Instant Noodles1: A Potential Vehicle for Micronutrient Fortification

Introduction
Instant noodles appear to have originated in Japan in the 1950s and, today,
are produced in over 80 countries worldwide. In 2001, over 1 million MT of instant Table 2
Ingredients used in the manufacture of
noodles were produced in China, about 700,000 MT in both Japan and Indonesia, instant noodles
270,000 MT in South Korea, 200,000 MT in Vietnam, 80,000 MT in Thailand, 50,000
MT in Taiwan, and 40,000 MT in the Philippines. Convenience and affordability are Ingredients Approximate amount
important factors contributing to its increasing popularity. Consumption has risen Main ingredients
steadily since 1995 in several Asian countries, except in Japan where it has Wheat flour 85-94%
remained stable (Table 1). In 2001 per capita annual consumption of instant Water As needed to make the dough
noodles ranged from about 5.5 kilograms in South Korea and Japan to 0.57 Salt (or Kan sui) 1-3% (or 0.5-1% of kan sui)
kilograms in the Philippines.
Additional ingredients
Table 1 Starch 1-2%
Per capita annual consumption (kilograms per person per annum) Edible oil 1-3%
of instant noodles in selected Asian countries
Antioxidants Minimum needed for technical
Country 1995 1996 1997 1998 1999 2000 2001 effect; varies with antioxidant used
South Korea 4.016 4.137 4.266 4.965 5.213 5.385 5.537 Stabilizers 0.1-0.5%
Japan 5.649 5.681 5.610 5.507 5.496 5.507 5.586 Emulsifiers 0.1-0.5%
Indonesia 2.543 2.823 3.078 2.901 3.095 3.219 3.363 Eggs/egg powder 1-3%
Vietnam 0.956 1.043 1.187 1.394 1.690 2.074 2.550 Vital gluten ~2%
Taiwan 1.880 1.942 2.004 2.004 2.040 2.004 2.058 Polyphosphates 0.1-0.2%
Thailand 0.758 0.849 0.994 1.042 1.138 1.244 1.362 Preservatives Minimum needed for technical
China 0.512 0.534 0.577 0.692 0.822 0.898 0.988
effect; varies with preservative used
Philippines 0.278 0.316 0.358 0.403 0.452 0.506 0.570
Colorings As needed
Source: EuroMonitor Report, May 2002.
Adapted from: Hou G. 2001. Oriental noodles.
The increasing consumption of noodles has led to concerted efforts to explore Adv Food Nutr Res 43:140-93.
the feasibility of using instant noodles as a vehicle for micronutrient fortification.
While several technological and implementation challenges remain, this food
appears to have the potential to be an effective food vehicle for micronutrient Figure 1
fortification. Simplified flow chart of instant noodle-
making procedure
Production of Instant Noodles
Instant noodles are made from wheat flour, starch, water, salt or kan sui (an
alkaline salt mixture of sodium carbonate, potassium carbonate, and sodium Wheat flour Salt water or Kan sui
phosphate), and other ingredients that improve the texture and flavor of noodles
(Table 2). Other flours may be mixed with wheat flour to make specific types of Mixing, resting, sheeting,
instant noodles; for example, buckwheat flour is added at 10-40% of wheat flour compounding, and re-sheeting
in the production of buckwheat noodles or soba. The popular noodles include
instant Chinese noodles, instant Japanese noodles, and instant European style
Slitting
noodles, which vary in the basic ingredients used to make the noodles. Instant
Chinese noodles use kan sui, whereas instant Japanese noodles do not, and the
European style noodles often are made with semolina (a coarse ground product Waving
of durum wheat).
The first step in noodle manufacturing involves dissolving the salt or kan sui,
starch, flavorings, and other ingredients (except flour) in water (Figure 1). This Steaming

mixture is added to the flour and the crumbly dough is rested to mature and then
kneaded to uniformly distribute the ingredients and hydrate all the flour particles.
Frying Oven drying
The dough is then passed through two rotating rollers to produce two sheets which
are compounded into a single noodle belt or sheet. The sheet is repeatedly folded
and passed through the rollers to facilitate gluten development, which gives the Fried instant noodles Dried instant noodles
noodle its stringy and chewy texture. The gap between the finishing rolls is
adjusted to produce the desired thickness of the noodle belt that is then Adapted from: Hou G. 2001. Oriental Noodles.
Adv. Food Nutr Res 43:140-93.
immediately cut. The wavy noodles are produced by setting the conveyor belt at
a slower pace than the cutting rolls above it. Alternatively, noodle strands 1. This document does not include fortification of traditional noodles such as spaghetti,
emerging from the slitter are hindered by metal blocks (weights) resulting in the macaroni, or other pasta products.
 Figure 2 noodle waves. Liquid seasonings are sometimes added to the noodle strands
Instant noodle-making production lines prior to cutting and molding into blocks or another suitable shape. The noodles
are then steamed at 100 ºC for 1-5 minutes, which gelatinizes the starch and
improves the texture of the noodles.
Bag Type Instant Noodle
Autowrapping M/C The next step is drying the noodles either by frying in oil (fried instant noodles)
Auto Fryer Inspection Conveyor
Cutting & Cooling Conveyor or drying with hot air (non-fried instant noodles). Frying the noodles in oil at 140-
Continuous
Rolling M/C Folding M/C 160 ºC for 1-2 minutes decreases the moisture content of noodles from 30-50% at
Mixing Water
Supply System Cushion Conveyor the steaming step to about 2-5%. While any edible oil is suitable for frying, palm
Steamer
Dough Mixer
Conveyor for Cartoning oil or palm olein is often used in Asia and mixtures of canola, cottonseed, and
Autowrapping M/C palm oils are commonly used in North America. In hot air drying, the noodles are
Slitter Heat Sealer
Multistage Type Cooling held at 70-90 ºC for 30-40 minutes to achieve an 8-12% moisture content. The
Compound Roller Take-Out Conveyor heating during frying or hot air drying further gelatinizes the starch and the
Dough Feeder Auto Fryer Feeding Conveyor
Cutting M/C Cup Feeder noodles now obtain a porous texture. Frying is the preferred method of drying and
Seasoning Unit
Bar Conveyor more than 80% of instant noodles are fried because hot air drying can result in
Auto Mixer
In-Direct Heating uneven drying that adversely affects the texture of the finished noodles. Non-fried
Steamer Equipment
instant noodles also require a longer cooking time. The disadvantage of frying,
Continuous Rolling M/C
however, is that fried noodles contain about 15-20% oil (compared with a
Cup & Bowl Type Instant Noodle
maximum of 3% fat in hot air-dried noodles) and are more susceptible to oxidation
and spoilage; the use of antioxidants prolongs the shelf life of fried instant noodles.
The dried noodles are then quickly cooled, checked for moisture, color, shape and
Figure 3
other quality characteristics, and packaged with seasonings using films that are
Volumetric feeder for adding impermeable to water and air.
micronutrient premix
Instant noodles are commercially available in two packaged forms - in a cup
Motor Hopper with the seasoning sprinkled over the noodles or in a pouch (or bag) with the
Control
panel seasoning provided in a sachet inside the pouch. Figure 2 shows the production
line to manufacture these two types of instant noodles. Instant noodles come in
several different flavors added to the seasoning - beef, chicken, pork, shrimp,
oriental, creamy chicken, chicken mushroom, and others. In the cup style instant
noodles, dehydrated vegetables and meats, as well as textured soy protein or flour
are often added. Because of their low moisture content and a fairly high sodium
Retromixer
content (about 2,100 mg per 100 g product), and the resulting low water activity,
instant noodles are stable and have a shelf life of 4-6 months in tropical areas and
6-12 months in the northern hemisphere.
They can be served after boiling in water for 1-2 minutes or soaking in hot water
Gear for 3-4 minutes.
reducer

Fortification of Instant Noodles

Outlet To ensure that the most vulnerable groups of the population benefit from food
spout fortification, the food vehicle must be consumed on a regular basis and in regular
amounts throughout the year by a large proportion of the population. It should also
be a food that is centrally manufactured by few plants so that micronutrients can
Information poster on fortified instant be added under controlled conditions and monitoring can be done effectively.
noodles in Thailand Both the choice of micronutrients and the amounts to add must be based on the
consumption patterns of the food vehicle and micronutrient needs of the
population, while still remaining within the safe upper limits of micronutrient intake.
In the case of instant noodles, a non-staple food, a micronutrient fortification level
of 10-30% of the RDA per serving (typically about one package of 55 grams) can
complement well any existing fortification of staple foods. The bioavailability of the
fortificant also needs to be considered in determining the amount of fortificant
added. In addition, fortificants must be chosen so as not to alter the organoleptic
properties or shelf life of the food.
Instant noodles can be fortified either by fortifying the flour used to make the
noodles or by fortifying the seasoning consumed along with the noodles.
Micronutrients including vitamin A, B1, B2, niacin, folic acid, iron, and iodine can
be added although the micronutrients and their overages will vary with each
approach. Choosing the appropriate form of fortificant is important to minimize
nutrient-nutrient as well as nutrient-food interactions and any resulting adverse
effects. Iron, for example, is a difficult mineral to add to foods as the most
bioavailable forms tend to promote fat oxidation resulting in the development of
unacceptable sensory changes in the finished food. Whereas dried ferrous sulfate
is the preferred form of iron to fortify wheat flour that is used within 1-2 months of
production, electrolytic iron (of particle size: 98% <48 µm) or ferrous fumarate are
better suited for wheat flour that is stored for a longer time2 before being used in
Source: Nutriview 2000/1 instant noodles production. Electrolytic iron may be also an appropriate form of
2. Nestel P. and Nalubola R. 2002. INACG Technical Brief. Technical brief on iron compounds fortificant for instant noodles seasoning to minimize sensory problems. The use of
for fortification of staple foods. INACG (ILSI), ILSI Press, Washington, D.C.
encapsulated fortificants will minimize interactions but these forms are expensive
and may increase the cost of fortification and, consequently, may negatively Figure 4
influence the affordability of the food by the vulnerable segments of the population. Seasoning sachet-forming machinery
Additionally, the bioavailability of encapsulated iron fortificants and their stability Seasoning Premix
Multi-layer plastic
during food processing, especially at elevated temperature and pressure wrapper Powder (with fortificant)
conditions characteristic of extrusion used in noodle making, are not known.
Chili Powder
Flour fortification - Wheat flour fortification at the mill has long been practiced
throughout the world and involves relatively simple technology. The fortification
process is accomplished by adding a micronutrient premix through a volumetric
feeder (Figure 3) located towards the end of the milling process. Micronutrients
are usually added together in the form of a single premix because it provides
better control over the concentration and distribution of micronutrients in the flour.
When considering fortification with multiple micronutrients, it is important to
consider interactions among the nutrients and, if necessary, use separate vitamin
and mineral premixes. Used as an ingredient, wheat flour that is fortified can result
in a fortified instant noodle provided appropriate considerations are given to the
effects of the noodle making procedures on the stability of the nutrients added to
flour. When flour is fortified at the instant noodle manufacturing plant, a volumetric
feeder and mixer added early on in the production line prior to the mixing of flour
with the salt/kan sui liquid will adequately fortify the flour before it is made into a
Seasoning Sachet
dough and fed into the rollers. In the production line illustrated in Figure 2,
fortificants may be introduced immediately prior to the “dough mixing” step. It is
important to ensure proper mixing and even distribution of the micronutrients in
the flour before dough formation.
Seasoning fortification - Fortifying the seasoning consumed along with the
Figure 5
noodles is commonly practiced in some parts of the world. In commercial
Retention of vitamins in cooked noodles*
preparations of fortified instant noodle seasoning in South East Asia, fortificants
are added along with the other seasoning ingredients to a ribbon blender and 90%
mixed thoroughly. The fortified seasoning is then packaged into a sachet (for
80%
pouch style) (Figure 4) or sprinkled over the noodles (for cup style). In the
production line illustrated in Figure 2, the fortified seasoning is introduced as a 70%

sachet immediately prior to the “auto wrapping” step for pouch style of instant 60%
noodles, and between the “feeding conveyor” and the “heat sealer” for the cup 50%
style of instant noodles. It is important to ensure proper mixing and even 40%
distribution of the micronutrients in the seasoning mixture. Fortifying the seasoning 30%
rather than the flour has an advantage in that the fortificants are not exposed to 20%
heat and moisture related to noodle processing. In addition, the fortificants are
10%
better protected being packed in a sachet in the pouch type of instant noodles.
0%
While it is relatively simple to add the fortificants, the challenge of ensuring the

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instant noodles remains. This challenge is greater as more micronutrients are

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added because micronutrients interact not only with each other but also with other
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ingredients in the seasoning matrix. However, at least three countries - Thailand, Source: Cereal Chem 62 (6): 476-477,1986.
Indonesia, and the Philippines - have succeeded in fortifying instant noodles * This study was done on traditional noodles, not instant noodles.
seasoning at a commercial level. Thailand and Indonesia are currently evaluating
its use as a public health intervention and exploring ways to improve the
formulation and effectively implement a national fortification program.
Figure 6
Stability of Micronutrients
Stability of vitamins in instant noodles
Data on the stability of micronutrients added to wheat flour during processing,
seasoning during processing and
storage, and cooking of instant noodles are not available. However, micronutrients
storage at room temperature
are routinely added to wheat flour that is made into traditional noodle products
such as spaghetti, macaroni, and other pasta products. Minimal losses of the B- 100%
vitamins were observed during noodle production with 80-100% retention after 95%
drying at a temperature of 75°C. About 60-75% of the B-vitamins added to flour
90%
were retained after cooking the noodles (Figure 5). Based on these data and given
the similarity in the exposure of food and micronutrients to different processing 85%
% Retention

factors (heat, pressure, and moisture) between pasta and instant noodle 80%
production, micronutrients added to wheat flour are expected to be fairly stable 75%
during the manufacture of instant noodles as well as during subsequent 70%
cooking/soaking.
65%
Vitamins added to the seasoning sachet are also stable, although their stability
varies with the type of packaging, seasoning ingredients, and moisture content of 60%

the seasoning mixture. Ideally, the sachet for the seasoning mixture should be
impermeable to light, moisture, and air. Packaging with aluminized Added Initial 3 mo 6 mo
polyethylene/polypropylene films is advisable. Using optimum packaging, data A B6
from Hong Kong show that about 85-100% of vitamins, including A, C, B1, B2, Source: Roche, Hong Kong, 1990. D3 B12
E Niacin
niacin, B6, B12, folate, biotin, pantothenic acid and E added to the rupiah (US$ 0.0002) per sachet of seasoning, amounting to a cost
seasoning mixture were retained after 3 months of storage at room of fortification of about 0.23% per package of instant noodles. The
temperature. As vitamins are gradually lost, about 75-90% of the total cost of fortifying wheat flour in the U.S. with 6.4 mg/kg of vitamin
added levels were retained after 6 months of storage (Figure 6). In B1, 4.0 mg/kg of vitamin B2, 52.9 mg/kg of niacin, 44.1 mg/kg of iron,
Thailand, vitamin A palmitate, encapsulated reduced iron, and 1.54 mg/kg of folic acid is less than US$ 1.00 per metric ton of flour
potassium iodide added to seasoning were stable for up to 3 or about 0.1% of the retail price of flour.
months at room temperature. In the United States, the cost of a volumetric feeder varies widely
Micronutrients added to the seasoning remain uniformly between US$ 5,000 and 7,000, while that of a ribbon or paddle
distributed during storage, although some settling was observed in blender/mixer varies between US$ 9,000 and 15,000. This
studies in Thailand. The micronutrient premix can be formulated to equipment, however, may be available locally at lower prices.
avoid or minimize adverse effects on the sensory characteristics of
the seasoning mixture or the finished instant noodles. For example, Country Practices
studies in Thailand showed that ferrous fumarate and iron EDTA Fortification of instant noodles with vitamin A, B1, B2, niacin, B6,
reacted with some ingredients (such as nutmeg) of the seasoning folic acid, iron, and casein (a milk protein) was initiated in 1994 in
mixture resulting in an unacceptable black color of the instant Indonesia. A survey conducted in 1996-97, however, found that
noodle soup. Encapsulated reduced iron, on the other hand, did not consumption of fortified noodles is related to socio-economic status
produce any adverse effects on the seasoning mixture or the with consumption being lowest in the poorer segments of the
finished instant noodles. The bioavailability of this form of iron population3. Although the efficacy of fortifying instant noodles has
fortificant, however, is not known. not been fully determined, one study conducted in Indonesia
provided promising results. Compared with a control product
Quality control (containing about one-half the vitamin A and iron as the fortified
Quality assurance and control ensures that the manufactured product), consumption of instant noodles fortified with 750 µg (2,500
food is safe, unadulterated, properly labeled, and meets all IU) of vitamin A and 9 mg of iron per 100 g for 3 months had a
company quality specifications and any government regulations. beneficial effect on vitamin A and iron status of pregnant women and
Quality control procedures for the fortification step can be easily children under 5 years of age4. Currently, about 50% of the instant
incorporated into the existing quality assurance system for the
noodles marketed in the country are voluntarily fortified.
manufacture of instant noodles. The micronutrient premixes must be
Thailand initiated voluntary fortification of seasoning in instant
tested against reference standards. Periodic testing must be done
noodles with vitamin A, iron, and iodine in 1996 after feasibility and
to ensure that the desired amounts of micronutrients are in the final
stability studies showed promising results. The government reduced
product, especially the ones that are most unstable, such as vitamin
taxes on imported fortificants, which facilitated gaining the
A. Quality criteria should be established for all key characteristics of
commitment of manufacturers, and established labeling guidelines.
the product, including fortification levels. Facilities, procedures, and
properly trained staff are, therefore, essential. Instant noodles fortified in amounts providing one-third of the Thai
Determination of vitamins A, B1, B2, niacin, B6, and folic acid is RDI are labeled “Fortified with iodine, iron, and vitamin A” on the
done using quantitative methods that employ the use of an HPLC or front panel. However, given that fortification is not mandated by
a spectrophotometer. Minerals such as iron can be determined government regulation, not all instant noodles are fortified. Currently,
using atomic absorption or spectrophotometric methods. When about 80% of instant noodles produced in the country are fortified
instant noodles are fortified with more than one micronutrient using and efforts are underway to improve the formulation and extend the
vitamin mineral premixes, one micronutrient (for example, iron) may shelf life, and promote universal fortification of instant noodles.
be chosen as a reference nutrient and its level determined during In the Philippines, about 85% of the instant noodles available in
routine quality control procedures. All micronutrients, however, the market are now voluntarily fortified. Although the fortification
should be determined occasionally to ensure adequate fortification range varies, most instant noodles contain seasoning that is fortified
with all micronutrients intended to be present in the food. with one-third of the national RDA of vitamin A, and some with iron
and iodine. Vietnam is also currently exploring the fortification of
Cost domestically produced instant noodles.
The cost of fortifying instant noodles includes the cost of the
micronutrient premix, equipment (feeders and/or mixers), Unlike micronutrient fortification of cereal flours, sugar, and
equipment maintenance, and added cost of quality control and oil/margarine, fortification of instant noodles, especially of the
personnel. The retail price of a 55 gram instant noodle package is seasoning that accompanies instant noodles packages, is a
about 2-18 roubles (US$ 0.05-0.48) in Russia, 5.00 baht (US$ 0.12) relatively new undertaking. Unfortunately, there is insufficient
in Thailand, and 800 rupiah (US$ 0.09) in Indonesia. In Thailand, information on critical issues such as the stability of micronutrients,
adding 20 mg of a micronutrient premix to the seasoning to provide bioavailability of fortificants, efficacy of fortification, and
267 µg of vitamin A, 5 mg of iron as encapsulated reduced iron, and effectiveness of the intervention. Nevertheless, overall consumption
50 µg of iodine as potassium iodide per package of instant noodles of instant noodles is growing steadily in many countries, the
is estimated to cost about 0.02 baht (US$ 0.0005), amounting to a fortification technology is available, and preliminary data on stability
cost of fortification of 0.3% per package. In Indonesia, adding 6 mg and efficacy are promising. Consequently, some countries are
of a micronutrient premix containing 270 µg of vitamin A, 28 mg of exploring the potential of instant noodle fortification as an effective
calcium, and 4.2 mg of iron (added to the dough) along with several public health intervention while manufacturers voluntarily fortify their
51608

other B-vitamins to the seasoning is estimated to cost about 1.8 products.

3. Melse-Boonstra A, de Pee S, Martini E, et al. 2000. The potential of various foods to serve as a carrier for micronutrient fortification, data from remote areas in Indonesia. Eur J Clin Nutr 54 (11): 822-7.
4. Muhilal. 1998. Noodles: a suitable vehicle for fortification. Nutriview 95/2.