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Pasta-Based Ready Meals and Technologies

10 July 20138 min reading
Need a quick, balanced and handy meal? This is a growing need among many consumers, especially when it comes to lunch time. Italian style restaurants and cafes always have lasagna on the menu. A popular choice when it comes to emulating traditional Italian cuisine, it has undergone many local variations in countries far away from Italy. An increasing number of consumers the world over readily enjoy a plate of lasagna: a tasty and balanced ready meal. A great alternative to your usual sandwich! To enjoy a delicious, hot pasta dish all it takes is a few minutes and a microwave. To produce enjoyable products which are of good quality and meet food safety standards, manufacturers need to combine tradition and technological innovation. The aim is to select the best systems which offer maximum hygiene and best product quality. PASTAS FOR ALL: WHICH PRODUCTS? THE GLOBAL PASTA MARKET TOP 10 COUNTRIES • Recent growth driven by Small pasta markets • Consumers increasingly discovering pasta’s numerous benefits - Affordability - Convenience - Versatility • Prepared according to local taste preferences PASTA SALES Pasta “Premiumization” • Premium options like chilled / Fresh Pasta have outperformed others - Fresh / healthy / gourmet - Opposite of canned ­- Examples of organic, natural, preservative-free, renewable packaging • Limited to developed countries ­- Much higher unit price ­- Dried pasta a low-price staple in poorer regions WORLD PASTA PRODUCTION About 13.5 million tons worldwide produced. The figure includes dry pasta production for retail, foodservices and industrial use (dry pasta used as an input value-added products, such soups, prepared frozen foods, boxed pasta dinners, etc.) Source: Survey co-ordinate by I.P.O. - data are update to October 2012 WORLD PASTA CONSUMPTION For over twenty years Storci S.p.A. has been making systems and machinery to produce dry pasta, fresh pasta, ready meals, gluten-free pasta and special pastas. In partnership with a large company operating in this sector, Fava S.p.A from Cento, Italy, it forms a world leading group in the construction of industrial lines for producing dry pastas and couscous, with a global market share somewhere in the region of 40%. Confident that the ready meals market is destined to grow, Storci and BS S.n.c. have joined forces to offer innovative and creative solutions in the preparation of lasagna, cannelloni and other pasta-based ready meals. Since 1980, BS has been working with expertise and reliability in the most important ready meals, fast food, ice-cream and confectionary markets. FRESH PASTA: LAWS, TECHNOLOGIES, SOLUTIONS A suitable answer can be found to all those difficulties which lie in designing a system for producing pasta-based ready meals, in particular those using sheeted pasta, such as lasagna and cannelloni: systems for producing the pasta sheets then cooking, cutting and portioning them, sauce and condiment dosing systems and systems for assembling ready meals in trays are just some of the elements which make it possible to obtain the very best with simplified process management. The obstacles which have to be overcome to achieve optimum product quality are without doubt linked to the process of cooking the sheeted pasta in water, but the secret of success really lies in the stages leading up to this step. Preparation of a high quality sheeted pasta which guarantees the best results in terms of ability to withstand cooking, pasta handling and dosing of all the ingredients used to put together a packaged product which has an appealing aspect and is enjoyable to eat: these are the main requirements which have to be managed with simple solutions offering foolproof results. Top level automation make it possible to reduce the number of qualified personnel required and prevent the risk of human error, while ease of cleaning and maintenance make a company’s self-control plan more effective. What distinguishes these systems is the care which goes into the organoleptic quality of the cooked and dressed pasta: the innovation incorporated in the Premix®, the Beltmix, the vacuum dough sheeter together with the simplicity of the lasagna pick-up robot and the sauce and grated cheese dosing units guarantee a unique taste experience. LEGISLATED NORMS ITALIAN Italian Presidential Decree (DPR) no. 187 – 09.02.2001 1. Bulk fresh pasta - Expiration max 5 days (without pasteurization - revoked) 2. Fresh pasta - Moisture level not less than 24% - Free water activity (aw) > 0.92 and < 0.97 - Heat treatment at least equivalent to pasteurization (only generically referred to) preservation, from production to sale, at a temperature of not more than + 4°C, +/- 2°C 3. Stabilized pasta - Moisture level not less than 20% - Free water activity (aW) < 0.92 - Heat treatments and production technologies that allow for preservation at room temperature FRESH PASTA: SINGLE HEAT TREATMENT TECHNOLOGY – Ingredient Dosing – Mixing – Kneading and Final Lamination/ Extrusion – Product Shaping – Pasteurization Heat Treatment – Surface Drying (T> 75°C) – Cooling – M.A.P. Packaging • Produced With Less Heat Damage • More Advanced & Modern • Technology • Preservation Organoleptic Characteristics • (*) hard to obtain and manage FRESH PASTA: DOUBLE HEAT TREATMENT TECHNOLOGY – Ingredient Dosing – Mixing – Kneading and Final Lamination/ Extrusion – Product Shaping – First Pasteurization Heat Treatment – Drying – M.A.P. Packaging – Second Pasteurization Of Packaged Product • Produced With More Heat Damage • > Hygienic Quality • < Organoleptic Quality STABILIZED PASTA: SINGLE HEAT TREATMENT TECHNOLOGY – Ingredient Dosing – Mixing – Kneading and Final Lamination / Extrusion – Product Shaping – Pasteurization Heat Treatment – Pre-Drying – Map Packaging • Produced With More Heat Damage (Greater If Fresh) • More Advanced Technology • > Product Quality • (*) hard to obtain and manage STABILIZED PASTA: DOUBLE HEAT TREATMENT TECHNOLOGY – Ingredient Dosing – Mixing – Kneading and Final Lamination / Extrusion – Product Shaping – First Pasteurization Heat Treatment – Pre-Drying – Map Packaging – Second Pasteurization Of Packaged Product • Produced With More Heat Damage • Maximum Hygienic Quality • Minimum Organoleptic Quality PASTA BASED READY MEALS: PRODUCTS, TECHNOLOGIES, SOLUTIONS FROZEN READY MEALS: SHORT AND LONG PASTA, GNOCCHI, PAELLA Convenience food: • Easy and fast to prepare • Microwave or prepare pan • Many recipes FRESH/FROZEN PASTA CUP Convenience food: • 2 min: easy and fast to prepare • Microwave • Many recipes: traditionals or innovatives COUS-COUS BASED READY MEALS Opportunity in European and North Africa markets? FRANCE 2010 Pasta production: 241.933 t Couscous production: 83.865 t READY MEALS LINE: SHORT-LONG-FILLED PASTA 1- Premix* dosing and pre-mixing system 2- Continuous extruder for long or short pasta 3- Tilting kneading machine 4- Automatic dough sheeter with single or double outlets 5- Ravioli – maker with two sheets of pasta 6- Cutting and trim return unit system 7- Continuous cooker 8- Product rinsing and cooling 9- Precooked pasta tilted lift belt and multi – head scales for dividing product into portions 10- Tray unstacker 11- Sauce storage tanks 12- Sauce dispenser 13- Weight control 14- MAP package closers A - Linear Cooker option B - Volumetric doser option C - Freezing option D - Double pasteurization option COMPLETE LINES WITH ROTARY COOKING-COOLING SYSTEMS Production, cooking, cooling and dosing of ready meals pasta based PROS • High flexibility: short, long and filled pasta • Big production and cooking capacity with short space • Simple to use and clean • High energy efficiency • Modular line according to the pasta shapes CONS • Not available for lasagna and cannelloni • Volumetric dosing unit: minimal damage of cooked products SEMI-AUTOMATIC ROTARY LASAGNA LINE CAPACITY: 600 - 1200 TRAYS/HR 1 - Discontinuous press with two basins 2 - Calibration units for longitudinal incision of sheeted pasta 3 - Continuous sheet cooker 4 - Sheet rinsing and cooling 5 - Crosswise sheet cutter 6 - Sauce storage tanks 7 - Sauce dispensers 8 - Rotary system with manual depositing of lasagne in the tray A - Application of the shaping, filling and cutting unit for producing precooked stuffed cannelloni SEMI-AUTOMATIC LASAGNA PRODUCTION LINE – CAPACITY: 2.400 TRAYS/HR 1 - Premix* dosing and pre-mixing system 2 - Beltmix* mixing system 3 - Automatic vacuum dough sheeter type STF- Total Vacuum 4 - Calibration units for longitudinal incision of sheeted pasta 5 - Continuous sheet cooker 6 - Sheet rinsing and cooling 7 - Crosswise sheet cutter 8 - Deyail of cannelloni shaper with stuffing supply pump 9 - Lasagna conveyor belt 10 - Sauce storage tanks 11 - Sauce dispensers 12 - Operators for manual deposit of lasagna in the trays 13 - Tray Closers A - Option involving the application of the unit for shaping. Filling and cutting the filled pre-cooked cannelloni B - Option involving the “rotary” type line installation (1 200 rays/hour) C - Freezing option D - Double pasteurization option AUTOMATED LASAGNA PRODUCTION LINE 1 - Premix* dosing and pre-mixing system 2 - Beltmix* mixing system 3 - Automatic vacuum dough sheeter type STF-Total Vacuum 4 - Calibration units longitudinal incision of sheeted pasta 5 - Continuous sheet cooker 6 - Sheet rinsing and cooling 7 - Crosswise sheet cutter 8 - Detail of cannelloni shaper with stuffing supply pump 9 - Lasagna conveyor belt 10 - Sauce storage tanks 11 - Sauce dispensers 12 - Robotized system for manual deposit of lasagna in the trays 13 - Tray closers 14 - Metal detector A - Cooling or freezing spiral option B - Double pasteurization option Advantages of automation: • Increase in the hourly capacity • Reduce the cost of labor for assembly trays • Elimination of manual contact with health benefits for the LOOKING IN TO THE CONSUMPTION IN THE FUTURE - Consumers increasingly looking to cook / prepare gourmet meals at home - New exclusive data from our newest product: Analyst pulse survey - Exciting new tool surveys our 800+ analyst pool in over 80 countries - 55% still cook meals entirely from raw ingredients on a regular basis
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