Production process of pressed noodles (dried noodles)
By improving the production process of Shengzhou pressed noodles, adopting old yeast and temperature and humidity control procedures, and combining them with tunnel-type air dryers, factory-scale all-weather production has been achieved. This has solved the problems of high labor intensity and poor hygiene conditions in the traditional production of Shengzhou pressed noodles, improved product quality and production efficiency, and expanded the consumer base.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-25
- Publication Date
- 2026-03-31
AI Technical Summary
Traditional Shengzhou pressed noodles production suffers from problems such as high labor intensity, poor hygiene, dry texture, inability to withstand boiling, poor extensibility, and easy breakage, resulting in a limited consumer base. Furthermore, the short production time and unstable supply make it difficult to achieve factory-scale and large-scale production.
The process involves soaking rice, grinding it into a paste, pressing and filtering it, granulating it into powder, steaming the powder, extruding it into strands, cutting the strands into strips, pressing and loosening them, steaming them to separate them, and then scooping the strips out of water and spreading them into cakes. Combined with the addition of old yeast and temperature and humidity control, the process is carried out by sun-drying and hot air drying through a tunnel-type air dryer, achieving factory-scale all-weather production.
It has achieved all-weather, factory-scale, and large-scale production, increasing output to 1800Kg/8h. The product is resistant to boiling, has good extensibility, is not easy to break, has a light and refreshing taste, meets food hygiene standards, is suitable for a variety of people, and is stable in storage.
Abstract
Description
Technical Field
[0001] This invention relates to the field of food processing, specifically to a production process for pressed noodles, i.e., dried noodles. Background Technology
[0002] Shengzhou Zha Mian (Shengzhou Pressed Noodles) is a traditional intangible cultural heritage and a gourmet agricultural product of Zhejiang Province. Made from early-season indica rice, it has a white color. Traditional processing relies on manual labor and requires sun-drying in the fields on sunny days, resulting in a short production period and difficulty in ensuring supply. Large-volume, concentrated orders are even more difficult to fulfill. Workshop-style production yields only 900 kg / 18 hours, requiring early mornings and late nights, high labor intensity, and hindering the transmission of skills. Workshop-style processing also suffers from poor hygiene conditions; outdoor drying exposes the noodles to insects, dust, and sand, thus failing to meet national food hygiene standards. Current products are dry and unsuitable for the elderly and those with indigestion, limiting the consumer base. They also suffer from poor boiling resistance, poor elasticity, and easy breakage, thus requiring urgent improvement.
[0003] Purpose of the invention
[0004] The purpose of this invention is to provide a simplified production process for pressed noodles (dried noodles), which can be produced in factories around the clock, with high efficiency. The finished product is resistant to boiling, has good extensibility, is not easy to break, has a long shelf life, and is light, fresh, smooth, chewy, non-drying, and easy to digest.
[0005] The production process of pressed rice noodles (dried rice noodles) includes the following steps: rice washing and soaking, grinding, filtration, granulation, steaming, extrusion into filaments, cutting of filaments into strips, pressing and loosening, steaming to separate the strips, and water-scooping and spreading the strips into cakes. The rice washing and soaking step uses indica rice as raw material. Water is first added to a rice trough, then the rice is soaked and stirred. After washing, the water is drained, and the rice is then fully soaked again. The grinding step uses a wet mill with a water supply temperature of 22-27℃, a rice slurry fineness controlled at 110-130 mesh, and a rice slurry temperature of 36-40℃. The filtration step involves placing the rice slurry into filter bags, evenly distributing it into filter frames, and then using a filter press. The process involves intermittent pressure filtration; in the pulverizing and granulation process, the moist powder is fed into the mixing tank of the pulverizing and granulating machine, pulverized by the agitator, and the shaped powder particles are discharged from the granulation tray, with the particle size of the raw powder particles controlled at 1.0-1.8 cm; in the steam granulation process, the raw powder particles are matured during the conveying process, with the steam conditions controlled as follows: steam pressure controlled at 0.5-0.6 Pa, and granulation temperature controlled at 110-130℃; in the extrusion into filaments process, the matured powder particles fall into the feed hopper of the extruder, are first rapidly cooled to 65-56℃, then pressed, and finally extruded into filaments; in the filament shearing into strips process, the filaments are sheared into strips of a predetermined length and then spread out. The aging process takes 3.5–4.5 hours. In the pressing and loosening process, edible oil is sprayed evenly onto the bundled strips, which are then loosened into non-sticky, unbroken strips on a shredding machine. In the steaming process, the strips are steamed for 35–45 seconds at a steam pressure of 0.5–0.6 Pa. In the process of scooping and spreading the strips into cakes in water, the strips are first cooled and loosened in low-temperature water, then cooled again with tap water, and finally scooped from the water into round cake molds according to a predetermined weight and evenly distributed. The improvement lies in the addition of a sourdough yeast, sun-drying, and hot-air drying process. The sourdough yeast is added before grinding the dough, and its dosage accounts for a certain percentage of the total weight. Rice 1.0-2.0% is mixed and stirred before water milling; during filter pressing, the indoor temperature is controlled at 20-30℃ and the humidity at 60-70% until the rice paste becomes moist powder, and the pH value of the moist powder is controlled at 4.8-5.2; the sun-drying and hot air drying processes are carried out in a tunnel-type air dryer. Sun-drying adopts an air blowing method. The round cake mold is first transported to the loading platform of the tunnel-type air dryer. The wet strips in the round cake mold are first dispersed, curled and evenly blown by air. Then, the hot air is alternately dried from top to bottom and from bottom to top in the hot air tunnel, controlling the chamber temperature at 38-42℃, humidity at 45-60%, and duration at 45-55 minutes.
[0006] The above-mentioned old yeast is prepared by: using extruded noodles (dried noodles) as raw material, first steaming them in water until cooked, and then crushing them.
[0007] The above-mentioned filter press process also includes the following inspection steps:
[0008] Open the filter press, knead the rice flour into a ball, and then open it up. It should be able to disperse on its own. If it does not meet the requirements, add 3-5% corn starch in the grinding and granulation process.
[0009] In the above rice washing and soaking process, the soaking time for indica rice is 2 to 4 hours.
[0010] The above-mentioned grinding process involves grinding indica rice using a grinder with a rotation speed of 900-1000 rpm. The grinder includes a rice feed hopper and a pulp outlet. The rice feed hopper is connected to a rice inlet pipe and an electric hot water tank.
[0011] The above-mentioned steaming powder process is carried out in a steaming cylinder with a built-in auger. There is a granulation inlet at the bottom and a discharge outlet at the top. Raw powder is fed to the granulation inlet and is conveyed and lifted by the auger. Cooked powder is collected from the discharge outlet to the granulation tray. The absence of white core is used as the criterion for maturation inspection of the powder.
[0012] The absence of white powder on the cross-section of the aforementioned steam-dispersed strips was used as the basis for the ripening test.
[0013] The aforementioned tunnel-type air dryer is equipped with a conveyor belt and adjacent drying boxes, as well as fans alternately arranged in the upper and lower parts of adjacent drying boxes. The fans are correspondingly arranged above and below the conveyor belt.
[0014] The net weight of the finished product after hot air drying is 110-125 grams per tablet.
[0015] The technical advantages of the solution provided by this invention are as follows: it enables all-weather, factory-scale, and large-scale production, with a yield of up to 1800 kg / 8h as of the application date. It addresses the pain points of traditional industry processes and the need for the inheritance of intangible cultural heritage skills. After numerous trials and errors, the optimal combination of old yeast and temperature and humidity control has been verified, ensuring that the resulting rice flour ultimately meets the pH target, avoiding acidification and dryness, and achieving full fermentation that is digestible and stomach-friendly. The rice flour is granulated for steaming, with sufficient steam absorption between and around the grains, combined with appropriate steaming conditions to ensure… The powder particles are thoroughly cooked, ensuring smooth extrusion into filaments in subsequent processes. Sun-drying and hot-air drying are seamlessly integrated on the same production line with high efficiency. Sun-drying uses an air-blowing method, which disperses, shapes, and evens out the thickness of the wet strips in the round mold while removing surface moisture. Up to four operational requirements are met in one step. Then, the semi-finished product is transported through a hot-air tunnel, where it is dried alternately on both sides to prevent moisture from returning. The finished product produced by this process is light and fresh in taste, smooth and resilient, resistant to boiling, has good extensibility, is not easy to break, and has a long shelf life. Detailed Implementation
[0016] The production process of pressed noodles (dried noodles) includes the following steps: soaking rice, grinding into a paste, pressing and filtering, grinding and granulating into powder, steaming the powder particles, extruding into strands, cutting the strands into strips, pressing and loosening, steaming to separate the strips, and scooping the strips out of water and spreading them into cakes.
[0017] S1) Rice soaking: Use early indica rice as raw material. First, put water into the rice trough, the water volume is 1 / 3 of the capacity of the rice trough. Then, pour the bagged early indica rice into the rice trough according to the predetermined weight of 1500Kg. After the rice grains are soaked in the water, stir and wash the rice. After washing, drain the water in the trough, and then add water again until it is 5cm above the rice surface. Soak for 2-4 hours.
[0018] S2) Grinding: When preparing the rice slurry, add 1.0-2.0% (or equivalent) of old yeast to the rice, mix them evenly, and then grind with water. A rice grinder is used, including a rice feed hopper and a slurry outlet. The rice feed hopper is connected to an electric hot water tank and a rice feed pipe equipped with a feeding motor, with a rotation speed of 900-1000 rpm. The electric hot water tank supplies water at a temperature of 22-27℃. The lower end of the rice feed pipe is located inside the rice trough. Fermentation begins when a thick rice slurry of 110-130 mesh (measured using standard molecular sieves), with a smooth texture and no fine particles, is obtained. The rice slurry temperature is 36-40℃.
[0019] Preparation of sourdough starter: Use dried noodles as the raw material for sourdough starter. First, steam them in water until cooked, then mechanically crush them.
[0020] The optimal amount of sourdough starter yeast, controlled at 1.0-2.0% of the rice content, is determined through multiple trials. Below 1.0%, fermentation is insufficient, resulting in a product that lacks elasticity and has a dry texture; above 2.0%, fermentation is excessive, leading to a product with a strong sour taste.
[0021] S3) Press filtration: Pack rice slurry into filter bags at 25Kg per bag and evenly place them in the filter press frame. Use a filter press to intermittently press and filter overnight until dawn. During pressing and filtering, the indoor temperature is controlled at 20-30℃ and the relative humidity is controlled at 60-70%. After fermentation, the rice slurry becomes moist powder. At this time, the fermentation ends and the pH value of the moist powder is controlled at 4.8-5.2.
[0022] Testing and Adjustment: Open the filter press, grab a handful of rice flour, squeeze it into a ball, and then open it. If the ball can disperse on its own, it is qualified. If it cannot disperse, add 3-5% corn starch by mass to the rice flour during grinding and granulation.
[0023] S4) Powdering and granulation: The wet powder is fed into the mixing tank of the powdering and granulation machine, and is powdered by the agitator. The formed powder particles are discharged from the granulation plate. The particle size of the raw powder particles is controlled at 1.0 to 1.8 cm.
[0024] S5) Steamed Powder Particles: During the conveying process, the raw powder particles are cooked. Steam is conveyed in a steaming cylinder with a built-in auger, and the steam pressure is controlled at 0.5-0.6 Pa, with an outlet temperature of 110-130℃. The inclined steaming cylinder has a particle inlet at the bottom and a discharge outlet at the top, ensuring that steam is emitted from the bottom of the steaming cylinder to indicate sufficient steam volume. The raw powder particles discharged from the discharge plate of S4) fall to the particle inlet and are conveyed and lifted by the auger. The cooked powder particles are collected from the discharge outlet to the discharge plate. The degree of cooking is determined by breaking open the powder particles to ensure that there is no white core powder, which can quickly confirm that the powder particles are cooked.
[0025] S6) Extruded into filaments, the cooked powder particles conveyed by the steamer fall into the feed hopper of the extruder, are first cooled to 65-56°C by a strong blower, and then discharged from the filament tray after being pressed by the extruder.
[0026] S7) Cut the filament bundle into strips. Cut the filament bundle into 35-40cm strips according to the predetermined strip length, and spread them on a cooling rack to age indoors for 3.5-4.5 hours.
[0027] S8) Press and loosen: First, spray edible oil evenly onto the aged bundles using a nano spray gun, then loosen them into discrete strips without sticking or breaking on a shredding machine. The edible oil to discrete strips are at a mass ratio of 1:1875 (in specific implementation, 0.8 kg of edible oil is weighed out for every 1500 kg of bundles).
[0028] S9) Steamed discrete strips: The discrete strips are placed in a wooden barrel and steamed for 35-45 seconds at a steam pressure of 0.5-0.6 Pa. After steaming, the discrete strips are tested for maturity by breaking the strips and ensuring that the cross-section shows no white powder.
[0029] S10) The strips are scooped out of the water and spread into cakes. The strips are first cooled and broken up in water at a temperature of less than 50 degrees Celsius. Then, they are cooled with tap water. The wet strips are then scooped out of the water into the round cake mold according to the predetermined weight (weighing 300-350g) and evenly arranged. The round cake molds are arranged in batches on a stainless steel frame.
[0030] S11) Sun drying and hot air drying are both carried out in a tunnel-type air dryer. Sun drying adopts the air blowing method. The round mold is first transported to the loading platform of the tunnel-type air dryer. The fan disperses, curls (patterns), evens out the thickness and removes surface moisture in the round mold. Then it is put into the hot air tunnel for alternating drying on both sides. The temperature is 38-42℃, the relative humidity is 45-60%, and the time is 45-55 minutes. The finished product with a net weight of 110-125 grams / piece is obtained after drying.
[0031] The tunnel-type air dryer is equipped with a conveyor belt and multiple adjacent drying boxes, as well as fans alternately arranged in the upper and lower parts of adjacent drying boxes. The fans are correspondingly arranged above and below the conveyor belt.
[0032] After being manufactured in a factory setting, this production process was certified by the Shengzhou Municipal Market Supervision Administration as meeting the hygiene requirements for food production and obtained a food production license.
Claims
1. The production process of pressed noodles (dried rice noodles) includes the following steps: washing and soaking rice, grinding into a paste, pressing and filtering, grinding and granulating, steaming the powder granules, extruding into filaments, cutting the filaments into strips, pressing and loosening, steaming to separate the strips, and rinsing the strips in water and spreading them into cakes. The rice rinsing and soaking process uses indica rice as raw material. Water is first poured into the rice trough, then the rice is added to soak and stir. After rinsing the rice, the water is drained, and then the rice is soaked in water again. The water milling process adopts a belt milling method, with a water supply temperature of 22-27℃, a rice slurry fineness controlled at 110-130 mesh, and a rice slurry temperature of 36-40℃; In the filter pressing process, the rice slurry is placed into a filter bag, evenly distributed into a filter pressing frame, and then intermittently filtered using a filter press. In the powdering and granulation process, the moist powder is fed into the mixing tank of the powdering and granulation machine, and powdered by the agitator. The shaped powder particles are discharged from the granulation plate, and the particle size of the raw powder particles is controlled at 1.0 to 1.8 cm. The steaming process involves maturing the raw powder particles during transportation. The steaming conditions are: steam pressure controlled at 0.5–0.6 Pa and particle outlet temperature controlled at 110–130 °C. In the extrusion to form filaments process, cooked powder particles fall into the feed hopper of the extruder, are first rapidly cooled to 65-56°C, then pressed, and finally the filaments are produced. The process of cutting the filament bundle into strips involves cutting the filament bundle into strips of a predetermined length, and then laying them out to age for 3.5 to 4.5 hours. The pressing and loosening process involves spraying edible oil evenly onto the bundle of strips, and then loosening them into discrete strips without sticking or breaking on a shredding machine. The process of steaming the discrete strips involves steaming the discrete strips for 35–45 seconds at a steam pressure of 0.5–0.6 Pa. The process of scooping strips from water and spreading them into cakes involves first cooling and breaking up the discrete strips in low-temperature water, then cooling them again with tap water, and finally scooping them from the water into a round cake mold according to a predetermined weight and arranging them evenly. Its features are, It also includes the processes of adding sourdough yeast, sun drying, and hot air drying; Add the starter yeast before grinding the rice, using 1.0-2.0% of the rice. Mix and stir before water grinding. During filter pressing, control the room temperature at 20-30℃ and the humidity at 60-70% until the rice paste becomes moist rice flour. The pH value of the moist rice flour should be controlled at 4.8-5.
2. The sun-drying and hot-air drying processes are carried out in a tunnel-type air dryer. Sun-drying is carried out by air blowing. The round mold is first transported to the loading platform of the tunnel-type air dryer. The air blows away, curls, and evens out the wet strips located in the round mold. Then, the hot air is alternately blown from top to bottom and from bottom to top in the hot air tunnel for drying. The temperature of the chamber is controlled at 38-42℃, the humidity at 45-60%, and the time is 45-55 minutes.
2. The noodle (powder) production process according to claim 1, characterized in that, The old yeast is prepared by using extruded noodles (dried noodles) as raw material, first steaming them in water until cooked, and then crushing them.
3. The noodle (powder) production process according to claim 2, characterized in that, The pressure filtration process also includes the following inspection steps: Open the filter press, knead the rice flour into a ball, and then open it up. It should be able to disperse on its own. If it does not meet the requirements, add 3-5% corn starch in the grinding and granulation process.
4. The noodle (powder) production process according to claim 1, characterized in that, In the rice washing and soaking process, the soaking time for indica rice is 2 to 4 hours.
5. The noodle (powder) production process according to claim 1, characterized in that, The grinding process involves grinding indica rice using a grinder with a rotation speed of 900-1000 rpm. The grinder includes a rice feed hopper and a pulp outlet. The rice feed hopper is connected to a rice inlet pipe and an electric hot water tank.
6. The noodle (powder) production process according to claim 1, characterized in that, The steaming process for powder particles is carried out in a steaming cylinder with a built-in auger. There is a particle inlet at the bottom and a discharge outlet at the top. Raw powder particles are fed to the particle inlet and conveyed and lifted by the auger. Cooked powder particles are collected from the discharge outlet to the discharge plate. The absence of white cores in the powder particles is used as the criterion for ripening.
7. The noodle (powder) production process according to claim 1, characterized in that, The absence of white powder on the cross-section of the steam-dispersed strip is used as the criterion for ripening inspection.
8. The noodle (powder) production process according to claim 1, characterized in that, The tunnel-type air dryer is equipped with a conveyor belt and adjacent drying boxes, as well as fans alternately arranged in the upper and lower parts of adjacent drying boxes. The fans are correspondingly arranged above and below the conveyor belt.
9. The noodle (powder) production process according to claim 1 or 8, characterized in that, The net weight of the finished product after hot air drying is 110-125 grams per tablet.