In the last article we touched on a very important and promising topic for small businesses in the form , indeed, at the present time it is very difficult to imagine life without semi-finished products. At the same time, the demand for products and the actual level of use of semi-finished products in the diet directly depends on the size settlement, the larger the city, the more semi-finished products are sold and actually consumed in it. This dependence is explained by a number of factors, including the financial component, the intensity of work and, most importantly, moral principles. No matter how funny it sounds, the last factor plays a fairly large role, because there are certain stereotypes about the usefulness and deliciousness of home-cooked food. Of course, now they are gradually leveled out and fade into the background in megacities and major cities, but firmly hold positions in the rest of the country.
Although such stereotypes (and maybe not stereotypes) are alive in big cities just step back a little into the shadows. But be that as it may, it is precisely this attitude that, on the one hand, acts as a certain kind of brake on the development of the entire market of semi-finished products (although it is already growing at a very high pace), and on the other hand, serves as an excellent springboard for the development of small businesses in this field. The reason, as you understand, is in a simple concept - homemade food - that is, the more homemade semi-finished products a small business can offer, the more successful it will be.
But this is all the theory of the general market for semi-finished products, and we will move on to one of the segments - this is the cutlet segment. Why is the production of cutlets the most interesting of the segments from my point of view? It's all about simple variety the cutlets themselves, or rather the recipes for their preparation, and secondly, some technological features, which allow small businesses to organize the production of cutlets quickly and immediately oust competitors from the market through “home recipes.”
And now a little more about the business idea itself, as you understand, we're talking about about the creation of cutlets, or rather, semi-finished ready-made cutlets. But first of all, let's just answer a few questions.
Why is the production of cutlets as semi-finished products profitable?
It's all about the recipe and the great popularity of cutlets in our market. With popularity, everything seems to be clear, but as for the recipe, that’s a separate question. Actually, if you set a goal, I think within one hour you can find at least several hundred recipes. At the same time, the recipe includes not only meat, but also other components, for example, the same bread, potatoes, onions, which in general allows you to reduce the real cost of a kilogram of minced meat, while observing the most important principle - the quality of the cutlets. Second important aspect is that meat used in the manufacture of semi-finished products does not belong to higher categories. It is quite possible to use meat trimmings without the same loss of quality; it doesn’t sound very good, of course, but in fact we are talking about normal meat, just not marketable.
Using only these two factors, it is quite possible to achieve the cost of finished cutlets lower than the cost of raw commercial meat on the market. That is, without deception and loss of quality. The real profitability of cutlet production is in the region of 80-90%, of course we are not talking about profitability in general; after minus the additional costs, the production workshop is quite capable of working with a profitability of 30%.
Why is it worth starting your business in semi-finished products with the production of cutlets?
From my point of view, it is worth starting, of course, about the implementation of a full-fledged workshop, with cutlets, for a number of reasons, but the most important of them is the huge variety of types of these same cutlets. Thus, using a minimal set of equipment (more on this in the next article), you can produce a huge range of products, that is, today we make veal cutlets, tomorrow with fish, the next day with the addition of vegetables, and so on. By the way, when I first encountered semi-finished products, the person started with the production of dumplings and certain problems arose there about this in the next issues of the business blog. With cutlets, there are no problems with variety: one thing today, another tomorrow, using the same set of equipment.
And now a little about the features of production and, most importantly, the sale of finished cutlets.
The first and most important thing is the organization of the workshop itself. It's all about production food products and as a result, in our country there are a lot of rules and requirements for such premises and storage places finished products. As a conclusion, it is necessary to find a normal (from the point of view of the SES) premises, preferably ready, but it is imperative that before renting it you need “the go-ahead” from the SES employees. That is, in all cases, my advice is to look for acquaintances or “friends” in this body, this will greatly help in the course of all your work. If you can’t rent the finished premises, then remember that the investment in the furnishings is quite large and you must be sure that the contract “suddenly” will not end in a year or the tenant will not request big money. Of course, the most the best option is its own premises.
The second is the development of documents for semi-finished products; I can honestly say that this issue is easily resolved, because today most of the recipes have already been developed and approved; all you have to do is present everything “correctly” to the inspection authorities.
The third is the equipment for the production of cutlets, this issue will be described separately, within the framework of the business idea itself, I can only say that you should not rush to extremes and buy powerful and expensive units, it seems much more expedient to buy units of average productivity. And in the case of increasing sales volumes, you can always go two ways - working in two shifts and purchasing a second unit of the same capacity (as needed). On the one hand, there will be no excess, on the other hand, you will always be insured in case of breakdown of one of the sets.
The fourth is no less important than the first, but more delicate; we are talking about the organization of sales itself. Actually, the whole secret of a successful start of a business idea lies in proper organization the process of marketing your products. Of course, the simplest and affordable option This is a simple placement of products in stores, but there are several but, firstly, to persuade stores to take your products for sale, and secondly, without having advertising and bright packaging (for it you need to have optional equipment) the likelihood that products will begin to be bought up is reduced to minimum levels. It can be noted that in this way it will also be possible to promote it, but this requires a lot of time and more time, and most importantly, all this time you need to somehow support the workshop and incur losses. A more optimal option is an aggressive advertising policy. I will not once again rewrite what I have already written about. The whole process is described in the article about. I think that using these tips and using a little creativity, finding regular customers won’t be too difficult.
These are actually all the main directions and tasks that need to be solved when organizing your own business for the production of semi-finished products in the form of cutlets.
2.4.2. Technology for the production of Moskovskie cutlets
The technological process for the production of semi-finished products includes the following stages:
– incoming inspection and acceptance of raw materials and materials
– preparing onions;
– preparation table salt and breadcrumbs;
– preparing bread;
– cooking minced meat;
– molding;
– cooling or freezing;
– packaging, labeling, transportation and storage;
– production control.
“Moskovskie” cutlets are produced according to technological instructions in compliance with sanitary rules for meat industry enterprises and veterinary and sanitary rules for workshops of enterprises for processing cattle and pigs, approved in the prescribed manner.
In production areas for cutting, deboning and trimming raw meat, the temperature should not be higher than 12ºC, and the relative humidity should not be higher than 75%.
Raw meat supplied for the production of semi-finished products is, if necessary, cleaned of dirt, blood clots and brand marks. After cleaning, the raw materials are sent for cutting, deboning and trimming, which are carried out in accordance with the current technological instructions.
When using frozen raw materials, they are defrosted in accordance with the technological instructions for refrigeration processing and storage of meat and meat products at meat industry enterprises, approved in the prescribed manner.
Frozen blocks are released from packaging and checked by control defrosting for their sanitary condition and correct trimming. Frozen blocks of beef and pork can be used without prior defrosting.
They are crushed on block cutters, crushers, grinding grinders and other similar equipment designed for crushing frozen blocks, without allowing the temperature to rise above Oº C, and sent for the preparation of minced meat. To prevent freezing of crushed frozen blocks, it is recommended to mix them with chilled or defrosted meat in a 1:1 ratio. It is allowed to use meat blocks with a core temperature of no higher than minus 6ºС without first mixing it with chilled or defrosted raw materials.
According to organoleptic indicators, defrosted meat must meet the characteristics fresh meat. Boning involves separating muscle, fat and connective tissue from the bone. This operation is carried out manually using knives. During deboning, each worker processes only certain parts of the carcass. When deboning, it is necessary to ensure that small bones, pieces of periosteum and cartilage do not get into the meat, which complicates subsequent trimming.
Boning and trimming of meat is carried out on tables made of of stainless steel or marble chips with removable wooden or plastic boards. Chilled meat on the bones with a temperature in the thickness of the muscles of 2ºС or defrosted meat with a temperature of at least 1ºС is sent for deboning. Boning meat by hand carries the risk of cuts to the left thumb, abdominal area, and groin area. To protect against them, you should wear chainmail mesh like an apron and gloves on two fingers of your left hand. Boned meat can be used to make sausages, chopped semi-finished products, and the chopped part can be used to make broths and feed.
Trimming is the process of separating connective tissue, cartilage, fat, blood vessels and small bones, and impurities from muscle tissue. The trimming is done manually using special knives. During the trimming process, meat is sorted into grades, depending on the amount of remaining fat and connective tissue. The less connective tissue in the meat, the higher the grade of meat. When trimming, from the beginning, individual pieces of meat are cut into several parts, along the line of muscle connection, then the muscle tissue is separated from the connective tissue. Pieces of meat after trimming should have a mass of 400 - 500 g. In pork, the fat content is increased to 30 - 50%. The average yield of premium trimmed beef is 15 – 20%. Meat is trimmed by grade or into one grade.
Beef is lived into three grades:
– highest grade – without fat, connective tissue and veins. The meat of the highest port is obtained mainly from the hind legs and shoulder blades, from the dorsal muscle;
– first grade – with a connective tissue and fat content of no more than 6%. First grade meat is obtained from all parts of carcasses;
– second grade – containing 20% connective tissue.
The second grade includes less valuable parts of carcasses: intercostals, shanks, breast meat, neck meat, and arable meat. The presence of small tendons and film is allowed in second grade meat. With single-grade trimming, meat is trimmed into one grade, removing films, tendons, cartilage, lymph nodes, bruises, and so on, without separating into grades.
Trimmed single-grade beef should contain no more than 12% connective fat tissue. When trimming beef, fat or fatty beef is also separated in the amount of 22% with a fat content of no more than 35%. Single-grade veal contains 6% connective tissue.
Pork is divided into lean, semi-fat, fat and single-grade. Lean pork consists of muscle tissue without any connective tissue or fat. Allowed content is 10% intermuscular or soft fat. Bold pork is obtained from hams and fillets.
Fatty pork consists of muscle tissue containing more than 50% intermuscular and soft fat. Fatty pork is obtained from the flank of the rib and other parts. During the trimming process, the meat is cut into pieces weighing from 100 to 500 g. Quality control of boning and trimming is carried out 3 times per shift by external inspection, assessing the quality of stripping bones from soft tissue, the degree of removal of cartilage, tendons, and fat during fattening.
Trimmed meat is sent quickly for processing; accumulation of processed raw materials is not allowed. When deboning the trimmings, the room temperature should not be higher than 12ºC, the relative air humidity should not be higher than 75%. Raw meat (beef, pork) is ground on a grinder with a grid hole diameter of 2–3 mm or on a cutter.
In order to improve the quality of semi-finished products, it is recommended to use pork cutlet meat with a fat content of up to 30%, beef cutlet meat with a fat and connective tissue content of no more than 15%, for Moskovskiye cutlets - from 15% to 20%. The specified selection of meat raw materials ensures a reduction in losses during heat treatment (frying) of cutlets, rump steak and beefsteak, which should not exceed 19% for cutlets, and 30% for rump steak and beefsteak.
Preparation of minced meat. The number of components of minced meat for the production of cutlets is established by the recipe, which indicates what raw materials and how much of it should be taken to prepare the cutlets. It is necessary to know in what quantity spices and table salt should be added, and what should be the yield of the finished product and the maximum permissible weight of the product. Usually the quality of raw materials, it the nutritional value, i.e. the quality of meat, fat, offal, vegetable and dairy products determines the grade of finished products.
Natural semi-finished products from minced meat are produced relatively rarely for technological reasons, in particular, due to the poor cohesiveness of minced meat and the possible collapse of the product during cooking, as well as for economic reasons. Other components used in the production of chopped semi-finished products are usually cheaper than meat, and due to this, the cost of the final product and its wholesale price are reduced.
Minced meat is a mixture of components, pre-prepared quantities corresponding to the recipe. The uniform distribution of ingredients, its structural and mechanical properties, and water-retaining emulsified capacity depend on the conditions of mixing and grinding and the sequence of loading containers. Proper preparation of minced meat not only produces homogeneous minced meat, but also leads to the fact that it binds a large number of water.
Preparation of minced meat is carried out in batch mixers or continuous minced meat preparation units. When working on continuous mince preparation units, weight and volume dispensers are used. When preparing stuffing, all components are loaded into the mixer, according to the recipe for the semi-finished product.
The sequence of adding the components into the mixer is as follows: chopped raw meat, wheat bread, water, onions, spices, table salt. The temperature of the finished minced meat should be no more than 14ºС.
The prepared minced meat is immediately sent to form the semi-finished product. Even short-term aging of minced meat is undesirable due to a possible increase in bacterial contamination.
Moskovskie cutlets must meet the requirements of technical specifications, be produced according to technological instructions in compliance with sanitary rules for meat industry enterprises and veterinary and sanitary rules for meat processing plant enterprises (shops), approved in the prescribed manner.
Spices are introduced into the recipe to give them additional taste, pungency and aroma. Flavoring and aromatic substances stimulate appetite, promote the secretion of digestive juices, and, therefore, better absorption of food.
Fresh onions are peeled and washed cold water. Dried onions are inspected and soaked in cold water for 3–4 hours. The water requirement for soaking is 775 g per 225 g of dried onions. The amount of water not absorbed by dry onions when soaking them is added when preparing minced meat. It is allowed to use fresh onions together with dried hydrated onions in a ratio of 50:50. Frozen onions without prior defrosting are sent for chopping. It is recommended to grind it together with raw meat. Chopped canned onions are added to the minced meat mixer without pre-treatment.
The mass fraction of salt in canned onions is 19% and is taken into account when preparing minced meat.
The shelf life of canned onions at temperatures from 0 to 4ºС and relative air humidity of no more than 75% is no more than 3 months from the date of manufacture. Onion preparation is carried out in separate rooms not used for other production operations.
Salt is used in dry form with preliminary sifting or in solution with water after filtering.
Breadcrumbs are sifted and passed through magnetic separators, if necessary. The bread, cut into pieces, is soaked in cold water and then crushed in a grinder through a grate.
Table 3
Recipe for Moskovskie cutlets
Semi-finished products with manufacturing defects (deformed, with deviations in weight, etc.), not frozen or not defrosted, are used in the preparation of chilled semi-finished products of the corresponding assortment in an amount of no more than 3% by weight of the minced meat being prepared. In this case, when making minced meat, you should take into account the amount of bread and breading contained in the cutlets sent for processing. From the prepared minced meat, cutlets are formed into oval-shaped flat cakes 2–2.5 cm thick. For the production of culinary products...
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Discoveries in Moscow microdistrict Maryino... for confectionery shops and meat products. IN... cutlets, azu, steaks, as well as a wide variety of salads. Bakery production ... production. Main technologist bakery production... in an antique shop, can not...
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The ultra-fast pace of life leaves us no chance to enjoy the comfort of home, and even more so, home-cooked food. This is where a variety of products that have already passed all stages come to our aid. technological process, except for the last one - preparation. as a business, based on this need, the direction is quite profitable, although it requires certain investments of funds and effort.
In general, these products can be divided into food and industrial. We, as consumers, are, of course, more interested in the former, since they are the ones that come to our stoves from store shelves.
From the name we can conclude that this product is already halfway through manufacturing process and requires only final processing - frying, boiling, stewing.
Semi-finished products can be vegetable, meat, fish, dairy, cereal, or combined.
The classification in more detail looks like this:
This list, of course, cannot be complete. It can be continued indefinitely, since the conditions modern life forcing technologists to come up with more and more new recipes.
The production of semi-finished products implies another classification, which is based on the principle of heat treatment. Frozen and chilled products are distinguished here. If we talk specifically about semi-finished meat products, they are also divided into different types by type of meat used - pork, beef, chicken and others.
On initial stage you need to decide what form your enterprise will take. There are two options - . In the first case, you will have to go through a simple registration procedure, but the second will open the doors to many supermarkets and large stores, since legal entities such enterprises work much more willingly.
As equipment you will need:
The only condition is that there should be enough space in your kitchen, especially when production begins to grow and you need extra hands to be able to process all orders. IN home business You can succeed if you are strict about the quality of your products. It will cost an order of magnitude higher than store-bought semi-finished products, but the client will also expect more from it. Minced meat should be tasty, most importantly – meaty, and in normal quantities.
BUSINESS PLAN FOR THE PRODUCTION OF CUTLETS
When developing a business plan for a small mini-shop for the production of cutlets, it is necessary to take into account a number of specific factors inherent exclusively to small businesses, so first we’ll talk about them, and then the real numbers.
1. Real cost of meat for the production of cutlets
2. Structure of the cost of finished products in the business plan for the production of cutlets
3. general characteristics cutlet business
Carrying out calculations for the production of any semi-finished products largely faces one significant problem, namely difficulties in determining the real cost of manufactured products. The reason for the difficulties is the same factor that determines the prospects for small businesses in this segment, namely the “flexibility” of the business. By the definition of “flexibility” we are talking, first of all, about the ability to very quickly change the recipes of manufactured products and literally adapt to the current market conditions. As an example, do we need fish cutlets today? No problem, by lunchtime the first batch of freshly prepared fish cutlets is already on store shelves. Do you want homemade cutlets for tomorrow? Not a question either.
At the same time, such competitive advantages make it possible not only to successfully conduct business, but also to frankly displace big players in a particular region, of course, provided that there is a properly constructed sales system and friendly relations with retail trade. But the same approach has a strong impact on the overall profitability of production, because whatever one may say, it forces the use of a certain business model. This business model is based on a flexible cost system, built primarily on systematic purchases of small quantities of raw materials, possibly with the exception of meat. But taking into account the fact that meat occupies approximately 50-60% of the total mass of finished products, significant fluctuations in prices for non-meat components can significantly reduce or, on the contrary, increase the profitability of a mini-cutlet production workshop.
Alternatively, I would suggest you when forming own business plan a small mini-cutlet workshop, or even in the future, create and systematically maintain tables of the real cost of finished cutlets, depending on the recipe and real purchase prices for raw materials. In my business plan I will give an example of two recipes - “school cutlets” and “village cutlets”, examples of which will show the difference both in the cutlet cost structure and possible changes.
We start any business plan, including forecasting business processes in the production of cutlets, with the main raw materials. To calculate a specific business plan, we take pork and beef as the main raw materials, although in practice it is necessary to include chicken, fish and vegetable cutlets in the calculations.
For any more or less reputable production, even in a small workshop, meat is purchased in half carcasses, which makes it possible to ensure an acceptable cost of raw materials. It is important to remember that after the primary processing process (boning and veining, you can read what it is here) the actual amount of raw materials decreases, which leads to an increase in its cost and so on.
REAL COST OF MEAT FOR CUTLETS PRODUCTION
As can be seen from the calculations, after the initial processing of half-carcasses, meat “rises in price” by 40% in relation to the initial purchase price, while losses can be minimized by selling waste. Under the waste in in this case we understand bones, lived and so on, selling them even at minimum prices will allow you to significantly increase the profit of your mini cutlet production workshop.
Product yield during primary cutting of half carcasses
As you can see, for every 100 kg of total weight we will get up to 25 kg of various waste, even if you sell such meat waste at a price of 20 rubles per kg, you can make good money. For example, with a total workshop capacity of 100 kg of finished products per day, such a small production will generate about 18 kg of meat waste; when sold, the net profit will be 360 rubles per day or 7,200 rubles per month. Of course she is profit is only 6% of total profit workshops for the production of cutlets, but as they say, it’s a small thing, but nice. Moreover, this figure is not taken into account in the calculations of the rest of the business plan, that is, it can be a pleasant bonus for the owner.
Let's move on to calculating the current cost per unit of output, since we are talking about a small workshop for the production of cutlets, we will calculate the cost of one kilogram of finished cutlets. To bring clear example We make calculations for two different recipes, “school cutlets” and “village cutlets”. The recipe is taken from ready-made specifications used in production cycles and, of course, taking into account the current GOST for semi-finished meat products (GOST R 52675-2006)
STRUCTURE OF THE COST OF FINISHED PRODUCTS IN THE BUSINESS PLAN FOR CUTLETS PRODUCTION
| Cost of production of “School” cutlets | ||||
| Ingredient | price, rub. | Expense for | Cost, rub.) | |
| per kg | 100 kg | |||
| Beef | 27.60% | 27.6 | 4 940.40 | |
| Pork | 34.10% | 34.1 | 6 342.60 | |
| Salt | 1.00% | 4.3 | 4.30 | |
| Ground pepper | 0.06% | 91.2 | 0.06 | 5.47 |
| Wheat bread | 12.40% | 12.4 | 248.00 | |
| Onion | 2.60% | 2.6 | 57.20 | |
| Breadcrumbs | 4.00% | 120.00 | ||
| Egg powder | 2.50% | 2.5 | 150.00 | |
| Water | 15.74% | 15.74 | 0.00 | |
| Total | 11 867.97 | |||
| Cost of 1 kg | ||||
| Cost of production of cutlets “village cutlets” | ||||
| Ingredient | Share (%) of the weight of finished dumplings | price, rub. | Expense for | Cost, rub.) |
| per kg | 100 kg | |||
| Beef cutlet meat | 54.00% | 9 666.00 | ||
| Raw beef fat | 5.00% | 100.00 | ||
| Wheat bread | 13.00% | 260.00 | ||
| Breadcrumbs | 2.00% | 60.00 | ||
| Fresh onions | 3.00% | 66.00 | ||
| Ground black pepper | 0.10% | 91.2 | 0.1 | 9.12 |
| Table salt | 1.20% | 4.3 | 1.2 | 5.16 |
| Drinking water | 21.70% | 21.7 | 0.00 | |
| Total | 10 166.28 | |||
| Cost of 1 kg |
As can be seen from the calculations, when using different recipes, the cost of a kilogram of finished cutlets can differ by 20%, and only “meat” recipes were taken. In this case, the main ingredient in the form of meat is about 60%.
It is interesting that the recipe for village cutlets is taken from the example prescribed in GOST itself and a fairly large amount of water (almost 22%) is provided by the state itself.
Based on the estimated cost and realistic performance indicators for the production of cutlets in a mini-workshop in volumes of 100 kg per day, you can calculate the gross revenue and gross production costs of your production. By the way, most equipment for the production of cutlets and other semi-finished meat products have a rated power much higher; the manufacturers themselves talk about a productivity of 100-200 kg per hour. But it’s worth considering that real business processes and nominal power are completely different things. Indeed, in order to ensure full load, it is necessary to increase staffing, as an example, for the continuous operation of the apparatus for forming cutlets and meatballs, it is necessary to ensure the same continuous preparation of meat, onions and other ingredients. This pace of work is ensured by expanding the staff, but the second question arises: how fast are the pace of product sales? It’s no secret that organizing production itself is only half the battle; the products produced also need to be sold. Practice shows that in the first stages the pace is 100 kg. per shift is the minimum level required for normal work, but if necessary, you can always saddle more.
General indicators of a small workshop in a cutlet production business plan
The set pace of work with a capacity of 100 kg. ready-made cutlets can easily be supported by 4 people, each of whom will be engaged in their own segment of work.
· - one on the deboning and trimming.
· - one preparation of minced meat and work with other ingredients from the selected recipe for cutlets.
· - one works with a forming (cutlet) machine.
· - and one more general worker (as a rule, with the functions of assisting the main workers of the workshop).
In addition to the main costs associated directly with the production of cutlets, there are so-called indirect costs (although in this business plan we also included some direct costs in the indirect ones, which is acceptable in a small business). In our small production they look like this:
Business plan for the production of cutlets - indirect costs of a mini workshop
Of course, expenses are taken based on average calculations and must be adjusted depending on the chosen region and, most importantly, taking into account its specifics; such an adjustment must be carried out not only with a business plan for semi-finished meat products.
Based on the calculations made, it is possible to generate final figures for the profit and profitability of the mini workshop:
GENERAL CHARACTERISTICS OF CUTLETS BUSINESS (CUTLETS PRODUCTION BUSINESS PLAN)
In general, profitability indicators are 20% not very bad for production areas, plus it is worth noting that with increasing sales volumes, the level of profitability will increase. The increase in profitability with an increase in production volumes of finished cutlets is primarily associated with a fairly significant share of indirect costs in the cost structure. So, in the estimated business plan of a mini-workshop, indirect expenses amount to 270 thousand rubles, which is more than 55% of all expenses of the workshop, but if you increase revenue by 2 times (as an example), accordingly, indirect expenses will remain at the same level, but direct expenses will increase also doubled (from 220 thousand to 440 thousand). At the same time, the profitability of the entire production will increase to 44%.
Based on the general indicators, we can draw a rather banal conclusion: the business idea of producing cutlets looks attractive and very promising, although it also has its pitfalls.
Semi-finished products come in large pieces and portions. Portions include: steaks, cutlets, entrecotes, rump steaks (with or without breading), zrazy, meatballs, meatballs, and other minced meat and meat products.
The general technology for the production of semi-finished meat products (in this case, cutlets) is as follows:
Technologies for the production of semi-finished meat products include many different operations, the implementation of which is helped by special devices.
Thus, the standard set for the production of semi-finished meat products or cutlets includes:
All this equipment is used on different stages production of meat products.
