24.Durum24.Durum-- und und TeigwarenTeigwaren--TagungTagungDetmoldDetmold, 28, 28--29.04.201029.04.2010

FAVA FAVA PresentationPresentation::RECENT DEVELOPMENTS IN PASTA PROCESSINGRECENT DEVELOPMENTS IN PASTA PROCESSING

FAVA Group FAVA Group ofof CompaniesCompanies

Dry pasta equipmentwww.fava.it

(280 Employees)

Burners, boilers, air conditioningwww.baltur.it

(210 Employees)

ExtrudersFresh, filled, precooked pasta

equipmentwww.storci.com(50 Employees)

ENRICO FAVAChairman

ENRICO FAVAChairman

LUIGI FAVAManaging Director

LUIGI FAVAManaging Director

Company HistoryCompany History OWNERSHIPOWNERSHIP

TOTAL SALES OF THE FAVA GROUP 2009

149 Mil €

MANUFACTURING SERVICESMANUFACTURING SERVICES

Headquarters and manufacturing workshop covering a total area of 20,000 m2

260 employeesSignificant 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’sengineers.  We are UL/CSA certified panel manufacturers.

Company HistoryCompany History

WORLDWIDE SALES & WORLDWIDE SALES & MARKET SHARE FIGURESMARKET SHARE FIGURES

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 ImpactCompany Industry Impact

COMPLEX PROJECTSCOMPLEX PROJECTS

• 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 ImpactCompany Industry Impact

FAVA in the WorldFAVA in the WorldFAVA operates on a worldwide basis with a large network of area representatives

Company Industry ImpactCompany Industry Impact

R&DR&D FACILITYFACILITYWeWe havehave 2 2 R&DR&D laboratorieslaboratories in:in:

FAVA HQ FAVA HQ –– specializingspecializing in dry pasta in dry pasta STORCI HQ STORCI HQ –– specializingspecializing in in freshfresh pastapastacertifiedcertified byby the the MinistryMinistry forfor ScientificScientific ResearchResearch..

OfferingsOfferings

FAVA R&D LABORATORYFAVA R&D LABORATORYOurOur lablab isis equippedequipped withwith::

Complete couscous Complete couscous linelineA A plantplant forfor long and short long and short goodsgoodsTwoTwo typestypes ofof gelatinizersgelatinizers forfordifferentdifferent technologiestechnologiesPressPressTwoTwo PREMIXesPREMIXes

StabilizationStabilization beltmixbeltmixTraditionalTraditional mixermixerVariousVarious additive additive dosingdosingsystemssystems –– liquidliquid//powderpowderVentilationVentilation tunnel tunnel forfor fan fan teststestsLabLab instrumentsinstruments forforproductproduct analysisanalysis

R&DR&D FACILITYFACILITYOfferingsOfferings

PREMIXPREMIX®®FAVA patented system

Perfect hydration Perfect hydration regardless of particle regardless of particle sizesizeHigh High transition speedtransition speed

No damage to productNo damage to product

Compact and easy to Compact and easy to useuse

Easy and quick to cleanEasy and quick to clean

TechnicalTechnical

... after the rapid transition in the PREMIX premixer....

Semolina particle size varies from 200 micron to 500 micron .....

TechnicalTechnical PREMIXPREMIX®®

Dough moistening uniformityDough moistening uniformity1 - Semolina particle-size: 280 – 390 micron (70%)2 - Hydration into PREMIX

TechnicalTechnical PREMIXPREMIX®®

3 - Dough at 31% with H2O colored blue

Plain and colored Plain and colored doughdoughTechnicalTechnical PREMIXPREMIX®®

TechnicalTechnical BELT BELT MIXERMIXER®®FAVA patented system

Semolina particles of various sizes .....

... after a short transition in the PREMIX pre-mixer ....

... after transition on the stabilization belt.....

... and at the inlet of the screw.

Semolina hydration phasesSemolina hydration phasesTechnicalTechnical BELT BELT MIXERMIXER®®

TechnicalTechnical BELT BELT MIXERMIXER®®

Operational advantagesOperational advantagesSelfSelf--cleaning system: cleaning system: maximum hygiene, no maximum hygiene, no encrustingencrustingFacilitating cleaning and Facilitating cleaning and maintenance operationmaintenance operationSafer operational conditionsSafer operational conditionsLow power applied = Low power applied = energyenergysavingssavings

TechnicalTechnical BELT BELT MIXERMIXER®®

M.E.S.M.E.S.Manufacturing Execution SystemManufacturing Execution System

M.E.SM.E.S: : isis a Software a Software ApplicationApplication expresslyexpressly createdcreated forfor the Pasta the Pasta EquipmentEquipment producedproducedbyby FAVA S.p.A.FAVA S.p.A.

MAIN GOAL MAIN GOAL ofof the the ApplicationApplication isis toto allowallow the the AcquisitionAcquisition and the and the StorageStorage ofof allall the the WorkingWorking Data Data comingcoming fromfrom Production Production LinesLines..

POSSIBILITY POSSIBILITY toto StoreStore and and ConsultConsult::•• ProductionsProductions•• MainMain VariablesVariables TrendTrend•• AlarmsAlarms•• OperatorOperator ActivitiesActivities

INTEGRATION INTEGRATION betweenbetween the the M.E.SM.E.S ApplicationApplication and and oneone or more or more LineLine SupervisorSupervisor isisallowedallowed byby the Total the Total CompatibilityCompatibility withwith the the SupervisorSupervisor native data (.DBF, .DAT).native data (.DBF, .DAT).

STORAGE STORAGE ofof the the workingworking data inside a data inside a RelationalRelational Database, Database, withoutwithout the the temporaltemporalrestrictionsrestrictions thatthat are are typicaltypical ofof the the LineLine SupervisorsSupervisors ((onlyonly last 3 last 3 monthmonth data), data), willwillallowallow toto satisfysatisfy the the newnew lawslaws regardingregarding TraceabilityTraceability in the in the FoodFood Area.Area.

The basic element of the The basic element of the M.E.S. programme is the M.E.S. programme is the ““batchbatch”” which in our case which in our case is identified within a is identified within a specific working time specific working time frame. Of course, the frame. Of course, the duration of this time duration of this time frame depends on the frame depends on the requirements of the end requirements of the end customer.customer.

M.E.S.M.E.S.Manufacturing Execution SystemManufacturing Execution System

This programme allows you to This programme allows you to illustrate all the stored data in illustrate all the stored data in the format of tables and trends the format of tables and trends which assists the operator in which assists the operator in identifying any anomalies identifying any anomalies arising during the set working arising during the set working time frame. time frame. We have also integrated further We have also integrated further data to provide the operators data to provide the operators with extra evaluation elements.with extra evaluation elements.

M.E.S.M.E.S.Manufacturing Execution SystemManufacturing Execution System

To do this, we have introduced To do this, we have introduced additional elements based on the additional elements based on the production phase underwayproduction phase underway

Moreover, we have identified the Moreover, we have identified the risk coefficients which highlight risk coefficients which highlight the critical points in the various the critical points in the various phases of production.phases of production.

In fact, hypothetically speaking, In fact, hypothetically speaking, if there is an accidental change if there is an accidental change in the normal production in the normal production process, the level of risk the process, the level of risk the product runs depends on the product runs depends on the specific zone it is in at that time.specific zone it is in at that time.

M.E.S.M.E.S.Manufacturing Execution SystemManufacturing Execution System

SupervisorSupervisor (X1)(X1)AllowsAllows toto acquireacquireand and viewview allall the data the data ofof a Single a Single LineLine (LN).(LN).

Can Can bebe installedinstalled on on the the samesame PC PC ofof the the LineLine SupervisorSupervisor (SV).(SV).

DoesDoes notnot requirerequireextra PC or Ethernet extra PC or Ethernet connection connection withwith the the SupervisorSupervisor PC.PC.

A FAVA A FAVA techniciantechnician isisrequiredrequired forfor the the installationinstallation. .

Database (DB) Database (DB) isislocatedlocated on the on the SupervisorSupervisor PC.PC.

Server (X2)Server (X2)

AllowsAllows toto acquireacquire and and viewview allall the data the data ofof oneoneor more or more LinesLines ((LN+LN+).).

RequiresRequires anan extra PC extra PC connectedconnected byby Ethernet Ethernet (ETH) (ETH) toto the the LineLine PCsPCs. .

The extra PC can The extra PC can bebepreparedprepared internallyinternally bybyFAVA FAVA TechniciansTechnicians..

No No modificationmodification requiredrequiredon the on the LineLine PCsPCs, , onlyonlyEthernet connection Ethernet connection mustmust bebe presentpresent ..

VIEWER (optional)VIEWER (optional)OPTIONAL OPTIONAL ApplicationApplication providedprovidedseparatelyseparately byby FAVA FAVA S.p.AS.p.A.. ..

forfor viewingviewing data data onlyonly ofof oneone ore ore more more LinesLines ((LN+LN+). ).

DoesDoes notnot installinstall the Database the Database (DB) and (DB) and doendoen notnot acquireacquiredirectlydirectly anyany data, so data, so itit requiresrequiresoneone ofof the the M.E.S.M.E.S. versionsversions --SupervisorSupervisor (X1) or Server (X2) (X1) or Server (X2) –– alreadyalready installedinstalled..

Can Can bebe installedinstalled on on everyevery PC PC connectedconnected byby Ethernet Ethernet toto the PC the PC wherewhere the Database the Database isis installedinstalled. .

No No particularparticular configurationconfiguration isisrequiredrequired, so , so therethere isis no no needneed ofofa FAVA a FAVA techniciantechnician forfor the the installationinstallation (a (a SetupSetup CDCD willwill bebeprovidedprovided directlydirectly byby FAVA FAVA S.p.A.)S.p.A.)

EVERYTHING FOR PASTA AND MORE

Pasta Fresca Line: latest installations

FRESH PASTA RANGEFRESH PASTA RANGE

FilledFilled pasta:pasta: Ravioli and TortelliniRavioli and TortelliniEggEgg Pasta:Pasta: Tagliatelle and LasagneTagliatelle and Lasagne

SemolinaSemolina Pasta: Pasta: TypicalTypical regionalregional productsproducts

FreshFresh GnocchiGnocchi

WHICH SOLUTION?WHICH SOLUTION?

MACRO AREASMACRO AREAS

FIRST TARGETS TO BE DEFINEDFIRST TARGETS TO BE DEFINEDPRODUCT TYPEPRODUCT TYPE

PRODUCT QUALITYPRODUCT QUALITYSHELFSHELF--LIFELIFE

REQUIRED DATAREQUIRED DATAAVAILABLE AREAAVAILABLE AREA

TYPE OF RAW MATERIALS AVAILABLETYPE OF RAW MATERIALS AVAILABLESHAPES SHAPES –– TYPE OF PACKAGING TYPE OF PACKAGING

PASTA FRESCAH >24% aw 0,92-0,97

STABILIZED PASTAH >20% aw < 0,92

PRODUCT WITH LESS THERMAL DAMAGE (HIGHER FOR FRESH PASTA)PRODUCT WITH LESS THERMAL DAMAGE (HIGHER FOR FRESH PASTA)MORE ADVANCED TECHNOLOGYMORE ADVANCED TECHNOLOGYHIGHER PRODUCT QUALITYHIGHER PRODUCT QUALITY

RAW MATERIAL DOSAGERAW MATERIAL DOSAGE

MIXINGMIXING

DOUGH MIXING AND FINAL LAMINATION / EXTRUSION DOUGH MIXING AND FINAL LAMINATION / EXTRUSION

PRODUCT FORMATIONPRODUCT FORMATION

THERMAL PASTEURIZATION TREATMENT THERMAL PASTEURIZATION TREATMENT

PREPRE--DRYING DRYING

PACKAGING IN MAPPACKAGING IN MAP

PRODUCT PASTEURIZATION PACKAGING

DOUGH MIXING FORMING

White chamber

PRE-DRYING PHASE

STABILIZED PASTA : SINGLE STABILIZED PASTA : SINGLE THERMAL TREATMENT THERMAL TREATMENT

TECHNOLOGYTECHNOLOGY

PRE-DRYING PACKED PRODUCT PASTEURIZATION

DOUGH MIXING FORMATION

PRODUCT PASTEURIZATION PACKAGING

PRODUCT WITH HIGHER THERMAL DAMAGEPRODUCT WITH HIGHER THERMAL DAMAGEMAX. HYGIENE QUALITY MAX. HYGIENE QUALITY -- MIN. ORGANOLEPTIC QUALITYMIN. ORGANOLEPTIC QUALITY

RAW MATERIAL DOSAGERAW MATERIAL DOSAGE

MIXINGMIXING

DOUGH MIXING AND FINAL LAMINATION / EXTRUSION DOUGH MIXING AND FINAL LAMINATION / EXTRUSION

PRODUCT FORMATIONPRODUCT FORMATION

FIRST THERMAL PASTEURIZATION TREATMENT FIRST THERMAL PASTEURIZATION TREATMENT

PREPRE--DRYINGDRYING

PACKAGING IN MAPPACKAGING IN MAP

SECOND PASTEURIZATION TREATMENT OF PACKED PRODUCTSECOND PASTEURIZATION TREATMENT OF PACKED PRODUCT

STABILIZED PASTA: DOUBLE STABILIZED PASTA: DOUBLE THERMAL TREATMENT TECHNOLOGYTHERMAL TREATMENT TECHNOLOGY

STABILIZED FILLED PASTA LINESTABILIZED FILLED PASTA LINE

PROLONGED DRYING PROCESS

PASTEURIZATION OF THE PACKETS

• Much lower cleaning time and lessbacteria charge toward traditionalmixers

• Colour improvement thanks to the reduced dough oxydation

• Easy maintenance: quickintervention times

• Limited installed power• Gluten formation process start

without mechanical stress

• PREMIX+ BELTMIX: unique and successful combination

FRESH PASTA MIXING SYSTEMS: BELTMIX

LONG CUT PASTA AND LASAGNA LINELONG CUT PASTA AND LASAGNA LINE

DOUGH DISTRIBUTION SYSTEMDOUGH DISTRIBUTION SYSTEM

TRANSLATION

LOADING

UNLOADING

FRESH FILLED PASTA LINE FRESH FILLED PASTA LINE 540 mm DOUGH SHEET540 mm DOUGH SHEET

No. 2 DOUGH-SHEETERS STF 540 TV

CONTINUOUS DOUGH FEEDING SYSTEM

RAVIOLI-MAKING MACHINE STORCI BY TECNAmod. RCA 540 B

DOUGHDOUGH--SHEETERSSHEETERS

TRADITIONALTRADITIONAL UNDER VACUUMUNDER VACUUM

MOD. STFMOD. STF MOD. STF TVMOD. STF TV®®

VACUUM DOUGHVACUUM DOUGH--SHEETERSHEETER

KNEADERS DETAIL MADE OF SAF STEELKNEADERS DETAIL MADE OF SAF STEEL

We have a patented range ofvacuum dough-sheetersmodel STF STF TVTV®®

Thanks to this machine, weobtain new improved doughsheet characteristics in terms of:

colourstretchabilitycompactnesselasticity

Humidity also becomes more uniform.

STORCI & QUALITYSTORCI & QUALITY

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

CERTIFIED QUALITY MANAGEMENT SYSTEM UNI EN ISO

9001:2000

PASTA FRESCAPASTA FRESCA

The laboratory is used for testing our machinesand carry out tests on different types of shapes, pasteurizing, drying processes and productpackaging.

All our clients’ enquiries are analyzed one by one in order to make a “personalized offer”.

An indication on the future of our industry

Countries with rooted pasta culture:Countries with rooted pasta culture:seek in pasta an improvement based on the link between nutritionseek in pasta an improvement based on the link between nutritionand healthand health

Countries where pasta culture is not deepCountries where pasta culture is not deep--rooted:rooted:develop a technology for pasta production and dryingdevelop a technology for pasta production and drying

International policies:International policies:tend to promote the development of this sectortend to promote the development of this sector

Pasta has currently acknowledged the role of a basic element:Pasta has currently acknowledged the role of a basic element:healthy and proper nutrition, economic and with exceptional healthy and proper nutrition, economic and with exceptional conservation elementsconservation elements

Thank you for your kind attention

ARRIVEDERCI