How to reduce breakage in instant noodle production

        Reducing breakage in instant noodle production is crucial to maintain product quality, reduce waste, and improve profitability. Here are the key steps to minimize breakage at different stages of manufacturing:  

1. Raw Material Selection & Dough Preparation

- Use High-Quality Flour: 

  - Opt for wheat flour (maida/atta) with 9-12% protein content for better elasticity.  

  - Ensure low ash content (<0.5%) for smoother dough.  

- Proper Hydration:  

  - Maintain 34-38% water content in dough (varies based on flour type).  

  - Use kansui solution (alkaline salt) for firmer texture (common in ramen noodles).  

- Mixing Time:

  - Overmixing makes dough brittle → Optimal mixing: 10-15 mins.  

2. Noodle Sheet Formation & Cutting  

- Rolling Process:  

  - Gradually reduce thickness in multiple stages(avoids stress cracks).  

  - Ensure even pressure in sheeting rollers.  

- Cutting Blades Maintenance:  

  - Use sharp cutting blades to prevent frayed edges.  

  - Adjust cutting speed to avoid stretching & snapping.  

3. Steaming (Gelatinization)

- Steam Time & Temperature:  

  - Optimal steaming: 2-5 mins at 100-110°C (ensures proper gelatinization).  

  - Under-steaming → Weak noodles → More breakage.  

  - Over-steaming → Too soft → Sticks together.  

- Uniform Steam Distribution: 

  - Use perforated conveyor belts for even heat exposure.  

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4. Frying/Drying Process 

For Fried Noodles:  

- Oil Temperature Control:  

  - 140-160°C for 1-2 mins (too high → brittle noodles).  

  - Use palm olein oil for better stability.  

- Frying Basket Shaking:  

  - Prevents clumping & ensures even frying.  

For Air-Dried Noodles: 

- Multi-Stage Drying:

  - Pre-drying (40°C, 30 mins) → Final drying (70°C, 2-3 hrs).  

  - Humidity control (30-40% RH) prevents cracking.  

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5. Cooling & Handling 

- Gentle Cooling Conveyor:  

  - Avoid sudden temperature drops → causes thermal shock breakage.  

- Minimize Manual Handling:  

  - Use automated transfer systems to reduce human-induced breakage.  

6. Seasoning & Packaging

- Vibrating Sieve for Seasoning: 

  - Ensures even coating without rough handling.  

- Packaging Machine Settings:  

  - Adjust sealing pressure to avoid crushing noodles.  

  - Use nitrogen flushing (for fried noodles) to prevent oxidation & brittleness.  

7. Storage & Transportation

- Avoid Moisture & Heat Exposure:  

  - Store in cool, dry (RH < 60%) conditions.  

- Strong Packaging Material: 

  - Use multi-layer laminated pouches (prevents crushing during transit).  

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Common Causes of Breakage & Solutions  

| Issue                                 | Solution |  

|-------------------------   - |-------------|  

| Brittle noodles                 | Adjust dough moisture, frying temp |  

| Cracking after drying       | Slow drying, humidity control |  

| Breakage during packing | Use soft cushioning conveyors |  

| Sticking & clumping       | Dust with corn starch (food-grade) |  

Final Tips 

✅ Regular Quality Checks – Test noodle strength at each stage.  

✅ Machine Calibration – Ensure rollers, cutters, and fryers are well-maintained.  

✅ Employee Training – Minimize rough handling in manual processes.  

By optimizing dough quality, processing parameters, and handling, you can reduce breakage to <5% in production.