Calculation of the amount of raw materials and supplies required to manufacture a given quantity of products. Calculation of raw materials and determination of tasks for teams of cooks. Operational control over production operations Calculation of raw materials and finished products

When compiling recipes, the consumption of raw materials and semi-finished products in kind and dry substances is calculated.

If the content of dry substances in raw materials deviates from the standard, an appropriate recalculation is made.

The recipes take into account the maximum permissible losses of raw materials during the manufacture of semi-finished products and losses at the finishing stage of semi-finished products, i.e. in the process of preparing finished products from them.

Production workers must wage a daily struggle to reduce losses: comply with the established technological regime for the production of products, use raw materials and semi-finished products sparingly, in particular, eliminate the spraying of bulk raw materials, strictly follow recipes, promote further mechanization and automation of production in order to reduce waste, the processing of which is accompanied by additional losses raw materials.

In recipes for the production of semi-finished products, the amount of raw material losses is visible from the quantitative relationship between the consumption and yield of dry substances.

So, for example, according to the recipe, the consumption of raw materials for 1 ton of Charlotte butter cream is 765 kg of dry substances, and 1 ton of the finished cream contains only 750 kg of dry substances, i.e. the consumption of raw materials in dry substances exceeded the yield of cream in dry substances by 15 kg.

Consequently, losses (in dry substances) amount to 1.96% of the amount of raw materials consumed.

When calculating working recipes, you should first determine the optimal dimensions
portions of prepared semi-finished products.

They depend on the volume of orders of the retail chain for certain types of products, on the working capacity of equipment and utensils at the enterprise.

When determining portion sizes, keep in mind that the smaller the portion, the greater the loss.

The amount of raw materials per serving of any semi-finished product is calculated based on the amount of raw materials per 1 ton of semi-finished product established by the recipe.

For example, you should prepare a portion of biscuit equal to 15 kg.

For 1 ton of biscuit you need 300 kg of flour.

Therefore, for 15 kg of biscuit you will need flour:

1000-300
15 -x
x = 15-300/1000 = 4.5 kg.

In the same way, the required amount of other types of raw materials is determined.

Tabled calculations of the amount of raw materials should be available for different portions, for example, 5, 7, 9 kg of biscuit, etc.

To recalculate in recipes the amount of semi-finished products per 1 ton of products, taking into account losses in finishing, you must use the information that indicates the losses taken into account in the summary recipes for raw material consumption.

The technique of calculating working recipes for making pastries and cakes from semi-finished products is much more complicated.

Collections of recipes for flour confectionery products contain the following features that must be taken into account when making calculations.

The consumption of semi-finished products per 1 ton of pastries and cakes is shown without taking into account the losses of semi-finished products formed at the stage of their finishing.

The consumption of raw materials for 1 ton of pastries and cakes in the summary recipe includes these losses, i.e., it provides for the raw materials necessary for the production of the amount of semi-finished products that will be lost.

The consumption of semi-finished products for scraps generated during the manufacturing process is provided in the recipes for 1 ton of pastries and cakes, but the consumption of raw materials for scraps is not taken into account in the summary recipe.

The technique for calculating working recipes is different for the following three groups of products: in the manufacture of which no scraps are obtained; during the production of which scraps from the entire product are obtained; the production of which produces scraps from one or several types of baked semi-finished products.

Below are examples of calculations of working recipes for these three product groups.

Example. Calculation of the working recipe for cakes, in the production of which
no scraps are obtained.

Recipe 108 (38). Cake "Boucher round, glazed with milk fondant."

Weight of 1000 cakes is 75 kg. Finishing losses are 2.5%.

When determining the consumption of semi-finished products for 75 kg of cakes, the number of semi-finished products per 1 ton of cakes provided for in the recipe is taken into account

The calculated quantity of semi-finished products without finishing losses, i.e. 75 kg, represents the true mass of the finished cakes.

Using these data, it is possible to check the mass of the cake at any stage of production.

So, the mass of the biscuit per cake should be equal to 29 g (29 kg: 1000), and after it is soaked in syrup, of which 10 g is consumed, it is already 39 g.

After gluing the sponge cake soaked with fruit filling, its weight will be 49 g, after glazing with fondant - 72 g and, finally, after decorating with fruit - 75 g.

The mass of 76.87 kg is the amount of semi-finished products that must be produced, taking into account the 2.5% loss of raw materials when finishing semi-finished products.

Consumption of semi-finished products per 1000 pieces (75 kg) of cakes

When determining the consumption of raw materials for the preparation of 75 kg of cakes, they proceed from the amount of raw materials per 1 ton of each semi-finished product established by the recipe

Table 114. Raw material consumption for the preparation of semi-finished products for 1000 pcs. (75 kg) cakes

The total consumption of each type of raw material can be determined directly from the summary recipe for 1 ton of finished products, published in collections of recipes.

For example, the flour consumption for 1 ton of products indicated in the collection of recipes is 148.7 kg, therefore, for 75 kg of products it will be: 148.7-75/ 1000 = 11.15 kg.

However, using the data from the summary recipe placed in the collection, it is impossible to determine the amount of raw materials required for the manufacture of each
semi-finished product separately.

Total consumption of raw materials for 1000 pieces (75 kg) of cakes, taking into account losses in finishing

22.05.2015

Due to the very wide range of products manufactured by enterprises of this profile, we will describe the methodology for determining: a) the amount of wood raw material necessary to produce a certain amount of peeled veneer from it; b) the amount of peeled veneer required to make a certain amount of one or another type of laminated wood from it.
For each of these cases, the following must be known: a) in the manufacture of veneer - its format, the required amount of veneer of each type, etc.; b) in the manufacture of plywood - its type, grades, formats, thicknesses, ply layers, the required amount of plywood of each type, etc. In educational design, calculations can begin with determining the productivity of size presses for a given number of them.
The essence of the methodology for calculating the raw materials required to produce a given amount of products comes down to a consistent increase in the volume of these products by the amount of waste and losses that occur at each stage of the technological process. In this case, calculations are carried out in the direction opposite to the flow of the technological process. The calculation can be carried out for the quantity of products manufactured per unit of time: hour, work shift, month or year.
Calculation of the amount of dry veneer required to produce a given amount of unsanded plywood. It is convenient to carry out such a calculation by sequentially filling out the columns of the table. 46. ​​The first six columns are filled in according to the stocknote data (for plywood cut to the maximum format).
Since enterprises allow re-cutting of plywood sheets into a smaller format due to the presence in their edge zones of such defects as cracks, wane, skew of sheets, incorrect width, weak corners, bubbles, etc., first of all, fill out columns 7, 8, 9, the last of which gives the actual quantity of products arriving at the plant warehouse.

Column 7 is filled in with data drawn from the experience of plywood manufacturing at our enterprises. It records the percentage of waste generated when re-cutting each type of plywood. For example, for general purpose plywood a"1 = 1%, plywood for export a"1" = 4...5%, aviation plywood a1"" = 10%. Column 9 is filled in with data on the amount of re-cut plywood, determined from a known value losses a1:

Let us remind you that processing allowances for the length and width of plywood sheets are usually 60-80 mm (on both sides).
Column 12 is filled in with data on the amount of unedged plywood, based on the known amount of waste when cutting a2:


Column 15 is filled in with data on the amount of dry veneer supplied to the package assembly area, based on the known value of losses a3:

Column 14 includes volumetric losses due to compression when gluing veneer:

Column 16 is filled in after establishing the percentage of A4 waste generated during sorting and edge gluing of veneer, its transportation, the production of veneer strips for repair machines and the production of samples for physical and mechanical testing of veneer. When calculating, the amount of waste can be taken as a4 = 2...3%
Column 18 is filled in with data on the amount of dry veneer coming out of the dryers, taking into account the waste listed above:

Column 17 includes the volume of veneer waste generated in the area of ​​sorting, repairing and re-gluing veneer:

When filling out columns 19 and 20 of table. 46 take into account the specified quantity of longitudinal and transverse plywood, as well as the structure of plywood sheets of each thickness.
Calculation of the number of logs required to produce a given amount of veneer. It is convenient to carry out this calculation in accordance with table. 47.
Column 1 contains the dimensions of the veneer sheets, determined based on the dimensions of the plywood sheets (column 3 of Table 46) and their structure. Column 2 contains data on the average thickness of veneer sheets, determined taking into account the compression of plywood:


The data from columns 19 and 20 of the table is transferred to column 3. 46. ​​Columns 4 and 5 are filled in after determining the percentage of losses due to veneer shrinkage in the tangential (at5) and radial (ar5) directions. Column 6 is filled in after calculating the total loss due to shrinkage along its width and thickness, which can be taken equal to without a large error

Column 8 is filled in with data on the amount of raw veneer, determined based on drying losses:

Column 7 includes volumetric losses due to drying of veneer across the thickness and width of the sheets:

To fill out column 11, you must first determine the number of required churaks, for which you can use the formula

This refers to losses resulting from the splitting of part of the logs, deviations in the dimensions of veneer sheets from the required ones, the production of samples to determine the physical and mechanical properties of veneer, etc.
The yield of veneer from the block can be slightly increased if we provide for the selection and use of part of the veneer-fragment. Experience shows that 15-20% of short pieces of its volume can be selected from flawed veneer.
Knowing the required number of blocks will allow you to determine their volume

Columns 9 and 10 are filled in after the required number of blocks N has been determined and the volumes of pencil and plain veneer obtained from a block of medium diameter have been calculated using formulas (55) and (56) from § 13.
If raw materials are delivered to the enterprise in blocks, then the calculation can be completed. But if the raw materials are supplied in ridges, you also need to fill out columns 12, 13 and 14 of the table. 47. Column 12 is filled in with data on the amount of waste generated when cutting logs into logs (a7). This waste can be accepted at a rate of 1-3%. Column 14 is filled in with data on the required volume of logs, taking into account the waste generated when cutting them into logs:

This completes the calculation of the raw materials required to produce a given amount of veneer. In the case when we are talking about the production of plywood from logs, both of the above calculations (Tables 46 and 47) must be combined into one. In this case, the yield of finished plywood, %, is determined as follows:

Using the data from the table. 46 and 47 allows you to determine other consumption coefficients for plywood of each brand and size. Consumption of dry veneer for the production of 1 m3 of finished plywood

As mentioned earlier, all the calculations given were made for the case of manufacturing unsanded plywood and without taking into account losses on samples intended to determine the physical and mechanical properties of plywood. If it is necessary to determine the consumption of dry veneer for the production of 1 m3 of sanded plywood, taking into account the indicated losses, then

The product of the three given expense coefficients is nothing more than

Finally, the product of the consumption coefficients R5 and R6 represents the amount of raw materials required to produce 1 m3 of dry veneer:

Knowledge of the consumption coefficient R7 is necessary if the company's product is dry veneer.
By completing the calculation of raw materials by calculating the indicated consumption coefficients, we have the opportunity to compare their values ​​with those that have been tested by many years of practice in the manufacture of veneer and plywood, thereby verifying the correctness of the calculations performed. It is convenient to summarize the data obtained as a result of calculations in tables. It is also necessary to draw up a wood balance.
Calculation of the amount of glue and its components required to produce a given amount of plywood. It is customary to distinguish between glue consumption: 1) technological, characterizing the amount of glue applied per unit area of ​​the surface to be bonded (grams per square meter); 2) production, characterizing the amount of glue spent per unit of manufactured products. In the production of plywood and other similar materials, consumption is usually calculated in kilograms per cubic meter. In contrast to technological consumption, all possible losses of glue are taken into account here, both during its preparation and during use. The rate of technological consumption of glue depends on its properties, the type of material being glued, the type of wood, the thickness of the veneer and the roughness of its surfaces, the gluing method, etc. To find it, you should use the relationship equation between all the above factors that affect the strength of the adhesive joint, as well as the equation , reflecting the dependence of the cost of manufacturing a given product on glue consumption.
Solving such problems will not cause difficulties if you use new methods of planning experiments.
Currently, the current technological standards for glue consumption are based only on data from many years of experience in gluing veneer. If it is necessary to determine the required amount of liquid glue for a given plywood production program, the norms of its production consumption, kg/m3, must first be determined using the formula

This formula is valid for the case of one-sided application of glue. If glue is applied to both surfaces to be glued, the production rate of its consumption should be doubled.
If bakelite film is used for gluing, the production rate of its consumption, m2/m2, is determined as follows:

The mass rate of film production consumption, kg/m3 is determined by the formula

To determine the total amount M of glue required for a given program, it is necessary to sum up the costs of glue used for gluing each type of material being manufactured, taking into account its layering and size:

So far we have been talking about glue consumption. The required quantity of its individual components is determined taking into account the glue recipe. So, if the glue consists of a1, wt. parts of resin, a2 wt. including filler and a3 wt. hours of hardener, then the required amount of each component is determined as follows:

The amount of water, kg, required to prepare an aqueous solution of hardener with concentration K, %, is determined as follows:

Calculation of the amount of materials required for the manufacture of bent-glued blanks. The consumption of dry veneer, m3, for the production of 1 m3 of bent-glued blanks is determined by the formula

The consumption of liquid glue, kg, for the production of 1 m3 of bent-glued blanks is determined by the formula

Calculation of the consumption of raw veneer, raw materials and glue components for the production of 1 m3 of bent-glued blanks is carried out according to the method given in the two previous sections of this paragraph.
Calculation of the amount of materials required for the manufacture of chipboards, The consumption of dry veneer, m3, for the production of 1 t of chipboard is determined by the formula

The consumption of raw veneer and raw materials for the production of 1 ton of chipboard is carried out according to the previously described method.
The consumption of bakelite varnish with a concentration of 50%, kg, for the production of 1 t of chipboard is determined by the formula

The amount of alcohol, l, per 1 ton of chipboard required to bring varnish with a concentration of 50% to the working concentration is determined by the formula

If the enterprise receives varnish with a concentration exceeding 50%, the additional amount of alcohol to bring 1000 kg of varnish to 50% concentration is determined by the formula

Raw materials are calculated based on the production program. We arrange it in the form of a table:

Table 6

4.2. Calculation of the area of ​​premises for receiving and storing products.

For educational purposes, you can use data on the composition of the premises of a warehouse group according to SNiP 2.08.02-89 for the type of enterprise being designed. Calculate the area of ​​the premises based on the specific load per 1 m 2 of the floor area of ​​the chamber (pantry), taking into account the recommended shelf life for each type of product or group of products and semi-finished products. The calculation method is set out in the textbook (Nikulenkova T.T., Yastina G.M. Design of public catering establishments, p. 69). The results of the calculation using formula (3.13) are presented in the form of table 7.

Table 7.

The total area of ​​the chamber is calculated by multiplying the usable area by the coefficient β - the coefficient of increase in area by passages (from 1.6 to 2.2).

If the enterprise receives semi-finished products of varying degrees of readiness, the calculation of the area of ​​the chamber for storing semi-finished products can be done by containers, equipment, in this case, by the area of ​​the containers in which semi-finished products are received and stored. Containers KP-300 and KP-160 are considered in this case as a means of moving and storing functional containers of various sizes, which directly contain semi-finished products.

Pre-production shop

If the designed enterprise operates on large-piece semi-finished meat products, peeled vegetables, root vegetables and processed greens, the calculation of production premises begins with the calculation of the pre-production workshop. The workshop should have dedicated lines for processing meat, fish and vegetable semi-finished products, as well as processing greens. The corresponding lines (sections) are equipped with the necessary equipment, which is calculated and selected according to the relevant catalogs. The basis of calculations is the production program of the pre-production shop in the form presented in Table 8.

Table 8.

Calculation of the number of production employees

The calculation of the labor force in the workshop is made on the basis of the production program of the workshop and the time standards for preparing dishes of each type, listed in the menu plan and produced in the workshop. The calculation is made using the formula:

N1 = n ∙ Nvr / 3600 ∙ Tcm ∙ λ, where

n – number of products (or dishes) produced per day, pcs, kg, dishes;

Nvr - standard time for manufacturing a unit of product, sec. (cm.

Appendix 7);

Tcm - shift duration, hour. (T = 7-7.2 or 8-8.2 h);

λ - coefficient taking into account the growth of labor productivity

The labor force calculation is tabulated in the following form:

Table 9

The total number of workshop employees, taking into account weekends and holidays, vacations, sick days, is determined by the formula:

where N 2 is the total number of workers in the workshop;

N 1 - estimated number of employees;

K 1 - coefficient taking into account weekends and holidays.

Calculation of mechanical equipment

The calculation comes down to selecting a machine with the required performance. The calculation record form is presented in Table 10.

Table 10.

Using catalogs of modern types of equipment from domestic and foreign companies, they select the machines necessary for slicing, chopping, loosening and other technological operations.

Calculation of refrigeration equipment

The main refrigeration equipment of production shops are refrigerated cabinets, prefabricated chambers and refrigerated containers in sectional tables.

Technological calculation comes down to determining the required equipment capacity in accordance with the amount of products simultaneously stored. The calculation is made using the formula:

Where E - capacity of the cabinet, chamber, kg;

Q- product weight, kg;

A coefficient that takes into account the mass of the container in which products are stored (for cabinets - 0.7:0.8; for chambers - 0.5:0.6).

The mass of the product is found using the formula:

Where q p - weight of one portion of the product;

P g- number of servings.

We summarize the calculation of the capacity of refrigerated cabinets in the table:

Table 11

According to the obtained total capacity of the refrigeration cabinet, we select refrigeration equipment (see Appendix 8).

Auxiliary equipment includes production tables, washing baths, shelving, and stock racks. Tables are calculated according to the standard length of the working area of ​​the table per 1 employee (on average 1.25 m). The calculation is given in table 12.

Tables are usually installed in several types: SP - 1200 - with a smooth table and shelves, SPM - 1500 - with a table and a washing tub, SPMM - 1500 - for installing small-scale mechanization equipment.

Calculation of production tables

Table 12.

Other auxiliary equipment is not calculated, but selected according to technological feasibility and sanitary standards.

In pre-production shops, the size of washing baths should be at least 600x600x850 mm.

Hand washing sinks are provided in all production areas.

The calculation of the workshop ends with finding the useful and total area of ​​the workshop (Table 13).

Table 13.

Usable area is the area occupied by all types of installed equipment. The total area additionally includes the area for passages, installation openings, and indentations from the walls. The area is calculated using formula (B.5) using the area utilization factor. Recommendations for calculating the total area of ​​various premises are given in the textbook.

Calculation of the area of ​​each production premises ends with finding, using formula (B.6), the actual coefficient of area utilization - the ratio of the usable area of ​​the workshop to the layout area, which allows us to judge the efficiency of using the area of ​​the designed premises.