We open a business for the production of thin pita bread

* In calculations, the average data for the World is used. The usual loaves and loaves on the shelves in grocery stores replaced various pita breads. Pita bread is unleavened white bread in the form of thin tortillas made from wheat flour. Pita bread belongs to the national cuisine of the peoples of the Caucasus and other regions of the Middle East and is also called “Armenian unbreakable bread” or “paraki”. It looks like a flat and very thin (0.2 - 0.5 cm thick) oval cake, which is about 90-110 cm long and about 40-50 cm wide and weighs no more than 250 grams. There is also another kind of thin pita bread called rolls. The latter are large (one roll sheet can reach a length of two meters).

The pita business is considered profitable and profitable, even despite the very high competition in this segment. The popularity of this trend is due to several factors. Firstly, pita bread is a universal product that can be used both separately and for cooking various dishes (for example, shawarma, various oriental casseroles, appetizers, etc.). In addition, unlike regular bread, pita bread is positioned as a healthy (dietary) product (yeast is not used for its preparation, although you can’t call it completely dietary), and its consumption practically does not depend on the season (while consumption white bread in the summer is noticeably reduced).

The technology for preparing pita bread is relatively simple and does not require special qualifications. It is enough to have at least a little experience and knowledge about the sequence of operations. For the preparation of real Armenian pita bread, special tandoor roasting ovens are traditionally used, but most entrepreneurs who open the production of thin pita bread prefer modern automated compact lines. Connoisseurs of “authentic” pita bread claim that a product prepared using modern equipment differs in taste and consumer qualities from pita bread baked in tandoor. However, undoubtedly, the first option is more profitable. According to the entrepreneurs themselves, the cost of baking pita bread on automatic equipment is two times lower. An additional advantage is the absence of problems with the ingredients.

So, to prepare 100 kg of ready-made pita bread, you will need (according to the recipes of manufacturers of equipment for preparing thin pita bread) 80 kg of premium wheat flour, 35 liters of water per batch and 50 liters of water for moistening, as well as 2.5 kg of salt. At the same time, the cost of one package of pita bread is about six to seven rubles, and the retail price is 3-4 times higher. Using automated equipment, you can produce up to 30-32 thousand pita bread per day. Such a line for baking yeast-free dough, as a rule, includes a rolling machine, a tunnel oven, a conveyor-humidifier, several storage and packing tables, a control panel, as well as exhaust hoods and pipes. The automated line is quite compact, does not take up much space, and two people will be enough to work with it.

However, automated thin pita bread production lines also have their opponents. The latter argue that when preparing pita bread it is impossible to exclude manual stretching on the matrix of the pita preparation. And if you do without this procedure, then the quality of the finished product will be much worse. In addition, they oppose the use of gas ovens for making pita bread, as the product baked in this way, they claim, acquires the smell of gas. Opponents of automation prefer to use standard equipment for baking bakery products, which include a vibratory flour sifter, a dough mixer, a dough sheeter, and a pita baking oven.

The process of making pita bread in this case is as follows. First, for at least half an hour, knead the dough in a dough mixer. For convenience, it is recommended that one batch does not exceed 25 liters. Then the kneaded dough is divided into separate pieces weighing 140 grams each. Before rolling, pieces of dough are covered with cellophane so that they do not dry out and are not airy. From each piece, using special equipment (a rolling machine), a cake is rolled out with a thickness of 5-6 mm and a diameter of 250 mm. The rolled cakes are stacked in piles that are sprinkled with flour to avoid sticking of the dough, and are also covered with cellophane. Then the cakes are pulled on a pillow matrix, on which baking is made.

Baking is carried out dry, that is, without greasing the frying surface with fat. This stage is considered the most important and determining for the quality of the finished product. The main difficulty faced by beginners is the selection of the correct ratio of ingredients (flour and water) to achieve the desired plasticity of the dough. As a rule, equipment suppliers also provide their recipes, but most likely you will have to determine the right ratio experimentally. According to this technology, two people can make 1000 pita bread per shift.

So, for the production of thin pita bread you will need a room with an area of ​​120 square meters. meters when installing an automated line or about 30 square meters. meters (when buying separate equipment - a dough mixer, oven, rolling machine, etc.). The production area may be in your property (ideally) or rented. The cost of renting an area of ​​100 square meters. meters will be about 55-70 thousand rubles, depending on location and region. The main thing is that the room met all sanitary norms and rules. In particular, it should have hot and cold water, sewage, ventilation (an ordinary fan window is also suitable). The ceilings should be whitewashed and the walls tiled. The room should not be located in the basement. In addition to the workshop itself, household and utility rooms (toilet, warehouse, etc.) will be required.

To work in the workshop for one shift, two people will be required to prepare and bake pita bread, as well as two people to pack finished products. Each employee must have a personal medical book. To sell pita bread, you will also need a sales representative with a personal car.

To organize a business for the production of pita bread, you will need to receive a number of documents: permission (notice) of the SES, a declaration (certificate) for the product. It will take about a month to complete all the necessary papers, which should be taken into account when planning the start dates of your bakery. Do not forget to make a floor plan in advance with the arrangement of equipment and coordinate it with firefighters and Rostekhnadzor.

Depending on the chosen production option, pita bread will require certain equipment. If you chose the option of automated production, you will need to purchase a production line (2.8 million rubles plus the cost of transportation and installation) and a dough mixer (not more than 100 thousand rubles). The dimensions of such a line are 1.2 by 8 meters. The term of its trouble-free operation, according to manufacturers, exceeds five years.

The cost of equipment when purchasing each position separately will be: a stove (60 thousand rubles), a dough mixer with a capacity of at least 25 liters (80-100 thousand rubles), a rolling machine (about 200-25 thousand rubles).

When buying used equipment, you can save up to 35-40% (depending on its condition). At first, you can do without a rolling machine and roll out the dough manually. But productivity in this case will be low, so it’s better to purchase auxiliary equipment. For starters, you can purchase one unit of each type of equipment, and then, as production volumes increase and your profit increases, you can buy additional machines.

About 50 thousand rubles will be spent on the purchase of the first batch of raw materials for the preparation of pita bread. There are no special requirements for raw materials, so there will be no problems with the search for suppliers. Look for options for quality and inexpensive raw materials and suitable working conditions. Although the suppliers of automated equipment claim that the main thing to maintain the necessary percentage of flour, water and salt is necessary for the preparation of products on such a line, and the quality and grade of the flour are not very important, experts nevertheless recommend not to save on ingredients.

When buying an automated line, some suppliers offer their customers ready-made label designs and a certain number of bags for packaging pita bread (for example, 20 thousand pieces). If your supplier does not have such bonuses or if you purchase all the equipment separately, then you will have to order the packaging yourself. The cost of a plastic bag with a sticker is less than one ruble apiece. But consider label design in advance. At first glance, this is a trifle that does not deserve much attention, but, as studies show, in the absence of other opportunities for promoting their products, it is a bright label that stands out against the general background and, first of all, attracts consumers to a new product.

Additional expenses include the salary of employees for one month (about 10-20 thousand rubles per person, depending on the region), the costs of opening an individual entrepreneur or LLC, registration of permits for production and sales (about 35 thousand rubles), other expenses (approximately 80-100 thousand rubles).

When determining the optimal volume of one batch, keep in mind that the shelf life of pita bread according to GOST is three days. But if desired, this period can be increased. The duration of the storage period depends on the quality and uniformity of the baked goods. Poorly baked pita bread is stored for no more than 2-3 days, and well-baked pita bread can retain its consumer properties for ten days.

Although the assortment of such a production is initially very limited, it can be somewhat expanded by baking, for example, in addition to the classic Armenian pita bread also tortillas - thin Mexican cakes. You can also introduce into the assortment other types of flat cakes from the cuisine of different peoples of the world, slightly changing the components and their ratio.

Think in advance of the distribution channels of your products. Pita breads are best sold through network trading companies and supermarkets, although getting into their shelves is not easy for a novice entrepreneur.

Payback periods depend on many factors. According to the experience of other entrepreneurs who use automatic lines, it is quite possible to recover their costs for organizing a business in five (with a full load of production and an established marketing of finished products) - nine months of work. A thin pita plant is a great option for a family business.

Sysoeva Lilia

(c) www.clogicsecure.com - a portal to business plans and guidelines for starting a small business 08/18/2019


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