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

Thank you for the attention

www.openfields.it