The raw materials used by production of pasta

Plan:

      Introduction … … … … … … … … … … … … … … … … … … … … … … …3

1 . The raw materials used by production of pasta … … … … … … … … … … … …..4

2 . Range, classification of products … … … … … … … … … … … … … … …. …. .7

3 . Main stages of production of pasta … … … … … …. …. …. …. …. …. …. …. …..10

4 . Main technological schemes of production of pasta … … … … … … … … … … …13

5 . The main units of macaroni production – the pressing device and a matrix … … ……19

6 . Ecological indicators of production … … … … … … … … … … …...   ….. …. …..24

      Conclusion …  … … … … … … … …  … … … … … … … … … … … … … … .26

The list of the used literature … …  … … … … … … … … … … … … …… … …. ….27

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Introduction

It is historically proved that the homeland of pasta is Italy.  In the Middle Ages pressing devices (to the device of these units the certain head is devoted) were put in action by means of horsepower or on water-mills, and at emergence of the first cars there were steam units.

In Russia it is considered year of origin of macaroni branch 1797 when there was opening the first macaroni factory in Odessa.

Pasta represents the products formed from wheaten dough in the form of tubules, threads of ribbons and figures and 13% dried up to humidity. They are characterized by a good keeping, transportability, speed and simplicity of preparation from them of food, and also high nutritional value and good comprehensibility.

Pasta has a number of advantages before the most widespread food. At storage pasta doesn't harden as bread, and are less hygroscopic in comparison with crackers, well is transported and remain (about one year and more) without deterioration of flavoring and nutritious properties. Pasta surpasses white bread as produce them from wheat flour with the maximum content of albumens in a nutrition value. They contain 9 - 13% of proteins, 75 - 79 usvoyaemykh of carbohydrates, 0,9 fats, 0,6% of mineral substances and B1, B2, PP vitamins, etc. Caloric content of pasta makes 360 kcal / 100. Comprehensibility their human body above comprehensibility of grain. Proteins of pasta are acquired for 85%, carbohydrates - for 98% and fats for 95%. From them it is possible to prepare quickly a dish as duration of their cooking is equal 5 - 15 min.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1.The raw materials used by production of pasta

The basic raw materials, we apply in macaroni production, the flour is. GOST 875 — 69 provides use as the main raw materials of macaroni production of wheat flour of the highest or the I grades. Thus the products of the best quality having amber-yellow or straw-colored color, turn out from a special macaroni flour of the premium (grain) received by grind of grain of firm wheat or soft vitreous wheat. From a macaroni flour of the I grade (a semi-croup firm or "soft vitreous wheat) products with a brownish shade of bigger or smaller intensity turn out. The baking flour of the highest or the I grades, received by grind of grain of soft wheat, is applied in the absence of a macaroni flour. The pasta received from a baking flour of the premium, has usually light-cream color, and from a flour of the I grade — dark and cream with a gray shade.

On appearance macaroni grain differs from a baking flour krupnoty parts (as at semolina) with a yellowish shade. Semi-grain consists of smaller particles, than a croup, and therefore with lighter shade (though gives more dark pasta). The baking flour of any grade consists of powdery particles, and than the grade of a flour, subjects it is lower has more dark shade.

The most important indicators of quality of a flour for pasta - color, a krupnost, quantity and quality of a crude gluten. From a flour with the low maintenance of a gluten fragile, crumbling products turn out. Quality of a crude gluten has to be not below the second group. Above the krupitchaty flour as it absorbs water more slowly is appreciated and forms plastic dough. The flour used in macaroni production, shouldn't contain in significant amounts the free amino acids, reducing sugar and active полифенолоксидазу (тирозиназу), causing darkening of dough and deterioration of finished products.

Warehouses of a flour happen tare storage (in bags) or unpacked. Both at tare, and at an unpacked way various versions of schemes of storage, preparation and flour giving to a press are possible.

Water is a component of macaroni dough. It causes biochemical and physics - chemical properties of dough. Use tap drinking water which has to be moderately rigid and meet the requirements of GOST-R of drinking water.

The additional raw materials applied in macaroni production share: on concentrating, raising the proteinaceous value of pasta; on flavoring and aromatic additives; improvers; vitamin preparations.

Main type of concentrating additives are proteinaceous dressers to whom fresh eggs, яйцепродукты (melange, egg powder), a gluten of wheat flour, casein, whole and powdered milk, whey, etc. concern.

Yaytseprodukta add at the rate of 260 - 400 eggs or 10 - 15 kg of melange on 100 kg. torments.

 

Nutrition value of pasta with an additive of 10% of powdered milk almost same, as the products enriched with egg products.

When using a wheaten gluten the content of albumens in products can increase by 30 - 40%. The gluten is withdrawal by production of wheat starch and its use as the dresser economically expediently.

Also proteinaceous isolates received from cakes of soy, sunflower and other oil-bearing crops are applied. They can serve as substitutes of egg products.

As flavoring additives by production of pasta use vegetable and fruit juice natural, concentrated or dry. Most often apply tomato paste and powders from tomatoes.

As improvers serve superficially - active agents. They promote improvement of quality of pasta which stick together when drying less and better keep a form when cooking.

For the purpose of enrichment of pasta it is possible to use heat-resistant water-soluble B1, B2, PP vitamins.

Quality of pasta in many respects depends on carrying out technological process.

Modern macaroni production represents the uniform automatic transfer product line. It consists of the following main operations: preparation of raw materials, preparation of dough, formation of pasta, drying, packing.

 

2 . The range of developed products

Depending on a form pasta subdivides into the following types: tubular, filamentary, taenioid and figured. In turn each of the specified types of products subdivide into types.

Tubular products depending on the sizes of cross section share on types: straws (diameter is up to 4 mm); special) diameter is from 4,1 to 5,5 mm), ordinary (diameter is from 5,6 to 7 mm), amateur (diameter more than 7 mm). Thickness of walls of tubular products has to be no more than 1,5 mm (about 2 mm in number of no more than 5% of the mass of products in packing unit are allowed).

To tubular products carry (fig. 3): macaroni —  a tube with a direct cut not less than 15 cm long; horns — a curved or direct tube with a direct cut from 1,5 to 10 cm long; feathers — a tube with a slanting cut from 3 to 10 cm long.

 

Figure 3. a – macaroni, b– horns, c – feathers

Filamentary products (vermicelli) by the sizes in section share on types (fig. 4); web (diameter no more than 0,8 mm); thin (diameter no more than 1,2 mm); ordinary (diameter no more than 1,5 mm); amateur (diameter no more than 3 mm).

Figure 4. Whip-like products: a - long, б – short cuts.

Ribbon- like  products (noodles) let out various names (fig. 5): smooth or corrugated, with direct, wavy or sawtooth edges etc. Width of noodles is allowed any, but not less than 3 mm, its thickness has to be no more than 2 mm.

 Figure 5. Ribbon- like (noodles) products: a - long, б – short cuts.

Macaroni specialities (fig. 6) can be issued any form and the sizes, but the maximum thickness of any part in a break shouldn't exceed: for the pressed products of 3 mm, for stamped — 1,5 mm.

Figure 6. Macaroni specialities: а – shells; б – scallops; в – bows, г – others, д - soup paste.

Depending on length pasta divides on long (from 15 to 50 cm) and short (from 1,5 to 15 cm). Macaroni makes only the long; vermicelli and noodles — both long, and short; horns, feathers, figured products — only short.

At last, on a way of formation short products share on short cuts and stamped.

 

 

 

 

 

3 . Main stages of production of pasta

         Process of production of pasta consists of the following main operations: raw materials preparation, preparation of macaroni dough, dough pressing, cutting of crude products, drying, cooling of the dried-up products, rejection and packing of finished products.

Raw materials preparation. Consists in flour sifting, separation from it metallomagnetic impurity, heating (temperature of a flour has to be not below 10 °C), mixing of different parties of a flour according to indications of laboratory of factory.

The water intended for kneading of dough, is warmed up in heatexchange devices, and then mixes up with cold tap water up to the temperature specified in a compounding.

Preparation of additives consists in their stirring in the water intended for kneading of dough. When using eggs them previously wash and if apply melange, it previously defreeze.

Preparation of macaroni dough. It consists of dispensing of ingredients (a flour, water and additives) and kneading dough.

Dispensing is carried out by means of batchers which give a flour and water with the additives dissolved in it a continuous stream to a mesilny trough in the ratio about 1:3.

In a mesilny trough there is an intensive hashing of a flour and water, moistening and swelling of particles of a flour — occurs kneadingdough. However unlike grain or egg sponge macaroni dough by the end kneadingrepresents not the continuous connected weight, and a set of the humidified separate lumps and crumbs.

Dough pressing. The purpose — to condense the kneaded dough, to turn it into uniform connected plastic test weight. and then to give it a certain form, to form it. Formation is carried out by dough breakdown through the openings done in a metal matrix. The form of openings of a matrix defines a form the vypressovyvayemykh of crude products (semi-finished product). For example, openings of round section will give vermicelli, rectangular — noodles etc.

Cutting of crude products. The vypressovyvayemykh consists of a matrix of crude products on pieces of the necessary length and in preparation them to drying in cutting. This preparation depending on a type of made products and the applied drying equipment consists or in an apportion of crude products on mesh conveyors, a framework or in tray cartridges, or in развесе long locks of crude products on special drying poles — бастуны.

Vypressovyvayemy products before sharp go to time are sharp intensively blow air for receiving on their surface of the dried crust. It prevents sticking of crude products to drying surfaces and adhesion of products among themselves during drying.

Drying of products. The purpose — to fix their form and to prevent possibility of development of microorganisms in them. It is the longest and responsible stage of technological process on which correctness of carrying out durability of products depends first of all. Very intensive drying leads to emergence in dry products of cracks, and very slow drying can lead to a souring of products.

At the macaroni enterprises use convective drying of pasta — blowing of a dried-up product by heated air.

The machine for preliminary drying of pasta

Cooling of the dried-up products. This process is necessary to level high temperature of products with the air temperature of packing office. If to pack pasta without cooling, evaporation of moisture will already proceed in packing that will lead to reduction of mass of the packed products.

Slow cooling of the dried-up products in special bunkers and the cameras called by stabilizers stores is the most preferable.

The cooled products subject to rejection during which delete the products which aren't meeting the requirements to their quality then products pack.

Packing. It is made or in small container (boxes, packages) manually either packing cars, or an embankment" in large container (a box, boxes, paper bags).

 

4 . Main technological schemes of production of pasta

Production of any kind of macaroni production always consists of the listed above stages, however a type of developed products, and also existence at factory of this or that equipment define the technological scheme of production of these products at any concrete factory. Macaroni factories make now long products according to three schemes, and short — on two. What distinctive features of each of these five schemes?

The scheme of production of macaroni with drying in tray cartridges. According to this scheme (fig. 7) develop macaroni of any diameter 20 — 25 cm long.

Leaving a matrix of a press 1 lock of crude macaroni by means of a riding table 2 stack in tray cartridges and cut. At many enterprises this operation is mechanized, it is carried out by raskladochno-cutting cars.

Figure 7 - The scheme of production of macaroni with drying in tray cartridges

The cartridges filled with crude products shift to trolleys 5 or carts and transport in drying office. Here beskaloriferny drying cabinets 4 to which densely substitute trolleys with the filled cartridges are established, or manually shift cartridges from the cart in a drying cabinet. Drying is that the air stream from the fan of the drying device passes through the macaroni laid in cartridges. Upon termination of drying finished products in trolleys or on carts arrive in packing office where products after cooling and rejection pack up manually or stack in large container an embankment. Empty cartridges in trolleys or on carts give to a press where process repeats again.

The main shortcomings of a cassette way of production of macaroni consist that a lot of manual skills and macaroni always are spent turn out bent. However still according to such scheme in our country develop bulk of macaroni. It is explained by that the cassette way doesn't demand the difficult and expensive equipment (drying cabinets, trolleys and carts make in workshops of the macaroni enterprises) and the big areas.

In recent years for the purpose of finishing of manual skills to a minimum at a cassette way of production of macaroni on a number of the enterprises the mechanized product lines are created. The scheme of one of such lines is given in fig. 8. Vypressovyvayemy a shnekovy press 1 lock of macaroni arrives in the raskladochno-cutting car 2 where occur mechanical laying and is sharp macaroni in tray cartridges 3. The filled cartridges pile manually on two chain conveyors 5, passing on both parties of the dryer. The dryer represents some cupboard drying devices installed in a row. At slow movement of piles

Figure 10. The mechanized product line for production of macaroni with drying in tray cartridges

cartridges drying of macaroni happens conveyors. Dry macaroni takes out from cartridges on a packing table 6, and empty cartridges give to the rayekladochno-cutting car for the next filling with crude products.

The scheme of production of long pasta on the automated product lines with drying by suspended way. According to this scheme in our country while make rather small amount of pasta. However thanks to high extent of mechanization and automation of all technological processes which are carried out by nepreryvnodeystvuyushchy cars and units, being a part of lines, this way of production of high-quality pasta (macaroni special and straws, vermicelli and noodles) gains ground at us in the country. Now according to this scheme in the macaroni industry lines of the Italian firm "Braybanti" and the domestic B6-LMG, B6-LMV and LMB lines similar to them work.

In fig. 9 the B6-LMV line scheme is represented. Continuous an operating press 2 выпрессовывает through a rectangular matrix of a lock which (samorazvesy) 1 are hanged out by the special machine gun on бастуны. In such state they arrive on drying. At first locks of macaroni pass drying in the preliminary dryer 5 where moisture from a semi-finished product, and then in the final dryer 4 in which moisture slowly is removed from products intensively is removed. In dryers бастуны with products move the conveyors located in some circles. The dried-up products on the bastunakh arrive in the stabilizer store 5, and then by car would act with бастунов and arrive on packing. Empty бастуны the chain conveyor move to  саморазвесу. Usually lines complete with packing cars for production packing in boxes.

Figure 11. The automated B6-LMV product line for production of long pasta

The scheme of production of long products on the automated product lines with preliminary drying on a framework and final drying in cylindrical cartridges. According to this scheme make long pasta on the automated product lines of the French firm "Bassano". In our country two such lines work. The line includes a macaroni press, the rasstilochny car, preliminary and final dryers, the stabilizer store and group of packing machines. The main advantages of this scheme — lack of dry waste and receiving absolutely direct products of identical length. It is reached by that cut on pieces of identical length pasta after preliminary drying on a framework passes final drying in rotating cylindrical cartridges. Thus, products are dried up in the course of continuous rolling on an internal surface of cylindrical cartridges that does them absolutely direct.

The production scheme the korotkoreeanykh of products on a complex but-mekhanieirovannykh product lines. The line (fig. 10) consists from two basic elements: shnekovy macaroni press 1 and dryers of continuous action 2.

Vypressovyvayemy products are continuously cut by any mechanism for are sharp short products and move on the top tape of the steam conveyor dryer. Being gradually poured from the top tape on underlying, products are blown by heated drying air.

Fig. 12. The scheme complex the mechanized product line for production of short cut products.

The dried-up products are cooled most often in vibrocoolers 5 or it is simple on the tape conveyors of the sufficient length giving them to packing office.

High extent of mechanization, flexibility of the scheme, big productivity gave it a wide circulation in our country in post-war years.

The scheme of production of short products on the automated product lines. Development of pasta according to this scheme differs from production on the previous higher extent of mechanization and automation of processes, higher quality of received products in connection with use of more long drying which is carried out in three stages — preliminary subdrying, preliminary and final drying.

Besides matrixes and cutting mechanisms for receiving shortly cut products of the line usually complete with slit-like matrixes for receiving a tape of dough and a stamp by cars that allows to develop on them also stamped products.

 

5 . The main units of macaroni production – the pressing device and matrixes

Shnekovye of the press classify by number of troughs of a testosmesitel (one - two - three - and chetyrekhkorytny), by number of pressing devices or pressing screws (one - two - and chetyrekhshnekovy), by existence and a place of pumping out of dough (in a testosmesitel or in the shnekovy camera), in a form of a matrix and by a tube design.

Now at our macaroni enterprises are operated domestic macaroni LPL-1M, LPL-2M and LMB press. The last are established in the automated LMB product lines, and also the automated product lines of the Italian firm "Braybanti", and the French firm "Bassano" — BBK 140/4 press.

The Rostov - on - Don engineering plant started release прессов the B6-LPSh series with a productivity of 500. 750 and 1000 kg/h of finished products.

To understand the principle of work of a press and purpose of its separate knots we will consider the technological scheme of one-korytnogo odnoshnekovy macaroni press with the round matrix, presented in fig. 14

Technological knots of a press are batchers of a flour 1 and waters 2, the testosmesitel consisting of a trough of 3 and a shaft of 4 with shovels, the pressing device which is turning on the shnekovy cylinder with a water shirt 6 and the screw 7, a press head, the replaceable matrix 10, the cutting mechanism 11 and the obduvochny device 12. Rotation of shaft of a testosmesitel and the screw is usually carried out from the uniform drive 5.

MATRIXES Kneading of dough, consolidation of the received kroshkovaty weight and formation of crude products are carried out now in the uniform unit — in a shnekovy macaroni press of continuous action, the main which working body is the matrix. The form of openings of a matrix defines a look the vypressovyvayemykh of products. Changing matrixes, it is possible to receive on the same press practically any kind of pasta. Thus, the press and a matrix are the capital equipment for kneadingand pressing of macaroni dough.