FROM POTATOES, AS THE HEROINE OF THE AGELESS SOVIET FILM CALCULATED, YOU CAN PREPARE MORE THAN A TEN DIFFERENT DISHES. AND THE DIRECTIONS OF ITS INDUSTRIAL PROCESSING ARE ALSO PRETTY MANY. AT THE SAME TIME THE PRODUCTION OF CERTAIN TYPES OF PRODUCTS IN RECENT YEARS IS STEADY INCREASING, AND THE OUTPUT OF OTHERS REMAINS AT THE SAME LEVEL, DESPITE THE PRESENCE OF DEMAND.
WHAT THE SUCCESS OF A PRODUCT IN THE MARKET DEPENDS ON, WHAT PROBLEMS DO PROCESSERS FACE, THE HEADS OF PROFILE ENTERPRISES AND REPRESENTATIVES OF INDUSTRY ORGANIZATIONS, PARTICIPATED IN THE POTATO UNION WEBINAR, DISCUSSED.
STARCH. GROWTH NEED QUALITY RAW MATERIALS
Potato starch is a product that Russia has been producing for many years in smaller quantities than it consumes. According to the Soyuzkrakhmal Association of Deep Grain Processing Enterprises, domestic plants annually produce about 11 thousand tons of potato starch, while the domestic market is about 30-32 thousand tons.
Describing the current state of the direction, the president of the association, Oleg Radin, states that at the moment there are only a few small enterprises for the production of potato starch in Russia, including: Chuvashyonkrakhmal LLC; Mglinsky Starch Plant LLC, Poretsky Starch OJSC, Syryatinsky Starch Plant LLC, SPPK Udacha, Pleshcheevsky Starch Plant JSC, Starch Products JSC (Shablykinsky Starch Plant).
The main problem hindering their development is the lack of a profitable raw material base in the country. As Oleg Radin notes, Russian enterprises are forced to produce starch from products that farmers could not sell to stores (in fact, from waste). On average, ten tons of table potatoes are processed into one ton of starch.
The director of the All-Russian Research Institute of Starch and Processing of Starch-Containing Raw Materials, a branch of the Federal State Budgetary Scientific Institution “Federal Research Center for Potato named after A.I. A.G. Lorch "Vasily Byzov. At the same time, according to the specialist, there are years when enterprises experience a shortage of products of this level (a vivid example: the 21/22 season). In addition, processors incur too high costs for the purchase of raw materials, which affects the profitability of production. The average farm price of Russian potatoes, according to the expert, is 22% higher than in the EU countries.
“The efficiency of the technology for processing potatoes for starch is ensured when using tubers with a starch content of at least 19% (in this case, no more than five tons of raw materials are required to produce one ton of starch), - explains Vasily Byzov, - and the processing plant should be located in close proximity to the raw material base, according to our calculations, within 50 km.”
Experts are unanimous that it is necessary to establish the production of technical varieties of potatoes in the country, although this will not be easy. There are many unresolved issues, one of them is the lack of Russian varieties with a high content of starch, breeders and seed growers still have to work on solving this problem.
It is equally important to awaken the interest of potato growers in growing high-quality raw materials for processing.
“In European countries, due to the high labor intensity of growing and storing potato tubers, the following basic principles have been established to stimulate the production of potato starch, - Vasily Byzov shares information, - potato producers (farmers, cooperatives) are shareholders of the processing plant and are financially interested in the sale of the final product - starch and its derivatives; companies have organized agronomic services that provide producers with seed material and recommendations for its cultivation. Profitability of starch production is achieved by reducing the cost of growing potatoes with high yields and high starch content. At the same time, the consumption of potatoes per 1 ton of starch is reduced to 4,5 tons and, accordingly, the specific energy costs for its processing are reduced.”
In Russia, there are examples when agricultural producers grow technical varieties of potatoes by order of a starch plant, but so far we are talking about minimal volumes. The situation could be changed by the appearance of a large-scale processor on the market.
«At least one large modern enterprise for deep processing of potatoes in Russia needs, - says Oleg Radin, - it must process about 100-120 thousand tons of industrial potatoes, obtain high-quality starch, replace imports and, possibly, send products for export.”
The launch of a new enterprise could also solve the problem of the production of highly demanded modified starches. “A large volume of food modifications is imported into Russia every year, worth more than $100 million, - explains the President of the Association "Soyuzkrakhmal", - earlier it was the products of large European manufacturers, now the market has begun to restructure towards China, Vietnam, Thailand. In Russia, food modifications are produced by only two enterprises, and this is only 20 thousand tons of the 94 thousand tons required by our industry. There is a demand for these products, but raw materials are needed for production, and these are either waxy varieties of corn, which we also do not have, or technical varieties of potatoes.”
FRENCH FRIES. EXPORT PLANS
Over six years of operation, the largest manufacturer of frozen french fries in Russia, Vee Fry LLC, has gained extensive experience in the production of raw materials for processing.
We Fray
The company is located in the Lipetsk region. Production capacity - 240 thousand tons of potatoes per year. Produces 3,5 million French fries daily.
Last year, raw materials for the plant were grown on an area of 7 thousand hectares, in the new year the volumes increased by another 2 thousand hectares.
«We work with farmers under two contracts, - explains the development director of the enterprise Sergey Marchenko, - first we sell to farmers
seed material of specialized varieties (85% of it is Innovator), according to the second - we buy the entire crop from them in a fixed period at a fixed price. Farmers pay for seeds after harvesting.
The company managed to achieve a serious breakthrough in the issue of seed supply. "At the start of the project, we imported thousands of tons of seeds from abroad, - recalls Sergey Marchenko, this year they bought only 100 tons, and then we are talking only about completely new varieties. Our goal - fully localize those of them that will be of interest to us».
The enterprise is also ready to work with Russian varieties that have the necessary properties. The only condition is the provision of a trial batch. "We take 30 kg, fry, evaluate the result, - comments the Development Director of Vee Fry LLC, - if you liked everything, the potatoes are not
turns black, we drive along the entire line (this requires 40 tons already). We get a good product, we can continue to work».
Reflecting on the prospects for the production of frozen french fries, Sergey Marchenko emphasizes that there is a demand on the market to increase the volume of product consumption. Thus, new Russian fast food chains have announced the launch of 70-100 restaurants a year. In response, the company is preparing to put a second production line into operation. But in the coming years, Russia is also expected to open several new enterprises of this profile at once, which creates a threat of overproduction.
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Processors now need to think about exports. "Sales issues - it's a nationwide problem, - Sergey Marchenko is convinced, - so that potato producers do not suffer, it is necessary to work out in advance the conditions that ensure the possibility of successful deliveries to foreign markets. We look forward to the state's help in these matters."
POTATO FLAKES. WORKING IN A DIFFICULT MARKET
Potato flakes producers also link the future of their sector with the development of export potential.
According to Alexandra Ponomarenko, Executive Director of Maxim Gorky Plus LLC, the domestic market was fully supplied with this type of product back in 2019. Processing companies tried to look for buyers abroad, although this has always been difficult to do.
LLC "Maxim Gorky Plus"
The maximum annual capacity of the enterprise at the moment is 29 thousand tons of the finished product. It processes up to 200 thousand tons of potatoes per season. Occupies 50% of the domestic market. Production capacities allow covering up to 80% of the entire cereal market.
«Foreign customers are very cautious about Russian products, and we are required to make a lot of efforts to obtain the required specification, its approval, testing, - Alexander Ponomarenko shares his experience, - from the moment you start interacting with a client until the first container is unloaded, it can take a year.”
In 2021, producers of potato flakes were forced to reduce export volumes to a minimum, this was due to a sharp reduction in the supply of raw materials and a rise in prices for it. "In the 21/22 season, the cost of purchased potatoes exceeded the average annual price level by four times, with a general deficit and a shortage of total consumption for processors, - says the executive director of Maxim Gorky Plus LLC, - this led to an increase in the cost of potato flakes in Russia to 180 rubles / kg without VAT and, as a result, a decrease in demand for products».
At the beginning of 2022, foreign products flooded into the Russian market. "In the first six months of 2022, European companies imported into the territory
Russia at least 5 thousand tons of potato flakes (which is higher than the standard total annual volume)- continues Alexandra Ponomarenko, - the average price for an imported product was about 115 rubles/kg without VAT. Such a decrease was also affected by currency fluctuations (from 87 rubles to 62 rubles per 1 euro in the period under review). At the same time, the price of domestic cereals reached 200 rubles/kg, and domestic producers experienced significant difficulties in selling their products.».
The consequences of that season are felt by producers a year later. According to the speaker, the company has not yet managed to return to volume dynamics
consumption within the country, and stocks of products made from expensive raw materials remain in warehouses. The company pursues an active policy of import substitution, trying to balance between maintaining an acceptable price and high quality products.
“Today, new players continue to enter the market, because the problem of recycling is extremely relevant, - sums up Alexandra Ponomarenko, - but the notion that potatoes can be used to produce cereals, which is a pity to throw away, is already outdated. This is a complex business, we have problems with the sale of products, we are looking for ways to regulate both exports and imports, but so far we have to deal with difficulties on our own».
CRISPY POTATOES (CHIPS). PRODUCE ON THE FIELD
General Director of Ozery JSC Sergei Pryamov began his speech with an interesting fact: annually enterprises of the Moscow region process 471 thousand tons of raw materials into crispy potatoes. Of all this volume, only 25 thousand tons are grown in the region (5,3% of the need!), The rest is imported from outside. Perhaps, for some of the farmers of the Moscow region, this will be a reason for reflection.
JSC "Ozyory"
The largest producer of potatoes and vegetables in the Moscow region. Has a line for the production of crispy potatoes, produces products under
own TM "Barin".
Presenting his vision of the trends in the development of the potato processing sector, Sergey Pryamov noted that in the near future many large processing companies will lose out to small enterprises.
“We anticipate that the crisp potato industry will grow through the spread of new technologies, - Sergey Pryamov explains, - Now there are many models of Chinese and Turkish vacuum fryers on the market, and every potato chips business can purchase a small line and produce local crisps without leaving the field.”
According to the expert, vacuum processing provides an opportunity to reduce the temperature and period of frying, reduce oil consumption, expand the range of varieties (by taste), that is, it allows you to get a high-quality interesting product with good profitability.