Instant Noodles Production
Instant noodles production is capital intensive and moderately challenging. It involves the use of different ingredients, automated/semi-automated machinery and effective marketing strategy. Others considerations are license, health safety issues, tax, factory location, labor and funding.
About Instant Noodles
Instant noodles are dried block form noodles cooked with seasoning. They are eaten raw, soaked in boiling water or cooked for 3 -5 minutes. The product originated in Japan found in regions of Southeast Asia and now common worldwide.
Noodles has low protein, minerals, vitamins, fiber but high in fat and carbohydrates. Top consumers of noodles are China, Indonesia, india, japan, Vietnam, united states. Others are Philippines, South Korea Thailand, Brazil, Russia and Nigeria.
- United states
- South Korea
Location, labor, license
Make sure the location has working utilities like water, electricity, good road network. Hire skilled labor in noodles production to handle the machinery. Register a business name and incorporate a limited liability company.
Next obtain trade license apply for value added tax. Apply for FSSAI license, BIS certification register a trademark. Comply with PFA Act /GMP get ISO 9001 certification, health safety protocols for food handling.
Instant Noodles Ingredients
Common ingredients in instant noodles is dry pre-cooked noodles, starch, salt, water. More are flour, oil starches, kansui, Hydrocolloids, polyphosphates. Guar gum is a hydrocolloid used to enhance water binding property in noodles and reduces cooking time.
While polyphosphates are additives used to improve starch gelatin. Potato starch is the most common ingredient because of enhanced chewiness, elasticity, water-holding property.
Oil fried noodles have less than 20% fat content and frying a common dehydration process. Kansui (9/1 sodium carbonate/potassium carbonate) is added to flour. Kansui aids gluten in noodles and contributes to chewiness.
Salt is added to flour dough during the preparation for better flavor, softer products while 30% water hydrates the dough for better gluten structure. The type of flour depends on the manufacturer’s preference. Different flour choices are buckwheat flour, wheat flour or rice flour.
Dry pre-cooked noodles
- potato starch
- Guar gum
Manufacturing Process of Instant Noodles
Manufacturing process of Instant Noodles starts with the mixer then the compound machine. It then goes through rollers, slitter and steam treatment.
They proceed to dipping bath, feeder, flash fryer and cooler. Final stages are weight checker with metal detector then feeder of continuous bags, weight checker and caser.
Instant Noodles Production Machinery
Medium /large noodles factories invest in line production machinery. Equipment are mixer, compound machine, rollers, slitter, and steamer.
Others include dipping bath, feeder, flash fryer, cooler, weight checker with metal detector. More equipment are feeder of continuous bags, weight checker and caser.
- Compound machine
- Dipping bath
- Flash fryer
- Weight checker with metal detector
- Feeder of continuous bags
- Weight checker and caser
Instant Noodles Production Process
Instant noodles is produced in different sizes flavor or taste. To eat them they only need re-hydration in boiling water for 3-4 minutes. The production process involves dry mixing then dough formation. Next is extrusion, sheeting, rolling or batter cooking method. Then pre-drying and drying stage before packaging.
Dissolve starch, flavoring, salt in water then mix in flour. Leave dough to mature. Knead the dough and place sheet through rotation rollers several times to create stringy texture noodles. To create the distinct wavy shape they are passed through slow-paced conveyor rollers. Once shaped they are steam for 5 minutes at 100C.
Next step is drying through either hot air drying method or frying. Dry heat method at 150C while common frying oil in the frying method is palm oil, cottonseed oil or canola oil. Oil content in the frying method is 20% which decreases shelf life of the noodles.
After drying the noodles are cooled with proper quality control of water content and shape. Small sachets of seasoning are placed in the packaged noodles.
The industry is very competitive therefore develop an effective marketing. Target marketing includes product branding, promotions and giveaways. Advertise on radio, television, online and print. Use billboards, flyers, posters, banners, signboards, business cards.