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IQF pasta manufacturing
IQF pasta manufacturing process managed with the Producepak app for food businesses: Pasta ingredients, pasta processing & manufacturing, pasta quality control, pasta packing, sales & shipping. Less raw material waste, more profit & traceability.

IQF pasta manufacturing

IQF Pasta Manufacturing

Pasta appeals to a wide range of lifestyles, budgets, and age groups due to its versatility, ease of preparation, availability and cost-effectiveness. According to the National Pasta Association (NPA), which supports and promotes the pasta industry, popular pasta trends fall into three main categories: the return of comfort food, interest in Mediterranean cooking and the rise of plant-based foods. Throughout the last few months, heightened interest in health, increased at-home cooking activity, and uncertainty about the future significantly intensified and reshaped these trends.

Families sheltering at home and adjusting to a new “normal” turned to pasta dishes for quick, easy, nutritious, and affordable meals. Other consumers, yearning for restaurant-quality meals and eager to experiment in the kitchen, purchased high-end pastas. As a result, in the retail sector, the pasta industry experienced unprecedented growth in all product forms—dry, fresh, frozen, refrigerated, and stuffed. At the same time, restaurant, cafeteria, and catering shutdowns decreased foodservice sales, forcing many manufacturers to rethink marketing plans.

A Need for pasta based Comfort Foods

The love of comfort food, and pasta’s integration into that category, is nothing new. For decades consumers have been turning to pasta during hard times. According to a recent Grain Foods Foundation survey of over 1,000 U.S. adults representing a cross-section of the population, approximately one-third of U.S. consumers named pasta (36%) and bread (29%) as foods that are comforting during a stressful time. More significantly, it also revealed that roughly the same percentage recognize bread and pasta among the most nutritious of all the comfort foods they turn to.

Recently, however, the type of comfort food has changed. Prior to the COVID-19 pandemic, pasta experienced a renaissance in comfort food. The NPA reported consumer upticks in modernized versions of classic dishes, notably “comfort food with a twist.” Popular items included vegetarian lasagna, stuffed tortellini, and healthy chicken parmigiana. However, during the pandemic, comfort foods and pasta dishes prepared in a more classic style have become a top food trend.

Consumers looking to return to the basics are searching for comfort and familiarity in an increasingly chaotic world, as evidenced by a recent survey conducted by NPA. The survey found that out of the 1,771 respondents who answered, nearly 24% of them noted their favorite pasta dish was the classic fettucine alfredo. Other classic dishes quickly followed, with 11% opting for chicken parmigiana, 10.7% choosing lasagna, 9.4% selecting classic carbonara, and 8.8% marking spaghetti and meat sauce as their favorite.

Further, according to a recent Wall Street Journal article, “the world’s largest makers of packaged foods say frozen pizza, pasta sauce, and mac and cheese are rising in favor as consumers in lockdown eat at home.” Likewise, a recent survey conducted by Nuovo, a specialty pasta manufacturer, noted that 70% of respondents indicated they consumed dry pasta at least once within the last three months. During that same period, 40% had dry flavored pasta (i.e. macaroni and cheese), 36% had egg noodles, 20% had frozen pasta, and 18% had refrigerated pasta.

Influence of Mediterranean Diet on Pasta

There’s no question that when it comes to Mediterranean cuisine, Italian food comes to mind. In the U.S., Italian food ranks third as the most popular ethnic cuisine, beat out only by Chinese and Mexican. Pasta plays a primary role in this cuisine.

Known for its health promoting properties, the Mediterranean Diet is enjoying a surge in popularity due to increased concerns around health and the role of diet in staving off illness. Key components of the diet include fruits, vegetables, seafood, lean meat, nuts and legumes, beans, and whole wheat. Pasta is a healthful ingredient that fits naturally into the whole wheat category. It is an ideal vehicle for adding healthful and plant-based foods as well as high protein items like lean meat and poultry into a diet. As concerns over health grow, consumers are turning towards lifestyle diet options like the Mediterranean Diet, which provides health benefits like the preservation of cognitive function, improved brain health, lowered risk of heart disease, and a reduced risk of breast cancer and depression.

Pasta’s prominent role in the Mediterranean Diet has not only elevated the ease and attractiveness of Mediterranean cuisine, but also fueled interest in another popular food trend: the rise of plant-based diets.

Plant-Based Popularity Grows

For consumers, plant-based diets that include pasta are particularly appealing for several reasons, such as the noted health benefits for both preventative health and controlling certain chronic illness. Sustainability is another driving force, as good-for-you foods that also benefit the environment experienced big jumps in sales. Pasta has the added benefit of being easy to prepare and budget friendly. According to Mintel data, 34% of pasta entrees at restaurants were labeled as vegetarian options, and the average pasta consumer, seeking out health benefits and a higher intake of protein, actually eats more servings of vegetables than non-pasta consumers.

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Restaurants Turn to Pasta Grocery Sales

While pasta fits easily into a plant-based lifestyle, non-wheat plant-based pastas have also risen. These pastas are made from other vegetables and legumes and cater to the gluten-free niche as well as consumers who simply want to try something new. According to the NPA 2019 State of the Industry Report, legume pasta doubled in growth every year since 2014. The introduction of these plant-based proteins into the pasta category also led to the growth of a “clean label” approach, in which all ingredients are lessened and simplified and do not include any ingredient that would be unfamiliar to a consumer.

Changing Times

Historically, consumption patterns have always been influenced by environmental, political, economic, and social factors. Consequentially, the COVID-19 pandemic dramatically impacted and increased pasta retail sales due to numerous reasons. As we see a global health crisis sweep the world, consumers likely gravitate toward the desire for healthier meal options and to adhere to healthier lifestyles via the Mediterranean diet and/or a plant-based diet. Additionally, the U.S. meat industry has taken a severe hit to their health and sanitation standards, and as a result had to close a number of meat processing facilities due to infected employees. This doubled down on the already sparse meat counters consumers were seeing at grocery stores. Pantry staples that were affordable, versatile, and easily accessible, like beans and pasta, quickly rose in demand.

As this “new normal” continues and “panic buying” remains a trending term, increased pasta purchasing and consumption likely will too.

What About the Future?

In an uncertain time, looking to trends can help determine the way of the present and the future. When it comes to pasta-consumption and sales, the pandemic both accelerated and changed existing trends as well as elevated new ones. Consumers rediscovered, not only the health benefits of eating pasta, but also its great taste and versatility and they are not turning back. Pasta is experiencing a rebirth. It has found its place in the increased consumption of comfort food, the continued popularity of the Mediterranean Diet and plant-based diet, and the robust growth in retail sales caused by the traits that pasta has always known to be true—its affordability, availability, versatility, and popularity.

These trends help to guide the pasta industry as we seek to satisfy our customers, maintain standards of health and wellness, and drive innovation for the future.

Legume-based IQF Pasta

CPG marketer keeps pulse with key market trends with IQF Pasta Manufacturing

As healthful, pulse-based pastas grew in popularity, marketers sought adaptations to meet consumers’ demand for convenience. These two key trends—healthfulness and convenience—were exactly what a major CPG marketing team needed to achieve with their microwaveable lentil pasta. But there was a problem.

Their lentil-pasta formulation couldn’t withstand the strenuous blanching process, preventing it from providing an al dente texture. The CPG team toiled for two years before bringing their IQF pasta challenge to us.

Our R&D team quickly redeveloped the lentil blend and adapted a precook process to produce the desired texture. The operational team then installed modified equipment to allow for the mass-scale commercialization and launch of the new lentil pasta. Then, only three months in, a new request came: attain the trending Gluten Free status and meet its rigorous testing. No problem. In fact, we went from initial request to market in an astonishing six months, delivering a successful and innovative new offering exceeding all expectations.

Pasta Trends Into 2021

Jan 18

Pasta is one of the most popular restaurant dishes in the world. It’s an incredibly versatile food that spans a wide range of cuisines, lifestyles, and budgets. The reasons for this popularity are constantly shifting—so which trends are the drivers going into 2021?

First and foremost, the COVID-19 pandemic fundamentally shifted the way we live, work, and dine. As dining in all but halted, customers turned to take out, delivery, or cooking at home. The pasta retail sector immediately saw growth for both dry and fresh pasta, and the world of restaurant carryout saw a shift to comfort food: pizza, desserts, and pasta.

Though it may seem as though nutrition was put on the backburner for many consumers, the healthy, doctor-favored Mediterranean Diet is also seeing a surge in popularity. Many people are choosing this option over fad diets like keto due to the health benefits in a year when staying well has become increasingly important. This diet includes a lot of vegetables, seafood, lean meat, and whole wheat, with whole grain pasta being an ingredient in many of the recipes.

The third key driver in pasta popularity is the rise of plant-based diets. As consumers focus on healthier lifestyles, many turned to plants as their main source of nutrients. A plant-based diet also has a tremendous impact on the environment, as meat processing is one of the major contributors to global warming. 2020 brought a renewed focus on activism, and choosing veganism or vegetarianism was one of the ways consumers could make a difference from the safety of home.

Pasta has been experiencing a renaissance for several years now, and 2020 only accelerated its growth. Its versatility, comfort, and health benefits should help take this popularity into 2021, but it’s important that we continue to innovate and create new ways for your consumers to… well… consume. Because if this year has taught us anything, it’s that we never know what’s just around the corner.

Reference: Zuanelli, Carl. “Changing Food Trends Fuel Pasta Popularity.” The Food Institute, 29 July 2020, foodinstitute.com/focus/pasta-trends/.

IQF pasta manufacturing
IQF pasta manufacturing

Each year, Zerega exhibits at the Shamrock Foods Expo, a food show for operator customers. If you read “PMZ Hits Two (Virtual) Trade Shows”, you’ll know that 2020 has become the year of online exhibitions. The Shamrock event was one of many that adapted to a virtual setting this year – but that didn’t stop its annual awards presentation, which spotlights booths from the prior year’s Expo that spans across 4 locations. Zerega’s booth was named 2019 Dry Grocery Expo Booth of the Year!

To pull off an award-winning booth, Zerega partnered with Shamrock Foods and our local broker network to prepare two different dishes for visitors to try. The dishes were prepared in typical foodservice fashion: the pasta was cooked and chilled, and then added to heated sauce and served. The first sample was a classic and beloved penne and marinara combination. The second was a spin on Asian-style noodles, using 3/16th fettucine (a thick noodle, like a wider linguine) served with a red curry sauce made with coconut milk. Vegetarian and vegan dishes have been trending over the years, and the goal of these two booth dishes was to inspire menu items for Zerega’s customers.

Exhibiting at the Shamrock Foods Expo is a great way for organizations to display their products and highlight their quality, features, and benefits, while simultaneously fostering relationships with new and old customers. Plus, cooking product in the booth turns it into an action station, which generates great energy on the trade floor – and leads to an award that signifies hard work pays off!

IQF Pasta company Philadelphia Macaroni Co. to Acquire A. Zerega’s Sons

Philadelphia Macaroni Company (“Philadelphia Macaroni”), a leading producer of dry and frozen pasta for the industrial ingredient, private label retail, and co-pack channels has acquired A. Zerega’s Sons (“Zerega”), a leading manufacturer of dry pasta for the foodservice, industrial ingredient and retail channels.

iqf pasta manufacturing
iqf pasta manufacturing

The acquisition positions Zerega as a wholly owned subsidiary of Philadelphia Macaroni. The transaction includes Zerega’s manufacturing and distribution facilities located in Fair Lawn, NJ and Lee’s Summit, MO. No changes are planned for Zerega’s existing operations.

The Zerega purchase will essentially double Philadelphia Macaroni’s production and packaging capacity to more than 700 million pounds annually; increasing manufacturing capabilities, adding strategically located facilities and channel expansion. Philadelphia Macaroni’s new President and CEO, Ed Irion, stated the acquisition creates the largest privately-owned pasta manufacturer in the United States. Irion added, “Zerega’s wide variety of pasta offerings further enhances Philadelphia Macaroni’s product portfolio and provides an immediate, meaningful presence in the foodservice channel. We believe the combination of these two well-respected pasta companies will provide expanded opportunities for both our customers and employee team members.”

Philadelphia Macaroni and Zerega are both family-owned businesses with generations of experience manufacturing pasta for multiple distribution channels. Luke Marano, Jr., Philadelphia Macaroni Executive Chairman, commented, “The combination of two great family businesses allows us to advance our diversification strategy and compete against larger players in the critical foodservice category with the required competitive scale.” He continued, “Our great-grandfathers who founded our companies were innovators and entrepreneurs,” referring to Antoine Zerega who is credited with building the USA’s first pasta plant in Brooklyn, New York in 1848 and Antonio Marano, who formed Philadelphia Macaroni in 1914 in the Italian market neighborhood of Philadelphia, PA. Mr. Marano added, “It will be the merging of similar cultures, core values and historical industry leadership but most important of all, a similar love of pasta!”

Houlihan Lokey acted as the exclusive investment banking advisor to Zerega. Connell Foley acted as Zerega’s legal counsel. Wells Fargo Securities acted as exclusive financial advisor and Fox Rothschild as legal counsel to Philadelphia Macaroni.

iqf pasta manufacturing

Company Description:

Philadelphia Macaroni Company manufactures dry, frozen and specialty pasta for industrial, private label, retail, and co-pack customers. Through its four pasta factories located in Pennsylvania, North Dakota, and Washington, the company produces and distributes pasta to an international customer base. Incorporated in 1914, Philadelphia Macaroni is a 5th generation family-owned business headquartered in Philadelphia, PA and employs over 400 workers across the country. The company also mills durum and hard red spring wheat for internal use as well as for sale on the open market through its division, Minot Milling Company located in North Dakota.

Sustainable & Regenerative IQF Pasta Manufacturing

Our vertical supply chain supplies sustainability

Perhaps the best-known brand in organic foods wanted to offer a truly farm-to-fork story. That meant being able to source identity-preserved wheat from specific farmers and track the grain every step of the way, from the fields to the milling facility, through the manufacturing and packaging process and all the way to consumers. This was no small task. And it was further complicated by the need to maintain established quality standards at a scale while still preserving traceability. Stumped, the renowned label turned to us and our vertical supply chain.

Our wholly owned subsidiary, Minot Milling, just happens to be one of the nation’s largest organic millers. We leveraged our organization’s talent to optimize the yield of the wheat—difficult given the scale of the mill. The fully traced wheat was then packaged and transferred to our plant, where it was both processed into the selected shape and specially packaged for the customer. The result? A marketing moment that defines the brand’s unyielding commitment to its organic authenticity.

IQF Instant Quick Freeze Pasta Manufacturing

Good separation and food safety is the top priorities for processors in the pasta and grains industries. OctoFrost equipment is trusted to successfully serve these priorities by biggest producers on these markets.

IQF Instant Quick Freeze Pasta Manufacturing

Natural Appearance

The full control over the blanching temperature and time in the IF Blancher is important for avoiding overblanching of sensitive products like pasta and grains. Further on, with an efficient chilling below 5°C in the OctoFrost™ IF Chiller a good product separation is achieved in the OctoFrost IQF freezer. The fully adjustable airflow in the OctoFrost™ IQF freezing tunnel and the gentle movement of the bedplates ensure no lumps of grains, and no damage of the pasta products.


IQF Instant Quick Freeze Pasta Manufacturing
IQF Instant Quick Freeze Pasta Manufacturing

Energy Efficiency

The rainshower and cross-flow systems which are at the heart of the IF Blancher and Chiller help achieve the quickest heat transfer while the recirculation system optimizes water consumption. The frequency converters installed on each OctoFrost fan in the IQF tunnel, translates in significant energy savings. By decreasing the fans’ speed, the overall energy savings can reach as high as 30% while preserving the product quality.


IQF Instant Quick Freeze Pasta Manufacturing
IQF Instant Quick Freeze Pasta Manufacturing

High Yield

The quick and efficient blanching and chilling together with the unique aerodynamics of the OctoFrost™ freezer, result into less snow formation when compared to other technologies, which means minimum dehydration and higher yield for the processor.


IQF Instant Quick Freeze Pasta Manufacturing

Food Safety: IQF Instant Quick Freeze Pasta Manufacturing

All OctoFrost equipment has easy-to-clean design for a reliable food safety. Every part of the blancher and chiller which comes in contact with the blanching and chilling water can be cleaned by CIP (Cleaning-In-Place). The free-standing body, lack of joints and exchangeable bedplates of the OctoFrost™ freezer contribute even further to a truly reliable food safety for IQF pasta and grains processors.

How to make perfect IQF Pasta: 

  • We manufacture our pasta items with tight tolerances to deliver the most consistent quality shapes and weights for our unique bite
  • We have created our own custom flour blend
  • Individually quick frozen (IQF) to lock in freshness and flavor
  • Our specialty pasta product fillings consist of only real ingredients, no imitations
  • We use only the highest-quality ingredients with no MSG, PHO’s, HFCS or preservatives

Turri’s pre-cooked short-cut pasta is IQF (individually quick-frozen) to preserve flavor, quality and consistency. We produce all popular pasta varieties using our own family recipes or custom recipes just for you. Turri’s Cavatappi is cork screw shaped pasta that is pre-cooked and individually quick frozen (IQF) to a firm “al dente” bite so it is ideal for pasta salads, mac & cheese or when served in your favorite sauce. Turri’s IQF pre-cooked pasta is proportionally packaged for easy preparation while minimizing waste. All of our products are produced to the highest quality and safety standards. Our pasta is made with the finest ingredients available and is ideal for ready-made and batch cooking. Turri’s Penne are pre-cooked and individually quick frozen (IQF) for fast and consistent preparation. Pre-cooked Penne are ideal for single serve entrees, batch cooking and especially for pasta bars and action stations. Turri’s Egg Farfalle are pre-cooked, egg enriched, and individually quick frozen (IQF) for fast, easy and consistent preparation. Farfalle pasta are ideal for single serve entrees, batch cooking and especially for pasta bars and action stations. Top class pasta is usually manufactured from fresh dough. We at Ebrofrost cook our long pasta for our customers, manufacturers of stir-fry /ready-made dishes and restaurant chain owners with high-grade fresh dough too – without additives and precooked to any point desired.

Besides wheat, we also manufacture gluten-free products as well as pasta made made from buckwheat or chickpeas. We purchase our products from the best areas of cultivation. All articles are individually quick frozen. Therefore, they can be processed according to our customers’ needs for both traditional and vegetarian-vegan dishes.

Regardless of the width, we can shape any large pasta to noodle nests flexibly from 50 to 300 g. With these portioned products, restaurant chain owners save time, because precooking and portioning are dispensed with. They optimize the workflows, shorten the waiting times for the guests down to a minimum, guarantee the best possible hygienic standards, and avoid food waste.

After the final cooking at home or in restaurant chains, the consistency and aroma of our pasta products are as just cooked.

IQF Long Pasta Nests

From 2 ounce nests of frozen long pasta to larger portions sizes we have the perfect solution for your meal or kit application.  Choose from Asian style noodles to Italian favorites like Angel Hair, Fettuccine, Spaghetti...in plain, whole wheat, gluten free and egg.
IQF Short Pasta &

Grains

Since the late seventies we have been making IQF pre-cooked short pasta we invented it!  Perfect and ready to use in your meals.  We can't list all of them and custom shapes are available.  Added to our line of pre-cooked items are IQF pre-cooked couscous and quinoa Product can be packed in totes or blended with other ingredients in pouches.  We can also enrobe and blend with ingredients.

IQF Stuffed Pasta

Our years in pasta manufacturing has taught us a few things.  Our customers rely on us to produce the highest quality product for their project.  From handmade speciality pasta to high speed automatic lines including Stuffed Shells, Lasagna Sandwhiches, Lasagna Roll-ups, Manicotti...filled with cheese, proteins and vegetables.




Pasta manufacturing process

Gustora Foods

Gustora Foods

Jul 12, 2018·3 min read

Pasta is a food that is loved by people of all age group. It is not just easy to make but can be a healthy food option when combined with veggies and nutritious sauces. This food is not just tasty but also has an interesting production process. The production process can be divided into a series of steps and has three key factors. The list of factors that influences the quality of production are raw material, presence of skilled employees and processing technology.

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Pasta manufacturing process
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Raw material

The pasta is made from a combination of Semolina and water. The semolina is easily digested by the body due to its high protein content and low starch content. Another flour used in the production of wheat is farina that is high-quality hard wheat that is used for making some types of pasta. According to the best pasta company in India, sometimes eggs are added to the mixture to give some colour and richness to it. However, there are some great pasta manufacturers in India like Gustora that focus on producing 100% egg free pasta for Indian consumers.

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Manufacturing process
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Manufacturing process
· Mixing and kneading: The first step in the process is mixing. The semolina is stored in giant silos that has a holding capacity of about 68,100 kgs. The Flour is moved to the mixing machine through pipes. Warm water is also piped to the same mixing machine to knead the mixture.
· Flavouring and colouring: If the product is an egg noodle then the eggs are added to the mixture. Vegetable juices, herbs and spices are added to the pasta if a flavoured variety has to be produced.
· Rolling: The final mixture is moved to the laminator where it pressed into sheets by large cylinders. The dough is flattened by a vacuum mixing machine while pressing air bubbles and excess water from the dough to arrive at the optimum water content of 12%.
· Pasteurization: The dough roll is then moved through a steamer that heats it to 104°C (220°) to make sure that it is free from bacteria.
· Cutting: The dough is given the shape according to the type of pasta that has to be produced. The pasta and macaroni manufacturers in India use different machines for producing different shapes of pasta.
· Drying: After cutting the next step in the process is drying. The pasta is placed in the drying tank where the moisture, heat and drying time are strictly regulated.
· Packaging: The dried pasta is folded in pre-measured amounts and filled into plastic containers. These containers are passed through a conveyer belt where these containers are sealed with a hot press. During the process, a small tube sucks the air of the container and replaces it with a mixture of nitrogen and carbon-di-oxide to increase the shelf life of the product.
This is the step by step process for pasta production that is followed by every pasta manufacturing company to produce your favourite pasta.

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Gustora Foods

Pasta manufacturers in India. Try variety of Pastas here: https://gustorafoods.com/

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Pasta manufacturers in India. Try variety of Pastas here: https://gustorafoods.com/

Jul 7, 2018

Whole Grain Pasta: A new Solution to Lose Weight

Pastas are famous for many reasons and that is why it is one of the most popular dishes around the globe. Manufacturers constantly innovate and bring a new variety of pasta every now and then. A healthy addition to this list of varieties is the whole grain pasta. Although it isn’t particularly a low-calorie food but it can be a part of your weight-loss diet.

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Whole Grain Pasta
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Whole grain pasta or wheat pasta are great supplements of insoluble fiber, carbohydrates and other nutrients. …

Read more · 2 min read

Jul 7, 2018

A Detailed Penne Pasta Nutrition Information for Pasta Lovers

The much-loved penne pasta is a type of macaroni that are about two-inch long, tubular shapes. The penne pasta is also known as mostaccioli. The name ‘penne’ is given because of its shape and diagonal cuts at the end that make it look more like a quill pen. This type of pasta is famous for its usage in popular dishes like Penne ala-Vodka that is served with tomato cream sauce spiked with vodka.

Calories

When it comes to calories, a cup of penne pasta has the same amount of calories as most other plates of pasta i.e. about 200 calories or alternatively, we can say that 100 grams of pasta contains around 141 calories. Overall, we can say that Penne pasta India are a lot more than a tasty dish and one of the best penne pasta producer in India is Gustora.

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