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INTRODUCTION

Noodles are one of the staple foods consumed in many Asian countries. Instant

noodles have become internationally recognized food, and worldwide consumption is on

the rise. The properties of instant noodles like taste, nutrition, convenience, safety, longer

shelf-life, and reasonable price have made them popular. Quality factors important for

instant noodles are color, flavor, and texture, cooking quality, rehydration rates during final

preparation, and the presence or absence of rancid taste after extended storage.

Microstructure of dough and noodles has been studied to understand the influence of

ingredients and processing variables on the noodle quality by employing scanning electron

microscopy.

Applications of newer techniques like confocal laser scanning microscopy and

epifluorescence light microscopy employed to understand the microstructure changes in

dough and noodles have also been discussed. Sincere efforts of researchers are underway

to improve the formulation, extend the shelf life, and promote universal fortification of

instant noodles. Accordingly, many researchers are exploring the potential of noodle

fortification as an effective public health intervention and improve its nutritional

properties. This review focuses on the functionality of ingredients, unit operations

involved, quality criteria for evaluation, recent trends in fortification, and current

knowledge in relation to instant noodles.

ABSTRACT

Starch noodles, produced from purified starch of various plant sources, are a major

category of Asian noodles. This review summarizes the current knowledge on:
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(1) Definition, naming, history and categories of starch noodles.

(2) The morphological, physico-chemical, thermal, rheological characteristics and

molecular structure of materials including mung bean starch, pea starch, sweet potato

starch, potato starch and corn starch.

(3) Processing technology of starch noodles including dropping, extruding and cutting.

(4) Structure of starch noodles: it is composed of hydrolysis-resistant crystalline zone,

network-like framework and filler mass.

(5) Nutrition of starch noodles: it could be evaluated by the digestibility of starch,

hydrolysis properties of gelatinized and retrograded starches, hydrolysis property of starch

noodles.

(6) Quality evaluating of starch noodles: it includes sensory, cooking and texture property.

Correlation between the physical properties of starch, processing variables and the sensory,

cooking and texture property of starch noodles are summarized.

(7) Quality improving for non-mung bean starch noodles:

(a) using other materials such as red bean starch, pigeon pea starch, potato starch,

sweet potato starch, corn starch, to substitute totally or partly mung bean starch;

(b) Adding chemically modified starch;

(c) Adding physically modified starch;

(d) Biologically treating starch;

(e) Using additives such as chitosan, polysaccharide gums.

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HISTORY

Noodles in various contents, formulations, and shapes have been the staple

foods for many Asian countries since ancient time. They can be made from wheat,

rice, buckwheat, and starches derived from potato, sweet potato, and pulses. Noodles based

on wheat are prepared mainly from three basic ingredients; flour, water, and salt. There

exist two distinct types of wheat flour noodles based on the presence and absence of

alkaline salts, regular salted noodles, and alkaline noodles.

The basic process of dough mixing, sheet forming, compounding,

sheeting/reduction, and cutting are essentially constant for all machine-made noodles.

Noodle strands coming out of cutting rolls can be further processed to produce different

types of noodles. This article analyzed all the major processes involved from raw material

to finished products in relation to noodle processing properties and cooked noodle texture.

Different ingredients and their functionality in noodle processing were discussed as well.

Guidelines were provided to select the right ingredients to produce high quality noodle

products. Processing properties, appearance, and color of noodles are the three key criteria

used to judge a process and raw material quality.

High quality noodles should be bright in color with very slow discoloration, have

an adequate shelf life without visible microbiological deterioration or oxidative rancidity,

and have appropriate flavor and textural characteristics, which will vary according to the

noodle type and region. Flour plays a key role in all aspects of noodle quality. Protein

content is positively correlated with noodle firmness and sometimes negatively correlated

with elasticity. Therefore, a correct range of protein content is important for textural

characteristics. Adequate gluten strength and extensibility is required in all noodle flours.
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Noodle dough must be strong enough to withstand sheeting, but not as strong as to cause

tearing or difficulty in sheet reduction. A good level of dough extensibility ensures that

dough sheets do not shrink back during successive roll passes. The importance of the

pasting properties of starch to the texture of cooked noodles has been well documented.

The required soft, smooth, and elastic textural properties of certain types of white

salted noodles can be best obtained from wheats with high starch paste viscosity and high

swelling starch properties. Alkaline noodles do not have the same requirement for high

starch swelling properties. Noodles made from flour with high swelling starches have softer

texture than those with low swelling starch. Noodles should be bright and slow in

discoloration with time after manufacturing. For white salted noodles, a white or creamy

white color is desirable. The level of natural yellow pigment levels (xanthophyll’s) in flour

is highly correlated with noodle color, and this is wheat variety dependent. For yellow

alkaline noodles, a bright yellow color is required, although the preference for the degree

of color development is regionally based. Noodle darkening increases with the increases

of flour extraction rate.

This is due to the action of polyphenol oxidase (PPO) enzymes, which are largely

located in the bran layer. Low flour extraction and ash levels are preferred for the

manufacture of noodles with a clean and bright appearance.

A relatively fine flour particle size enables even hydration during mixing and

optimum, uniform gluten development during sheeting. Increased starch damage, however,

is associated with poor noodle color and undesirable high cooking loss and excessive

surface swelling.
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I. COMPANY BACKGROUND

Monde Nissin Corporation is one of the best and well-known company providing

its goods and services in and outside our country. It is a private company and won the

fractures different kinds of food products such as noodles, biscuits and others. September

4, 1979 when the Nissin Corporation was first established. Betty Ang founded it according

to the alignment of Forbes Asia. Their manufacturing building can be found at three

locations. Main Branch at Sta. Rosa, Laguna during 1980 up to present time and the other

braches located at the Manila. The Monde Nissin Corporation was originally incorporated

as Monde Denmark Nissin and among its product were Nissin Butter Coconut and Nissin

Wafer. In 1989, the company ventured into the instant noodles under Lucky Me! Brand,

marketed mainly for the lower class and it has become the leading brand of the instant

noodles in the Philippines. The company later launched the very first dry noodle in

pouches, the Lucky Me! Pancit Canton and the first bowl noodle, Lucky Me! Supreme La

Paz Batchoy. In 2002, the company acquired M.Y, San Corporation, the manufacturer of

the popular brands, Skyflakes, M.Y. San Graham Crackers, Fita and many more. Their flag

waived logo colored red and orange endeavors to be a venue where people can continuously

learned and develop, helping them to achieved their highest potentials as human beings;

thus effectively contribute attaining a common good through genuine partnership. For more

than three decades now, Monde Nissin has steadily and aggressive risen to be one of the

country’s leading food manufacturers.

PRODUCTION AND CAPACITY

The company operates every day from Monday to Saturday and since that they have

a very innovated machines and flexible manufacturing system, they can produce 750
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pouches per minute, meaning 45,000 per hour and the overall standard output daily they

produced is 6-10 million a day.

MONDE NISSIN PHILIPPINES

Founder : Mr. Momofuku Ando (1910 - 2007)

President and CEO : Mr. Koki Ando

Balibago Plant : three shifts / day

Number of Employees = 250 employees

= 216 regular operators

Area = 30,000 sq. meter (4-storey)

OUR PRODUCTS

Monde Nissin is the company behind the iconic Filipino brand and instant noodle

giant Lucky Me! and several leading products in the biscuits and snacking categories.

Noodles: LUCKY ME!

 Instant Mami (noodles with soup in pouch)

 Pancit Canton (dry noodles in pouch)

 Special (special noodles in pouch)

 Supreme (cup noodles)

 NamNam All-3-in-1 Seasoning

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Monde Nissin Biscuits, Wafers, and Cookies

 Butter Coconut

 Wafer

 Stick Wafer

 Cube Wafer

 Bread Stix

 Eggnog

 Coco Bites

 Marie

 Waffle Deluxe

 Voice

 Bingo

 Sumo

 One-One Rice Snack

Monde M.Y. San Biscuits

 Sky Flakes

 Fita

 M.Y. San Grahams

 Butter Cookies

 Danish-style Butter Cookies

 Happy Time

 Mixed Up
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Bakery

A. Monde

 Special Mamon

 Special Cream Puff

 Belgian Waffle

 Crispy Waffle

 Muffin

 Caramel Bars

 Brownies

 Baked Puto

B. Walter Bread

 Sugar Free Wheat Bread

 Sugar Free Wheat Pan de Sal

 High Fiber Weight Control Bread

 Double Fiber Wheat Bread

 Whole Wheat Raisin Bread

 Thick

 Slice Super Loaf

Snacks

 Pringles Potato Chips In Can  Rice Crisps

 Pringles Bites
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Cereals: Kellogg's - under licensed

 Kellogg's Corn Flakes

 Kellogg's Frosties

 Kellogg's Cocoa Frosties

 Kellogg's Froot Loops

 Kellogg's Special K

 Kellogg's Coco Pops

 Kellogg's Coco Loops

 Kellogg's Coco Chex

 Kellogg's Rice Krispies

 Kellogg's All-Bran

 Kellogg's Raisin Bran

Beverages

 Dutch Mill  Nudie Juice

 Kratos Iced Coffee  Jelly Vit Jelly Drink

Culinary aids

 Lucky Me! NamNam  Quorn

 Mama Sita's (domestic

distribution)

Others

 Smoothie Bebe
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CHALLENGES

Cost of factory defect: The tourist of their power plant told us that one of the major

operation challenge that they have encounter are the lack of seasoning that was discovered

in the end of process or already at the hand of consumer in this case they have to replace

with another one has a seasoning. This will probably add to the cost of the production, as

well the loss of their customer loyalty and negative effect to their employee’s performance.

Machine failure: When we are looking at the machine while it was in the process of

delivering the noodle from one stage to other, it seems to stock up. It does not flow very

well and begin to drop on the floor. So, some factory worker will have to come and fix it

until it flow well again, after 1-2 min it begins to stock up again.

Maintenance throughout the whole process: Keeping in place a wide array manu-facturing

company such the machine, employee, customer, competitor and market truly requires

continuous improvement principle.

ECOLOGICAL/NATURAL ENVIRONMENT CHALLENGES

Since Monde Nissin manufacturing is a fully automated manufacturing system all

throughout the process of their mass variety of product from making the noodle and

seasoning up to packing stage, the whole production process of their operation depends

largely on the electricity. Black-out or system breakdown caused by natural calamities or

typhoon usually will totally paralyze the entire production.

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COMPANY PROCESS

A. What is the process type they use?

Monde Nissin is a conglomerate of manufacturing company that produces noodles,

biscuits, and some dairy products that fit the needs and tastes of every Filipinos and because

they produce a high volume of products with a high standardized requirement, the process

type that they are using is continuous.

Continuous process type totally fits the requirement and capacity of the factory for

they have seven phases of producing noodles which are organized from the very first step

until the last, and they are producing six to eight million pouches of noodles in a day.

B. Is the process automation/technology/innovation base?

The process is innovated by the types of machines they are using for the different

types of processes such as in mixing where all of the ingredients for noodles will be mixed

together in a large mixing machine. Then after that the huge dough will be flattened by a

big roller machine then are skittered by an automatic machine blades then cut into strips

then fried and cooled to prepare it for packaging. In their packaging section, they are using

robots which have sensors to include the condiments in the pouch of the noodle and these

in turn were able to produce 250 pouches of machines per minute.

C. Describe their process and facilities layout?

The layout that they are using is a production line type for the first steps up to the

sixth of creating noodles, there were no human intervention. Then labor and engineers can
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only be found on the seventh step of the process which is packaging for they need to take

charge of the robots in case that there will be a failure into the sequence.

D. How do they apply line balancing and avoid bottle neck in the process?

They apply line balancing by having fully automated machines and having only

eight persons per assembly line to avoid process congestion.

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II. SITE LOCATIONS

MONDE NISSIN MAIN BUILDING

Balibago Rd, Balibago Sta. Rosa, Laguna

74R2+H4 Santa Rosa, Laguna

DIRECTION FROM SLSU MAIN CAMPUS TO NISSIN MONDE CORP. STA

ROSA, LAGUNA
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BRANCHES IN MANILA

22 F Ayala Ave, Makati, 6750 Metro Manila

H23G+76 Makati, Metro Manila

9 Sheridan, Mandaluyong, Metro Manila

H3C2+QP Mandaluyong, Metro Manila

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III. PLANT LAYOUT

Guest
Room
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IV. MAJOR EQUIPMENTS AND SPECIFICATIONS

a. DOUGH MIXER MACHINES

Max. Loading Capacity : 500kg

Voltage : 380V or customized

Power (KW) : 2.2

Dimension (L x W x H) : 1450 x 1100 x 2200) mm

Hopper material : stainless steel

Rotating speed : 300rpm

b. COMPOUND ROLLER
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Type : Dried noodles

Production Capacity : 2 - 15 Tons / 8hrs

Voltage : 380V / 50HZ

Power (KW) : 65 - 150

Dimension (L x W x H) : 60 x (5 - 15) x 5 m

Weight : 30 tons

Material : 304 Stainless Steel

c. CONVEYOR STEAMER/ACCUMULATOR

Production Capacity : 99%

Voltage : 220/380V

Power (KW) : 5.2

Dimension (L x W x H) : (420 x 75 x 135) cm

Weight : 150kg

Material : Stainless Steel

Capacity : 200-300kg/hr.
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d. SLITTER MACHINE

Production Capacity : 2 - 9 lanes

Overall shape (L x W x H) : 3800 x 3200 x 3300

e. AUTOMATIC HORIZONTAL PACKING MACHINE

Capacity: 50-200 packs/minute

Floor Space: (L x W x H) = 5,400 x 1,020 x 750 mm.

Power Consumption: 4.56 kW.

Net weight: 1,000 kg.

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V. FUNCTIONALITY OF RAW MATERIALS / INGREDIENTS

The main ingredients for instant noodles are wheat flour, salt, or kansui (alkaline

salt mixture of sodium carbonate, potassium carbonate, and sodium phosphate), and water.

Other ingredients like starch, gums, emulsifiers, stabilizers, antioxidants, coloring, and

flavoring agents are also added to improve the texture, eating quality, and shelf life of

instant noodles (Table 1). Nowadays, instant noodles are also fortified with protein,

minerals, and vitamins to improve their nutritional value.

Table 1 Ingredients used for manufacturing instant noodles (Hou and Kruk, 1998; Hou,

2001)

Wheat Flour

Starch properties are also important in determining quality of noodles as their

texture depends largely on gelatinized starch (Bushuk, 1998). Variations in starch

properties have been found to play a major role in noodle softness and viscoelastic

properties (Crosbie, 1991; Konik et al., 1992, 1993; Yun et al., 1997). Pasting
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characteristics (Oda et al., 1980; Zhang et al., 2005a), peak viscosity (Bhattacharya and

Corke, 1996), flour swelling volume (Crosbie, 1991), amylose:amylopectin ratio, and

damaged starch (Oh et al., 1985a) determine the noodle properties. Flours with low

gelatinization temperatures are preferred for rapid hydration during cooking. Higher starch

damage is associated with poor noodle color, undesirable high cooking loss, and excessive

surface swelling (Hatcher et al., 2002). The fine particle flour with lower starch damage,

therefore, results in good cooking quality of noodles. The rheological properties of raw

WSN have been found to be mainly influenced by the size of starch granules, where the

small starch granules exhibited high amounts of water absorption during dough preparation

and a dense packing of starch granules inside a thin gluten-strand network. However, the

rheological properties of cooked WSN were mainly dominated by the amylose content and

fine structure of the amylopectin, which resulted in the differences in water absorption and

cooking time required for cooked WSN (Huang and Lai, 2010).

Processing of wheat dough during instant noodle preparation and storage alters the

enzyme resistance of starch. Dhital et al. (2010) studied the effect of processing and storage

conditions of instant noodles on formation of resistant starch (RS). It was seen that dough

forming operation did not contribute significantly to the formation of RS; however,

steaming of the noodle strand under pressure, frying, and storage time increased RS content

of noodle. The rate of increase and quantity of RS was higher at refrigerated condition

compared with that of room temperature. It was concluded that the gelatinized and

fragmented amylose molecules undergo molecular reassociation or retrogradation during

storage, which results in increased RS content. Furthermore, the retrogradation process

may occur rapidly in the beginning and slow down with time.
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Water

Water is another essential ingredient, which is necessary for gluten formation,

which provides viscoelastic properties to dough required for noodle processing. The

amount of water needed for noodle processing is optimized to hydrate the flour and develop

a uniform dough sheet. The optimum water absorption for noodle is affected by protein

content, protein quality, damaged starch, and other physical properties of flour (Park and

Baik, 2002). The water absorption level recommended for noodle processing is about 30–

38% based on flour weight. Water absorption level has a major impact on the amount of

work required in processing as well as color. There was a significant decline in textural

characteristics with increasing water absorption (Edwards et al., 1996; Hatcher et al., 1999;

Park and Baik, 2002). Sheeting, cutting, and drying of noodles become difficult when water

absorption deviates more than 2–3% from the optimum level. Insufficient water results in

noncohesive stiff dough and less extensible noodle sheet while too much water results in

dough stickiness handling problems during processing (Hatcher et al., 2008c). Optimum

water absorption can be determined using a mixograph or farinograph (Oh et al., 1986;

Seib et al., 2000) and by experienced personnel on the basis of dough handling properties.

Salt and Alkaline Reagents

The amount of salt added in noodles is usually 1–3% of flour weight. Salt has

strengthening and tightening effect on the gluten, which may be due to its inhibitory effect

on proteolytic enzymes, or by direct interaction of the salt with flour proteins. Thus, it

significantly improves sheeting properties of dough, especially at high water absorption

levels. Incorporation of salt reduces cooking time, enhances flavor, provides softer but
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more elastic texture, and inhibits enzyme activities and the growth of microorganisms (Fu,

2008).

Alkaline salt can be used alone or in combination with different salts, depending on

local preference. The most commonly used alkaline salts are sodium and potassium

carbonates. Other alkaline reagents, such as sodium hydroxide and bicarbonates are also

used in some countries. The type of alkaline salt used also affect the quality of noodles

(Hatcher et al., 2008c). Addition rates of alkaline salts are 0.5–1.5% for noodles with strong

alkaline flavor and 0.1–0.3% as a quality improver for instant noodles. The unique yellow

color associated with addition of alkaline salts in common wheat used for noodle

preparation is due to endogenous flavonoids undergoing a chromophoric shift. i.e., turning

yellow, in the presence of alkali (Asenstorfer et al., 2006; Hatcher et al., 2008b). The

changes in dough characteristics associated with alkaline pH fundamentally influence the

behavior of the gluten proteins resulting in tougher, tighter, and less extensible dough. The

toughening of dough with alkali addition has a very significant impact on the processing

properties and the texture of the final products. The addition of alkali increases water

absorption potential of noodle dough, gives noodles a firmer texture, increases both the

breaking and cutting forces of noodles (Sung and Sung, 1993), retards starch gelatinization,

and increases starch paste viscosity (Bean et al., 1974; Terada et al., 1981).Ong et al. (2010)

found that gluteninmacropolymer (GMP) extracted from alkaline dough was gummy,

sticky, more opaque and had higher gel strength than that from salted dough. GMP gel

strength also increased significantly after dough resting in alkaline dough suggesting the

role of GMP in increasing dough stiffness.

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Fat/Oil

Oil represents about 20% of the total weight of the final product. The most common

frying oil used in Asia is palm oil because of its good frying performance, heat stability,

availability, and relatively low cost. Partially hydrogenated soybean and canola oil can also

be used for frying. Frying oil has a significant effect on the flavor of instant noodles; the

frying oil should be of good quality. During frying, the quality of oil deteriorates as a result

of chemical reactions, prolonged, and continuous heating, which may pose food safety

concerns and sensory failures. Therefore, heat stability is a major concern in selecting

frying oil. The quality of frying oils can be judged by its color, flavor, free fatty acids,

peroxide value, iodine number, melting point, and smoke point.

Improvers and Preservatives

Polyphosphates, hydrocolloids, emulsifiers, antioxidants, and starches are

commonly used as additives to improve product quality in noodle processing. Various

additives used in instant noodles along with their functional properties have been presented

in Table 2.
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In the dough system, polyphosphates act as chelating agent, modify the dough

processing properties and retard the discoloration discoloration process of fresh noodles.

Polyphosphates accelerate gluten bonding, which improves noodles elasticity, flexibility,

texture, and chewing properties; facilitate the starch gelatinization during cooking,

allowing morewater retention in the noodle and reduces water cloudiness while cooking

(Hourant, 2004). They are dissolved in water before the mixing of the dough, and their

usage rate is typically 0.1% of flour weight.

Hydrocolloids such as guar gum, locust bean gum, alginates, and carboxymethyl

cellulose (CMC) are widely used in instant noodle processing. The addition of gums (0.1–

0.5%) improves rehydration characteristics of noodles during cooking, modifies the texture

and overall “mouthfeel” of finished product, and decreases the fat uptake during frying of

instant noodles as they are hydrophilic and have high water binding capacity. Gum and

starch improved binding and mechanical network in the dough. Insufficient water in the

dough apparently reduced cohesion in the dough, whereas excess water reduced the

functionality of gum and starch (Yu and Ngadi, 2006). Choy et al. (2010) examined the

effects of varying microbial transglutaminase (MTGase), sodium stearoyl lactylate (SSL),

and water on product texture and color of instant noodles. MTGase and SSL improved the

textural properties of noodles prepared with lowprotein flour due to enhanced development

of structure within the noodles with no significant difference in noodle color. MTGase and

water also affected fat uptake with an inverse relationship between water incorporation and

uptake. Choy et al. (2012) also reported that the combined use of acetylated potato starch

(APS) and CMC primarily affects textural attributes of hardness and adhesiveness, rather

than other quality parameters of instant noodles. However, addition of CMCalone had a
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negative impact on the cohesiveness values of cooked instant noodles with minimal effects

on stickiness and fat uptake, whereas APS enhanced noodle hardness without significantly

affecting the cohesiveness values. It was concluded that APS can be used as an ingredient

for enhancing noodle eating quality in case of lower protein wheat flours.

Lee et al. (2008) studied the effects of addition of alginate on physicochemical,

rheological, and noodle-making properties of wheat flour. With the addition of alginate,

noodles exhibited an increase in cooked weight, cutting and tensile forces, and yellowness

while there was a decrease in cooking loss, lightness, and redness. Carotenoids and

flavonoids pigments of wheat and alkaline reagents contribute to color of noodles.Natural

and synthetic colors are also used to enhance the color. Food colorants such as β-carotene

are often used in the formulation of udon noodles to adjust the creamy yellow color.

Tartrazine is commonly added to intensify the yellow color of Hokkien noodles in

Southeast Asia (Crosbie and Ross, 2004). Natural coloring agents, such as vitamin B2 are

used in addition to kansui to fulfill consumer’s preference of having lower amounts of

alkaline salts in yellow Chinese alkaline noodles.

Steamed and deep-fried instant noodles have a high fat content of 15–22%, and

oxidative rancidity is the major factor limiting shelf life. Antioxidants like butylated

hydroxyanisole (BHA), butylated hydroxytoluene (BHT), propyl gallate (PG), and tertiary-

butylhydroquinone (TBHQ) are widely used to overcome rancidity problems in the

finished product. Of these, TBHQ has been shown to have best antioxidant activity (Fu,

2008). TBHQ is regarded as the best antioxidant for protecting frying oils against oxidation

and, like others, it provides carrythrough protection to the finished fried product

(Dobraszczyk et al., 2006).

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Various enzymes, i.e., TGase, lipases, oxidoreductase, and amylases have also been

included in the formulations of instant noodles, primarily to enhance the texture of the

noodles. TGase increases break strength of uncooked dried noodles as well asfirmness of

cooked noodles by forming glutamyl-lysine crosslinks in gluten. TGase induces the

formation of high molecular weight polymers, despite the low lysine content in gluten

proteins; reinforces the network structure; modifies the gluten viscoelasticity, and also

improves thermal stability of gluten during processing (Motoki and Seguro, 1998). Wang

et al. (2011) observed that the addition of TGase improved the rheology and processing

properties, cooking quality as well as elasticity of noodles prepared from oat dough

containing exogenous proteins (vital wheat gluten and egg albumin), thus suggesting that

TGase can be utilized for developing gluten free noodles and enhance the quality of

noodles from nonwheat flours. Lipases have been stated to reduce surface stickiness and

increase firmness of cooked noodles. Oxidoreductases, such as glucose oxidase, on the

other hand not only increase noodle firmness, but also reduce stickiness and cooking loss

in noodles. Surface application of amylases is proposed to reduce the surface stickiness in

packaged as well as precooked noodles (Crosbie and Ross, 2004). However, addition of

alpha-amylase in WSNs resulted in undesirable soft texture (Cato et al., 2006).

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VI. PROCESS FLOW CHART

To avoid risks related to production, the NISSIN FOODS Group is stepping up

operations management under ISO 9001 (management systems for quality control and

quality assurance) implemented at each plant and moving ahead with efforts to obtain ISO

22000 (food safety management systems) certification. Based on the ISO 22000 standard,

we are engaging in integrated risk management from raw materials procurement to

production and distribution and strengthening safety measures.

Our production plants achieve high-volume production of high-quality food

products using production lines automated at every step, from flour input to the packaging

of finished products. Here we introduce the processes involved in the production of Cup

Noodles.
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VII. MANUFACTURING PROCESS

Noodle processing typically comprises mixing raw materials, resting the crumbly

dough, sheeting the dough into two dough sheets, compounding the sheets into one,

gradually sheeting the dough into a specified thickness, and slitting into noodle strands.

For instant noodles preparation, strands are steamed and dehydrated by drying or frying

followed by cooling and packaging with the seasonings.

Mixing

Ingredients other than flour are pre-dissolved in water, stored at 20–30◦C while salt

water can be prepared separately. Wheat flour and water along with other weighed

ingredients are mixed first at high speed and then at low speed, giving a total time of 15–
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25 minutes in industries while at laboratory scale researchers have used a mixing time of 4

to 5 minutes (Yu and Ngadi, 2004; Park and Baik, 2004b;Wu et al., 2006). The mixing

time, however, also depends on the type of mixer used. In contrast, to bread processing,

function of mixing for noodles is to distribute the ingredients uniformly and to hydrate the

flour particles. There is little gluten development during the mixing stage in flour having

low water absorption capacity. The degree of gluten development, however, is significant

in high water absorption dough (>35%) with long mixing time (>15 minutes). Mixers

commonly used in the noodle industry include horizontal mixer, the vertical mixer,

continuous high-speed mixer, low-speed super mixer, and the vacuum mixer. Mixing is

also influenced by the quality of flour, volume of water added, presence or absence and

amount of certain ingredients (especially salt and alkaline salt), and temperature and

humidity of processing environment.

Flour of high protein content and damaged starch tends to produce larger dough

crumbs during mixing that may result in uneven hydration (Azudin, 1998). Mixing is

usually followed by dough resting. This step allows the crumbly mixture to rest for a period

of time to accelerate further hydration of flour particles and to redistribute water in the

dough system. Resting improves processing properties and facilitates gluten formation

during sheeting. This is achieved by the relaxation of the gluten structure already formed

during mixing. Resting is carried out by mixing dough at very low speed (5–8 rpm) for 10–

20 minutes. Mixing at low speed avoids the formation of large dough pieces during resting

and also serves feeding of the sheeting rolls in the continuous process. Resting also

determines the degree of starch gelatinization during steaming (Wu et al., 1998).
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Sheeting

After mixing, the crumbly dough is compressed to form continuous dough sheet,

which is folded or compounded and passed through subsequent rolls. The sheeting process

is intended to achieve a smooth dough sheet with desired thickness, and a continuous and

uniform gluten matrix in dough sheet. At the sheeting stage, number of passes through

rolls, roll diameter, sheeting speed, and reduction ratio are the main factors affecting dough

sheet characteristics. The thickness of dough sheet is reduced gradually to avoid damage

to the surface and gluten structure, which is controlled by roll gap settings in a series of

smooth rolls. With each successive pass, the roll diameter should decrease gradually so

that compression distance and pressure are also reduced. Dough sheets are rested to allow

gluten structure relaxation or mellow the gluten and make it more extensible by slow

passage on a zigzag conveyor in automated plants.

Cutting/Slitting and Waving

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The dough sheet is cut into noodle strands of desired width with a slitter. The width

and shape of noodle strands are determined by cutting rolls. Noodles can be either square

or round in shape according to various slitters used. In case of instant noodle production,

noodle strands are continually fed into a traveling net conveyor, which moves slower than

the cutting rolls above it. The speed differential between noodle feeding and net traveling

results in a unique waving of noodle strands. For instant noodles, the cutting rolls are

numbered from 18–22. Numbering represents the number of edges on a piece of 30-mm-

wide sheet. For example, a number 18 cutting roll has 18 edges that result in a noodle strip

width of about 1.7 mm. Noodle strands are cut into a desirable length by a cutter.

Steaming and Molding

The cut and wavy noodle strands are conveyed to a steam chamber to cook them

by exposing to a temperature of 100◦C for one–five minutes. The degree of cooking during

steaming is critical and depends on the original moisture content of noodle; amount,

pressure, and temperature of steam; and steaming time. Under steamed noodles will have

a hard core and will be difficult to cook properly, whereas over steamed noodles are soft

and sticky. Steaming is a key process in the manufacture of instant noodles. A high degree

of starch gelatinization is required for the production of hot-air dried instant noodles.

Superheated steam at high temperature can be used to partially cook, rapidly drying them,
 Page 32

thus, creating an instant noodle without the necessity of frying in oil (Pronyk et al., 2008).

Steam cooking of starch–water mixture triggers a number of physicochemical and

functional changes in starch granules, such as the loss of granular structure associated with

melting of crystallites and underlying helices, and the generation of an amorphous structure

(Dhital et al., 2010). The degree of starch gelatinization determines noodle rehydration

rate, firmness, and viscoelasticity, and it is mainly controlled by the steaming process.

Steaming time is longer for hot-air dried noodles than for deep fried noodles. Excessive

swelling of starch on the noodle surface, which causes many processing problems, should

be avoided during steaming in instant noodle production. Noodles cooked by steaming are

cooled and extended to separate the strands and cut into one serving size. Weight of noodles

is regulated by the number of strands produced by cutting rolls and length of strands.

Noodles strands are further folded before cutting for the square type products. The cut

noodles are placed in molder of square, round, bowl, or cup shape, depending on the desired

product shape before moving to the fryer or drier.

Frying/Drying

After steaming and molding, noodle blocks are fed into frying baskets, which are

mounted on the traveling chain of a tunnel fryer. The baskets filled with noodle blocks are

immersed in hot oil for deep frying. Dehydration of the exterior surface drives water to
 Page 33

migrate from the interior to the exterior of the noodle strands. Eventually, some of the water

in the noodles is replaced by oil (Dana and Saguy, 2006). Many tiny holes are created

during the frying process due to mass transfer, and they serve as channels for water

penetration upon rehydration in hot water. The frying temperature and time are usually

varied from 140 to 160◦C, for 60 to 120 seconds, respectively. The cup noodles are fried

at a higher temperature and longer time as compared with the bag type noodles. The frying

process should be optimized to obtain fried noodles with good sensory properties, low fat

content, and low fat decomposition products. Deep frying of noodle removes moisture,

incorporates oil into noodles, gelatinizes starch before the free water is evaporated, and

creates both external and internal porous structures in the noodle that facilitates

rehydration. Noodles drying can also be done by hot air to produce instant dried noodles.

Frying is the preferred method of drying as non-fried instant noodles require a longer

cooking time. The lesser fat content in case of instant dried noodle makes them attractive.

Elimination of oil in the drying of instant noodles may alleviate health concerns about the

fat content and presence of trans-fatty acids from partially hydrogenated and hydrogenated

oils while providing the consumer with a convenient and healthy food product. But the

acceptance of dried instant noodles is largely dependent on obtaining good textural

properties and eating quality.

Packaging
 Page 34

Frying or drying is followed by cooling the product to room temperature to avoid

rapid oxidation and other changes. The cooled noodles are packed into a bag along with a

soup base sachet. While for the cup noodles; powdered soup base is sprinkled over the

noodles and sealed with shrink film. Seasonings and dehydrated vegetables are included in

soup base. Higher fat content makes the noodles susceptible to oxidative changes and

development of rancid flavor. Thus, proper packaging plays important role in extending

the shelf life of the product. The onset of rancidity can be delayed by addition of antioxidant

in the frying medium. The rancidity of instant noodles is also accelerated in the presence

of ultraviolet light; hence, noodles are essentially packaged in reddish yellow or green

packaging material without any transparent parts. The packaging material used for noodles

are polypropylene or polyethylene film for bag noodles and polyester for cup noodles.

VIII. MATERIAL MASS BALANCE

Input Raw Materials:

Wheat flour

Palm oil

Sodium Polyphosphate

Sodium Carbonate

+ Tatrazine

Product:

= 55 grams instant noodles

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IX. BREAKEVEN POINT ANALYSIS

FINANCIAL ASPECTS

A. Fixed capital

i. Land and Building Amount (In PESO.)

Land 1000 Sq. Mts. @ P3,000.00 3,000,000

Cost of construction of shed

225 sq mtr. @ P50,000 / Sq. Mtr. 11,250,000

Total 13,250,000

ii. Machinery and Equipment

Sl. Description Amount (In Peso)

1. Vertical type powder

mixer 500 kgs. cap

with motor complete 100,000

2. Dough mixer blade type

75 kgs. Cap 200,000

3. Noodles making power operated machine with

different size die-heads 220,000

4. Wooden trays 1000 pcs. size 2'×3' 50,500

5. Plastic Buckets 4 each of

20 liters cap. 8,000

6. Aluminum/Galvanized

iron water tape pipe line fittings 60,500

 Page 36

7. Water boiler-fuel heated

75 Liters cap. 79,000

8. Installation of machinery

and equipment 12,000

9. Office furniture etc. 30,000

Total 562,000

iii. Pre-operative Expenses Amount (In Peso)

Legal expenses, start-up expenses,

establishment cost, consultancy fee,

estimate fee, interest and

trial runs, etc. 25,000

Total Fixed Capital Amount (In Peso.)

1. Land and Building 13,250,000

2. Machinery and Equipment 562,000

3. Pre-operative Expenses 25,000

Total 13,837,000

B. Working Capital (per month)

a. Personnel

Sl. Designation No. Salary Total

No. (In Peso.) (In Peso.)

1. Manager 1 30,000 30,000

2. Supervisor 1 25,000 25,000

3. Chemist 1 25,000 25,000

 Page 37

4. Clerk 2 20,000 40,000

5. Peon/Watchman 1 18,500 18,500

6. Skilled Workers 2 20,000 40,000

7. Unskilled Workers 4 16,500 66,000

Total 244,500

b. Raw Materials including Packaging Requirements

Particulars Qty. Rate Total (In Peso.)

1. Wheat Flour 13 MT 10,000 130,000

2. Starch “2 MT 10,000 20,000

3. Chemicals, salt, etc. L.S. – 7,000

4. Packaging Material L.S. – 30,000

Total 187,000

c. Utilities Amount (In Peso.)

1. Power 50,000

2. Fuel 14,500

3. Water 4000

Total 68,500

d. Other Contingent Expenses Amount (In Peso.)

1. Postage and Stationery 2,000

2. Telephone 2,000

3. Consumable Stores 3,000

4. Repairs and Maintenance 6,500

5. Transport Charges 8,000

 Page 38

6. Insurance 4,500

7. Sales Expenses 4,000

8. Miscellaneous Expenditure including

advertisement, legal fee and

entertainment charges 7,000

Total 37,000

Total Recurring Expenditure

a. Personnel 244,500

b. Raw Materials including Packaging Requirements 187 ,000

c. Utilities 68,500

d. Other Contingent Expenses 37,000

Total 537,000

C. Total Capital Investment Amount (In Peso.)

1. Fixed Capital 28,462,000

2. Working Capital 537,000

Total 13,837,000

FINANCIAL ANALYSIS

A. Cost of Production (per year) Amount (In Peso.)

1. Total recurring cost per year 6,444,000

2. Depreciation on building @ 5% 662,500

3. Depreciation on M/C @ 10% 26,600

4. Depreciation on office equipment @ 20% 6,000

5. Interest on total capital investment @ 14% 1,937,180

 Page 39

Total 9,076,280

B. Turn Over (per year)

Item Qty. Rate Amount

(In Peso.) (In Peso.)

Fresh Noodles in

55 gms./pack 2,727,273PCK 5.50 15,000,001.50

C. Net Profit (per year)

= Sales – Cost of production

= 15,000,001.5 – 9,076,280

= 5,923,721.50

D. Net Profit Ratio

= (Net profit per year / Turn Over per year) × 100

= (5,923,721.5 / 15,000,001.5) × 100

= 39.49%

E. Rate of Return

= (Net profit per year / Total investment) × 100

= (5,923,721.5 / 13,837,000) × 100

= 42.81%

F. Break-even Point

Fixed Cost Amount (In Peso.)

1. Depreciation on Building @ 5% 662,500

2. Depreciation on Machinery 26,600

3. Depreciation on Office Equipment 6,000

 Page 40

4. Interest on Total Investment 1,937,180

5. Insurance 4,500

6. 40% of salary and wages 1,173,600

7. 40% of other contingent expenses 62,160

Total 3,872,540

BREAK EVEN POINT

B.E.P. = (FC × 100) / (FC + P)

B.E.P. = (3,872,540× 100) / (3,872,540+5,923,721.5)

B.E.P. = 39.53%
 Page 41

X. QUALITY CONTROL

A. What are dimensions of Quality that is visible/associated to their operations of

product?

The dimensions of quality that are visible on their products or operations are:

 Performance: Its manufacturing processes requires a very intensive care and

monitoring using a computer aided machine that automatically control the machines

and that there are only few people present in most of the production processes.

 Reliability: Filipinos’ love for the brand developed through the years as Lucky Me!

has always been understanding and responsive to its valued consumers through

continuous innovations in its products.

 Conformance: Filipinos are known for its love for noodles and soups, and the taste of

Lucky Me! noodles we are not surprised that it meets the standard tastes of every

Filipino.

 Durability: Lucky Me! and other several products lives usually last for nine months

because they do not add preservatives and they use green tea as a substitute for water

to increase the life of noodles.

 Aesthetics: The Lucky Me! logo visually sends the signal of the brand’s care for its

consumers. A graceful circle runs around the “Lucky Me!” text to give a feeling of a

warm embrace from a good friend. The waft connotes the pleasant aroma and freshness

of the meal ahead. It triggers happy memories of light, bonding moments of sitting

around, sharing life, and eating together over fantastic, flavorful, and fuss-free meals.
 Page 42

 Perceived Quality: Monde Nissin is the company behind the iconic Filipino brand and

instant noodle giant Lucky Me! and several leading products and various categories.

B. What Quality practices they adopt?

Nissin Monde has a wide variety of product brands which are best known for its

quality taste and price that has grown into a household brand enjoyed by almost every

Filipino family. And to ensure quality, its plants have adapted a management system in line

with ISO 22000:2005 that conforms to the international standards for Food Safety

Management Systems.

Just for the second year now, Lucky Me! has received the honor of being the Most

Chosen Fast- Moving Consumer Good brand in the Philippines based on Kantar World

panel Brand Footprint report for 2015. Kantar World panel is an international company

dealing in consumer knowledge and insights based on continuous consumer panels.

Through market monitoring, advanced analytics and tailored market research solutions,

Kantar World panel analyses what people buy what they consumed and the attitudes behind

this behaviour.

The brand of Lucky Me! initially topped the list in 2013, surpassing local and

international brands in terms of consumer reach points. Per Kantar World panel’s latest

report, Lucky Me! has reached 98% of the households in the Philippines and is purchased

almost every week. The recognition strengthens Lucky Me!’s drive to bring only the best

quality products to the consumers, putting value to the time-tested trust on the Philippines’

number 1 brand.
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C. What is the quality philosophy/motto they practice?

Kainang Pamilya Mahalaga (Family Mealtime Matters): In 2007, Monde Nissin,

under Lucky Me!, launched Kainang Pamilya Mahalaga (Family Mealtime Matters)

advocacy. It focuses on the promotion of frequent family meals together as a way to

strengthen the foundations of the Filipino family. The advocacy was supported by

Presidential Proclamation 326 dated January 2012, which declared every 4th Monday of

September to be Kainang Pamilya Mahalaga day. Monde Nissin, through its flagship brand

Lucky Me!, launched the Kainang Pamilya Mahalaga (Family Mealtime 11 Matters)

advocacy which aims to encourage families to gather during dinner and share meaningful

conversations over meals. Studies showed that children who share mealtime with their

families are less likely to get into illegal substances, vices, alcohol, tobacco, and unhealthy

relationships leading to pre-marital sex. Done regularly, shared meals help nurture the bond

between parents and children which is instrumental in shaping the children’s future.

Educational Assistance: Monde Nissin recognizes the significance of building

human resource in paving the way for growth and development of the nation. Empowering

the future leaders involves investing on education for the youth. For almost ten years,

Monde Nissin has been extending support for its employees’ children through scholarship

grants. In 2015, one hundred academically exceptional students in the elementary and high

school levels are granted with financial aid.

Zero Wastewater Discharge and Waste Management: Monde Nissin values water

as a basic need. The company ensures efficient usage of water in all areas of production

and maintains zero wastewater discharge by using 100% of its wastewater for auxiliary

purposes such as gardening and toilet facilities. In the area of waste reduction, the
 Page 44

manufacturing plant decreased the total volume of wastes in its waste management

facilities by 30% in 2015. Systematic approach to waste management is observe on a daily

basis, which consists of responsible waste segregation and disposal. Reuse and recycling

of utilizable materials are observe as part of the plant’s waste recovery efforts.

D. What, when and where is the Inspections occur in their operations?

Saturdays allotted for preventive maintenance since the company’s processes use

more machines than human labor. Then every month, there are preventive maintenance

inspections on the air conditioning systems.

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XI. OBSERVATIONS ON THE WORKING ENVIRONMENT CONDITIONS:

Noise: The company adopts a very secured policy with regards to their visitors and since

that we were not able to enter the production floor, we were not able to determine if there

are any noise in any of the processes that are unbearable. Nevertheless, it seems that the

there will not be some people to be affected for the first six processes in the production,

there are no workers or employees present.

Vibration: The only vibration that we noticed was the one that created by the machines

because we are only looking at a clear wide glass to watch the processes. And when we

touched the glass, we felt that there is really a vibration and that was created by the

machines, but its degree is tolerable.

Illumination: The lightning systems used in the production are appropriate for each step

of the process and since that humans can be only found at the packaging section, there are

no worries that the quality of the products will be affected.

Ventilation: There is an enough ventilation in the plant and because of that workers and

employees can be reassured that they will not get any chronic illness or diseases.

Humidity: The temperature in the plant is moderate and it is tolerable by human. However

In some of the production floor where there are large machines, the temperature is really

above normal and for that reason, there are no workers involved in the processes where

large machines are present.

Safety: The workers and employees are guaranteed of the fact that the production facilities

they are working in were created according to standards.

 Page 46

Waste disposal: The wastes incurred in the production are being disposed through the

water vaporizing machine and that means that the company are not just producing high

quality products, but they also ensures that they help in the endeavor of protecting the

environment.

Why do you think the business decided to locate its operation in the Area?

Costs: The location of the company is based on a required expenditures for setting up

engineering centers and covering ongoing operating activities since that they are a highly

automated manufacturing company. Included are the costs of buying or leasing land, office

equipment, communications, wages, training, taxes, and IT infrastructure, and these costs

are lowered compared in Metro Manila rates.

Accessibility: Laguna is the first province south of Metro Manila providing business easy

access to the biggest domestic market and to the most extensive transport mode to reach

global clients. Connected by the expanded and modernized South Luzon Expressway

(SLEX), the country’s premier financial hub in Makati City and the Manila International

Airport (MIA) are both mere 20- minute drive from the major business and Industrial

districts of the Province.

Raw Materials: The primary ingredients in making up noodles are flour, eggs, water, and

sugar. These ingredients are abundant in the province of Laguna since it has 60,624

hectares of alienable and disposable agricultural land. Laguna is also well known for its

abundant supply of fruits such as lanzones, rambutan, papaya, mango, pineapple. Some

large farms also cater to ornamental plants and cutflower production. About 41,253 ha or
 Page 47

23.44% of Laguna’s total land area is forest land which is ideal for growing coconuts,

tropical fruits, and exotic plants.

Labor Supply: Laguna is a bastion of responsible, talented, motivated, hardworking, and

highly skilled work force. Laguna boasts of its industrious and professional work force that

is readily available from its population of over 2.5 M (Philippine Census, 2007). If need

be, migration of professional and skilled talents to nearby provinces and Metro Manila is

easy to fully cover labor requirements. The Laguneños bring their positive and caring view

of life in their work, a plus to any business endeavor.

Climatic Conditions: Laguna is relatively dry from November to April and wet during the

rest of the year. The eastern portion of the province stands astride the southernmost portions

of the Sierra Madre mountain range. It is surrounded by Laguna Lake, formerly called “La

Laguna Encantada”, one of the only 18 living lakes in the world. Laguna Lake is the largest

inland lake in the country.

Reliable Power Supply: Laguna has more than enough stable power supply to cover the

requirements of businesses and industries. Three power generating plants currently operate

– the Botocan hydro-electric plant (25MW), Caliraya hydro-electric plant (23.5 MW), and

the Makban 9 geothermal plan (20MW). Meralco, the main electricity distributor of Metro

Manila, has also the franchise for most of Laguna.

 Page 48

XII. CONCLUSION

Concerning to the demand of many Filipinos, we conclude that the production of

noodles is making a big deal to our industry. Rather than the instant noodles is affordable,

from the name itself instant noodles, it is very easy to prepare although not as healthy rice.

Also as a college students, we are involve in the experience of just like others who

are also in a lack of financial especially on weekends, we turn to depend in instant noodles

and its very affordable price. In addition, sometimes due to our cravings especially in

Pancit Canton.

Instant noodles for sure have a very contribution to industry and to our growing

economy. The Monde Nissin Corporation is doing their hard job to continue the contagious

and still going up contribution of their products to help many poor Filipino people. and

because of this activity, we understand now the heart of one company which is really

wanting to make our lives easier and dependable with their small contribution as business

and growing company.

In the Philippines, as in neighboring countries, the demand for noodles continues

to be on the rise. Instant noodles has become a new staple of many poor Filipinos. This

increase popularity of instant noodles can be due to the fact that it is cheaper and easier to

prepare than rise. Pillow type product makes up the 94% of the noodles industry in the

market and expanded its market through the introduction of new products. Monde Nissin

Corporations adheres to these market demands in providing the Filipinos in noodles in an

instant by not compromising our health concern.

 Page 49

XIII. REFERENCES

Websites

 https://www.slideshare.net/CharlotteBance/nissin-monde-final-paper

 https://www.omicsonline.org/open-access/studies-on-preparation-and-quality-of-

nutritious-noodles-by-incorporation-ofdefatted-rice-bran-and-soy-flour-2157-

7110-1000629.php?aid=81918

 https://slideplayer.com/slide/12690600/

 https://www.coursehero.com/payment/?get_doc=13511679

 https://www.scribd.com/doc/50935134/Nissin-Monde-Philippines-Plant-Analysis

 https://www.researchgate.net/publication/293821671_An_overview_of_noodles_

and_cheese_balls_production_in_Biggest_food_industry_in_Nepal_and_Internshi

p_report_on_quality_control_of_food_products_of_Chaudhary_Group_Nepal_F

UDCO?fbclid=IwAR3tFp5cTvFctzbFKLS-Tj3E-

gaJ2JU1SUsmIAkMSzOQm5FJL3kvnBKhOHc

 https://instantnoodles.org/en/noodles/process.html

 https://web-japan.org/kidsweb/hitech/ramen/ramen02.html

 https://www.bhg.com/recipes/how-to/cooking-basics/how-to-make-homemade-

noodles/

 https://www.sciencedirect.com/science/article/pii/S0963996907001962

 https://www.hsph.harvard.edu/news/hsph-in-the-news/instant-noodle-

consumption-linked-to-heart-risk-in-women/

 https://www.deliaonline.com/ingredient/noodles
 Page 50

PDFs

 Power and Performance for the Noodle making Industry

 Instant Noodles: Processing, Quality, and Nutritional Aspects

 Fortification Basics:

Instant Noodles1: A Potential Vehicle for Micronutrient Fortification

 Breakeven Analysis – How to analyze and compute BEP

 Wastewater from Instant Noodle Factory as the Whole Nutrients Source for the

Microalga Scenedesmus sp. Cultivation

 FEASIBILITY OF COMMERCIAL INSTANT NOODLE PRODUCTION IN

ARGENTINA: A JOURNEY TO A FASCINATING VALUEADDED

PRODUCT

by JUAN FINELLI

B.R.A., Universidad Tecnologica Nacional, 2009