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Pasta Technology Introduction to Pasta Technology Bühler AG Ali Kocak Process Engineer

Pasta Technology - Swisstribology · Introduction to Pasta Technology Bühler AG ... Pasta consumption (per capita and year) ... Ærather rough surface due to

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Page 1: Pasta Technology - Swisstribology · Introduction to Pasta Technology Bühler AG ... Pasta consumption (per capita and year) ... Ærather rough surface due to

Pasta Technology

Introduction to Pasta Technology

Bühler AGAli KocakProcess Engineer

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Definition of the term pasta

Pasta is a product of any kind of shape which is made from ground grain products with or without the addition of eggs and/or additives by dough formation, shaping and dryingwithout the use of any fermentation or baking process.

Occasionally it is treated before drying with hot water or steam(Instant Pasta or gluten free raw material).

(Source: EU directives for Pasta)

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Pasta consumption (per capita and year)

- Italy 26.0 kg - Austria 5.6 kg- Venezuela 12.9 kg - Belgium/Luxemburg 5.4 kg- Tunisia 11.7 kg - Estonia 5.3 kg- Greece 10.4 kg - Spain 5.0 kg- Switzerland 9.7 kg - Slovakia 5.0 kg- Sweden 9.0 kg - Bolivia 4.8 kg- USA 9.0 kg - Netherland 4.4 kg- Chile 8.2 kg - Lithuania 4.4 kg- Peru 7.5 kg - Latvia 4.4 kg- Germany 7.4 kg - Dominican Republic 4.0 kg- Argentina 7.2 kg - Australia 4.0 kg- Brazil 6.7 kg - Israel 4.0 kg- Portugal 6.7 kg - Costa Rica 3.8 kg- Hungary 6.5 kg - Panama 3.8 kg- Canada 6.5 kg - Finland 3.2 kg- Czech Republic 6.0 kg - Columbia 3.0 kg- Russia 6.0 kg - Poland 3.0 kg- Turkey 6.0 kg - Rumania 2.7 kg

Statistics – Consumption (2008)

Source: UN.I.P.I.

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Italy 3’161’000USA 2’000’000Brazil 1‘500‘000Russia 858’000Turkey 606’000Egypt 400‘000Venezuela 350’000Germany 305’000Argentina 291’300Mexico 280’000France 252’000Spain 234’000Peru 231‘000Canada 170‘000Chile 155‘000

Poland 150‘000Greece 145’000Japan 144’000Columbia 131‘000Tunisia 110‘000India 100‘000Portugal 78’000Czech Republic 70’000Hungary 70’000Dominican Rep. 65’000Rumania 52’000Switzerland 49’000Bolivia 43’000Guatemala 38’000Austria 38’000

England 35‘000Ecuador 32‘000Slovakia 22’000Costa Rica 22’000Sweden 20‘000Jordania 20‘000El Salvador 13‘000Syria 9’000Lithuania 6‘000Panama 4‘000Latvia 1’800Estonia 1‘400

Statistics– Production in Tones (2008)

Source: UN.I.P.I.Estimated world pasta production 12.3 Mio Tones (2008)

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General overview – pasta making process

RAW MATERIAL

DOUGH FORMATION DRYING FINAL

PRODUCT

e.g. Polymatik Press- Triticum Durum

Durum wheat

- Triticum Aestivum

Hard wheat

Soft wheat

- etc. (e.g. Corn, Rice)

Dried, uncooked Pasta

(e.g. Spaghetti)

e.g. C-Line Long Good Dryer

e.g. C-Line Short Good Dryer

- Pasta are conveyed

on sticks

- Pasta are conveyed

on belts & in elevators

Cooked Pasta(e.g. Spaghetti)

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Raw Materials: Durum, Hard- and Soft wheat

Durum wheat

TRITICUM DURUMTRITICUM DURUM TRITICUM AESTIVUMTRITICUM AESTIVUM

Hard wheat(Bread wheat)

Soft wheat(Cookie wheat)

- Slightly vitreousstructure

- Floury inclusions - Semolina and flour

production- Protein content 11-13%- Hardness 40 – 75 %

- Flour appearance- Soft- Flour production- Protein content 9-11%- Hardness < 35 %

- Vitreous structure- Strong yellow color- Semolina production- Protein content 13-15%- Hardness 100 %

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Unit operations involved in pasta dough processing

Semolinaheterogeneous bulk solid

0 – 400 µm

Waterwater content30-33 %wb

Extrusionpressure up to

110 bar

Pasta doughhomogeneous dis-

tribution of starch and protein

Hydration andplasticization

Dough formation andstructure homogenization

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Drying & structure stabilization - principle based on combined heat and mass transfer (convection drying)

Air flowAir flow

mass transfer(water) to air

heat transferto pasta

Moisture gradient during drying within pasta strand (e.g. spaghetti)

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Dryer types: Short good dryer/ Long good dryer

e.g. C-Line long goods dryere.g. C-Line short goods dryer

- Pasta is conveyed

on belts

- Pasta is spread

on sticks

+ further dryer types e.g. drum dryer or dryer for special formats such a “nests”

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Effect of High Temp. drying on textural properties of cooked pasta

Relative depth of penetration atF = 0.1 N

Stickiness

Firmness

Schematical cross section of pasta

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Effect of High Temp. drying on physical properties of dried pasta – solubility of the protein fraction

Reduction of the protein solubility happens during HT treatmentAggregation and densification of the protein matrix

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Effect of High Temp. drying on physical properties of dried pasta – surface roughness

Pictures from: Zweifel (2001). Dissertation ETH Nr. 14073

Pasta surfaceafter extrusion

Atomic Force Microscopy

Pasta surfaceafter HT-drying

Low temperature dryingrather rough surface due to non embedded starch granules

High temperature dryingsmoothing of the surfaceas a result of evenly embeddedstarch granules

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Effect of High Temp. drying on properties of cooked pasta –stickiness

from: Zweifel (2001). Dissertation ETH Nr. 14073

Higher drying temperatureand lower product moistureduring HT-drying:

reduced stickinessdue to higher densityof protein matrix andconsequently less free amylose on the productsurface

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Final product – objectives regarding wheat pasta in general

nice, desired shape

no cracks

desired colour (depends especially on raw material properties (ash content) & drying parameters)

desired firmness especially at al-dente point

desired surface integrity (low sliminess) after cooking

cooking loss as low as possible especially at al-dente point