Noodle Process PDF

Engr. Ramsey G. Fernandez  Objectives Hydrate Uniformly Activate gluten flour and other dry ingredients incorporate in the dough formed all ingredients...

Engr. Ramsey G. Fernandez  Objectives Hydrate Uniformly Activate gluten flour and other dry ingredients incorporate in the dough formed all ingredients  Objectives Hydrate Uniformly Activate gluten flour and other dry ingredients incorporate in the dough formed all ingredients TOPICS: Raw Process Machine Process Materials parameters Good Dough Computational Activities Characteristics Analysis  WHEAT FLOUR Alkali Solution Dough PREMIX CHILLED WATER SALT MIXING Raw PROCESS Materials  Raw Materials PREMIX CARBONATES PHOSPHATES An alkaline agent used to accelerate swelling power of gluten Has the tendency to make Increases noodlesmooth, soft, elastic & firm hydration and water binding so as to increase Develops elasticity of noodle & cooking time brings that smoother and chewy texture.  Raw Materials HARD SOFT Protein: 13.2-13.8% WHEAT FLOUR Considered as the framework or skeleton of It is considered as the muscle of the dough. the dough Extensibility Elasticity  Raw Materials IMPORTANCE ✓ Improves sheeting properties of dough ✓ Enhances Flavor SALT Strengthens ✓ Provides softer but more elastic texture the gluten of dough and has ✓ Inhibits enzyme activity and inhibitory effect on growth of microorganisms proteolytic enzyme.  Machine Modes of Mixing 2. Continuous 1. Batch Ingredients are All ingredients are loaded continuously charged into into the mixer together the mixer Mixing takes place as the material travels Dough discharged from from the charging port the mixer in a single lot to the discharge nozzle Output : measured in kg/batch Dough continuously discharged Output : measured in kg/hr  Machine Batch Mixer (Upright) (Shallow) Mixing Mixing Chamber Chamber Vertical Horizontal Equipped with 1 Vertical blade Has flat and angular blades No need to scrape the dough (dough Requires dough scraping (wet dough movement cleans the wall ) tends to stick on the side) The mixer generates more heat – less Shallow chamber generates less heat more water water added added Dough has bigger lumps. Good dough movement due to the flat and angular position of its blades.  Machine Continuous Mixer Flour Mixture Simultaneously dispensed at a controlled flow rate. Alkali Solution Passes through a rotating arm with irregular shaped paddles forming the dough Microfeeders Dry Mixer Alkali Tanks SHEAR MIXER  Click to add text Click to add text Click to add text Click to add text ALKALI TANK JET MIXER METERING ROTARY TABLE TANK FEEDER KNEADER MIXING PROCESS  MIXING PROCESS ALKALI TANKS RECEIVING HOPPER KNEADER METERING TANK ROTARY TABLE FEEDER MIXER Process Parameters Temperature < 14oC Alkali Parameters pH 9-10 V iscosity 50-65 cP S helf Life 8 hours A lkali Mixing Time 15 minutes Machine Parameters K neading Time 10-15 minutes Dough Moisture 30-32% Dough Parameters Dough Temperature < 36oC Process Parameters Temperature < 14oC Alkali Parameters pH 9-10 Viscosity 50-65 cP Shelf Life 8 hours Alkali Mixing Time 15 minutes Machine Parameters Kneading Time 10-15 minutes Dough Moisture 30-32% Dough Parameters Dough Temperature < 36oC Process Parameters S ticky dough Too long increase in dough temperature Mixing Time No proper hydration and activation of gluten Too s hort Non homogenous U neven waving and difficult to manage thickness More H 2O Dough sheet will hang down during sheeting Amount of Water Dough sheet tear off easily L es s H 2O P roduce partially cooked noodle Incomplete Paddles Uneven distribution of ingredient Flour in dough Ageing of Dough Too long Darken color and sour smell Produce big lumps and hardens the dough GOOD DOUGH CHARACTERISTICS PEA SIZED CRUMBLY SMOOTH IN FEEL SMOOTH EDGES WHEN FORMED INTO A BALL  IWS Metrics in Mixer CENTERLINE RUNNING LINE STANDARD SHUTDOWN OPERATION START UP Activities SHUTDOWN OPERATION START UP Activities COMPUTATIONAL ANALYSIS  FLOUR THEORETICAL YIELD 𝑤𝑒𝑖𝑔ℎ𝑡𝑛𝑜𝑜𝑑𝑙𝑒,𝑘𝑔 𝑵𝒐𝒐𝒅𝒍𝒆 𝑫𝒓𝒚 𝑾𝒆𝒊𝒈𝒉𝒕 = (1 − %Fat − %MC)𝑁𝑜𝑜𝑑𝑙𝑒 𝑝𝑐 𝑤𝑒𝑖𝑔ℎ𝑡𝑓𝑙𝑜𝑢𝑟,𝑘𝑔 𝑭𝒍𝒐𝒖𝒓 𝑫𝒓𝒚 𝑾𝒆𝒊𝒈𝒉𝒕 = 1 − 𝑀𝐶𝐹𝑙𝑜𝑢𝑟 𝑏𝑎𝑡𝑐ℎ 𝑤𝑒𝑖𝑔ℎ𝑡𝑓𝑙𝑜𝑢𝑟,𝑘𝑔 1− 𝑀𝐶𝐹𝑙𝑜𝑢𝑟 𝑏𝑎𝑡𝑐ℎ 𝑇𝑌 = 𝑤𝑒𝑖𝑔ℎ𝑡𝑛𝑜𝑜𝑑𝑙𝑒,𝑘𝑔 (1 − %Fat − %MC) 𝑁𝑜𝑜𝑑𝑙𝑒 𝑝𝑐  COMPUTATION Given Parameters: FLOUR WEIGHT PER BATCH = 200 kg/batch %MCFlour = 12% %Fat = 18.5% %MCNoodle = 3-5% WeightNoodle Per piece = 0.068 kg Number of Pieces per Case = 72  COMPUTATION Total Yield = 3339.66 pieces per batch Cases/Batch = 46.38 cases per batch