Pasta Technology Introduction to Pasta Technology Bühler AG Ali Kocak Process Engineer
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 drying without 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) 2 Bühler
Statistics Consumption (2008) 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 Source: UN.I.P.I. 3 Bühler
Statistics Production in Tones (2008) Italy 3 161 000 USA 2 000 000 Brazil 1 500 000 Russia 858 000 Turkey 606 000 Egypt 400 000 Venezuela 350 000 Germany 305 000 Argentina 291 300 Mexico 280 000 France 252 000 Spain 234 000 Peru 231 000 Canada 170 000 Chile 155 000 Poland 150 000 Greece 145 000 Japan 144 000 Columbia 131 000 Tunisia 110 000 India 100 000 Portugal 78 000 Czech Republic 70 000 Hungary 70 000 Dominican Rep. 65 000 Rumania 52 000 Switzerland 49 000 Bolivia 43 000 Guatemala 38 000 Austria 38 000 England 35 000 Ecuador 32 000 Slovakia 22 000 Costa Rica 22 000 Sweden 20 000 Jordania 20 000 El Salvador 13 000 Syria 9 000 Lithuania 6 000 Panama 4 000 Latvia 1 800 Estonia 1 400 Estimated world pasta production 12.3 Mio Tones (2008) Source: UN.I.P.I. 4 Bühler
General overview pasta making process RAW MATERIAL DOUGH FORMATION DRYING FINAL PRODUCT - Triticum Durum Durum wheat e.g. Polymatik Press e.g. C-Line Long Good Dryer Dried, uncooked Pasta (e.g. Spaghetti) - Pasta are conveyed - Triticum Aestivum on sticks Hard wheat e.g. C-Line Short Good Dryer Cooked Pasta (e.g. Spaghetti) Soft wheat - Pasta are conveyed - etc. (e.g. Corn, Rice) on belts & in elevators 5 Bühler
Raw Materials: Durum, Hard- and Soft wheat TRITICUM DURUM TRITICUM DURUM TRITICUM AESTIVUM TRITICUM AESTIVUM Durum wheat Hard wheat (Bread wheat) Soft wheat (Cookie wheat) - Vitreous structure - Strong yellow color - Semolina production - Protein content 13-15% - Hardness 100 % - Slightly vitreous structure - Floury inclusions - Semolina and flour production - Protein content 11-13% - Hardness 40 75 % - Flour appearance - Soft - Flour production - Protein content 9-11% - Hardness < 35 % 6 Bühler
Unit operations involved in pasta dough processing Semolina heterogeneous bulk solid 0 400 µm Water water content 30-33 %wb Extrusion pressure up to 110 bar Pasta dough homogeneous distribution of starch and protein Hydration and plasticization Dough formation and structure homogenization 7 Bühler
Drying & structure stabilization - principle based on combined heat and mass transfer (convection drying) Moisture gradient during drying within pasta strand (e.g. spaghetti) heat transfer to pasta mass transfer (water) to air Air flow Air flow 8 Bühler
Dryer types: Short good dryer/ Long good dryer e.g. C-Line short goods dryer e.g. C-Line long 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 9 Bühler
Effect of High Temp. drying on textural properties of cooked pasta Stickiness Relative depth of penetration at F = 0.1 N Firmness Schematical cross section of pasta 10 Bühler
Effect of High Temp. drying on physical properties of dried pasta solubility of the protein fraction Reduction of the protein solubility happens during HT treatment Aggregation and densification of the protein matrix 11 Bühler
Effect of High Temp. drying on physical properties of dried pasta surface roughness Pasta surface after extrusion Atomic Force Microscopy Pasta surface after HT-drying Low temperature drying rather rough surface due to non embedded starch granules Pictures from: Zweifel (2001). Dissertation ETH Nr. 14073 High temperature drying smoothing of the surface as a result of evenly embedded starch granules 12 Bühler
Effect of High Temp. drying on properties of cooked pasta stickiness Higher drying temperature and lower product moisture during HT-drying: reduced stickiness due to higher density of protein matrix and consequently less free amylose on the product surface from: Zweifel (2001). Dissertation ETH Nr. 14073 13 Bühler
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 14 Bühler