food Marketing & Technology 3/2021

Processing
noodles through a continuous,
automatic, and reliable process with
little operator intervention required.
This model is a six stages single screw
low shear cooking-extruder. Instead of
applying traditional pressurized batch
cookers, there is the option of using
native raw flours and cooking in a
continuous extrusion cooker. This will
drastically reduce raw material costs and
ensure precise control of all parameters,
resulting in an excellent and consistent
product. This specific application is
the result of GEA’s experience in the
production of continuous cooking
extruders, achieved through more
than four decades at the forefront of
cooking extrusion processes.
Creating a noodle nest
Located at the end of the extruder,
the nesting machine is one of the
most distinctive parts of the noodle
production line. The well-designed
headpiece of the GEA xTru extruder
regulates the flow pressure, ensuring
the extruded product flows evenly
over the entire die surface. The dough
is then equally distributed when
inserted into the die. This guarantees
that a homogeneous product with
precise shape and weight enters the
nesting machine. The nesting machine
is composed of two cutting units – an
upper and a lower unit – equipped with
rotary blades and fixed counter blades
that continuously cut the extruded
product and precisely define its length
thanks to the adjustment system. Once
cut, the product is conveyed into the
forming tubes where a powerful jet
of compressed air controlled by the
pneumatic system gives the nest its
final shape.
After that, the nest is unloaded
onto the forming cups, which are
then conveyed on a belt to the heat
treatment area. Attention to hygiene
and cleanliness is a prominent feature
of all of the machinery that makes
up GEA production lines. The nesting
machine is no exception: Made of
stainless steel, it is equipped with a
waste recovery system that optimizes
production while at the same time
ensuring ease of cleaning.
Thermal treatment
Further thermal treatments include
high-performance steaming units as
well as fast or super-fast, medium, or
high temperature continuous dryers.
These were developed based on our
experience with dry pasta and are
suitable for the production of lowfat
noodles. Drying is an important,
smooth, and stable process, with gentle
variations depending on the product
and ambient conditions. Generating
the right specific microclimate is
the key to guaranteeing the most
efficient drying profile with the lowest
energy consumption, thus reducing
the machine’s energy footprint. The
keywords for GEA’s thermal treatments
are: hygienic execution and easy
maintenance, proper insulation, active
thermal control (ventilation flow,
correct temperature profile), full
parameter control, cleaning, energy
efficiency, and low TCO.
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food Marketing & Technology • June 2021
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