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Raw Material
Noodles can be made from wheat flour alone or in
combination with buckwheat flour. Wheat flour noodles
include Chinese and Japanese type noodles. There are many
varieties in each noodle type, representing different
formulation, processing and noodle quality characteristics.
Noodles containing buckwheat are also called soba, meaning
buckwheat noodle. These noodles are typically light brown or
gray in color with a unique taste and flavor. Chinese type
noodles are generally made from hard wheat flours,
characterized by bright creamy white or bright yellow color
and firm texture. Japanese noodles are typically made from
soft wheat flour of medium protein (discussed later). It is
desirable to have a creamy white color and a soft and elastic
texture in Japanese noodles.
2. Quality Requirements
In many cases, physical quality measurements of
wheat and wheat test methods are similar and
independent of end products made. For example,
wheat should be clean and sound, high in test weight,
and uniform in kernel size and hardness. These
characteristics result in efficient milling and high flour
extraction, and, possibly, optimum quality end
products. The US Federal Grain Inspection Service
grades a wheat according to the test weight, defects,
wheat of other classes present and other
contamination. The Falling Number test is done to
determine wheat sprout damage level. Wheat kernel
hardness, diameter, weight and their distribution can
be measured using a Single Kernel Characterization
System. Wheat kernel hardness deserves particular
attention since it affects the tempering conditions,
flour starch damage level, flour particle distribution
and milling yield. Damaged starch not only absorbs
more water but may also reduce noodle cooking and
eating quality. Accordingly, noodle wheat should not
be too hard, and milling processes should be
controlled to avoid excess starch damage. The
uniformity of wheat kernel hardness appeared to
improve milling performance (2). Low ash content in
flour is always an advantage
for noodles since flour ash is traditionally viewed as
causing noodle discoloration. One of the important
noodle flour specifications is ash content, although
there is no guarantee that low ash flour can always
make desirable color noodles. The presence of the
enzyme polyphenol oxidase (PPO) in the flour is
believed to be partially responsible for noodle
darkening. Thus, it may be useful to measure the
activity of this enzyme in the wheat. Wheat protein
content is often determined, and gluten strength can
be evaluated by a sedimentation test. Different noodle
types require different protein contents and dough
strength (discussed later). Generally speaking,
Chinese type noodles need hard wheat of high protein
content and strong gluten, and Japanese noodles
require soft wheat of medium protein content.
3. Salt Used
Based on the absence or presence of alkaline salt in the
formula, noodles can be classified as white (containing salt)
noodles or yellow (containing alkaline salt) noodles. Alkali
gives noodles their characteristic yellowness. White salt
noodles comprise Japanese noodles, Chinese raw noodles or
dry noodles. Chinese wet noodles, hokkien noodles,
Cantonese noodles, chuka-men, Thai bamee, and instant
noodles fall under the yellow alkaline noodle category.
4. Size
According to the width of the noodle strands, Japanese
noodles are classified into four types.
(Table I).
Name Characteristics
1. YFM-serial
YFM-serial is the frying instant noodle production
line. The instant noodles will be ready to serve simply
by soaking in hot water for 3-5 minutes. The dry
instant noodles can also be consumed as snack.
Process name: 1. Flour conveying => 2. Mixing ingredient => 3. Aging => 4.
Compound rolling => 5. Slitting and ripple forming => 6. Steaming => 7.
First cooling => 8. Cutting fold => 9. Frying => 10. Arranging => 11. Cooling
=> 12. Inspecting conveying => 13. Final Product
Background
In one recently-completed project, Kemin looked at replacing
200ppm synthetic TBHQ (tert-butylhydroquinone) in frying oil
(RBD palm olein) with natural, proprietary, rosemary extract
(Kemin's Fortium brand). During the study, the quality of the
frying oils was evaluated pre- and post-frying through an
analysis of decomposition materials—polar compound and
peroxide values, alkenals, and free fatty acids.
Shelf-life studies of the instant noodles were carried out at two
storage temperatures: In ambient conditions (25°C), and in the
oven (45°C). Accelerated tests were done on noodle samples
that were kept at ambient temperature—using the Oxygen
Bomb Test and Oxidative Stability Instrument—on a regular
basis throughout the shelf-life studies.
Test results
As expected, noodles without any antioxidant treatment were
the least stable. Over the months, oxidative stability of the
noodles dropped, which was most obvious after nine months
of storage at room temperature. In comparison, oxidative
deterioration of instant noodles fried in oil with 200ppm TBHQ
was the least, compared to other antioxidant treatments and
the control. The most effective natural antioxidant was
reportedly rosemary extract. After 39 weeks of storage at
ambient temperature, the PV of the control noodles exceeded
10 milliEquivalent/kilogram, rendering the noodles unfit for
human consumption. By week 12 at storage temperature of
45°C, the PV of the 200 ppm TBHQ and natural-rosemary
extract noodles were still below 10 milliEquivalent/kilogram.
Findings
Natural-rosemary extract was able to replace TBHQ without
sacrificing quality. With no legal use limitations, the inclusion
rate of natural antioxidants can be increased to improve the
stability and shelf-life of instant noodles—beyond what can be
achieved with only 200 ppm TBHQ.
Health/cost benefits
Consumer awareness and growth in the premium-food market
has contributed to the use of more expensive natural
antioxidants. Still, synthetic food antioxidants are holding onto
market share owing to the fact that they are by far lower-cost
products. Usually, a manufacturer's first reaction is resistance.
S/he may believe that switching to a natural antioxidant is an
option too expensive to even consider. However, if one looks
closely, cost at the retail level is negligible. By deciding to go
the ‘natural’ route with instant noodles, marketing and sales
departments need to be more actively involved in delivering
the premium image of their product to market. What is an
additional cost of less than 1 cent per cake, in comparison to a
company’s opportunity to take the lead in the market with a
clean label?