The process: Semolina is mixed with water. The mixture is drawn to give to pasta the shape. Pasta then passes through the drying phase to remove the excess moisture. Then it is cooled down and packaged.
Receipt and stocking of raw materials
Raw materials, mainly durum wheat semolina but also egg products, arrive at the plant.
In this first phase there is a qualitative analysis by the laboratory. If analysis shows positive results, raw materials are released to flour stocking area. Semolina is stored in the silos from which, later, the production line draws.
The ordered recipe of flours goes through the process. Quantities and qualities are continuously recorded in order to allow the traceability. Flours are then: mixed in the Premix (brevet Storci spa), weighted according to the recipe, checked with a metal detector, sent on a pneumatic transport to the decanter cycle.
Flours are then mixed with water and with what is needed for the recipe. The mixture is stabilized on a belt and then moved to a vacuum kneading machine, where it is de-aerated.
The mixture is taken by screws and push through the dies (extrusion) which give the wished shape.
Pasta is then moved through the drying area, losing gradually moisture. It remains there till it gets dry and stable.
In each packaging line the product is weighted and packaged in the primary packaging (film or paper boxes) and then in the secondary packaging, then palletized.
Pallets are transported by computer-driven shuttles.
Each pallet is covered with nylon and assigned identification labels.
The products are packaged in cardboard boxes and the cardboard boxes are then loaded onto pallets which are transferred by means of fully automated operations. The pallets are identified by means of a label and are sent directly to the automated warehouse. This is the beginning of the finished product storage process. Furthermore, a logistics area set up in the Riese Pio X plant, combines automation with functional performance. It represents a gem of modernisation, specifically designed for a self-supporting warehouse with 25,000 pallet rack shelvings that in turn has allowed for the reorganisation and internal rationalisation of the production process.
The Pasta ZARA development plan includes a similar project for the Muggia plant too, where, in actual fact, a record storage space of 66,000 pallet rack shelvings is to be provided.
Finally, the system calls up the pallets automatically, ensuring that the pasta is kept as short a time as possible in the warehouse. The pallets reach the loading bays just a few metres from the lorries to be loaded. With this system up to 10 lorries can be loaded an hour per production plant. The product is then delivered to the customers on the means of transport.