How to set up a pasta factory - Second part

Selling 250 kg/h of dry pasta with 'The 4 Cs of Marketing'

The production of dry pasta: always-valid business

For more than a century, dry pasta has constantly grown in its consumption. It is part of the stories of our grandparents, who went to buy loose pasta or our parents, who experienced the economic boom with the birth of the great Italian brands now known worldwide. Today, pasta acquires new vitality for several reasons. Attention to nutrition and health favours those producers who know how to respond to this need, using grains with a short supply chain, whole-meal flours, protein-free, gluten-free blends or ancient and organic grains.

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The care taken by consumers in choosing the products has resulted in a reduction of sales of famous brands, on the one hand, whereas, on the other hand, has opened new possibilities in this sector for small farmers, aspiring entrepreneurs or already active businessmen in other food sectors. They will benefit from a technology that has been refined over the decades to produce a type of pasta that can be sold at very high prices and is certainly interesting for an entrepreneur.

So, let's analyse in detail how to enter this sector. We will see a video tutorial made at one of our customers, we will explain the production process of dry pasta, the training necessary to produce it and how to approach the market with a business plan.

How is dry pasta manufactured?

Pasta drying process consists in thermally treating the fresh product to make pasta dehydrate till a residual humidity of 12%, thus complying with law. The initial mixing, made of semolina and water, must have a humidity of about 30%. The water added to the semolina during the process helps the product to become malleable, so that it can be shaped as desired.

This simple introduction belongs to the traditions of each of us; it becomes more complex on the base of the capacities and times of production.

A good pasta maker, as well as a good entrepreneur, knows how to weigh up times, quantity and quality of his product.

The machines and ingredients necessary to the production are always the same but may vary for capacities reasons. 

The most important machine is undoubtedly the press. In the press, semolina and water are mixed together and afterwards the dough is transformed in a shape of pasta. The dough is pushed through a die, usually made of bronze, that gives shape to the pasta. Later, a circular blade cuts it according to the desired length. The capacity of production of the press establishes the dimensions of a pasta factory. All the machines following the press must have capacities such to match the press.

Once pasta is shaped like tortiglioni, penne, fusilli, spaghetti'is deposited onto trays for short pasta or sticks for long pasta. These two phases can have different levels of automation according to quantity and pasta maker's needs. The larger the capacities, the more automations should be considered, both for logistics and personnel reduction costs.
 

Dry pasta production line - 250 Kg/h

We have thus made the pasta and laid it onto trays or sticks for the drying phase. The drying phase is a thermal treatment by which the humidity of the product decreases from 30% to 12%, possibly in less than 12 hours (so that a double daily working swift is possible). It is indeed a very strong treatment that can jeopardize the success of the most delicate shapes such as spaghetti. To reduce the drying times and make the product more resistant, it is necessary a pre-drying phase. The pasta maker calls it 'preincartata'.

We are ready now to proceed to the drying phase. In the artisan pasta-factories the drying is always static. The pasta is positioned inside the dryers for a time ranging from 8 to 12 hours approximately. Th drying bend is set by the pasta maker and is established so that pasta is dehydrated homogeneously from its core to the external part.

This is the phase when a pasta maker puts into practice all his experience.

After drying, the residual humidity at 12% is verified by a sample check and the 3-year expiration date can be certified on the label. At this point, the packaging phase is missing, but we will talk about it later on.

Setting up a dry pasta factory

On this page, we will be talking about a pasta factory manufacturing 250 kg/h short and long dry pasta. kg of pasta is produced daily in 8-hour work. The management of these quantities has an impact not only on production but also on sales and distribution. We are going to study the marketing rules to be respected to start and manage a business. P. Kotler, renowned manager and professor, author of "Marketing Management" among others, since the 90s has established himself as a point of reference for all those companies that would like to make a name for themselves in their market. His rules, which we are commenting below, are still current today but have been reviewed and integrated after the big break of the internet, social media, the whole media world our lives steep-in nowadays. Let's analyse the universal law of the 4 Cs of marketing:

the Customer (or Product)

1 - The customer's perception of product: by product we mean everything that contributes to communicating its quality. We therefore speak of quality in terms of what the customer perceives as such, thanks to the brand, message, colour or description. Pay close attention to the difference between perceived quality and intrinsic quality of the product. What matters in sales is only the perceived quality, nobody cares about intrinsic quality... except the producer.

 

the Cost

2 - The price does not simply mean "low price". Many products would not sell if they were cheap, such as a Rolex or a Ferrari. By price, we mean the monetary consideration of the "value" attributed to the product by the consumer. It is part of a company's pricing policies and is established on the basis of production costs, the cost that the market is willing to spend for that kind of product and the value perceived by the customer. It is therefore not enough to love your artefact, you also need to know how to transmit your love.
 

the Communication

3 - Communication, in a broader sense, represents all those actions taken by a company to bring a potential customer toward the product: catalogue, website, sales representative, social media, print media, radio. Communication has been enduring an epochal transformation in the last twenty years. Television, which in the 90s was the undisputed queen, has been suffering a hard blow from the birth of Google, YouTube and social networks. This change represents a considerable opportunity for all small producers. Just be patient and creative, with a positive attitude to changes.

the Convenience

4 - Point of sale: or distribution. Presence of the product and characteristics of the place where it is sold. If we wanted to sell a Rolex, we would hardly be able to do it in a hardware store. More suitable would be a beautiful jewellery shop downtown. The same goes for its presence in the shop. The product must be displayed, hard to sell it by mail order. Staying with this metaphor also when speaking of pasta, let's carefully choose our sales channels and ensure that our product is in view.

 

5 - Packaging

... Packaging: no, I am not wrong. The rules are still four but, in my opinion, packaging is so important in the world of dry pasta that it must be added to the other four. Observing any pasta shelf in a shopping center, we immediately realize its importance and its attractive power.

Training for pasta maker

Training starts just from the very first visit to a factory and basically never ends. Once analysed your expectations, we will visit a customer of ours who has the same kind of plant. We will see in detail the machines in operation, their dimensions, the handling of the goods; we will follow the entire logical process from the semolina to the packaging of the finished product. Once the plant has been built, in addition to the test technician, we provide the services our technologist in charge of the new projects. We will monitor your activity both in person and remotely. With your consent, thanks to our IoT staff, we will be able to intervene with our technicians without being physically present on site, enter your drying programs and assist you, always, wherever you are. You will also have at your disposal our Training Center (a real pasta factory with our lines installed and not a simulation laboratory) and our R&D Lab. In both, you will be able to carry out production tests and / or professional training, with the full cooperation of our experts.

Dry pasta production plant

What frightens more is the easiest thing to do. Apart from a normal drinking water supplying system and the possibility of being reached by the electricity network, there is nothing else to hinder the construction of the system. You just send us the dwg file of the floor plan and our technicians will provide you with all the useful instructions for masonry work and connections. Just engage any construction company. About six months after the order confirmation, we will come to install your complete dry pasta line.

With competitive price and timely delivery, Decao sincerely hope to be your supplier and partner.

Example of an automatic short and long pasta line plant with (from left to right) entrance, office area, changing rooms. Production area with production plant and dryers. Above, raw material storage area. Central area intended for packaging. On the right the finished product storage and shipping area.

Assistance, Guarantee and Safety

Assistance Guarantee and Safety are three aspects of a plant that are usually set aside a little by the evaluations of an entrepreneur. By assistance, it is intended to be able to receive spare parts in a very short time. Every day without a spare part is a day without production. One day less turnover.

More info about our Service: Spare parts and overhauls.

The warranty keeps us safe from unforeseen expenses. Especially if we are far away from the supplier company, it is important to have an extended warranty well beyond the legal requirements.

Never approach a supplier company that does not comply, even stubbornly, with all safety regulations. Pasta machines work at enormous pressures and have a high level of automation with great technology in motion. Safety is an ethical duty rather than a legal one.

Which figures should we use?

As entrepreneurs, we will necessarily have to build a network of contacts that can help us follow all those activities related to our company although not representing its core business. In the first place:

HACCP:  Analysis Lab

A food analysis laboratory should be selected. To find the one closest to you,  guarantying its professionalism, it is advisable to consult the website of the Ministry of Labor. Here you will find the complete list of analysis laboratories that can draw up your haccp manual and help you navigate the labyrinth of Italian legislation, and above all certify sample analyses inside the factory.

Grant award

Before using your own capital, it is always advisable to seek advice from a company specializing in financing. Be careful, we are not talking about accountants, but real service companies specialized in the study of regulations related to grant awards. They also deal with the preparation of the necessary docs.  Their reward is a percentage of the funds eventually obtained.

Our pasta production line and Macaroni Production Machine is summed up by a number of pasta macaroni processing technical engineers who have more than ten years of experience. 
Loyal pasta line has a number of lines on pasta technology patents, which can provide you with the most detailed past macaroni spaghetti production formula and process documents, which can save macaroni processing  plant costs while improving good pasta development in the macaroni past spaghetti manufacturing industry makes your pasta project profitable in the pasta products manufacturing industry. 
The raw material of pasta production line  is flour, how much profit can a pasta business make? many Pasta Company produces between usd of pasta a day. 
Even if all of this were plain dry pasta, it could bring in between usd and usd  in retail sales each day.

The profit margin with a  pasta factory is very high: the cost of the raw material rarely exceeds 30% of the selling price of your pasta products

What is the production process of pasta? 

Pasta products are made by mixing ground wheat, water and eggs. These ingredients are usually added to a continuous, high-capacity screw extruder which can be equipped with a variety of dies that determine the shape of the pasta.
Pasta comes in many shapes and has different properties. Different flavours

The dry macaroni is made from durum wheat or other wheat.
The line standard requires the addition of 5.5% egg and egg yolk. The macaroni production process involves the addition of water to coarse flour, semolina, flour and other ingredients to form a stiff dough of approximately 30% moisture, which is then pressed, cut by a mill, dried, dried and so on.

To open a pasta factory, it is a good idea in the current pasta market
You need to prepare a workshop of 50 square meters, which must be equipped with everything needed to prepare the pasta and sell the product itself.
Then you need either a pasta line or a macaroni line, in fact the two processes are similar.
One line can be used for the production of two or more products.
In the current pasta market environment, a small pasta factory can be managed by a family or by 2 - 3 people.
Barilla , Store brands , Mueller's , Ronzoni , Creamette , Buitoni ,American Beauty ,Skinner, San Giorgio pasta brand manufacturer can reach a profit of 30% of the raw material !
This income is the average for pasta and macaroni businesses.
 

The -1 Macaroni Production Machine has reasonable design and superior performance. These equipments are developed by our macaroni industry designers in combination with many years of macaroni production experience.
The production process of macaroni equipment is rigorous and serious. Every equipment detail has been carefully considered and checked at multiple levels, so the final product is very ideal.
The macaroni production line can produce a variety of foods, such as pasta, shell potato chips, white fungus shaped potato chips, pentagonal potato chips, cat ear shaped potato chips, macaroni, rice, chrome-plated noodles, etc. Different molds can be used to produce different foods. shape.
We can also make macaroni pasta models according to customer requirements to meet more customer needs.
Loyal is a professional manufacturer of macaroni equipment and pasta equipment.
The dedicated pasta production line technical team is here to help you. Solve any type of mechanical equipment and process problems in pasta production workshops.
If you buy our macaroni equipment and pasta equipment, we will provide you with the most reasonable price,
In the food manufacturing industry, to ensure that you save costs while bringing you the greatest economic benefits.
If you have any requirements for macaroni production process and pasta production process, please contact us as soon as possible. In addition, our service is also very good, whether it is pre-sale, in-sale, after-sale or technical service, it is the best quality.
We look forward to your visit.
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What Is Difference Between Pasta And Macaroni?
How Is Italian Pasta Made?
How Is Pasta Made In Industry?
What Is The Process Of Pasta?
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A Complete Buying Guide For The Macaroni Production Machine:

1. What is difference between pasta and macaroni?
Macaroni is a type of dried pasta that looks like a narrow tube. Although it is an Italian delicacy, it is famous all over the world. It is made from durum wheat and no eggs are used in its preparation. As macaroni is a type of pasta, it is also made from dough, from which pasta is also made.

2. Brief introduction of macaroni production machine
The macaroni production line mainly uses potato starch, corn starch, flour, etc. as raw materials, using a screw extruder and a unique extrusion molding process to produce short pasta and macaroni with various shapes that are popular on the market, such as crisp peas, shells, spirals, etc. Square tube, round tube, and wave shapes.
The macaroni making machinery adopts the most advanced technology in the industry to mix water and flour more fully. It can complete raw material mixing, extrusion, molding, drying, cooling, and packaging in one step. The entire production line is produced in an assembly line with very high automation. One or two people can complete the processing process, which can greatly save manpower and improve work efficiency.

3. Benefits of macaroni production machine
(1) The macaroni production line has reasonable design, high degree of automation and precise control of extrusion parameters.
(2) The main engine is equipped with high and low pressure screws, which increases the use range of raw materials, reduces costs and improves product quality.
(3) The screw is made of alloy steel and special technology, the screw life is longer, and the modular system structure is adopted, which can be combined at will. To
(4) The visualized automatic temperature control system makes the temperature control more intuitive, which is convenient for observation during operation and is clear at a glance.
(5) The whole machine is made of stainless steel, beautiful and atmospheric, and has a long service life. There are no pollutants or three wastes during the processing. The final product is high-quality and healthy, with excellent taste and rich nutrition.
4. Limitation of macaroni production machine
The macaroni making machine has many advantages, but it also has some shortcomings. For example, because the production line uses very advanced machines and all parts are excellent, compared with the previous equipment, the cost may be higher. Some, the cost is higher, but its performance is very superior, and the benefits brought by it are also higher.
In addition, because the production line involves a lot of equipment, although the degree of automation is high, there are many points that need to be paid attention to during operation. You may not pay attention to a certain equipment failure will cause the entire production line to stop running, so it is in use. During the process, carefully check the working condition of the equipment.
5. How macaroni production machine Works
The raw materials are mixed with water in a mixer, and the mixed flour is fed into the macaroni extruder by a vertical screw conveyor. The cylinder wall of the extruder is double-layered. The cavity is cooled by water and installed at the outlet end of the cylinder liner. There is a molding die. The wet flour is extruded from the die hole and rotated and cut into wet macaroni. The product automatically falls into the pre-drying machine. After pre-drying, it automatically falls into the far-infrared dryer. After drying, it automatically falls into the cooling device. After cooling, it is packaged The machine is packaged as a finished product.

6. Parts of macaroni production machine
(1) Feeder: Installed on the main engine, screw feeding, the quantity is adjustable, the system includes engine, screw, mixer and machine frame.
(2) Extruder: Use mixing, cutting, extrusion and other processes to make the material mature at low temperature, and strictly control the temperature of the roller and screw to meet the material requirements.
(3) Cutting machine: The shelf is fixed on the head of the mold and rotates and cuts the material under the push of the pulley.
(4) Heating machine: Divided into five zones, the heating temperature can be adjusted individually.
(5) Transmission system: The power of the main engine is transmitted to the screw through the V-belt and reducer.
(6) Control system: It can centrally control all parts of the host, which is the key to the production line.
(7) Vacuum pump: For macaroni, the biggest problem is that there are bubbles and air in it. With a vacuum pump.

If you want to learn more, please visit our website Macaroni Production Line.