Equipment for making corn sticks. How to start a corn pops business. Workshop room

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Before organizing any business, it is worth finding out whether it is relevant in the consumer market or not. The production of corn sticks may not be a very relevant business, since the products are not among the necessary products for every day. At the same time, the consumption market for this product is growing steadily, it is in demand, and children and adults willingly buy it.

Brief business analysis:
Costs of setting up a business: up to 1 million rubles
Relevant for cities with the population:from 100 thousand people
Industry situation:average competition
Difficulty of organizing a business: 2/5
Payback: up to 1.5 years

Children love them as a tasty, sweet dessert; adults use them as a snack with milk or kefir. Corn sticks as breakfast cereals have been familiar to more than one generation in our country, since their production began in the USSR. Even then this product was very popular.

Starting with small capacities, over time the entrepreneur can expand the range and produce additional similar products from the category of breakfast cereals. The main factor for the successful development of this business is the presence of stable sales channels for products and 100% utilization of production capacity.

To organize a business producing corn breakfasts, you need reliable information about the product market, reliable suppliers of raw materials, and the required amount of start-up capital. You can collect and analyze information through a business plan. It must reflect the state of the local and regional market in relation to products and competitors and real opportunities to occupy a niche in this business.

In a business plan, it is necessary to work out each stage:

business registration;
selection of premises and its preparation;
purchase and installation of necessary equipment;
selection of specialists and workers to service production;
justification of the chosen technology;
marketing, establishing product sales channels;
calculations of costs and return on production.

Business registration

The best option for registering a business is an individual entrepreneur, with OKVED codes – 52.27.39; 52.1. The manufacture of products in the form of corn sticks is not subject to mandatory licensing. But it is required to obtain the appropriate certificates for the products manufactured, so it is necessary to have a package of documents according to the technical specifications. To carry out the technological process, approvals from the sanitary and fire services are required.

Workshop room

The best option for locating a workshop may be production areas that previously operated various food shops. Premises adapted for food production are also suitable.

No less attractive is the option of building your own prefabricated industrial building from sandwich panels. The costs of this construction quickly pay off and your own premises become more profitable than renting the same space.

For a production workshop with a small productivity of up to 30 kg of products per hour, a room of 60 m² is sufficient. An additional 30 m² is needed for the warehouse space, and 20 m² for utility rooms. All communications must be installed for all premises, from water supply to ventilation.

The essence of the technological process for producing corn sticks is the processing of small grains in a special unit called an extruder. In addition to this machine, the production line also includes other equipment:

mixer for corn grits;
powdered sugar mill;
dispensers;
overpass;
oil supply apparatus;
screening plant;
pan for panning;
device for packaging products;
band conveyer.

The production capacity and cost of the entire production line mainly depends on the extruder options:

a unit with a capacity of up to 30 kg of corn products per hour;
single-screw extruder producing up to 100 kg of product per hour;
twin-screw extruder with a capacity of up to 250 kg of product per hour.

Both domestic and imported equipment are presented on the Russian market.

Production technology

In accordance with the technological stages, the process of making sticks from corn grits looks like this:

The cereal is cleaned on a vibrating tray.
Then salt is added to it (1% of the total amount of the mixture).
At a small percentage of humidity, water is added to the cereal and the entire volume is mixed.
The resulting mixture enters an extruder, heated to 170°C-190°C. The mixture, under the influence of temperature and steam pressure, increases in volume, turning into a plastic mass. It is squeezed out under pressure into the outlet of the extruder, turning into a foam-like mass, multiplied in volume. A knife configured for periodic movements cuts off the squeezed-out air sticks, which are carried by a current of air to the receiver, where they are dried.
The finished sticks are moved to a coating unit for adding additives: powdered sugar, cinnamon, vanillin, vegetable oil.
Then comes the last stage - packing the sticks into packages using a filling machine.

To obtain one ton of corn products, the following main ingredients are required:

corn grits – 720 kg;
Sunflower oil – 130 kg;
powdered sugar – 130 kg;
salt – 7 kg.

Attention! Despite the simple recipe and fast technological process, the production of sticks has its own nuances. The ratio of products included in the recipes for their preparation is of great importance. Their taste depends on this. Therefore, it is important that this process be under the control of an experienced specialist - a technologist.

Supply of raw materials

The quality of the finished product directly depends on the quality of corn grits. In order for the supply of raw materials to be constant, it is necessary to establish cooperation with manufacturers of corn grits. In Russia, the production of corn and corn grits is carried out in the southern regions: Krasnodar, Stavropol Territories, and the Black Earth Regions.

Staff

In the technological process of a small workshop it is necessary to involve several specialists:

extruder operators – 3 people for shift work.
Technologist.
Mechanics of a production line.
Warehouse workers.
Packers.
Car driver.

In addition to these employees, the company's staff requires: an accountant, a sales manager, a marketer, and a production manager.

Marketing and sales channels

Cooperation between a small company producing corn sticks and chain stores or large grocery stores is not profitable, since they charge a high percentage for shelf space. In addition, they are reluctant to cooperate with unknown manufacturers. A good option would be to establish connections with small grocery stores and cafes. But the best option is to create your own retail outlets in shopping centers, markets, etc.

To promote products, it is necessary to use different marketing methods: outdoor advertising, bright packaging, advertising campaigns in local media, booklets for small wholesale buyers.

Competition in this type of business is quite high, therefore, it is necessary to actively search for new markets, using serious investments in an advertising campaign.

Costs and return on business

Initial investments in organizing a business, including the purchase of raw materials, equipment, and advertising campaigns, can amount to about 1,000,000 rubles. This amount is distributed as follows:

The cost of the production line depends on the power of the extruder. A line designed for small volumes of products can cost about 750,000 rubles.
Installation and setup will cost another 100,000 rubles.
The purchase of raw materials for one month of work, with a consumption of 60 tons, will cost 120,000 rubles.

Direct costs for producing one ton of product:

raw materials - from 20 thousand rubles.
Packaging materials - from 5 thousand rubles.
Salary for core workers - from 300 thousand rubles
Payment of utilities – 50 thousand rubles.

The cost of producing one ton of corn products will be about 60,000 rubles (taking into account the costs of purchasing raw materials, packaging, wages and utility costs). The wholesale price of one ton of sweet sticks is 100,000 rubles.

A production line with a capacity of 30 kg of product per hour produces 240 kg per shift. At full capacity, the monthly output of corn sticks will be 60 tons.
The annual income from product sales will be 6,000,000 rubles. After deducting all expenses, net profit will be 4,500,000-5,000,000 rubles.

So, the production of corn sticks is a fairly profitable business, with a payback of 1.5 years, in which it is worth investing. But having decided to tackle it, you need to take into account the nuances raised in the article.

How are corn sticks made?

How to start a corn sticks business?
What do you need to start producing corn sticks?
Documents required for organizing production
Requirements for production premises
Staff
Financial business plan

The correct choice of the type of business is the main factor influencing its successful promotion. If you choose food products, the likelihood of success is guaranteed. And if these products, moreover, are made practically out of thin air, a project that will generate profit will be guaranteed to be 100% successful. An example of this type of activity for beginners can be considered business idea for the production of corn sticks. The share of air in corn sticks is 70%! The corn mixture in it has a share of only 30%. The demand for such products is constantly high, since not only kids want to pamper themselves with tasty, aromatic, crispy sticks. Adults love them no less. The technical process of making corn sticks is not complicated, the technology has been worked out, and there should be no pitfalls. Therefore, investments in such a business will be recouped quickly, and it will definitely be profitable.

How to start a corn sticks business?

The first and most important issue that needs to be resolved very responsibly is the choice of equipment. You can get burned with low-quality equipment even at the start, since the entire operation of the enterprise opened by a newcomer will depend on its performance.

Today, a huge variety of equipment for the production of corn sticks is offered. You should not opt for Chinese cars. Of course, good examples of such equipment are produced in China, but very often, under the guise of Chinese machines, low-quality equipment made “on the knee in the basement” is sold. You need to buy equipment from proven companies that have been working in the market for a long time. This choice will allow you to have a guarantee for the supplied equipment and the possibility of its service and repair by qualified personnel.

Western equipment can also not be considered, its prices are high, and it will take a very long time to pay for itself. Among domestic manufacturers today there are quite a few whose products are of high quality and reasonable prices.

What do you need to start producing corn sticks?

The production equipment consists of stick production line and packing machine. The purchased equipment is usually installed turnkey in production by specialists from the manufacturing company. Therefore, there should be no problems with setting up a workshop for the production of corn sticks.

Raw materials:

corn grits;
salt;
sugar;
sunflower oil.

Equipment:

extruder with coating complex;
packaging machine;
belt conveyor;
mixer (cereal preparation);
oil supply apparatus;
vibrating tray;
dispenser with mill (for powdered sugar);
packaging machine.

The production of sticks can be fully automated. The quality of the product and its uniformity, taste characteristics can be ensured by the settings of the production line. It should be taken into account that such a line can be designed for round-the-clock continuous operation. The main thing is to ensure proper care of the equipment, carry out scheduled maintenance and repairs, and then you can operate it for many years.

You can choose a powerful line; in one shift it will produce up to 1 ton of finished product (about 120 kg/hour). In this case, the power consumption will be up to 30 kW hour. An extrusion line with such productivity can cost almost 1 million 500 thousand rubles.

It is still better for a novice entrepreneur to purchase a line with low productivity - up to 30 kg/hour. Such a complex will cost about 450,000 rubles. Installation and adjustment work - 100,000 rubles.

You also need to have your own transport to transport raw materials and products. To fully equip a small production facility, you will have to spend about 1 million rubles. You can achieve a stable income in about six months.

Documents required for organizing production

For launching a corn sticks production project You can register as an individual entrepreneur or a legal entity . OKVED for the production of corn sticks– 52.27.39, 52.1. Before starting work, you need to obtain permission from the SES and fire department.

This type of business is not subject to licensing.

In addition, you need to draw up documents for production - develop technological regulations and register them.

Requirements for production premises

It is advisable to choose premises on the territory of existing food factories. They are well adapted for this type of activity. If there is no such production nearby, warehouse premises will do.

It is important to pay attention to good ventilation in the production area. To carry out sanitary and hygienic procedures, you need to find a room with connected communications - water, energy supply.

For a small workshop with a stick productivity of 30 kg/hour, you need about 30 sq.m., the same amount is needed for a raw materials warehouse and the same amount for finished products. It is necessary to provide a living room for workers; its minimum area must be at least 20 sq.m.

Staff

For production, it is necessary to hire the required number of workers in accordance with the operating mode of the new production. If the production of corn sticks will be carried out in one shift, it is necessary to hire:

extrusion line maintenance worker – 2 people;
loader;
packer

If a novice entrepreneur deals with product sales issues himself, there is no need to hire an intelligent sales manager. You can also do your accounting yourself.

Financial business plan

In online stores you can buy corn sticks in bulk at an average price of 100 rubles/kg by weight. Packaged sticks are sold for 350 rubles/kg. Accordingly, the cost of a ton of produced products will be, depending on the type of packaging, from 100,000 to 350,000.

To make one ton of corn sticks it costs:

corn grits – 720 kg;
powdered sugar – 130 kg;
salt – 7 kg;
sunflower oil – 130 l.

It is necessary to take into account monthly expenses for wages, taxes, and the creation of a stock of raw materials.

The line can produce 240 kg of sticks daily. During the year, the production will produce 60 tons of products worth 6 million rubles. The business project will pay for itself in approximately 3 months. Production profitability will be 25% according to plan.

Many people clearly associate certain sweets with childhood. This includes ice cream, lemonade and, of course, corn sticks. How this airy delicacy is made at the factory and whether it is possible to make sticks at home, you will find out in this article.

What are corn sticks made from?

Raw materials for the production of corn sticks are immediately supplied to the plant in large quantities. Literally tons of it are delivered to the enterprise. The raw materials are made from durum corn, powdered sugar, salt and refined deodorized vegetable oil. These are all the ingredients required to make corn sticks, familiar to everyone since childhood.

The composition or with a different flavor is similar, but instead of powdered sugar, simply salt or an appropriate flavoring is added, such as bacon, cheese, etc.

Equipment for making corn sticks

The production line for the production of corn sticks includes several types of equipment: a mixer for preparing cereals, a mill for producing powdered sugar, an extruder, a coating complex, a powdered sugar dispenser and a device that packages corn sticks. How products are made at the factory and at home and in what volume depends on the power of the extruder. By the way, the same equipment is used in the production of other breakfast cereals.

The device for making sticks comes in low, medium and high power. It is suitable for small, medium businesses and large factories respectively. In the first case, the productivity will be 30 kg of products per hour, in the second - 100 kg per hour, in the third - 250 kg per hour.

Corn sticks: how they are made at the factory

Thus, the cost of equipment depends on the size of the enterprise. How are corn sticks made at the factory?

The entire technological process takes no more than 10 minutes. During an 8-hour production shift, about three tons of sweet treats are produced. The production process itself consists of several stages:

First, corn grits are fed to an extruder, the temperature inside of which ranges from 40 to 150 degrees.
Under the influence of high temperature and pressure, the raw material acquires the consistency of dough.
The plastic mass falls onto a special matrix with holes, when passing through which the dough sharply increases in size, as if exploding and acquiring the structure of a corn stick. This happens due to a sharp change in pressure. The shape and size of the holes on the matrix determine what the corn sticks will be: round, square, star-shaped, etc.

The sticks that come out of the extruder remain too wet, so they do not have their own taste and do not yet crunch on the teeth. To do this, they need to be glazed and dried in a special drum.

How to make corn sticks with flavoring additives

At the next stage, after the products leave the extruder, they are dried in a special drum. Next, the sticks enter the coating complex - this is a device that resembles a long drum, with the help of which powdered flavoring additives are applied to the products. At the same time, vegetable oil is supplied through the sprayer. It is heated inside the drum and sprayed evenly in a small amount onto the corn sticks. How are they glazed? Read on.

After the sticks are saturated with oil, they go into the next compartment of the drum. Here they are sprinkled with powdered sugar on all sides. When it comes into contact with warm vegetable oil, it melts, forming a sweet glaze on top of the product. At the next stage, ready-made sticks come out of the drum. Then they are packaged by special equipment in automatic mode. Finished sticks are packaged and sent to the warehouse, and then directly to the wholesale buyer.

How to make corn sticks at home

You won’t be able to make corn sticks at home without special equipment. Products acquire an air structure only when passing through an extruder, which provides the necessary sharp pressure drop. Neither a traditional screw meat grinder, nor especially in this case, can replace professional equipment.

How to make corn sticks at home? Very quickly if equipment and raw materials are available. First of all, for this you will need a special apparatus for making corn sticks UKP-M. The productivity of the device is 15 kg of products per hour.

To prepare the sticks, corn grits are first poured into a special funnel on the body, passed through a humidification system and subjected to thermoplastic processing. The entire process occurs almost instantly in a continuous mode. Then the mass is pressed at a certain speed through a special matrix with cutting, which gives the required shape to the finished product. The simplest corn sticks are ready! Now they need to be coated with glaze or sprinkled with powdered sugar, and they can be served.

In addition to corn sticks, the UKP-M device is used for the production of products from wheat, pearl barley, rice in the shape of stars, tubes, etc.

When deciding to occupy a niche in the food products industry, it is important to choose a product that is in high demand among consumers. In addition, having limited financial capabilities, it is advisable to choose a direction in which investments will be reduced as much as possible. Products such as corn sticks fully meet all these criteria. If you buy equipment for the production of corn sticks, arrange supplies of high-quality raw materials and think through ways to sell the finished product, you can achieve high incomes.

Our business assessment:

Starting investments – from 700,000 rubles.

Market saturation is low.

The difficulty of starting a business is 6/10.

Corn sticks are a product belonging to the category of breakfast cereals. Recently in Russia there has been a tendency towards a significant increase in its consumption.

The popularity of corn sticks among the population, as well as the simplicity of the technology, make this business attractive for a novice entrepreneur. And the organization of the mini-workshop itself implies the production of high-quality products, packaged in bags of 50 and 150 grams. Manufacturers today have a great opportunity to launch their own food enterprise, which will quickly recoup all investments. By experimenting with flavors and packaging design, you can sell finished products both wholesale and retail.
But how are corn sticks made? And what needs to be taken into account when launching a workshop?

Process of releasing corn sticks

An important advantage of the planned business is the simple technology for the production of corn sticks. All stages of production here are carried out using special equipment, and therefore the share of manual labor is reduced to a minimum.
The technology for making corn sticks involves mixing raw materials in certain proportions and further thermal and mechanical processing. But despite the simplicity of the steps, it is the product recipe that plays a big role here. The taste and quality characteristics of the sticks will ultimately depend on the ratio of the components. And since every operating enterprise keeps secret the ratio of all substances used, a qualified technologist should be hired for production, who will experiment with the recipe, and in the future will control the process of producing sticks, monitoring the input raw materials and technological regimes.

In general, the corn sticks production line processes the following raw materials:

corn grits,
powdered sugar,
sunflower oil,
salt,
water.

To reduce the cost of producing corn sticks, it is worth agreeing with suppliers on wholesale supplies of raw materials. And it’s great if the bases are located as close to the workshop as possible.

Workshop technical equipment

Extruder for the production of corn sticks

To launch uninterrupted production of corn sticks, it is important to purchase high-quality equipment that meets all the norms and requirements of the food industry. There shouldn’t be any problems with this, since there are plenty of offers for technical equipment on the market. And the main selection criteria here come down to an analysis of the planned sales volumes and the amount of starting capital.

The standard equipment of the line includes the following names of machines and devices:

mixers for bulk and liquid components,
dispensers,
sugar mill,
sifter

In addition to the production line, you will need to purchase a packaging machine. However, more expensive lines are also equipped with it.

The final price of equipment for corn sticks varies widely, depending on the type of extruder and power. For example, a line with a capacity of up to 30 kg/h, which includes a single-screw extruder for corn sticks, costs ≈500,000 rubles. More powerful lines (up to 250 kg/h), with a twin-screw extruder, will cost much more - up to 2,500,000 rubles.

It is advisable to equip a mini-workshop with low-power equipment, since at first it will be difficult to sell large batches of finished products.

A small-sized machine for the production of corn sticks will not require large areas. An area of 60 m2 is sufficient to accommodate the line. But in the workshop it is additionally necessary to provide premises for warehouses and staff rooms.

How much profit will the business bring?

Some time before opening your own production of corn sticks in Russia, it is important to plan distribution channels for finished products. And since the entrepreneur’s profit will directly depend on sales, we rely specifically on wholesale customers.

But this comes with many problems:

Large hypermarket chains, as a rule, sell only branded products.
Hypermarkets sometimes set fees that are unaffordable for small businesses “for the opportunity to be represented on the shelves.”

Therefore, when planning a small enterprise, it is better to try to conclude agreements with wholesale grocery stores or small regional stores.

The business plan for the production of corn sticks must also include calculations of the profitability of the enterprise. And how quickly the workshop will recoup all costs and reach “0” will largely depend on the investments made.

To register a workshop, buy an extruder for the production of corn sticks, prepare the premises for work and purchase raw materials, you will need at least 1,000,000 rubles. If you think about buying a supported production line, then 700,000 rubles will be enough. As for profit, everything will depend on the volume of production and the pricing policy of a particular region. On average, a small package of sticks costs 8-12 rubles on the wholesale market. The cost of the product is at least 40-60% lower.

The business idea involves creating a workshop for the production of corn sticks in plastic packaging, weighing 50 and 150 grams. The products will be positioned in the middle price category and sold in the region where the production is located, within one region. The main target market segment is families with “average” and “below average” income levels with one or more children. The main places for selling products are our own outbound trade (through a non-stationary network), as well as non-chain retail in the home region.

Assessing the potential and prospects for business development

Corn sticks- a fairly massive food product that is very popular in Russia. According to the marketing classification, corn sticks belong to the category of breakfast cereals, the market of which in Russia is growing quite quickly - at the level of 5-10% per year. There are several factors on which the future growth of this market is based and good prospects for business development are created.

Firstly, consumers of corn sticks in Russia are almost all age groups of the population - although the children's target segment, of course, dominates in the market structure.
Secondly, we have already formed ten-year traditions of consuming this product, which also creates good prospects for the business of producing corn sticks.
Third, sales of this product have virtually no seasonal component - there is demand for sticks all year round, and therefore the manufacturer can count on the stability of the financial flows of its business.
Fourthly, A significant role in stimulating demand for corn sticks belongs to the producers themselves. By actively experimenting with brands, flavors, and packaging design (one must still remember that the main target group of consumers - children - are very susceptible to these parameters), a manufacturer can fuel demand for its sticks.

Sales channels

As for product sales channels, they depend on such parameters as the scale of production, as well as the price category in which the product is presented. Naturally, from the point of view of proximity to the consumer, an excellent option for establishing sales is to supply food chains. However, there are some nuances here:

Leading retail chains will agree to take only a branded product - a brand known to consumers, actively supported by marketing (advertising, consumer-promotion events in the hall).
In addition, the networks have quite high fees "for entry".
It is also extremely important for chains to ensure timely deliveries, and in all chain stores.

Therefore, promoting corn sticks through food chains only makes sense if the business is large enough and the product covers at least several regional markets. It should be remembered that on the shelves of chain stores you will have to compete fiercely with imported premium sticks that are well known to customers - in this regard, investments in marketing may turn out to be too high and not meet the expectations of business owners.

At the same time, medium-sized, and especially small businesses of a regional scale (serving one market - city, region), offering an affordable middle and economy class product, should build sales differently. In particular, for micro-businesses it seems effective to have their own retail network (for example, outbound trade in the central markets of the city). In order to ensure the sale of products on a somewhat larger scale, it is advisable to cover the city’s food stores (as well as kiosks, tents, stalls, etc.), delivering finished products to these points with our own transport.

Technology

The technological process for the production of corn sticks involves thermal And mechanical processing of corn grits, adding water and other ingredients during the cooking process (according to the recipe).

To make corn sticks, you will need raw materials (corn grits, salt, powdered sugar, sunflower oil), as well as drinking water. The consumption rate per 1 ton of sticks for raw materials is:

cereal - 720 kg;
salt - 7 kg;
powder - 130 kg;
butter - 130 kg.

Equipment for the production of sticks in Russia is offered by various manufacturers, in particular the Prodselmash plant. The complete Prodselmash line includes a mixer for preparing cereals, a mill for powdered sugar, an extruder, a belt conveyor, an installation for preparing and supplying an oil suspension, a coating drum, a powdered sugar dispenser, a trestle and a vibrating tray-sifter.

At the same time, the productivity of the line, and therefore the price, depends on the extruder options. In particular, the same Prodselmash offers three options:

low-capacity extruder (up to 30 kg of sticks per hour) for mini-production sites (option cost - 443.5 thousand rubles);
single-screw extruder of medium productivity (up to 100 kg of sticks per hour) for small businesses (option cost - 2831.0 thousand rubles);
twin-screw extruder E2SH-150 with increased productivity (250 kg of sticks per hour) for medium-sized businesses (option cost - 4316.5 thousand rubles).

For a small business producing corn sticks, a production space of 100 m2 will be sufficient, of which about 60 m2 will be allocated directly for the line, another 25 m2 for a warehouse for raw materials and finished products, 15 m2 for utility rooms for workers.

No additional equipment is required for storing raw materials, as well as finished corn sticks.

Feasibility study of the project

Start-up investments in starting a business include:

Purchase of a line for the production of corn sticks with a capacity of 30 kg per hour - 443.5 thousand rubles.
Delivery and installation of equipment - 100 thousand rubles.
Repair of the premises in accordance with the requirements of the SES - 200 thousand rubles.
Creation of inventory - 200 thousand rubles.
Other expenses - 50 thousand rubles.

The total starting investment in the project to organize a business in the production of corn sticks will be 993 000 rubles

Revenue calculation:

The standard productivity of the line is 30 kg of product per hour, which, when operating in an 8-hour mode, will be 0.24 tons per shift. Provided 100% load and an operating mode of 250 days, the annual production volume of corn sticks will reach 60 tons.

The wholesale price of corn sticks is about 5 rubles per 50 gram package, which is equivalent to 100 thousand rubles per 1 ton.

Thus, the annual revenue will be 6,000,000 rubles.

Reference Information:

The workshop reaches self-sufficiency: 3 months after the start.
Reach 100% productivity: 6 months after launch
Planned profitability: 25%
Return on investment: 18 months