CHAPTER I: PRODUCT QUALITY AND SPECIFICATION

I. Product description
Instant noodles, often known as instant ramen, are noodles that are cooked in oil,
dried, and sold in compact quantities, typically with a flavor packet of dry herbs. They
are a form of convenience meal that may be swiftly prepared. Most instant noodles
require only boiling water and may be made in a microwave oven or on the stovetop.
Instant noodles are well-known for their ease of preparation and inexpensive cost.

Instant noodles are mainly produced using processed wheat flour. They may also
include dry veggies, dried tofu, or precooked meats like shrimp. A little sachet of
spices and powdered stock is frequently added while making soup. The full noodle
package may be offered in plastic packaging or in a polystyrene cup. Qualities of
instant noodles have gained popularity all over the world thanks to factors like taste,
nutrition, ease of use, safety, extended shelf life, and affordable pricing. Additionally,
instant noodles are employed as a last-minute and space-saving meal.

More than 80 countries now use instant noodles, which have gained popularity as a
dish worldwide. The noodle sector provides consumers with 95.4 billion servings
each year across the globe, and the needs are growing (Fig. 1). China leads the globe
in noodles consumed (Fig. 2), with Indonesia, Japan, and Vietnam following in order
of consumption. This information comes from the globe Instant Noodle Association
(WINA, 2011). Noodle consumption in India had been relatively low, but it has
significantly increased over the last five years—more than five times, according to
WINA (2011)—with 2940 million packets (bags/cups) consumed as of right now
(Fig. 3).

Figure 1: Consumption of instant noodles in world in recent years (WINA, 2011).

Figure 2: Consumption of instant noodles in different countries [data figures
represents 100 million packets; plotted using data from WINA (2011)]
 Figure 3: Consumption of instant noodles in India (WINA, 2011).

II. Primary and secondary package

1. Primary packaging
Primary packaging, often known as a consumer unit, is packaging that is closely
related to the product itself. The primary packaging's major function is to confine,
safeguard, and/or preserve the finished product, especially from contamination.
There are two distinct categories exist for instant noodle primary packaging

1.1. The bag-packed instant noodles

The first batch of instant noodles came in little packages. A composite plastic film,
having an inner layer of polyethylene and an exterior layer of cellophane, is used
to seal the packaging bag. A composite plastic sheet made of polyester and
polypropylene, or basic packaging made of regular paper and plastic, can also be
used as the packaging material. The entire package was successfully made leak-
proof and airtight with this design. The plastic can be creatively visually printed in
high definition to meet branding requirements. Manufacturers can also choose to
 employ basic packaging consisting of regular paper and plastic components, or
they can use a composite plastic sheet composed of polyester and polypropylene.

Noodles that come in bags typically include a spice packet inside and are boiled in
continuously boiling water for three to four minutes before being served.
Nevertheless, this method necessitates that the customer travel inconveniently with
a bowl to combine the components for the meal.

1.2. The bowl-packed/ cup-packed instant noodles

It is composed of non-toxic, heat-resistant materials, polystyrene foam plastic, and
paper that has been covered with anti-seepage and heat-resistant substances. The
core layer of an instant noodle bowl is typically made of food-grade polyethylene
(PE) material, covered in a layer of plastic film on cardboard. But due to its
exorbitant cost, the selling price was three times greater than that of the instant
noodles in bags so they’re not as popular as instant noodle bags. Cup/ bowl
noodles are instant noodles in a waterproof polystyrene cup with the seasoning
sprinkled over the noodles and are ready to serve after pouring hot water into the
bowl and resting for two–three minutes.

Thanks to technological advancements, we can now do more with wasted

products. One of the better instances of this are paper bowls with PE film lining
inside, which use recycled paper at an efficiency of roughly 60 to 70%. Because of
its sturdy design, noodles can be protected from harm of any kind. By using
recycled materials, we can now produce more affordable, higher-quality noodle
packaging while also protecting the environment and our ecosystem through the
creation of sustainable packaging. Because of the PE lining inside, these bowls are
resistant to liquids and should only be thrown away when no longer in use. This
means they can be used for extended periods of time.
2. Secondary packaging
 The outer packaging that encloses the prescription component and serves as a
means of connecting packages is known as secondary packaging. Corrugated
cartons are utilized as the secondary packing material for instant noodles. These
consist of a few material layers that are more firmly attached to one another than
they would be if they were separate layers. By filling the space between an outer
and interior liner, a material with a flute serves to fortify and consolidate the entire
item. When delivering a range of products safely, corrugated containers are the
best choice. Since they strike the ideal mix between strength and lightness.
Together with their structural strength, they are resistant to moisture and abrupt
temperature fluctuations.

III. Criteria for evaluation of product quality

Instant noodles, a global culinary phenomenon, offer an undeniable allure: quick,
convenient, and seemingly everywhere. But beneath the affordable price and rapid
preparation lies a world of varying quality. If you are choosing noodles based on
quality, the most crucial component is the consumer's choice. Although customers
have wide variations in these aspects, raw material properties—especially those
related to flour and component formulation—as well as processing factors all have an
impact on appearance (color, shape, and size), texture, flavor, eating quality, and
cooking quality. Below is a list of popular metrics used to evaluate the quality of
noodles.
1. Color
As color indicates a product's initial visual qualities, it remains a crucial quality element.
The color selection of the consumer is a major determinant of the quality of the noodles.
It is expected that noodles will have a yellowish tone or a brilliant, creamy appearance.
While polyphenol oxidase (PPO) activity and flour ash content are thought to influence
noodle whiteness, yellowness in noodles is caused by factors like the presence of lutein
pigment or xanthophylls in wheat flour, or the addition of food colorant by
manufacturers. It is said that flour with a protein concentration exceeding 13% reduces
brightness and yellowish tonality, presumably as a result of PPO and proteolytic enzyme
activity. These typically come from the bran fraction and combine with the phenolic
elements in the flour and the tyrosine groups in the protein to generate dark compounds
known as melanin. This is primarily to blame for the color's decreased brightness and
yellowish tone. Given that the presence of bran particles in flour is a function of flour
extraction rate, this suggested that flour extraction rate was another parameter to take into
account. It has been demonstrated that the velocity of flour extraction greatly affects the
color and texture of noodles. The high protein flour used in Korean noodles—which
typically has less starch to reflect light—was blamed for the noodles' dullness. Although
using medium-protein flours that yield a respectable level of brightness in the items
would be preferred, additives can be used to reduce the PPO activity linked to high-
protein flour. The oxidation of tyrosine moieties in wheat flour proteins mediated by non-
PPO is another type of darkening observed in noodles.
A better assessment of noodle color can be obtained through colorimetric analysis using
the Hunter Lab colorimeter, which uses the L* (lightness to darkness), a* (redness to
greenness), and b* (yellowness to blueness) qualities. The L* value of instant noodles
rose as the flour's SDS sedimentation volume increased, but it decreased as the amount of
salt- and alcohol-soluble protein in wheat flour rose. Since protein fibrils interact with
wheat particles and one another to promote particle stiffness and resistance to
denaturation, a high volume in an SDS sedimentation test shows gluten strength. SDS is a
protein denaturant.
2. Texture
One of the complex components of noodles that varies greatly by region is texture. This
is because different regions have different wheat qualities, salt or alkaline combinations,
and processing variables including steaming, sheeting, and dehydration techniques.
Noodle quality is influenced by a variety of factors, including flour quality and protein
content. Reduced protein concentration in the wheat flour produced finished noodles with
a rough texture. Adjectives including stickiness, smoothness, hardness/firmness, softness,
elasticity, cohesiveness, gumminess, and chewiness can be used to describe the texture of
noodles. Noodle texture can be assessed using both sensory and objective methods,
similar to color, while instrumental analysis has been demonstrated to be more suitable
for yielding a more consistent result. The easy-to-use and efficient texture assessment
method is called Texture Profile Analysis (TPA). It offers several textural attributes in
one test, such as cohesiveness, hardness, gumminess, chewiness, and stiffness. The
results are said to be similar to what is observed when chewing with the mouth.
Recent research has looked at microscopy, and studies of microstructure have been used
widely to look into how ingredients, formulas, and processing methods affect the texture
of noodles. Cantonese noodles, or fresh alkaline noodles, and fast noodles dough were
found to have similar microstructures; however, the noodles underwent different
microstructural changes as a result of frying, steaming, and final cooking.
3. Flavor
One cannot emphasize how important flavor is in quick noodles. While cooking, it can
please the palette, but if the flavor becomes rancid after a longer period of storage, the
product may not be accepted. Fast fried noodles gain a distinct flavor from the deep-
frying process. While seasoning has a complimentary effect during cooking, the use of
salt in the recipe and the frying process are thought to contribute to the development of
flavor in uncooked noodles. When deciding whether the flavor of quick fried noodles is
still appealing after being stored for a long period, the oil's quality is by far the most
significant factor. The way that oil quality affects noodle flavor can either give noodles a
nice texture and aroma from shortening or give them a rotten, off flavor.
4. Oil uptake

Instant noodles lose moisture when they are fried because of the temperature; eventually,
some oil fills in the moisture gap. In addition to adding to the rancid off-flavor that
develops during storage and contributing to the health issue connected with excessive oil
consumption, oil absorption is a crucial factor in the economics of instant noodles since it
can significantly increase production costs. Since gluten creates a rigid structural
network, it is hypothesized that gluten content and quality play a part in the amount of oil
that noodles absorb during frying. Therefore, increasing the dough's elastic properties
suggests that the noodles would absorb less oil.
There are regulations for sanitary instant noodles that evaluate a number of parameters,
including oil content, in Asian countries where instant fried noodles are a quickly
growing product and market. These guidelines' descriptions of chemical detection
techniques were thought to be pricy, labor-intensive, and time-consuming processes.
Alternatives have been the subject of some inquiry, especially those that are consistent
with routine. This has led to the development of faster, less expensive, more accurate, and
nondestructive techniques for estimating the oil content of specific instant noodles.

5. Cooking quality
A number of factors, such as cook time, cooking loss, and rehydration rate, affect the
quality of the food cooked. Instant noodles that have been cooked should be able to
withstand dissolving when boiled, which will minimize the amount of organic matter that
breaks down into the water while the noodles cook, and they should also be sufficiently
cooked and tender in a short amount of time, they are computed as time and cooking loss.
A noodle strand is usually chosen at the beginning of the cooking process and pressed
between two glass plates until the white core in the center of the strand has just
disappeared. This method is known as the optimal cooking time. Cooking loss is
computed by vaporizing an aliquot of the cooking water to estimate the ratio of organic
matter residue in the water during cooking to the dry weight of the noodles.
Cooking yield, sometimes referred to as cooking volume or weight, is the weight or
volume that the noodles acquire as a result of absorbing water while cooking, and it's
used as a gauge for cooking quality. As a result of the expansion and imprisonment of
starch granules in a coagulated protein matrix during cooking, a continuous and
reinforced network is formed, which aids in maintaining process integrity. As mentioned
earlier, the structural characteristics of pasta and dry noodles are identical, as is the
method of water absorption and rehydration during cooking—fried noodles, on the other
hand, have unique structural characteristics that facilitate moisture absorption. Basically,
when dry bread is cooked, water is absorbed due to the crystalline domains' kinetics of
melting. With longer cooking times, water would seep concentrically into the center of
the noodles as a plasticizer that enhanced polymer mobility, increasing the weight of the
noodles—also referred to as cooking weight, volume, or yield. AACC standard 66-50.01
can be used to compute cooking yield, which is the percentage weight difference between
cooked and uncooked noodles.
6. Criteria for evaluation of product quality in Vietnam
Beside 5 factor that we listed above, we still have the quality evaluation of instant
noodles in Vietnam that regulated in TCVN 5777:2004.
Sensory properties
Name of properties Requirements
State The noodles before cooking: intact,
regular, evenly glossy, no significant
defects.
The noodles after cooking: put hot water
in, after 4 minutes, the noodles still
specialty chewy. After 8 minutes, the
noodles is insignificant bloated.
Color Have the specialty yellow at both side.
Allow to have one side darker.
Flavor The dry noodles: no odor, or strange
smell, have the regular smell of noodle.
Noodles water: The fatty aroma of
 noodles and spices, has a sweet taste, does
not taste strange.
Table 1: sensory properties
Physic-chemical properties
Properties Value
Protein value (%) ≥ 10
Humidity (%) ≤5
Fatty value (%) 15÷20
Nitrogen value of all spice bags (%) ≥2
NaCl value in noodles (%) ≤4
Insoluble ash value in HCl (%) ≤ 0,1
Mg KOH/g, acid value ≤2
Peoxyde value, mg Na2S2O3 0,002N in 1g ≤ 0,4 (noodles)
prototypes: ≤ 0,5 (satay oil)
- In noodles
- In satay oil
Table 2: Physic-chemical properties
Microbiology properties
Properties Maximum value
Total number of aerobic microorganisms 104
in 1g product
Number of Coliforms in 1g product 10
Number of Escherichia coli in 1g product 3
Number of Staphylococcus aureus in 1g 10
product
Number of Clostridium Perfringens in 1g 10
product
Number of Bacillus Cereus in 1g product 10
Number of Salmonella in 25g product Do not allow to have
Total number of yeast, mold in 1g product 102
Table 3: Microbiology properties
Net weight and mass deviation
Type Allow deviation (g)
70g ±2
85g ±3
1000g ±10
Table 4: Allow deviation
*With noodles product that bigger than 1000g, allow mass deviation is ±1%
Hygiene properties: regulated by Ministry of Health.
IV. Storage conditions and shelf-life
1. Storage conditions
Instant noodles are a common pantry staple that provide an easy and affordable way to
make quick meals. However, appropriate storage has a major role in their quality and
shelf life. Unlocking the full potential of these quick treats requires an understanding of
the dance between moisture, temperature, and packaging.

Moisture is the main enemy of instant noodles. They have a long shelf life because of
their low moisture content, which is attained via deep-frying or drying. This inhibits
microbiological growth. Nevertheless, this process is reversed when they are exposed to
humid surroundings. The noodles lose their characteristic crispness and texture as a result
of absorbing moisture from the air. Additionally, this may encourage the growth of mold,
endangering both flavor and safety.

Instant noodles are therefore best kept in a cool, dry place. Aiming for humidity levels
below 60% decreases moisture absorption, while ideal temperatures range from 50°F
(10°C) to 77°F (25°C). Perfect choices include pantries, kitchens, and cupboards that are
kept away from heat sources like boiling pots, stove or heater.
But storage is more than just the surroundings. The kind of packing is quite important.
The ideal way to store unopened packets is in their original packaging, which is made to
keep them fresh and shield them from outside influences. It is advised to move the
noodles to an airtight container as soon as they are opened but not cooked. This prolongs
their shelf life by protecting them from possible contaminants including dust, insects, and
odors. Noodles that have been cooked should cool before being stored in a refrigerator,
they also needed to be store in airtight containers or plastic wrap which can help preserve
their texture and flavor and they ought to be eaten in two to three days.
Although that, we should not commonly store them refrigerator or freezer. Though these
appear to be secure choices, the refrigerator's cool, damp atmosphere can result in a
soggy texture and subdued flavors. However, freezing can lead to cell rupture, which
might change the texture and possibly result in the creation of ice crystals when they
thaw. Furthermore, heat and intense sunshine can hasten the disintegration of the noodles'
oil, giving them an unpleasant taste and reduced quality.
2. Shelf life
Time is the silent enemy of the instant noodle, a global phenomenon associated with
cheap and convenience. Although it has a respectable shelf life, producers are always
working to increase it.
The idea of moisture control is fundamental to longer shelf life. The water content of
instant noodles is carefully reduced to a level that is hostile to the majority of bacteria.
Low moisture levels, which are attained by deep-frying or drying food, prevent the
growth of microorganisms, which is the main cause of spoiling. Throughout the course of
the product lifecycle, manufacturers employ a variety of ways to maintain this low
moisture level:
- Advanced Drying Techniques: vacuum drying and freeze drying are two modern
drying methods that remove moisture more effectively with the least amount of
structural damage to the noodles. These cutting-edge techniques guarantee
complete drying, significantly increasing shelf life.
- Packaging Innovations: when it comes to controlling moisture, packaging is
essential. Metallized films and multi-layered laminates are examples of materials
with low moisture permeability that manufacturers use to stop moisture from
leaking in during storage and transit.
- Optimizing the Ingredient Profile: Choosing products that have a low moisture
content by nature can also help improve shelf life. For instance, substituting dry
vegetables for fresh ones might reduce the amount of moisture in the mixture.
Instant noodles' oils and fats are prone to oxidation, which can result in strange aromas
and a decline in quality. The following strategies are used by manufacturers to prevent
oxidation and maintain the flavor and scent of the noodles:
- Antioxidants: By scavenging the free radicals that start the oxidation process,
antioxidants like TBHQ or vitamin E can be added to considerably slow the
process.
- Oxygen-Scavenging Packaging Materials: Oxygen-scavenging films are among
the packaging materials that actively absorb oxygen within the container, resulting
in an oxygen-depleted environment that inhibits oxidation.
Beyond these tried-and-true methods, the search for extended shelf life is an ongoing
process of development. Scholars are investigating new methodologies, like:
- Natural Antimicrobials: as an alternative to synthetic preservatives, using natural
antimicrobials made from plants and spices can be safer and more environmentally
friendly.
- Edible Coatings: by applying edible coatings composed of biopolymers, shelf life
can be further increased by establishing a physical barrier against oxygen and
moisture.
- Techniques for Aseptic Packaging: aseptic packaging can completely do away
with the requirement for preservatives by sanitizing the product and the container
before closing.
 V. Explain characteristics/ properties of the primary packaging materials of
your food product and present appropriate packaging system

1. Characteristics/ properties of the primary packaging materials

The chosen material of primary packaging usually is plastic (generally flexible). For the
bag type is polypropylene and for the bowl/cup type is polyethylene (PE). They all have
the same characteristics will be stated below:
- Complies with tamper-resistance standards
- They need to ensure that the product doesn't react with them and shield the
preparation from external factors.
- It needs to be non-toxic.
- It must be FDA authorized and not add any taste or odor to the product.
- the packaging material should be easily obtainable, disposable, and have good
machineability and printability.
- The wrapping material ought to be compatible with the product and resistant to oil
and grease.
However, they also have distinctive characteristics to be apply with each type of
packaging. For the polyethylene:
- It is regarded as the foundation of packaging films.
- Polyethylene is definitely of interest due to its low water vapor transfer.
- Polyethylene films are widely used in lamination since they don't include many
plasticizers or other chemicals.
- Its value is increased by its ability to heat seal.
- EVOH, a copolymer of polyethylene and polyvinyl alcohol, exhibits exceptional
gas barrier qualities, particularly in a dry state.
For the polypropylene:
- Because they are stiffer than polyethylene, polypropylene films are more
machinable and have a higher degree of clarity.
- A issue with the product has been its poor saleability, however vinyl coating and
PVDC have helped to solve that.
- Because they may lock in place after twisting, many PP types have been
specifically designed for twist-wrap applications.

2. Packaging system
2.1. Primary packaging
For the bags-packed noodle: the packing procedure is an automation wonder in and of
itself. Fast machine handles a range of phases with ease, such as:
- Noodle block feeding: Precisely distributing precooked noodle blocks onto a
conveyor belt starts the procedure.
- Insertion of seasoning sachets: The noodles are automatically accompanied by
precisely measured amounts of seasoning packets.
- Pillow wrapping: The combined product is fed into a machine called a form-fill-
seal (FFS), which forms the film into a bag that resembles a pillow and firmly
seals it.
- Then the noodles will be casing and put into corrugated cardboard boxes for the
secondary packaging

Figure 4: bags noodle packaging

For the cup/bowl-packed noodles: cup or bowl sealing machine cooperating with
dispenser machine for seasoning sachet, powder and/or fork and after that they get
sealed and labeled with the following steps:
- Filling for cups: steamed noodles are carefully poured into sterile cups.
- Toppings and seasoning: the cup is topped with measured amounts of dried
veggies or other toppings, as well as seasoning packets.
- Liding: to create an airtight barrier that maintains freshness and seals in flavor, a
foil lid is heat-sealed over the cup.
- Application of the sleeve: a paper or plastic sleeve is wrapped over the cup to
offer branding, nutritional data, and frequently a handy heat barrier while drinking.
 Figure 5: Cup/Bowl noodle packaging machine

2.2. Secondary packaging

Distributing products is made easier and protection is further improved by secondary

packaging for both bags-packed and bowl/cup-packed noodles. Frequently embellished
with visually appealing branding and nutritional data, cardboard boxes serve to organize
individual bags and offer structural integrity. After that, the boxes are piled up on pallets
for the wrapping process then get transported and put into warehouse for storage.