Couscous Instant pasta. Trend to perfection.

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1 Couscous Instant pasta. Trend to perfection.

2 Uniform, productive, fully automatic. Couscous tradition paired with innovation. Outstanding appearance loose, round, and free-flowing Attractive, round dough granules that flow freely, are crispy and yet soft in the mouth simply perfect! The tiny dough granules whether produced in the traditional manner by hand or on high-tech Buhler production lines are made using water, durum semolina, and steam. Buhler experts are not only masters in the production of couscous, but also capable of making exquisite pasta from the same raw material durum semolina. And for both traditional dishes, it is the color, taste, and correct bite of the end products that fill consumers with enthusiasm. Process reliability constant and productive Traditional raw materials are transformed through a fully automatically controlled process into top end products. To obtain gluten-free granules, it is indispensable to ensure that an entirely enclosed protein envelope surrounds the gelatinized starch. This enables the optimally gelatinized starch to swell, resulting in an easy-to-prepare instant product. Correct steam-conditioning and gentle drying guarantee that the protein envelope remains intact throughout the process and prevent sticky starch from escaping to the outside. The drum sieve separates the trop fin granules, which are then forwarded onto a continuous belt scale. The separated product characteristics are registered electronically and the water quantity is adjusted automatically. As a result, the agglomeration parameters remain stable thereby ensuring constant line capacity. The result is a free-flowing product obtained from a fine-tuned, energy-saving process. Old craft high-tech solutions Buhler combines over 100 years of experience in pastaproduction with cutting-edge research and laboratory analysis. Couscous produced on Buhler systems readily bears comparison with any traditionally made couscous. But instead of diligent, skillful hands, it is the patented Buhler agglomeration process that produces perfectly shaped granules. As with the home-made product, cooking is done using steam, which Buhler research has shown to be the best method even in terms of physics alone. Steam heats the moist granules in the fastest way possible. However, rather than applying a couscoussier for this purpose, Buhler uses a belt-type steam conditioner of sophisticated design. This Buhler machine relies on an enclosed system, which does not require any outside intervention. This prevents mechanical strain, which causes the granules to crack and the couscous to stick. Before drying, the swollen agglomerates are gently separated in a detacher that has been purpose-designed for the couscous process. At this point, couscous made by the traditional manual method would be ready for consumption. In the Buhler process, it undergoes the additional operations of drying and packaging carefully classified into fine, medium, and coarse grades. All that now has to be done to prepare this convenient instant product is to heat it in water and allow it swell, or to steam it in the traditional way. Couscous the gently produced instant meal that looks exactly like the home-made product. 2 BUHLER Pasta & Extruded products Couscous/Instant

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4 Instant pasta a lifestyle product. Fast convenient trendy. Quickly prepared convenient & trendy Why not take advantage of the convenience food trend of today s modern lifestyle! With Buhler, you can now offer your customers the most convenient way to prepare exquisite pasta instant dry pasta, precooked using steam. Gently mixed and kneaded The Buhler Polymatik pasta press ensures gentle intermixing of the raw materials typically durum semolina and water supplemented with additives such as proteins or salt, producing a particularly uniform protein texture. Plant operators, who already rely on proven Buhler grinding technology to produce semolina, can further optimize the water absorption capacity and therefore the steaming characteristics of their instant pasta by selective particle size control. Cost-efficient drying Thin-walled and gelatinized instant pasta must lose its moisture in a controlled, uniform and slow manner and this within a minimized drying time. Buhler drying lines have been designed with reduced energy consumption and low stressing of the instant pasta in mind. This is achieved through the excellently insulated and technologically sophisticated Buhler drying zones, which ensure an optimal drying process that is matched to the specific shape of the product and the raw material. Gently cooked with steam Precooked using steam, the instant pasta will gelatinize uniformly and gently, retain its shape and, unlike the products obtained in conventional processes, not lose any starch. Hot steam, applied to the instant pasta from all sides on the steam-conditioning belt, ensures quick swelling of the finished pasta. The wall thickness of instant pasta is a mere 0.4 to 0.6 mm. As a result, the gentle Buhler process is crucial for achieving a top end product quality. The Buhler steamconditioning process complies with the relevant food grade regulations. Gourmet pasta ready for instant enjoyment: Instant pasta produced on Buhler lines will swell immediately in hot water and tastes exceptional. 4 BUHLER Pasta & Extruded products Couscous/Instant

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6 Four steps to perfect couscous. Efficient and gentle production. Homogeneously mixed for brilliant appearance The patented Buhler agglomeration process produces couscous granules of perfect color and shape that flow freely and, once cooked have that very special bite. In a drum sieve, the automatic Buhler line mixes and agglomerates semolina, fine semolina and water into perfectly rounded granules without fractured edges. The secret: Gluten proteins envelope the starch granules and thereby prevent them from sticking. Before steam-conditioning, the drum sieve separates any unsuitable granules that may be present. Excessively fine granules are returned to the mixer. Excessively coarse granules are fed to a shredder, specially designed for the couscous process, where they are reduced and returned to the sieve. The moistening, screening and mixing operations take no longer than 15 minutes. The sieves inside the drum can be changed quickly and easily, enabling the particle fineness to be rapidly adjusted to seasonal or market-related requirements. Clean and economical The perfect granules are loaded in layers onto belts and steam-cooked. The Buhler process slashes the steam-conditioning time by 50 percent down to 5 minutes. This cuts energy consumption and results in a non-sticking product. Inside the Buhler belt steamer, the sealed-off, stainless steel belt runs between the upper and lower hoods, which protect the steam inlet pipes and condensate drain. The steam cooking unit has been designed to force the steam to flow from the lower hood through the loosely piled product. The upper hood contains the thermometer and exhaust system, which aspirates the steam and discharges it to the atmosphere. This ensures that the production area remains free of steam. The integrated belt cleaning system ensures automatic cleaning during production. Immediately after steam cooking, a detacher, purpose-designed by Buhler for the couscous process, once again loosens and separates the individual granules. 6 BUHLER Pasta & Extruded products Couscous/Instant

7 Efficient and gentle drying The Buhler drum dryer receives the moist and hot, optimally swollen agglomerates. The water content at the inlet is approx. 35 percent. The water content is gently reduced to between 10 and 12 percent within 60 to 90 minutes, which is twice as fast compared to conventional processes. The fully automated Buhler process enables energy consumption and costs to be reduced as a result of the appreciably shorter drying time. All the end consumer has to do to prepare a delicious meal is to allow the gently dried, steam-conditioned, instant product to swell for a few minutes in hot water. Fast and gentle grading A Buhler plansifter is used to obtain a finished couscous consisting of granules of uniform size and shape. The dried granules are rapidly and gently classified into coarse, medium, fine and extrafine particle size grades. The excessively fine particle fraction amounting to less than 5 percent is remixed with the raw material at a controlled rate and reprocessed. Excessively large agglomerates are reduced in a roller mill and regraded by the plansifter. Ultimately, the purpose of this closed-loop grading process is to achieve an optimal yield without product loss. 7

8 Technical data. Couscous process 1 2a Semolina/flour 2 Material feed system 3 Water metering system 4 High-speed mixer 5 Mixer 6 Drum screen 7 Belt scale 8 Belt dryer 9 Drum dryer 10 Cooler 11 Plansifter 12 Roller mills with 1 st and 2 nd reduction stages Agglomeration Steam-conditioning Drying Grading Design options Throughput Twin-shaft Mixer Drum Steam- Drum Fluidbed Plansifter 4-roller mill (kg/h) mixer sieve conditioner dryer cooler Newtronic x 1x 1x 1x 15/ x 800/ x 2x 2x 2x 15/10-D 300 2x 800/250 Dimensions/capacity Capacity Dimensions Electrical capacity Heating capacity High-grade steam Oil-free compressed air (kg/h) LxWxH at 6 8 bar at 6 8 bar x6x9.3 m 230 kw 490 kw 600 kg/h 30 m 3 /min x7x10.5 m 410 kw 980 kw 1200 kg/h 60 m 3 /min Instant pasta process Pasta press 2 Conveyor 3 Steam-conditioner 4 Shaking predryer 5 Belt dryer 6 Cooler Mixing/kneading Steam-conditioning Predrying Drying Cooling Capacity Dimensions Pasta press Steam-conditioner Shaking Belt cooler (kg/h) LxW H predryer dryer x5.5x8.8 m 1x 1x 1x 1x 1x x5.5x8.8 m 1x 2x 1x 1x 1x BUHLER Pasta & Extruded products Couscous/Instant 8

9 Fully automatic control. Fine-tuned controlled monitored. Monitoring and automatic readjustment Buhler lines enable you to produce top-quality coarse, medium, fine and extrafine couscous in a continuous process with capacities ranging from 1000 to 2000 kg/h, in addition to instant pasta at outputs from 500 to 1000 kg/h. The stateof-the-art Buhler Pastelec control system ensures easy line operation, low energy costs and optimal process control, enabling cost-efficient production of top-quality instant products based on the traditional process stages. Fine-tuned, controlled, and monitored The fast and gentle patented Buhler agglomeration process for producing couscous and extruded instant pasta creates a uniform protein texture in the products. This enables durum semolina, fine semolina and water to be transformed into high-grade instant products while complying with the relevant food grade regulations. The automatically controlled process is characterized by its low energy consumption and gentle product treatment. High operating reliability The practice-oriented, easy-to-use user interface visualizes the process status on a continuous basis. All the important data is automatically registered and processed. Plant Care, the integrated maintenance program for production lines, automatically regulates the temperature and humidity, proposes timely maintenance routines, and can if required be accessed directly by Buhler experts through a local area network (LAN). BUHLER Pasta & Extruded products Couscous/Instant 9

10 PE en DF Bühler AG CH-9240 Uzwil, Switzerland T F pasta@buhlergroup.com