Fried Instant Noodle Production Line - Bag - Folded
Folded / Bag / Fried Instant Noodle Processing Equipment Solution
The fired instant noodle is the most common style for noodles on the market, due to the lower cost for the wrapping materials and wrapping equipment used in the bag noodle production line, and the small size of bag noodle which is easy for stacking in storage and shipping. The bag noodles get easily in to the consumer market with low price and become standard home-base food. Folded Noodles are produced by the Cutting and Folding Machine. The noodles are cut into sections with fixed length, at the same time get folded in half and turn into noodle blocks, with the shape of square or rectangle.
In the flour mixing process, it is optional to use batch type mixing or continuous mixing. The Batch Type Flour Mixer consists of two mixers with patented design which take turns to make dough batches, maximum 500 ~ 650kg per batch, includes auto-mixing procedure, multi-step mixing, and variable speed setting, and offers high quality mixing with SGS verified test results. Alternatively, the Continuous Flour Mixer takes a step further to produce dough continuously with a fully automatic system, and replace the manual activating of mixing and discharging, to reduces the manpower and product discrepancy. And the Continuous Flour Mixer is also adaptable for automatic feeing of multiple recipe ingredients by combing with additional screw conveyors.
In term of frying, the Continuous Fryer used in CCK Fried Instant Noodle Production Line has gone through several major improvements which reduce the oil content in the noodle product, reduce leakage of oil fumes, and provide customization for multi-stage fryer-frame lifting which offers more access for cleaning and maintenance.
Fried Instant Noodle Production Line (Bag) Folded - Equipment Layout
- Capacity: Up to 720 packs per minute, product weight 70g. (* The actual capacity varies depends on the product weight requirement.)
- Easy Operation: Automatic control system with PLC and HMI interface offers immediate access to the production status, parameter setting, failure diagnosis, trouble shooting and remote monitoring.
- Safe: Safety devices and system, and safety guards to ensure the safety for operation.
- Hygiene: All area that has direct contact with food product is made of stainless steel or food grade materials. With structure design to reduce dead corners and provides cleaning access such as cleaning doors or detachable doors.
- Energy Saving: In every aspect of design, energy saving and reduction on material waste is considered carefully, such as the smooth transfer between each process, less residue at the dough discharging in the Flour Mixer, less steam leakage for the Multi-Stage Steamer, etc.
- Sustainable: We select reliable parts and materials of good quality, and strive for accuracy and precision during manufacturing and machine assembly. Trials and tests are carried out before dispatching to ensure the equipment can last for many years.
- After-Sale Service: For each production line equipment, we offer guidance on installation, line commissioning, and operation training, with provision of operation manual and relative documentation.
|Flour Supply||Flour storage tank → Temporary flour tank (by using vacuum suction, or compressed air blow)|
|Alkaline Solution Supply||Alkaline Solution Mixing Tank blends the solution powder with water → Alkaline Solution Storage Tank (only for Continuous Mixing) or Alkaline Solution Weighing Tank (only for Batch Type Mixing)|
|Mixing||● Continuous: High Speed Rotary Mixer → Kneader|
● Batch Type: press button to start the Batch Mixer → multi-step mixing → press button to discharge the dough.
|Dough Conv.||Aging → Delumper breaks big lumps.|
|Dough Sheet Forming||Dough is transformed into dough sheet with 1 ~ 2 Rollers, the subsequent rollers gradually make the dough sheet thinner and stronger.|
|Continuous Pressing||Continuous pressing by multiple Rollers → slitting → waving → lane separating.|
|Steaming||The noodles are cooked with saturated steam in the Multi-stage Steamer.|
|Cutting and Folding||The noodles are cut into fixed length and folded in half. (* Options: Seasoning Conveyor can be added with showering, spraying or submerging system for seasoning.)|
|Frying||Noodles enter the baskets → deep fried and dehydrated → high pressure Air Knife removes the excess oil.|
|Cooling||Bar Conveyor organizes the noodle blocks → Blowers with filters draw air into the Cooler → noodle cooling.|
|Orderly||The Orderly Conveyor reduces the number of noodle lanes into 2 ~ 4 lanes, to match the number of packaging lines.|
|Wrapping||Wrapping with seasoning sachets → wrapping into big bags → casing → box stacking on the pallet (manual or with robot hand) → pallet wrapping → warehouse. (* Options: metal detecting or weight checker)|
|* The actual production parameters, such as product weight, size, steaming time, frying or drying time and temperature, etc. are provided by the customer and act as the basis for the production line planning.|
- Related Products
The flour handling and dosing system for instant noodle processing line usually includes flour sieving machine, vacuum blower (vacuum pump), air-lock or rotary valve, dust collector, screw conveyor, and the flour storage tank or silo. The main function is to transfer the wheat flour from the flour storage tank or silo to the temporary flour tank above the Mixer on the instant noodle processing line.Generally, there are several flour-transferring methods for the flour dosing system, including vacuum suction, compressed air blow, and screw conveyor. Among them, due to the totally enclosed structure, the vacuum system and compressed air system are adaptable for long distant transfer. It can avoid contamination of foreign bodies or residue inside the pipes, and the systems are also easy to operate. On the other hand, the screw conveyor has simple structure which is easy for maintenance, low energy consumption, but with a down side for its residue and cleaning difficulties. Therefore, the screw conveyor is mostly used in flour transfer for short distance.The common procedures for the flour handing and dosing system of one instant noodle processing line are as the followings. ● Flour storage tank → Manually pouring flour into the sieving machine → Temporary flour tank → Mixer. ● Flour storage tank → Manually pouring flour into the sieving machine → Mixer. ● Flour storage tank → Temporary flour tank → Mixer. ● Flour storage tank → Mixer.
The function for Alkaline Solution Mixing Tank is to mix salt, sodium carbonate (soda ash), or other soluble ingredients with water, and blend well until the powder solution is completed dissolved. The alkaline solution is prepared beforehand for the dough making in the Flour Mixing Machine.
Alkaline Solution Weighing Tank is only used in the Batch Type Flour Mixing System. The main function is to provide the Flour Mixing Machine with fixed amount of alkaline solution for every batch.
The Batch Type Flour Mixer consists of two sets of Horizontal Twin Shaft Plough Shear Mixer, and is proven to achieve high quality mixing with SGS certified test results. Maximum capacity reaches up to 500~650kg per batch, with 28~30 % water content. Safety devices with interlock system are provided for operational safety. Cylindrical inner shell design with precision welding and surface polishing reduces dough residues and is easy for cleaning. During production, the two Mixers take turns to produce dough batches and each batch takes around 20 minutes. The mixing procedure is fully automatic with multi-step mixing cycle and variable speed setting. While the Mixer body is jacketed, customization is also available for heating jacket, cooling jacket or no jacket. Exhaust vents are provided for moisture release, and extra manual dosing holes can be added upon request.With the patented design of twin shafts with plough choppers, the dough inside the Mixer is agitated up and down and also circulate gradually left and right. This allows the alkaline solution to reach every corner within the mixing tank and be evenly distributed. The trial test for mixing performance has been carried out in our factory. Random samples were taken and sent for analyzation in the SGS organization, to obtain the data of the moisture and salt. The report has proven that after mixing the moisture content reaches uniformity all over the whole dough batch, and shown a very satisfying mixing result.
The Continuous Flour Mixer consists of one High Speed Rotary Mixer and one Twin Shaft Plough Shear Kneader. Once the mixing is activated, the dough batch is produced continuously without stopping. It does not require the repetition of manual activating the mixing and discharging. This reduces manpower and product discrepancy. With high rotary speed and centrifugation, the High Speed Rotary Mixer rapidly blends the alkaline solution with flour, and the uniform mixing is achieved in extreme short time. The mixing performance excels even the traditional Batch Type Flour Mixer. The Kneader provides further process of aging and kneading, with very similar design as the Batch Type Flour Mixer, and has all the same advantages such as the patented design of twin shafts with plough choppers, safety devices with interlock system, hygienic design for easy cleaning, and jacketed tank body. The Continuous Flour Mixer is also adaptable for automatic feeing of multiple recipe ingredients by combing with additional screw conveyors.
The main components for the Dough Conveyor is a belt conveyor and the Delumper shaft. The completed dough after mixing falls on the belt and rests while being shifted towards slowly the outlet. At the end of the belt conveyor, the Delumper shaft breaks the bigger lumps and the dough falls down into the Sheet Forming Machine.
The standard Dough Sheet Forming Machine consists of three sets of rollers. From the Dough Conveyor, the dough falls down and enters into Roller No.1 and Roller No. 2 at the same time. With help from the Dough Pusher Plate, two dough sheets are formed, overlay on the belt conveyor and enter into Roller No. 3 to be combined into one single sheet. There is another way of Dough Sheet Forming which uses only one single set of roller to transform the dough into dough sheet, and the subsequent rollers gradually make the dough sheet thinner and stronger.
The standard Continuous Dough Sheet Pressing Roller consists of 6 ~ 7 sets of rollers, the Slitter (Shredder) and the Waving Conveyor at the outlet. After being pressed and stretched continuously, the gluten in the dough becomes strong and the thickness of dough sheet gradually reduces with uniformity. Finally, the dough sheet is slit (shredded), becomes continuous noodle strings with waves and is divided into several lanes.
The standard type of Multi-Stage Noodle Steamer has 3 stages. Customization for 5-Stage Steamer is also available. The main components of the Steamer are the Outer Mesh Conveyor, Inner Mesh Conveyor, Steamer Chamber, and Exhaust Hoods at the inlet and the outlet. From the Waving Conveyor, the continuous wavy noodles are transferred onto the Steamer Mesh Conveyor, enters the Steamer Chamber, and are cooked with saturated steam. Each stage has one thermometer for monitoring the heating condition. Individual steam supply is available for every stage to optimize the steaming efficiency. The Steamer Chamber is equipped with heat insulation to reduce the heat lost for energy saving.
The Cutting and Folding Machine is only used in Bag Type Processing Lines. The main components are cooling blowers, one rotary shear cutter assembly, and folding mechanism. Firstly, the fan blowers cool down the steamed noodles and remove the surface moisture. Then the noodles enter the cutting blade and are cut into sections with fixed length, at the same time get folded in half and turn into noodle blocks. The shape of noodle blocks can be square or rectangle, and is suitable for bag noodle packaging. The folding mechanism of Cutting and Folding Machine manufactured by CCK has gone through several major improvements which reduce the issues for noodles sticking and irregular folding. The noodle blocks appear better in shape with less size variation, and produce less noodle chipping waste.
The Wet Noodle Conveyor is only used in Folded Noodle Processing Line. The main function is to give extra taste and flavor to the noodle blocks, by using different methods like showering, spraying or dipping. The mesh trays of stainless steel carry the noodle blocks through the seasoning area. Seasoning Storage Tank and pump is below the conveyor. At the outlet, the Blower Air Knife removes excess liquid from the noodle blocks.
The major components of Continuous Noodle Fryer are one basket conveyor, one hold-down plate (basket cover) conveyor, a frying pan, exhausts hoods with oil vapor cyclone separator, oil strainer, cooking oil circulation and heating system, and fryer-frame lift mechanism. The noodle blocks sit in the basket and enter into the frying pan to be deep-fried and dehydrated in high temperature. The Blower Air Knives at the outlet removes the excess oil from the noodles. For the oil circulation and heating, the cooling oil is pumped from the frying pan through the oil strainer to filter out noodle chips, and sent to the Heat Exchanger. Then the heated oil flows back to the frying pan.The Continuous Noodle Fryer manufactured by CCK has gone through several major improvements which reduce the oil content in the noodle product, reduce the leakage of oil fumes, and provide customization for multi-stage fryer-frame lifting which offers more access for cleaning and maintenance.
The Strainer is a standard component for the Continuous Noodle Fryer. The noodle chips are filtered through the mesh conveyor, and brought out to a collecting tray during continuous production. This helps to reduce the accumulated noodle chips inside the frying pan, and maintain the quality of cooking oil.
The Conveyor Cooler consist of one Bar Conveyor, one Cooling Conveyor with pushing rods, the cooling chamber, Blowers and Exhaust Blower(s). The Bar Conveyor organizes and transfers the noodle blocks into the Conveyor Cooler. The Blowers are fitted with filters and draws air into the cooling chamber to cool down the fried noodle blocks. The hot air is exhausted through the Exhaust Blower(s) on the top of Conveyor Cooler. The center of the fried noodle blocks after frying may usually reach over 100°C. After cooling, the noodle temperature drops down to 36°C, and then are transferred to the next processing stations for packaging and storage.
The Orderly Conveyor is only used in Bag Noodle Processing Lines. The major components are one belt conveyor and guiding frames. The Orderly Conveyor reduces the number of noodle lanes into 2 ~ 4 lanes, according to the requirement of the processing line layout.
After the Conveyor Cooler in one bag type instant noodle production line, there are 2 ~ 4 sets of bag noodle wrapping machines, planned according to the requirement of production line capacity. The procedure for bag noodle packaging system may vary from case to case, but usually includes top chain conveyors, belt conveyors, sachet dispensers, pillow wrappers, case packing, box stacking and pallet packing. With lower cost for equipment and packing materials, and the convenience for storage and shipping with the small product size, the bag noodle packaging system offers the most economical solution for instant noodle packaging.In terms of manufacturing for the bag noodle packaging system, we co-operate with packaging suppliers. We will recommend reliable brands to the customer who may directly consult and make order from the packaging equipment supplier. The required quantity for packing machine and the requirement for machine coordination will be provided during the layout planning for the processing line.
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