إنتاج المعكرونة الفورية المقلية على نطاق صغير: مراحل المعالجة الرئيسية
The production of fried instant noodles on a small or artisanal scale involves a carefully controlled sequence of steps designed to create a product with long shelf-life, quick rehydration, and desirable texture. instant noodle machine korea Unlike large-scale fully automated lines, small-scale operations often combine manual skill with essential machinery. Here are the core processing stages.
1. Dough Mixing and Kneading
This foundational stage determines the noodle’s basic structure. High-protein wheat flour is fed into a mixer.instant noodle machine korea A brine solution containing salt, alkaline agents (kan sui), and sometimes phosphate is added in precise proportions. The alkaline salts are crucial as they strengthen gluten, give noodles their characteristic yellow color, and a firm, springy texture. The mixture is kneaded into a cohesive, crumbly dough crumb, ensuring even hydration without over-developing the gluten, which would make sheeting difficult.
2. Dough Sheeting and Compound Lamination
The crumbly dough is passed through a series of paired sheeting rollers. Initially, it forms a thick, ragged sheet. This sheet is folded and passed through the rollers repeatedly—a process called laminating. This sequential rolling and folding aligns the gluten network into uniform sheets, eliminates air pockets, and creates the layered structure essential for the noodles’ final bite. With each pass, the roller gap is reduced, gradually thinning the dough to the desired final thickness (usually about 1-1.2 mm).
3. Noodle Slitting and Waving
The continuous, thin dough sheet is then guided through a slitter, a roller fitted with cutting blades that slit it into numerous fine, parallel strands. instant noodle machine korea These straight strands immediately enter a waving conveyor. Here, a pair of patterned, low-speed rollers gently fold the noodles back and forth into the distinctive wavy block. The waving creates looser packing, which is critical for efficient subsequent steaming and frying. The noodles are cut to length and drop into perforated molding trays.
4. Steaming
The noodle blocks on trays are conveyed through a steaming tunnel. Exposure to saturated steam at around 100°C for 1-2 minutes partially cooks (gelatinizes) the starch on the noodle’s surface and within. This process sets the noodle’s basic shape, reduces oil absorption during frying, and prepares the starch for rapid rehydration later. Proper gelatinization is vital; under-steaming leads to poor texture, while over-steaming makes noodles sticky.
5. Deep-Fat Frying
This is the definitive step for creating fried instant noodles. The steamed noodle blocks are automatically released into a continuous fryer filled with hot oil (typically palm oil at 140-160°C). The frying process achieves several goals simultaneously:
- Moisture Removal: It rapidly reduces the water content from ~35% to 3-6%, creating a porous, dry structure.
- Pore Formation: The vaporizing water creates a fine network of microscopic pores and tunnels throughout the noodle block.
- Texture & Flavor Development: The starch and proteins undergo Maillard browning reactions, developing color, a characteristic fried aroma, and a crisp texture.
- Shelf-Life Extension: The low final moisture content and the coating of oil inhibit microbial growth and staling.
6. Cooling and Packaging
The hot, oily noodles are conveyed out of the fryer onto a cooling conveyor, where ambient or forced air reduces their temperature to near-ambient. instant noodle machine korea This prevents condensation in the final package, which would lead to sogginess and spoilage. The cooled blocks are then paired with separate flavoring packets (containing powdered soup base, dehydrated vegetables, etc.) and packaged in airtight, moisture-proof bags or cups. Nitrogen flushing is often used to displace oxygen, further extending shelf life and preventing rancidity.
Key Consideration for Small Scale: The efficiency and consistency of a small-scale line hinge on precise control at each stage—especially dough moisture, steaming time, and frying temperature/time.instant noodle machine korea This process transforms simple ingredients into a convenient, shelf-stable staple with a unique texture defined by its frying process.
