Pasta Background

Pasta is a universally enjoyed food, and almost every country serves a type of noodle.
In China, it is mein; Japan, udon; Poland, pierogi; Germany, spaetzle. The popularity of
pasta can be attributed to several factors: it is easily manufactured, it takes up little
storage space, it is easy to cook, and it is rich in complex carbohydrates.
Ancient Etruscan meals of gruel and porridge were eventually replaced with more
appetizing unleavened bread cakes. Food historians believe these cakes may have been
the precursor to pasta. Opinions about where the noodle originated vary. The Italian
explorer Marco Polo has been commonly credited with bringing the noodle back to Italy
from his travels in the Orient during the 1300s. However, some contend that a close
examination of Polo's papers reveals that he reported enjoying a certain type of noodle
in China, comparing it favorably to the pasta he was accustomed to eating in Italy.
Nevertheless, it is true that Chinese noodles have been around for centuries.
The vermicelli-like transparent noodles are made from the paste of germinated mung
beans and are usually soaked in water before they are boiled or fried. (Pasta has not
always been prepared by boiling. In fact, boiled noodles were once considered a
relatively bland meal. Frying or grilling were the preferred preparations.) Koreans claim
to have taught the Japanese how to make soba noodles in the 12th century, using
Chinese buckwheat grown in the northern regions where rice paddies could not
survive.
Early French writers also mention a dish called pastillum, essentially a ravioli-like pouch
filled with meat. However, the Italians have staked the claim so vehemently that today
we generally think of pasta dishes as Italian in origin. In fact, the word "pasta" comes
from the Italian phrase "paste (dough) alimentari (relating to nourishment)."
The first industrial production of pasta occurred in Naples in the early 15th century. The
site was chosen for its naturally fluctuating temperatures, sometimes as much as four
times a day, which provided the hot and cold temperatures necessary for drying.
Mechanical drying was not invented until 1800.

Raw Materials
Pasta is made from a mixture of water and semolina flour. Semolina is a coarse-ground
flour from the heart, or endosperm, of durum wheat, an amber-colored high protein
hard wheat that is grown specifically for the manufacture of pasta. With a lower starch
content and a higher protein content than all-purpose flours, semolina flour is easily
digested. Farina, rougher granulations of other high-quality hard wheat, is also used to
make some pastas. The semolina and farina flour are enriched with B-vitamins and iron
before they are shipped to pasta plants.
Eggs are sometimes added to the mixture for color or richness. Federal guidelines
stipulate that egg noodles contain a minimum of 5.5% egg solids. Vegetable juices, such
as spinach, beet, tomato, and carrot, can also be added for color and taste. In recent
years, the addition of herbs and spices such as garlic, basil, and thyme has become
popular.

The Manufacturing
Process

Mixing and kneading

 1 The semolina is stored in giant silos that can hold up to 150,000 pounds (68,100
kg). Pipes move the flour to a mixing machine equipped with rotating blades.
Warm water is also piped into the mixing machine. The mixture is kneaded to a
lumpy consistency.

Flavoring and coloring

 2 Eggs are added to the mixture if the product is an egg noodle. If pasta is to be
a flavored variety, vegetable juices are added here. A tomato or beet mixture is
added for red pasta, spinach for green pasta, carrots for orange pasta. Herbs and
spices can also be folded in for additional flavoring.

Rolling

 3 The mixture moves to a laminator where it is pressed into sheets by large

cylinders. A vacuum mixer-machine further flattens the dough while pressing air
bubbles and excess water from the dough to reach the optimum water content
of 12%.

Pasteurization

 4 The roll of dough moves through a steamer, which heats the dough to 220°F
(104°C) in order to kill any existing bacteria.

Cutting

 5 Depending on the type of noodle to be produced, the dough is either cut or

pushed through dies. Ribbon and string-style pasta—such as fettucine, linguine,
spaghetti, and capellini (angel hair)—are cut by rotating blades. To make tube or
shell-shaped pasta such as rigatoni, ziti, elbow

macaroni, and fusilli, the dough is fed into an extruder which then pushes it
through metal dies. The size and shape of the holes in the die determine the type
of pasta.

To make vermicelli and capellini, the pasta dough is pushed through holes
between 0.8-0.5 mm in diameter. The cutting machine then cuts the pasta into
 lengths of 10 inches (250 mm) and twists it into curls. Spaghetti ranges from 1.5-
2.5 mm in diameter and is left straight.
Tortellini (filled pasta rings) are made on a separate machine. The machine cuts
small circles from a roll of dough. A bucket of ricotta cheese mixture drops a pre-
measured amount of cheese onto the circle of dough. The dough is then folded
over and the two ends are joined to form a circle.
To make ravioli (filled pasta squares), premeasured quantities of cheese filling
are dropped by machine at pre-measured intervals on a sheet of pasta. Another
sheet of pasta is placed over this sheet as it moves along a conveyer belt. The
two layers then pass under a cutting machine that perforates the pasta into pre-
measured squares.

Drying

 6 The pasta is placed in a drying tank in which heat, moisture, and drying time
are strictly regulated. The drying period differs for the various types of pasta. It
can range from three hours for elbow macaroni and egg noodles to as much as
12 hours for spaghetti. The drying time is critical because if the pasta is dried too
quickly it will break and if it is dried too slowly, the chance for spoilage increases.
The oxygen level in the tank is also regulated, and lab technicians test frequently
for salmonella and other bacteria.

Careful handling of the pasta during the drying period is also crucial. Spaghetti is
the most fragile of the noodles and is therefore hung high above the floor.

Packaging

 7 Fresh pasta is folded in pre-measured amounts into clear plastic containers. As

the containers move along a conveyer belt, a plastic sheet covers each container
and is sealed with a hot press. At the same time, a small tube sucks the air of the
container and replaces it with a mixture of carbon dioxide and nitrogen to
prolong the product's shelf-life. Labels listing the type of noodle, nutritional
information, cooking instructions, and expiration date are attached to the top of
the containers.

Dried pasta is loaded, either manually or by machine, into stainless steel buckets
(usually of heavy gauge type 304) which move along a conveyer belt to the
appropriate packaging station. The pasta is measured by machine into pre-
printed boxes, which also list the type of noodle, ingredients, preparation, and
expiration date. Again, careful handling is important. For example, because
lasagna noodles are particularly fragile, workers place them on metal slides that
ease the pasta into boxes. The boxes are then sealed by machine.
 Conveying system can be constructed in "S," "C," or "Z" configurations, or as
horizontal conveyer belts. These systems move the pasta up and down and
across the plant at heights up to 10 feet (3 m). Workers at the floor-level stations
monitor the packaging process. The mechanism allows for workers to package
the pasta manually if necessary.

Quality Control
The manufacturing of pasta is subject to strict federal regulations for food production.
Federal inspectors schedule regular visits to insure that the company is adhering to
goverrnment laws. In addition, each company sets its own standards for quality, some
of which are set in practice before the pasta reaches the plant. Lab technicians test the
semolina flour for color, texture, and purity before it is removed from rail cars. Protein
and moisture content are measured and monitored on sophisticated quality control
computer software.
In the plant, technicians constantly test the pasta for elasticity, texture, taste, and
tolerance to overcooking. Plant workers are required to wear haimets and plastic
gloves. Mixing machines are scrupulously cleaned after each batch of pasta passes
through them. The drying process is strictly monitored to guard against spoilage.

The Future
Pasta continues to increase in popularity. The National Pasta Foods Association
estimates that the average American will eat more than 29 pounds (13 kg) of pasta each
year by the turn of the century. Highly rated for its nutritional value, pasta is an ideal
meal for people who are paying more attention to their dietary intake. In addition,
people are finding less time to prepare meals, and pasta is easily made.
Pasta manufacturers are responding to this demand by introducing a wide variety of
dried and fresh pastas. One recent innovation is no-boil pasta that is partially cooked
at the plant, making this already easy-to-prepare food even simpler to bring to the table
at mealtime. New lines of fat- and cholesterol-free ravioli are on the market as well as
organically-grown pasta products. Two new grains, South American quinoa and
Egyptian kamut, are being used to make wheat-free pasta.