session 7 –round table - openfields
TRANSCRIPT
Session 7 – Round Table
Innovation in the durum wheat – pasta chain
ModeratorRoberto Ranieri, Open Fields srl
Bologna, 19 – 21 September 2018
A Sustainable Durum Wheat Chain for Food Security and Healthy Lives
Short summary on the innovations of pasta value chain in the last 50 yearsRoberto Ranieri (Open Fields srl, Italy)
Keep adding value to pasta worldFrancesco Pantò (Barilla G. e R. F.lli spa, Italy)
Nutritional and healthy pasta claimsMarina Mastromauro (Pastificio Attilio Mastromauro, Italy)
Effect of the patent “Gluten Friendly” on pasta Pasquale Casillo (Casillo Group, Italy)
High tech pilot tool for researchers to investigate ingredients and pasta performances under industrial conditionsLuciano Mondardini (Pavan – Italy)
Traceability of the pasta supply chainValeria Terzi (CREA, Italy)
Session 7 - Scientific Program
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Short summary on the innovations of pasta value chain in the last 50 years
Session 7: Innovation in the durum wheat – pasta chain
Roberto Ranieri, Open Fields srl
A Sustainable Durum Wheat Chain for Food Security and Healthy Lives
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1960s: Introduction of high production capacity lines;1967: The "Pasta Purity" law;1974: The Creso Case demonstrates that durum can be cropped in colder areas;1981: WB881 the first desert durum – Top quality variety;1999: Optical sorters application in durum wheat; 1999: The Fava – Storci new press joins the ranks;2001: Debranning breakthrough technology - first industrial implementation to durum2006: Polymatik™ pasta press for various raw materials
2010: The Aureo Case shows that top quality durum wheat can be grown out of the
irrigated desert
Summary
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Innovations of pasta value chain in the last 50 years
Innovations of pasta value chain in the last 50 years
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1960s 1967 1974 20102001 20061981 1999
The evolution of pasta processing: high
production capacity lines
The "Pasta Purity" law
The «Creso Case» demonstrates that durum
can be cropped in colder areas
WB881- Desert Durum -
Top Quality Durum Wheat
Optical sorting application to durum wheat
PolymatikTM pasta press for a wide variety of
raw materials
The «Aureo Case» shows that top quality durum
wheat can be grown out of the irrigated desert
Debranning breackthrough
technology
The Fava – Storci new press joins
the ranks
Source: https://www.barillagroup.com/en/press-releases/1877-2017-barilla-turns-140-history-italian-family-company-good-food-“good-you-good; https://pasta.museidelcibo.it/il-prodotto/storia/; «Pasta d’archivio. Scienza e storia del più antico campione di pasta (1837-1838)». Archivio di stato di Parma, Barilla Alimentare spa, Università di Parma.
1960s: Introduction of high production capacity lines
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• Since the 1960s, Braibanti and Fava started proposing pasta lines
reaching a very high productivity (2-2,5 tons/h) if compared to the
average production volumes of that time (1 ton/h).
• The need then arises to have a larger plant and in 1969, the largest
pasta factory in the world opened in Pedrignano, on the outskirts of
Parma by Barilla: 120 meters of production line,1.000 tons of pasta
per day.
• By the end of 70s the technologists understood the importance of
increasing the drying temperature for reducing the production time,
improving the cooking quality of pasta with a consequent increase
in production volumes, reaching a production of 5 ton/h.Improvement of competitiveness
Cooking quality
improvement
Development of continuous drying system
increase in production
volumes in the unit of time
Source: http://www.aidepi.it/component/content/article.html?id=468:la-legge-di-purezza-che-da-oltre-quarant-anni-certifica-la-qualita-della-pasta-italiana&jjj=1533647663115
1967: The "Pasta Purity" law
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The Law for Pasta Pureness (L. 580/67 and subsequent
amendments - in particular the DPR February 9th, 2001, No.
187) is the norm introduced in 1967 to establish the quality
parameters that allow Italian pasta to excel in the world.
It prescribes as a fundamental principle the obligation to
produce pasta exclusively with durum wheat in compliance
with precise analytical parameters, such as moisture,
proteins, ashes, acidity, which must be respected in the
production and marketing of pasta (milled products
described: semola, semolato, semola integrale, rimacinata).
“…But there are also other limits to guarantee the quality of the product that is our symbol, unique thing in the world, of which we are very proud, which aims to
strengthen the image of Italian pasta and enhance its production, imposing those high quality standards that contribute to
the international reputation of Italian flagship product”.
Riccardo Felicetti, President of Italian Pasta makers of Aidepi
The Creso durum wheat, selected at the former CNEN (now
ENEA) Casaccia Research Centre, thanks to the knowledge on
the radiation effects on plants, was obtained by irradiating the
Cappelli variety with gamma rays.
After have been released in the National Register of durum
wheat varieties in 1974, in few years it became the most
cultivated variety in Italy: according to ISTAT, the cultivated area
passed from a few tens ha in 1973 to over 400,000 ha in 1982.
Creso ten years after the registration, constituted the 58.3% of all
certified seed of durum wheat in Italy, sign of its rapid and
exceptional diffusion in Italy.
Source: http://old.enea.it/produzione_scientifica/pdf_EAI/2010/6/CasoCreso.pdf8
1974: The Creso Case demonstrates that durum can be cropped in colder areas
Italian cerealrevolution: from an agronomic, economic and
varietal poverty, to «high-tech»
crop production
High productivity, adaptability and
resistance to diseases and rusts
Excellent quality in pasta making
Economic benefits for
farmers and pastamakers
Desert Durum®
Anything previously grown in Arizona
fields
High quality
and quantity stability
Traits highly
valued by mill
operators
Ideal for pasta
making
One of the sought-
after wheats in the world
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1981: WB881 the first Desert Durum –Top quality variety
Source:http://onlinedigeditions.com/publication/?i=282209&article_id=2330854&view=articleBrowser&ver=html5%23%7B%2522issue_id%2522:282209,%2522numpages%2522:1,%2522view%2522:%2522articleBrowser%2522,%2522article_id%2522:%25222330854%2522%7D#
• In the mid-’80s the WB881 variety got the attention of the Italian pasta makers.
• 1974: Foundation of «Western Plant Breeders» to produce a durum wheat with greater yield of high-quality grain;
• High-quality northern Arizona durum varieties crossed with high-yielding southwest desert varieties.
• Ideal climate in the desert;• High water availability from
the Colorado river;• Use of nitrogen fertilization.
• Low moisture content;• Ideal shape, dimension and
consistency of the grains;• High semolina extraction rates.
• Water efficient and water-rise;
• Great rotation crop for Arizona farmers;
• Identity Preserved contracts;
• Not for pasta anymore.
• Strong gluten;• High protein content;• Bright yellow semolina color.
1999: Optical sorting application to durum wheat
Source: Inamdar, A.A and Suresh, D.S., 2014. Application of color sorter in wheat milling. Int. Food Resear. Journal, 21 (6), 2083-2089.https://www.buhlergroup.com/global/en/downloads/Grain_Brochure_EN_WEB.pdf
First application of the optical sorting technology to durumsince the middle ’90s: Sortex optical technology for riceadopted and adapted to durum mill.
Progressive replacement of the former methods ofdurum grain selection (by weight and shape…) by theexploitation of camera technology that has allowed torecover durum wheat lots which was previouslydischarged as ergot, boiled/black kernels, buntedkernels…
Safety and qualityimprovement throughthe detection of allknown defects andforeign materials.
Schematic diagram of a typical optical sorting machine. (Inamdar et al., 2014)
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Grain inspectionsystem
Pneumatic ejectionsystem
Acceptedgrain
Rejectedgrain
DATA PROCESSING
UNIT
Storage and feeding system
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1999: the Fava – Storci new press joins the ranks
Source: http://www.fava.it/default.asp?lang=EN; http://www.fava.it/pdf/news/rassegna/49.pdf
Perfect hydratation of the raw materials
Any mechanical pressure exerced
Any heat generation
Drastical reduction of the oxidation of the rawmaterials
Enhancement of the yellow colour and brightness of the pasta
Easy management, low running costs, easy and fast to clean
A new press equipped with a stabilizationbelt mixer
Companies producing debranning tech:
DELFINO&GIANCASPRO TECNOARDEA TAE,
BUHLER, OCRIM, TAE,, SATAKE, LOPORCARO,
SCHULE…
Increase of the debranning
machines models available on the
market
Improvement on the efficiency of
the abrasive material
Improvement on the mechanical
technologies
Several Pros
2001: Debranning breakthrough technology -first industrial implementation to durum
Source: http://www.openfields.it/sito/wp-content/uploads/2014/11/110919-openfields.pdf12
The debranning of wheat is a pre-milling treatment that allows a controlled and progressive removal of the grain's layers.
First application to durum milling process: Barilla implementation of a Tecnoardea Engeneering (TAE) technology to its Ferrara mill.
In the same period Casillo Group adapts Satake equipment for durum debranning and installs the technology in the mills too.
Economics
Process
Product quality
Food safety
Success of the transfer of the technology on durum wheat
processing
Debranning
Source: http://www.buhlergroup.com/global/en/products/polymatik.htm#.W2gmoi3lClM
2006: Polymatik™ pasta Press for a wide variety of raw materials
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Released in 1994 only for semolina processing, in 2006 the Polymatik™ Press revolutioned the way of making pasta, becoming the
only one-step solution in the market for gluten-free pasta: the starch is gelatinized directly in the Polymatik ™ Press.
It is extremely flexible, and its configurable mixing and kneading elements can be adjusted to individual raw-material properties.
That is why even gluten-free ingredients such as corn, rice and quinoa can be processed thanks to the steam and hot water
injection.
Proven technology for flexible usage of wheat or gluten-free raw materials
Shorter mixing times than traditional technology for brightly colored pasta
Reduced downtime and waste thanks to fast recipe changes
Increased food safety thanks to the self-cleaning mixer-kneader
Benefits
A unique solution for semolina, flours, and gluten-free raw materials
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2010: The Aureo Case shows that top quality durum wheat can be grown out of the irrigated desert
«AUREO is a top quality durum wheat that came out from the alliance
Barilla – Produttori Sementi Bologna (today Syngenta)*. It is characterized
by:
• High in Protein Content, always above 15% dm,
• Very High in Gluten Strenght, always above 90 “Gluten Index”
• High in yellow color content, above 24 ”b”
Grown in Southern Italy, it has enabled Barilla to replace high-quality
varieties grown in the South West of the USA, increasing the production and
quality of the Italian supply chain and, at the same time, reducing the
environmental impact».
For example, in 2011, AUREO led to saving of more than 40 MILLION m3 of
water, not to mention CO2 emissions associated with transportation of
wheat from the USA.
* One parent came from CIMMYT germplasm and the segregating population waslooked after by University of Bologna.
Source: https://www.syngenta.it/prodotti/sementi/frumento-duro/aureo; https://www.barillagroup.com/en/groups-position/barilla-and-wheat-truth-point-point
AUREO
Exceptionalgluten and
proteinquality
Designedfor the Voiello pasta supplychain
Very good attitude to
pasta making
Goodcombinationof yield and top quality
traits
Excellent resistance to water
stress
High vitrosity of the seeds