24.Durum- und Teigwaren-Tagung Detmold, 28-29.04.2010
FAVA Presentation: RECENT DEVELOPMENTS IN PASTA PROCESSING Company History OWNERSHIPOWNERSHIP FAVAFAVA GroupGroup ofof CompaniesCompanies
ENRICOENRICO FAVA FAVA LUIGILUIGI FAVA FAVA ChairmanChairman Dry pasta equipment ManagingManaging www.fava.it DirectorDirector (280 Employees)
TOTAL SALES OF THE FAVA GROUP 2009 149 Mil €
Burners, boilers, air Extruders conditioning Fresh, filled, precooked pasta www.baltur.it equipment (210 Employees) www.storci.com (50 Employees) Company History MANUFACTURINGMANUFACTURING SERVICESSERVICES
Headquarters and manufacturing workshop covering a total area of 20,000 m2 260 employees Significant percentage of components are built in house. Local shops are utilized when work load surges occur. Control systems and electrical panels are completely built in‐ house. Software is produced by Fava’s engineers. We are UL/CSA certified panel manufacturers. Company Industry Impact
WORLDWIDEWORLDWIDE SALESSALES && MARKETMARKET SHARESHARE FIGURESFIGURES Annual sales turnover 2009 –EUR 76 million. Total World‐wide Market Share: 35% Domestic Market Share: 85% Export Figures: approx. 80% of FAVA lines are exported. Pasta line production outputs: Range from 750 –9000 kg/h From January 1996 were sold 330 high capacity pasta lines From the beginning of the company were sold more than 2.250 pasta lines Company Industry Impact COMPLEXCOMPLEX PROJECTSPROJECTS
• PRODUCTION LINE FOR LONG GOOD HOLLOW FUSILLI • SPECIALTY LINE FOR STEAMED PRECOOKED CURLY LASAGNA • WASH-DOWN PRESSES FOR FROZEN PASTA • SPECIALTY LINE FOR GLUTEN-FREE PASTA WITH GELATINIZATION PROCESS • 6.000 KG/H SHORT GOODS LINE FOR TRICOLORED PASTA (*) • LONG GOOD LINE FOR AMERICAN LASAGNE WITH AUTOMATIC PACKAGING • TRAY LINE FOR NEST AND FLAT LASAGNE CAPACITY 1200 KG/H (*) • SHORT GOODS LINE FOR 9.000 KG/H (*) • LONG GOODS LINE FOR 6.000 KG/H (*)
(*) worlds large Company Industry Impact FAVAFAVA inin thethe WorldWorld
FAVA operates on a worldwide basis with a large network of area representatives Offerings R&DR&D FACILITYFACILITY We have 2 R&D laboratories in: FAVA HQ – specializing in dry pasta STORCI HQ – specializing in fresh pasta certified by the Ministry for Scientific Research. FAVAFAVA R&DR&D LABORATORYLABORATORY Our lab is equipped with: Stabilization beltmix Complete couscous line Traditional mixer A plant for long and short goods Various additive dosing systems – liquid/powder Two types of gelatinizers for Ventilation tunnel for fan different technologies Ventilation tunnel for fan tests Press Press Lab instruments for Two PREMIXes product analysis Offerings R&DR&D FACILITYFACILITY ® Technical PREMIXPREMIX FAVA patented system
PerfectPerfect hydrationhydration regardlessregardless ofof particleparticle sizesize HighHigh transitiontransition speedspeed
NoNo damagedamage toto productproduct
CompactCompact andand easyeasy toto useuse
EasyEasy andand quickquick toto cleanclean ® Technical PREMIXPREMIX
Semolina particle size varies from 200 micron to 500 micron .....
... after the rapid transition in the PREMIX premixer.... ® Technical PREMIXPREMIX DoughDough moisteningmoistening uniformityuniformity 1 - Semolina particle-size: 280 – 390 micron (70%) 2 - Hydration into PREMIX 3 - Dough at 31% with H2O colored blue ® Technical PREMIXPREMIX PlainPlain andand coloredcolored doughdough ® Technical BELTBELT MIXERMIXER FAVA patented system ® Technical BELTBELT MIXERMIXER SemolinaSemolina hydrationhydration phasesphases
Semolina particles of var ious sizes .....
... aft er t r ansit ion on ... aft er a shor t the stabilization transition in belt ..... the PREMIX pr e-mixer ...... and at t he inlet of the screw. ® Technical BELTBELT MIXERMIXER
® Technical BELTBELT MIXERMIXER OperationalOperational advantagesadvantages
SelfSelf--cleaningcleaning system:system: maximummaximum hygiene,hygiene, nono encrustingencrusting FacilitatingFacilitating cleaningcleaning andand maintenancemaintenance operationoperation SaferSafer operationaloperational conditionsconditions LowLow powerpower appliedapplied == energyenergy savingssavings
M.E.S.M.E.S. ManufacturingManufacturing ExecutionExecution SystemSystem M.E.S: is a Software Application expressly created for the Pasta Equipment produced by FAVA S.p.A.
MAIN GOAL of the Application is to allow the Acquisition and the Storage of all the Working Data coming from Production Lines.
POSSIBILITY to Store and Consult: • Productions • Main Variables Trend • Alarms • Operator Activities
INTEGRATION between the M.E.S Application and one or more Line Supervisor is allowed by the Total Compatibility with the Supervisor native data (.DBF, .DAT).
STORAGE of the working data inside a Relational Database, without the temporal restrictions that are typical of the Line Supervisors (only last 3 month data), will allow to satisfy the new laws regarding Traceability in the Food Area. M.E.S.M.E.S. ManufacturingManufacturing ExecutionExecution SystemSystem
The basic element of the M.E.S. programme is the “batch” which in our case is identified within a specific working time frame. Of course, the duration of this time frame depends on the requirements of the end customer. M.E.S.M.E.S. ManufacturingManufacturing ExecutionExecution SystemSystem
This programme allows you to illustrate all the stored data in the format of tables and trends which assists the operator in identifying any anomalies arising during the set working time frame. We have also integrated further data to provide the operators with extra evaluation elements. M.E.S.M.E.S. ManufacturingManufacturing ExecutionExecution SystemSystem
¾ To do this, we have introduced additional elements based on the production phase underway
¾ Moreover, we have identified the risk coefficients which highlight the critical points in the various phases of production.
¾ In fact, hypothetically speaking, if there is an accidental change in the normal production process, the level of risk the product runs depends on the specific zone it is in at that time. SupervisorSupervisor (X1)(X1)
¾ Allows to acquire and view all the data of a Single Line (LN).
¾ Can be installed on the same PC of the Line Supervisor (SV).
¾ Does not require extra PC or Ethernet connection with the Supervisor PC.
¾ A FAVA technician is required for the installation.
¾ Database (DB) is located on the Supervisor PC. ServerServer (X2)(X2)
¾ Allows to acquire and view all the data of one or more Lines (LN+).
¾ Requires an extra PC connected by Ethernet (ETH) to the Line PCs.
¾ The extra PC can be prepared internally by FAVA Technicians.
¾ No modification required on the Line PCs, only Ethernet connection must be present . VIEWERVIEWER (optional)(optional)
¾ OPTIONAL Application provided separately by FAVA S.p.A..
¾ for viewing data only of one ore more Lines (LN+).
¾ Does not install the Database (DB) and doen not acquire directly any data, so it requires one of the M.E.S. versions - Supervisor (X1) or Server (X2) – already installed.
¾ Can be installed on every PC connected by Ethernet to the PC where the Database is installed.
¾ No particular configuration is required, so there is no need of a FAVA technician for the installation (a Setup CD will be provided directly by FAVA S.p.A.) EVERYTHING FOR PASTA AND MORE Pasta Fresca Line: latest installations FRESHFRESH PASTAPASTA RANGERANGE
Filled pasta: Ravioli and Tortellini Egg Pasta: Tagliatelle and Lasagne Semolina Pasta: Typical regional products Fresh Gnocchi WHICHWHICH SOLUTION?SOLUTION? MACROMACRO AREASAREAS
PASTA FRESCA STABILIZED PASTA H >24% aw 0,92-0,97 H >20% aw < 0,92
FIRST TARGETS TO BE DEFINED PRODUCT TYPE PRODUCT QUALITY SHELF-LIFE
REQUIRED DATA AVAILABLE AREA TYPE OF RAW MATERIALS AVAILABLE SHAPES – TYPE OF PACKAGING STABILIZEDSTABILIZED PASTAPASTA :: SINGLESINGLE THERMALTHERMAL TREATMENTTREATMENT TECHNOLOGYTECHNOLOGY PRODUCT WITH LESS THERMAL DAMAGE (HIGHER FOR FRESH PASTA) MORE ADVANCED TECHNOLOGY HIGHER PRODUCT QUALITY
RAW MATERIAL DOSAGE
MIXING
DOUGH MIXING AND FINAL LAMINATION / EXTRUSION
PRODUCT FORMATION
THERMAL PASTEURIZATION TREATMENT White chamber PRE-DRYING
PACKAGING IN MAP
PRODUCT DOUGH PRE-DRYING PHASE MIXING FORMING PASTEURIZATION PACKAGING STABILIZEDSTABILIZED PASTA:PASTA: DOUBLEDOUBLE THERMALTHERMAL TREATMENTTREATMENT TECHNOLOGYTECHNOLOGY PRODUCT WITH HIGHER THERMAL DAMAGE
MAX. HYGIENE QUALITY - MIN. ORGANOLEPTIC QUALITY RAW MATERIAL DOSAGE
MIXING
DOUGH MIXING AND FINAL LAMINATION / EXTRUSION
PRODUCT FORMATION
FIRST THERMAL PASTEURIZATION TREATMENT
PRE-DRYING
PACKAGING IN MAP
SECOND PASTEURIZATION TREATMENT OF PACKED PRODUCT
DOUGH PRODUCT PRE-DRYING PACKED PRODUCT MIXING FORMATION PASTEURIZATION PACKAGING PASTEURIZATION STABILIZEDSTABILIZED FILLEDFILLED PASTAPASTA LINELINE
PASTEURIZATION OF THE PACKETS
PROLONGED DRYING PROCESS FRESH PASTA MIXING SYSTEMS: BELTMIX
• Much lower cleaning time and less bacteria charge toward traditional mixers • Colour improvement thanks to the reduced dough oxydation • Easy maintenance: quick intervention times • Limited installed power • Gluten formation process start without mechanical stress
• PREMIX+ BELTMIX: unique and successful combination LONGLONG CUTCUT PASTAPASTA ANDAND LASAGNALASAGNA LINELINE DOUGHDOUGH DISTRIBUTIONDISTRIBUTION SYSTEMSYSTEM
TRANSLATION
LOADING UNLOADING FRESHFRESH FILLEDFILLED PASTAPASTA LINELINE 540540 mmmm DOUGHDOUGH SHEETSHEET CONTINUOUS DOUGH FEEDING SYSTEM RAVIOLI-MAKING MACHINE STORCI BY TECNA mod. RCA 540 B
No. 2 DOUGH-SHEETERS STF 540 TV DOUGHDOUGH--SHEETERSSHEETERS
TRADITIONAL UNDER VACUUM
MOD. STF MOD. STF TV® VACUUMVACUUM DOUGHDOUGH--SHEETERSHEETER
We have a patented range of vacuum dough-sheeters model STF TV®
Thanks to this machine, we obtain new improved dough sheet characteristics in terms of: ¾ colour ¾ stretchability ¾ compactness ¾ elasticity
Humidity also becomes more uniform. KNEADERS DETAIL MADE OF SAF STEEL STORCISTORCI && QUALITYQUALITY
CERTIFIED QUALITY MANAGEMENT SYSTEM UNI EN ISO 9001:2000
INDUSTRIAL RESEARCH LABORATORY QUALIFIED BY THE M.I.U.R. (MINISTRY OF EDUCATION & UNIVERSITY RESEARCH)
OFFICIAL GAZETTE No. 160 – July 2006: LAB PUT ON THE REGISTER ACKNOWLEDGED AT NATIONAL LEVEL PASTAPASTA FRESCAFRESCA
The laboratory is used for testing our machines and carry out tests on different types of shapes, pasteurizing, drying processes and product packaging.
All our clients’ enquiries are analyzed one by one in order to make a “personalized offer”. An indication on the future of our industry
¾ Countries with rooted pasta culture: seek in pasta an improvement based on the link between nutrition and health
¾ Countries where pasta culture is not deep-rooted: develop a technology for pasta production and drying
¾ International policies: tend to promote the development of this sector
¾ Pasta has currently acknowledged the role of a basic element: healthy and proper nutrition, economic and with exceptional conservation elements Thank you for your kind attention ARRIVEDERCI