday life. The three main values ​​on which our business rests: cook with pleasure and love what you do; bring benefit and joy to consumers; make a profit in order to have...
	Investments: Investments 11,000,000 - 15,000,000 rubles. Konigsbacker is a chain of European bakery cafes. The first bakery opened in 2012, and today the network already has 20 facilities in Kaliningrad and the region. Wide range always fresh delicious baked goods according to the best European recipes, gave Konigsbacker the love of the townspeople and guests of the region, including it in the “must-see” list of Kaliningrad. The cozy interior, designed by a leading design studio in the Netherlands, sets a high standard for real…
	Investments: Investments 250,000 - 750,000 rubles. “Sdobny Dom” - appeared in 2005 as a supplier of a new product for the Urals - frozen semi-finished bakery products for finishing baking. In essence, this is a highly prepared baked product that requires defrosting and baking. With its help, you can open a bakery in a minimal area and with minimal costs. This technology came to our market from Europe and has a number of advantages...	Investments: 3,000,000 - 6,000,000 rubles. Do you want a delicious business with the aroma of baking? Then open your own bakery. Of course, you can say that this is quite a troublesome task, because you not only have to look for premises, buy equipment, hire and train workers, but also find an excellent technologist who can make all your wishes regarding products come true. Yes, it is difficult, but not with a franchise.…
	Investments: from 450,000 Good afternoon My name is Victoria Bogdanova, I am the founder of the bakery chain “Bread from Tandoor”, a graduate and resident of the Moscow School of Management “SKOLKOVO”, I studied at the Le Cordon Bleu culinary school in Paris and London. The franchise of the bakery chain “Tandir Bread” was founded in 2014, and is the only tandoor bakery franchise with a registered trademark in…
	Investments: 400,000 - 750,000 rubles. Bakery "Khlebnitsa" is a modern bakery offering hot baked goods made from natural products and at affordable prices. We do our job well and are proud of it. We bake delicious bread for people of all ages, views and beliefs. The Khlebnitsa bakery is always located within walking distance in high-traffic areas and is always in sight. This is exactly the approach...