How Small-Scale Fried Instant Noodles Are Formed: A Step-by-Step Guide

Fried instant noodles are a popular convenience food worldwide, known for their quick preparation and long shelf life. Small-scale production follows a structured process to ensure quality, texture, and flavor. This article explains how small-batch fried instant noodles are formed, from dough mixing to final frying.

1. Ingredients Mixing & Dough Preparation

The process begins with blending key ingredients:

• Wheat flour (main structural component)
• Water (hydration for gluten development)
• Salt & Alkaline agents (e.g., kansui) – improves elasticity and chewiness
• Optional additives (starch, gluten, emulsifiers for texture enhancement)

The mixture is kneaded into a smooth, elastic dough.

2. Dough Sheeting & Thickness Reduction

The dough passes through a series of rollers to form thin, uniform sheets:

• First Roller: Creates a thick dough sheet (~10 mm).
• Subsequent Rollers: Gradually reduce thickness (final sheet ~1 mm).
• Dusting with flour prevents sticking.

3. Noodle Strand Formation

The thin dough sheet is slit into noodle strands using a cutting machine with adjustable blades:

• Straight noodles (knife-cut style)
• Wavy noodles (curled for better texture)
• Thickness varies (0.8–1.2 mm, depending on product type)

4. Steaming (Partial Cooking)

The noodle strands pass through a steam tunnel (100°C for 1–3 minutes) to:

• Gelatinize starch for better texture
• Reduce frying time later
• Improve shelf stability

5. Noodle Block Shaping (for Instant Cups/Packets)

For block-style instant noodles:

• Noodles are folded into a mold
• Pressed into a compact shape
• Pre-dried slightly to hold form

For cup noodles:

• Noodles are loosely packed to allow even frying

6. Deep-Frying (Key for Crispiness & Preservation)

The noodles are fried in 170–180°C oil (palm oil, soybean oil, or blended oils) for 60–90 seconds:

• Removes moisture (reducing water activity for shelf stability)
• Creates porous structure (helps rehydration later)
• Adds flavor & crispness

After frying, excess oil is drained via vibration or centrifugation.

7. Cooling & Packaging

• Cooled to room temperature to prevent condensation
• Packaged with seasoning sachets (flavor powder, dehydrated veggies, oil)
• Sealed in airtight bags/cups to maintain freshness

8. Quality Control Checks

Small-scale producers ensure:
✔ Oil content (15–20% for optimal crispness)
✔ Moisture content (<10% for shelf stability)
✔ Texture & rehydration time (should soften in 3–5 minutes in hot water)

Conclusion

Small-scale fried instant noodle production involves precise dough preparation, shaping, steaming, and frying to achieve the desired texture and shelf life. While the process is similar to large-scale manufacturing, small producers often focus on artisanal flavors and quality control.

Would you like details on seasoning formulations or alternative (non-fried) noodle production methods?