1. Pengenalan: What is an Instant Noodle Production Line with packaging Machine ?
An Instant Noodle Production Line with Packaging Machine is a fully automated, industrial-scale system designed to produce, cook, dry, and package instant noodles efficiently and hygienically. These production lines are essential for manufacturers that want to meet growing global demand while maintaining product consistency, keselamatan, and shelf stability.
This complete line includes stages for dough mixing, steaming, noodle cutting and shaping, frying or air-drying, penyejukan, and integrated automatic packaging.
2. Global Demand and Market Trends
The instant noodle market has witnessed exponential growth across Asia, Afrika, Latin America, and Eastern Europe. According to World Instant Noodles Association (WINA), more than 120 billion servings are consumed globally each year.
Key Trends:
- Growth in cup noodles dan non-fried noodles
- Increasing demand for automated packaging
- Expansion into healthier and gluten-free noodles
- Integration with AI-driven quality control
3. Types of Instant Noodles
Your production line can be tailored to produce various types of noodles:
- Fried instant noodles (most common)
- Steamed and air-dried noodles (healthier option)
- Cup noodles (pre-packaged in bowls or cups)
- Bagged noodles (loose block in foil/paper/plastic)
Each noodle type requires slight changes in processing and packaging components.
4. Overview of the Production Process
The instant noodle production workflow typically follows these steps:
- Mixing ingredients (flour, water, garam, additives)
- Dough sheeting and compounding
- Steaming the noodle sheet
- Cutting and forming noodle strands
- Frying or drying
- Cooling and alignment
- Weighing and packing with seasoning sachets
- Sealing and labeling
- Carton boxing and palletizing
5. Core Components of Instant Noodle Production Line
| Component Name | Fungsi |
|---|---|
| Pengadun Doh | Forms uniform dough from ingredients |
| Compound Roller | Sheets and compacts dough |
| Steaming Conveyor | Steams noodles to cook them halfway |
| Cutting Device | Cuts noodles into fine strands |
| Fryer or Dryer | Removes moisture, improves shelf life |
| Penghantar Penyejuk | Lowers temperature before packing |
| Seasoning Feeder | Dispenses seasoning sachets |
| Automatic Packing Machine | Wraps and seals noodles |
| Metal Detector | Ensures food safety compliance |
| Coding & Labeling System | Prints expiration and batch numbers |
6. Detailed Breakdown: From Dough to Final Packaging
6.1 Dough Preparation and Mixing
High-speed vacuum mixers combine wheat flour, alkaline water, and optional nutrients under controlled pressure, forming elastic dough.
6.2 Sheeting and Rolling
Multiple rollers compress the dough into sheets with adjustable thickness.
6.3 Steaming Section
Steaming gelatinizes starches, forming the desired noodle texture. Temperature ~100°C.
6.4 Cutting and Curling
The steamed sheet is cut into strands and curled into characteristic wavy shapes using rotary knives.
6.5 Frying or Hot-Air Drying
Fried in palm oil at ~150–160°C for 90–120 seconds, or air-dried for health-conscious products.
6.6 Cooling Zone
Air-cooled to ambient temperature to avoid condensation in sealed packaging.
6.7 Weighing and Sachet Insertion
Each noodle block is paired with flavor powder, oil sachet, or dehydrated vegetables.
6.8 Automatic Packaging System
Noodles and sachets are packed in cups or flow-wrapped using advanced horizontal or vertical FFS (form-fill-seal) systems.
7. Types of Packaging Machines for Instant Noodles
7.1 Horizontal Flow Wrap Machine
- Ideal for pillow-type plastic packs
- Speed: 100–300 packs/minute
7.2 Cup/Bowl Noodle Packaging Machine
- Handles containers with lids
- Integrated with sealing and labeling
7.3 Vertical FFS Machine
- Great for seasoning sachets
- Forms bag, fills, and seals automatically
7.4 Cartoning and Bundling Machine
- Groups packs into retail boxes
- Shrink-wrapping option available
8. Packaging Material and Shelf Life Considerations
| Material Type | Penerangan | Faedah |
|---|---|---|
| BOPP/PP Film | Common for bagged noodles | Low cost, moisture barrier |
| Paper Cups + Foil Lid | Used for cup noodles | Microwave safe, stackable |
| Multi-layer Pouches | For seasoning packets | High barrier, preserves aroma |
Shelf life typically ranges from 6 months to 12 bulan, depending on oil content and packaging material.
9. Technical Specifications of the Production Line
The following table presents detailed technical specifications for an average industrial-scale instant noodle production line with packaging machine:
| Spesifikasi | Value/Range |
|---|---|
| Kapasiti pengeluaran | 30,000 - 300,000 packs/day |
| Output Speed | 80–300 noodle cakes/min |
| Dough Mixing Volume | 50–500 kg/batch |
| Steaming Temperature | 98–105°C |
| Frying Oil Temp (Fried noodles) | 150–165°C |
| Drying Temp (Non-fried noodles) | 75–95°C |
| Packaging Machine Speed | 80–200 packs/min |
| Bekalan kuasa | 380V / 50Hz / 3 Phase |
| Total Power Consumption | 100–250 kW (depending on scale) |
| Bahan mesin | Food-grade SUS304 stainless steel |
| Air Pressure (for packaging) | 0.6–0.8 MPa |
| Water Consumption | 2–4 m³/hr |
| Line Length | 20m–70m (based on capacity & layout) |
All parts in contact with food meet FDA, CE, dan ISO 22000 standards.
10. Layout and Space Planning
Proper factory layout planning helps ensure workflow efficiency, food safety, and ease of cleaning. A medium-scale instant noodle line (Mis., 150,000 packs/day) typically requires:
- Factory Area: 800–1,500 m²
- Zones:
- Raw material receiving & storage
- Dough processing and steaming area
- Drying or frying section
- Cooling & packaging zone
- Final packing & dispatch
- Considerations:
- Linear flow from raw to finished product
- Separate entry/exit for raw materials and staff
- Drainage system for easy CIP (Bersih di tempat)
- Controlled humidity in drying area
11. Energy and Utility Requirements
Proper estimation of energy and utilities is essential for budgeting and plant engineering.
| Resource | Consumption Estimate (Per 1000 kg) |
|---|---|
| Electricity | 150–250 kWh |
| Steam | 300–500 kg |
| Water | 2–4 m³ |
| Compressed Air | 5–10 m³/hr |
| Frying Oil (if used) | 0.8–1.2 kg per kg of noodle block |
You can optimize consumption using:
- Heat recovery systems
- High-efficiency burners
- VFD-controlled motors
- Solar preheaters
12. Automation and Control Systems
Modern instant noodle lines are highly automated, integrating PLC and HMI control systems to ensure consistency and monitoring:
Ciri-ciri Utama:
- Touchscreen control panels (HMI)
- SCADA integration for real-time analytics
- Recipe management system
- IoT remote diagnostics
- Sensors for pressure, temperature, speed
- Automatic alarm and fault detection
Operators can switch between products, adjust parameters, or monitor maintenance alerts directly from the screen.
13. Production Line Capacity and Scalability
Production lines are available in various configurations to suit every business size:
| Skala Pengeluaran | Output Capacity (Packs/Day) | Sesuai untuk |
|---|---|---|
| Small Scale | 20,000–50,000 | Local noodle shops, SMEs |
| Medium Scale | 80,000–150,000 | Regional food manufacturers |
| Large Scale | 200,000–300,000+ | Exporters, global brands |
Lines can be upgraded by:
- Adding more drying/frying tunnels
- Upgrading to multi-head packaging units
- Installing robotic pick-and-place arms
14. Maintenance and Cleaning Procedures
Proper maintenance ensures longevity, hygiene, and performance.
Daily Tasks:
- Clean extruder dies and steaming chamber
- Drain and filter frying oil (if applicable)
- Sanitize cutting knives and conveyor belts
Weekly Tasks:
- CIP: clean-in-place piping, steam lines
- Oil change in gearbox, motor greasing
- Air filter and water filter cleaning
Monthly Tasks:
- Calibrate sensors and PLC systems
- Replace worn-out belts or Teflon sheets
Use food-safe detergents dan anti-microbial coatings to prevent contamination.
15. Food Safety and Compliance Certifications
Your instant noodle production line must comply with the following standards:
| Certification | Penerangan |
|---|---|
| CE | European safety and machinery compliance |
| ISO 22000 / HACCP | Food safety management system |
| FDA / LFGB | Material safety for food-contact surfaces |
| GMP | Good Manufacturing Practices |
| SGS/BV Reports | Independent verification of equipment and hygiene |
Manufacturers should supply full documentation termasuk:
- Electrical schematics
- User and cleaning manuals
- Maintenance schedule
- Spare parts list
16. Key Manufacturers and Global Suppliers
When choosing a supplier, consider:
- Experience and reputation
- Spare parts availability
- Training and support
- Customization capabilities
Top Global Suppliers:
- Nissin Engineering (Japan)
- Bühler Group (Switzerland)
- Pavan Group / GEA (Italy)
- DT Food Machine Co., Ltd. (China)
- Anko Food Machinery (Taiwan)
- Unitherm Food Systems (USA)
17. Investment Costs and ROI Analysis
Investment depends on output scale, level of automation, and configuration.
| Line Type | Anggaran kos (USD) |
|---|---|
| Small Scale | $50,000–$100,000 |
| Medium Scale | $150,000–$300,000 |
| Large Scale | $400,000–$800,000+ |
ROI Factors:
- Local market demand
- Profit margin per pack
- Labor cost savings
- Packaging cost per unit
Most factories recoup investments within 12–24 months.
18. Case Studies and Industrial Applications
Case Study 1: Vietnam – Medium Scale Line
- Output: 120,000 packs/day
- Pembungkusan: pillow packs with triple sachets
- ROI: 16 bulan
Case Study 2: Kenya – Non-Fried Line
- Output: 30,000 cup noodles/day
- Powered by solar preheating system
- ROI: 22 bulan
Case Study 3: Mexico – Large-Scale Export Line
- Output: 300,000 packs/day
- Fully automated SCADA integration
- Export to USA and Canada
19. Common Issues and Troubleshooting
| Issue | Cause | Penyelesaian |
|---|---|---|
| Broken noodle strands | Over-mixing or dull cutters | Adjust sheeting tension, replace blades |
| Oil degradation | Reused too many cycles | Use auto-filtration or oil sensor |
| Packaging misalignment | Timing off or sensor failure | Recalibrate sensors and conveyor sync |
| Noodle sticking in fryer | Incorrect starch gelatinization | Recheck steaming temperature |
20. RFQ – Frequently Asked Questions
Q1: Can I customize the shape and size of noodle cakes?
Ya. You can customize molds, die plates, and cutter sizes.
S2: What is the difference between fried and non-fried noodles in machinery?
Fried noodles require fryers, oil filters, and exhaust hoods; non-fried noodles use longer air-dry tunnels and steam optimization.
Q3: How long does installation take?
Typically 30–60 days, including training.
Q4: Can one line produce both cup and pillow packs?
Ya, dengan interchangeable packaging modules.
S5: Is local language supported in control systems?
Ya, HMI panels can be programmed in multiple languages.
Q6: Can seasoning be inserted automatically?
Ya. Sachet dispensers handle multiple packets per pack.
Q7: What is the oil consumption rate?
Roughly 0.8–1.2 kg oil per kg noodles for fried types.
Q8: Is it easy to switch products or sizes?
Ya. Most lines allow tool-free changeover in 30–60 minutes.
Q9: What kind of labor is needed?
A line of 150,000 packs/day may need 6–10 operators per shift.
Q10: What maintenance support is available?
Manufacturers offer remote diagnostics, alat ganti, dan onsite visits.
21. Future Innovations in Instant Noodle Processing
- AI-Powered Inspection Cameras to detect defects in real-time
- Smart Fryers with adaptive oil management
- Eco-friendly packaging materials like biodegradable films
- Modular plug-and-play systems for fast expansion
- Robotic arms for cartoning and palletizing
- IoT connectivity for predictive maintenance
22. Kesimpulan: Why Invest in a Line with Integrated Packaging?
A fully integrated instant noodle production line with packaging machine offers:
- Higher productivity and profit margins
- Reduced manual labor and human error
- Improved food safety and traceability
- Quicker ROI with scalable operations
- A competitive edge in domestic and export markets
Whether you’re a startup or a global food brand, this investment is the backbone of success in today’s instant noodle industry.