Bacteriological purity, natural taste and composition, nutritional properties, no additives or preservatives making egg products GROVO® is ideal for cooking for children. They can be used for the production of a food of children of preschool and school age, as evidenced by the Conclusion vniipp (all-Russian Research Institute Pricepurchase Industry).
Plant for the production of pasteurized egg products is located in a quiet area surrounded by forests, where the air is not contaminated by industrial emissions or dust,, which is typical for areas with intense activities in the poultry farms. This is a key aspect for the production process and is beneficial to the quality of the final product.
The plant was built in accordance with the strictest hygienic requirements. Used only for permitted food enterprises tile, special flooring, washable water-repellent and ceilings in all production areas. Fully automated climate system ensures maintenance of the necessary climatic parameters.
The division is designed so that it was easy to observe the strictest rules of the system of production control HACCP. The plant is divided into a zone of pre-treatment and the egg breaking, and the so-called «clean zone», where is concentrated the production itself. These two zones have no points of intersection, therefore, the contact finished product with raw material at the enterprise is not possible.
he production is equipped with Italian equipment «AVITEC», allowing to produce more than two dozen different types of products based on pasteurized eggs. This equipment uses innovative Russian technology EasyLifeEgg. It gives you the opportunity to obtain pure, high-quality dietary product that meets all safety requirements, ready to eat, with high shelf life – 56 days.
In the process of production of egg products (chicken egg yolk, albumen и egg) GROVO not use preservatives and additives, as high shelf life is achieved by pasteurizing and use sterile containers. That completely eliminates the presence in the plant of the preservatives, so and space to store them.
The company RusAgroGrupp delivers the finished products at many Russian enterprises. Pasteurized egg products – a unique product that combines high quality, safety and ease of use in production.
RosAgroGrupp offers products in two most convenient types of packaging:
- BAG-IN-BOX is a sterile plastic bag (10; 20kg).
- PET bottles – modern and reliable packaging.
The quality of the products is the sine qua non of the overall policy of the company “PKF RusAgroGrupp”.
One of the factors of production in a safe, benign and competitive products is the certification of the quality management system and food safety based on HACCP principles. The manufacturing process begins with selection of raw material suppliers. Farms supplying raw materials to the enterprise, should be successful of infectious and invasive diseases of poultry. Shall provide letter of guarantee on absence in feeds for poultry GMOs.
Egg products, which are produced at the enterprise are stored at temperatures below 0°C and above 4°C. shelf Life of pasteurized egg products — 56 days.
The production includes the following steps:
1. Prepare eggs.
For the production of pasteurized egg products are used hen eggs according to GOST R 52121. When it comes to the production they have to be fresh or chilled 0 to 4°C. Before feeding into the breakdown they are subjected to visual inspection and ovoscope, and then sorted into benign and of poor quality. The last stage of raw material preparation is to wash the contaminated eggs.
2. Download eggs.
Acceptance and loading of the eggs is carried out in the isolated from the the entire process inside. The vacuum created in the soft silicone cups, the eggs are captured from the cells and loaded on rollers, delivering them onto the main frame extender.
3. A breakdown of the eggs.
With roller loaders eggs come to another room at the center of the car. They are cut with knives, and special cups, there is a division between the yolk and white. To avoid mixing protein with the egg yolk extender is equipped with «e-inspection», which allows using special cameras connected to the program to detect the presence of yolk in the cups.
4. Collect shells.
Shell emerging from the center of the machine, is collected in a container located outside the center of the room.
Received the egg mass is thoroughly filtered in order to eliminate the remnants of the eggshell, egg membranes and other things. Automatic filters consist of a basket with very small slices (0.6 mm), which are continuously cleaned by a rotating scraper.
Homogenization allows to achieve maximum uniformity and complete mixing of oily part with water components of the product. Homogenization of the egg is produced at a pressure of 10-20 bar, protein bar 5-10, yolk — 40-50 bar.
Heating of the product is conducted into the heat exchanger, where hot water at a constant temperature of 70°C and egg wash the two opposite surfaces of the same plate. Pasteurization is carried out in «continuous flow», i.e. the product never stops the process of thermal processing from the input to output. In the process of pasteurization, the protein is heated to 57.5°C , egg –to 63.5°C, the yolk — to 64 °C. Age of product at a given temperature is achieved by supporting pipe, where the heated fluid flows and retains its temperature for 300 sec. Automatic security system returns the product for re-pasteurization, if the temperature at the exit of the pasteurizer is lower than the preset: for a protein of 56.5 °C, for egg 62°C for yolk 62 °C.
8. Installation BARELY ( EasyLifeEgg )
On customer request, the product is pasteurized in the apparatus for extending the storage (installation EasyLifeEgg). In the installation there is a saturation of the product with carbon dioxide and ultraviolet radiation (protein) that allows you to extend the shelf life of the product up to 56 days. Mass fraction of carbon dioxide in the finished product is less than 2%.
After pasteurization, the product is cooled to 3 to 4 °C to stop the propagation of very few remaining colonies of bacteria.
Packing is carried out in a separate room.
- Bag-in-Box filling machine. Semi-automatic machine allows the operator to be placed in sterile plastic bags at 10, 20 kg (low-density or high-density polyethylene), automatically fill and close.
- Disposable PET bottles. a volume of 0.9 l or 0.5 l.
Negative deviation to net content of the nominal amount of each packaging unit is regulated by GOST 8.579 (section 4.2, table A1, A2) and should not exceed 3 % for nominal mass 500 g ,15 g — for nominal masses between 900 and 1,000 g of 1.5 % for nominal mass 10,000 g , 1 % of nominal mass 20 kg.
THE REQUIREMENTS FOR CLEAN PRODUCTION.
In the production process, our company is committed to high standards of quality, safety and purity. Production cycle, washing and preventive disinfection of the equipment, technological equipment and means of transport carried out in accordance with the requirements of «Veterinary-sanitary rules for enterprises (departments) of poultry processing and production of egg products».
To control sanitary condition at least once in 15 days is conducted microbiological analyses of swabs from each unit of technological equipment, inventory, containers, premises in accordance with the «Instructions on the procedure and frequency of control of content of microbiological and chemical contaminants in meat, poultry, eggs and their products» (paragraph 2.3.2).
One of the conditions of issue safe, benign and competitive products is the certification of our company quality management system and food safety based on HACCP principles and ISO/TS 22002-1:2009. The security system defines a systematic approach to the analysis of technological processes, identification of risks of chemical, physical and biological origin and their elimination.
The company has developed and approved a production control, which is to test the entire production process, raw materials, auxiliary materials, finished products. The combination of all the above measures can guarantee the safety of end products and the absence in its composition of pathogens.
CONSTANT MONITORING OF TECHNOLOGICAL PROCESS
The enterprise uses Italian equipment «AVITEK», which is equipped with computer program control over the production process. The essence of the program lies in the preservation and analysis of the production process. Data from each production run are printed out on paper in the form of graphs and stored on a flash card.
SELECTION OF SUPPLIERS
An important factor in the production of quality products is the right choice of supplier. Our company makes to suppliers of several demands, chief of which is the safety of raw materials (eggs). According to the regulations of our company providers are attached to each raw batch the documents in accordance with the plan of the input control. These requirements apply to auxiliary materials (boxes, bags, bottles, caps for bottles), lubricating materials, cleaning and disinfectants.