Everyone, of course, knows that the so-called crab sticks are not made from crabs, but from fish. The mixture that underlies the product known in Russia as crab sticks is called surimi and came to us from Japan, where it has been used in cooking since the 12th century. Surimi is finely ground fish meat, thoroughly cleaned of fats, blood, enzymes. Surimi is white in color, neutral in taste and odorless. For many centuries in Japan, surimi has been used to simulate various seafood. In Russia, surimi replaces expensive crab meat and is an important ingredient in many salads. Some people believe that surimi is made from fish waste, so the product is not healthy. This is not true. Surimi is a concentrated fish protein and is made from freshly caught ocean fish fillet processed no later than 6-10 hours from the time of capture. Surimi is made from mentai, hake, blue whiting, itoyori, croaker, horse mackerel, sardine. Fillet does not undergo heat treatment.
About 5 million rubles will be required to open own production of crab sticks. Fixed assets will be used to purchase production equipment and equip warehouses with refrigeration units.
Equipment for the production of crab sticks is supplied from China. Estimated cost of the line, including delivery and configuration of equipment, is 1.5-2 million rubles.
The production line consists of a machine for grinding frozen blocks, a twin-screw grinder, a cutter, a starch mixer, a dye preparation mixer, a mass mixer with a cooling jacket, a batch-forming machine (MFP), a form former with forced cooling of the formation chamber, and a two-section coagulator tunnel type, tunnel cooler, machines for thin cutting and folding, dyeing plants, horizontal wrapping machine with cutting angle, hole conveyor-stand, vacuum packaging machine, sterilizer packed packages, cooler, dehydrator unit airflow, low temperature cooling tunnel.
To place a line with a production capacity of 100 kilograms of products per hour, a workshop with an area of 220-250 square meters will be required. The line is served by 19 people per shift. A line with a production capacity of 60 kilograms per hour will occupy about 150 square meters of area. The number of workers is 14 people. The average wage of workers is 15-16 thousand rubles. In addition to the workshops, the production room should have a refrigerated warehouse for storing frozen raw materials. The equipment of a freezer with a volume of 500 cubic meters costs about 700 thousand rubles. At the finished goods warehouse, a constant temperature of 2-6 degrees should also be maintained. Crab sticks are sold not only chilled, but also frozen, since they are stored frozen for up to six months.
The composition of crab sticks usually includes surimi minced fish, drinking water, starch, vegetable oil, egg and vegetable protein, salt, sugar, natural food additives (thickeners, flavorings, colorings, flavor enhancers). As a result, minced fish is obtained from 30 to 50 percent. The more stuffing, the higher the quality of the product. Good crab sticks should be soft and elastic to the touch, tender and juicy in taste.
You can find a surimi provider online. For bulk purchase, one centner of minced meat will cost between 6, 000 and 10, 000 rubles.
Only a few companies are engaged in the production of surimi in Russia, so China is the main supplier of raw materials. Over the past five years, serious disruptions in the supply of surimi to Russia have already occurred twice, the last time due to bureaucratic innovations that the Chinese manufacturers did not manage to adapt to in time. However, equipment for the production of minced fish has recently begun to be supplied to the Russian market, so it is likely that crab stick producers will soon switch to domestic raw materials.
Potato starch is needed as a connecting link for fish protein molecules; after heat treatment, it gives the sticks additional elasticity. The proportion of starch should not exceed 10 percent, otherwise the sticks will be too dry. The wholesale price of potato starch is from 20 rubles per kilogram.
Surimi mince does not have its own taste or aroma, therefore, natural or identical aromatic and flavoring additives, for example, carrageenans (E-407, E-410), sodium glutamate (E-621) are used. To simulate the color of natural crab meat, the sticks can be coated with a layer of tinted dough, which includes natural dyes, paprika and carmine. As stabilizers, sorbitol and diphosphate can be used. These substances stabilize colors, improve the consistency of the product, and slow down oxidative processes.
The production cost of one kilogram of crab sticks is 50-60 rubles. In the wholesale market, the cost of a kilogram of products is about 100 rubles. Thus, in the production of 480 kilograms of sticks per shift, the profit will be about 20 thousand rubles.
The packaging of crab sticks with special equipment applies the trademark, product name and consumer information. Standard package sizes are 100 and 200 grams.
Registration of a trademark is an optional procedure, but it makes sense to go through to protect your products from unfair competitors. The situation when someone begins to produce a similar product under a similar name or logo is not uncommon for the Russian market. Registration of a trademark gives the copyright holder an advantage in the competition, since he may prohibit the use of signs similar to his trademark.
The organization that carries out the registration of trademarks is called the Federal Executive Authority for Intellectual Property. Both a legal entity and an individual entrepreneur can apply for registration.
The cost of paperwork for the examination and registration of the brand is 5-6 thousand rubles. The application registration fee is 2700 rubles. The fee for examination of a trademark application is 11500 rubles.
In accordance with GOST, certain information must be indicated on food packaging. All information must be printed in Russian, duplication in foreign languages or languages of the peoples of Russia is possible. Information should be legible and clearly understood.
The product name - crab sticks - is applied in a clearly distinguishable font that stands out against the main background. The following is the clarifying information: “frozen”, “chilled”. Information about the manufacturer must be given: name and legal address, production and packaging addresses, trademark.
Net weight and composition of the product are indicated. The ingredients are arranged in decreasing order of quantity in the product. If the mass fraction of the ingredient is less than 2 percent, you can omit it on the packaging. Be sure to list the nutritional supplements contained in the product (stabilizers, flavorings, flavor enhancers, dye, etc.), indicating their group names and indices according to the International Digital System or the European Digital System. Nutritional value is indicated as the mass of proteins, fats, carbohydrates, macro- and microelements per 100 grams of product. Next, indicate the storage conditions of crab sticks (from 0 to +6 degrees), shelf life and date of manufacture.
Natalya Merkulova
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08/18/2019