Raw materials

Noodles are 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 noodles or pasta plants.

Eggs are sometimes added to the mixture for color or richness. Guidelines stipulate that egg noodles contain a minimum of 5.5% egg solids.

The semolina is stored in giant silos. 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.

Eggs are added to the mixture if the product is an egg noodle. Flavor (and for instance premix of mineral and vitamin for WFP noodles) are added here. Herbs and spices can also be folded in for additional flavoring.

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%.

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

• 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. The size and shape of the holes in the die determine the type of pasta.
• To make vermicelli (or noodles), the pasta dough is pushed through holes between 0.8-0.5 mm in diameter. The cutting machine then cuts the pasta into desired lengths and twists it into curls. Spaghetti ranges from 1.5-2.5 mm in diameter and is left straight.

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. 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.

• Dried pasta is loaded, either manually or by machine, into stainless steel buckets (usually of heavy gauge type) 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. 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 3 m. Workers at the floor-level stations monitor the packaging process. The mechanism allows for workers to package the pasta manually if necessary.