New non-fried instant noodle production line

In recent years, the market for fried instant noodles has gradually contracted, prompting fierce competition among major instant noodle companies. To differentiate themselves, these companies are striving for product innovation, with many focusing on the development of healthier non-fried instant noodles. However, despite these efforts, non-fried instant noodles have yet to gain widespread consumer acceptance due to their inferior taste and longer preparation time.

For instant noodle manufacturers, achieving success with new product lines is particularly challenging when limited by low-capacity equipment. The capacity and stability of the production line's core equipment play a crucial role in enabling continuous automation. Key factors influencing production output include the speed of dough extrusion and the width of the dough. To boost output, one might consider increasing the screw diameter to widen the dough or raising the screw speed to enhance extrusion rates. However, after conducting thorough research on existing equipment and consulting with manufacturers, it became clear that expanding the capabilities of the original machinery is not a feasible solution.

Shangbaotai’s Advantages in Noodle Production Lines

Shangbaotai Group is a global leader in the manufacturing of noodle processing lines, beverage packaging equipment, and plastic molds. Headquartered in Taiwan, the group operates with a robust infrastructure, supported by two key subsidiaries. Shangbaotai Group boasts over 60 state-of-the-art numerical control machines, including the MIKRON high-speed processing machine from Switzerland and the GT-630 5-axis machining machine from Taiwan, ensuring precision in every step of the manufacturing process.

• Advanced Technology and Precision Manufacturing: Shangbaotai Group leverages cutting-edge technology, including high-speed processing machines and multi-axis machining centers, to produce components with exceptional precision. This advanced machinery enables the company to build noodle production lines that can handle large-scale operations while ensuring consistency and quality. Shangbaotai’s commitment to technological innovation, particularly in automation and smart manufacturing, has resulted in production lines that are highly efficient, with minimal need for manual intervention, thereby reducing errors and enhancing overall productivity.

• Tailored Solutions with Global Expertise: With decades of experience in precision machining and process technology, Shangbaotai offers customized solutions to meet the specific needs of its clients. The company’s deep industry knowledge allows it to fine-tune production lines for optimal performance, whether the goal is to increase production speed or improve product quality. While Shangbaotai operates globally, it remains attuned to the unique requirements of different markets, delivering production lines that are not only technologically superior but also tailored to local market demands.

Problems in the production process

The first problem is that the thickness of the extruded dough is uneven. The dough is extruded into a cylindrical shape by a screw. Because the inner ring rotates with the screw, the dough is subject to rotational shear, so the quality of the dough is difficult to control. The screw is not supported and fixed in the cylinder, so the gap between the inner ring and the outer ring changes when the inner ring and the outer ring rotate. After the dough sheet is extruded, the thickness of the sheet is very different. The thin part is only 0.5mm and the thick part is 1mm. If the screw and cylinder are directly enlarged, the difference in thickness will be greater.

 Question 2: In the production process, after a period, black spots will be mixed in the surface. This is because the processing accuracy of the screw is not enough, and the screw design of the screw is not reasonable enough, which causes some dough to stick to the screw and form carbonization at high temperature. Over time, the carbonized dough will be more and more, and will agglomerate in the screw, causing the screw to block. In order to avoid black spot contamination of the products, production companies must remove the screw every few hours for cleaning. If the machine is simply scaled up, it can easily aggravate this phenomenon.

 Question three: it is very difficult to disassemble and clean. When disassembling the screw of small equipment, it is necessary to remove the connecting shaft of the screw and the reducer and then use an iron rod to pass through the reducer to eject the screw from the rear. If not removed in time, the flour will be carbonized in the cylinder and difficult to eject. Through the redesign of the screw length-diameter ratio and the screw structure, the processing accuracy of the screw is improved, so that the dough is evenly mixed in the cylinder.