Pavan Dry Pasta ENG

DRY PASTA PROCESSING
Cutting edge technology developed by pioneers

PIONEERING RESEARCH
By travelling our own path and imagining the future, we got there before the others.
We have developed futuristic technologies and continue to refine them
TOTAL VACUUM TAS TECHNOLOGY ADVANCED RESEARCH

Vacuum technology has been The Thermo Active System has We have our own area dedicated
used on Pavan lines for over 60 revolutionised the way pasta is to R&D, with pilot plants, flexible
years. A pioneering choice that dried. An avant-garde system production lines and analysis
has stood the test of time, yelding higher quality pasta in laboratories equipped with all
developed and perfected to less time. the instruments required to carry
create the current solutions. out chemical, rheological and
nutritional tests.
EXCELLENT PASTA FROM ANY TYPE OF RAW MATERIAL
The technology developed by Pavan facilitates the use of any type of

ingredient. The percentage of protein present is fundamental to the quality
of the pasta as it gives strength to its texture. By applying technologies such WE KNOW
as TAS, climatic zones and vacuum, it is possible to make excellent end The gluten matrix,
products even from flours with low protein contents. High temperatures fundamental to the quality
are excellent for processing products made from weak flours and bread of the pasta, is formed
wheat flours with low protein contents because they facilitate coagulation when the dough is mixed
and improve the quality of the pasta. under ideal temperature
and humidity conditions,
WE KNOW avoiding all mechanical
We know how to handle stress
every type of ingredient.
Even flours with low
gluten contents can
be made into excellent
products
DRY PASTA | Pavan cutting edge technology 1

WATER, FLOUR AND VACUUM: THE THREE INGREDIENTS
Pavan was the first company to extensively apply vacuum technology during the
shaping stage, from pre-mixing to the exit of the extruded product
DOUGH
The total vacuum
EACH STAGE UNDER VACUUM affects the organoleptic
properties of the pasta,
This extensive application of vacuum technology formation of gluten. The evaporation effect caused by
provides many advantages for the finished product. the vacuum lowers the temperature of the semolina also providing for
The hydration of the semolina is more homogeneous during the mixing and extrusion stages; this prevents brighter colours and
and this reduces defects and white specs. The thermal stress and results in a pasta with better a higher quality end
vacuum allows for the addition of a greater quantity cooking performance. product
of water during the mixing stage, which improves the
THE FOUNDATIONS OF QUALITY
The gentle shaping stage results in pasta with brighter colours. The
complete vacuum blocks the enzyme Poliphenol Oxidase, responsible
for the oxidisation of the semolina pigments, thus preserving the amber WE KNOW
yellow colours given by the carotenoids and flavonoids. The vacuum also The vacuum process
deactivates the enzyme Lipoxygenase, responsible for turning colours minimises the
grey and the development of unpleasant odours caused by the oxidation development of
of the lipids. The partial deactivation of alpha and beta amylase leads to a reducing sugars. This
reduced occurrence of the Maillard reaction, i.e. the pasta turning brown means less starch
during drying. release during cooking
and less stickiness
2 DRY PASTA | Pavan cutting edge technology DRY PASTA | Pavan cutting edge technology 3
PRESS
PHP
The press is the head of the
line: the dough is formed
here and the product is
extruded and sent to the
drying process
OPTIMUM DRYING
The drying stages are the most delicate and important phases in the production
process, critical to achieving an excellent product
TAS - THERMO ACTIVE SYSTEM AND HIGH TEMPERATURES

TAS technology includes drying and stabilisation and the progressive temperature increase block
stages. It maintains the product in a plastic and the expansion of the starches and activate proteinic
porous state throughout the process and keeps the coagulation. The result is a product with improved
development of the Maillard reaction under control. colour and cooking performance.
The rapid reduction in the water content of the pasta
Colour Texture Hygiene
HIGH PERFORMANCE TECHNOLOGY TAS

The drying stages in the
Thanks to the integrated software that controls the duration of each Pavan process actively
individual stage according to the drying diagram settings, it is possible to modify the properties
keep the temperature and humidity conditions constant by transferring DRYERS of the pasta such as
excess humidity from one zone to another. Without the need for external
machinery, the integrated technology keeps the production process These are made its colour, flavour and
uniform, manages the humidity and temperature values and reduces from stainless steel cooking performance
power consumption, with drying times of less than two hours for and anti-corrosion
short-cut pasta and less than five hours for long-cut pasta. Another materials to provide
added value of the high temperature process is that it eliminates the
decades of service
risk of contamination, for a hygienically safe product.
THERMO ACTIVE SYSTEM
The process that changed the way pasta is dried
00 A1 S1 A2 S2 >
Status 0 Drying area Stabilisation area Drying area Stabilisation area Final status
Freshly extruded The first drying stage The moisture is concentrated in the The following drying stages The moisture is allowed to After successive drying and
pasta contains dries the outer heart of pasta. The water is able to reduce the moisture levels to distribute itself uniformly stabilisation stages the ideal
approximately 30% layers. distribute itself uniformly in this zone the desired concentration. through the product during moisture concentration level
water with a lower temperature and higher the stabilisation and is achieved, usually around
humidity level. conditioning stage. 12.5%.
Relative humidity of air %
120
Air temperature °C
A1 GREAT FLEXIBILITY, MAXIMUM SCOPE FOR CUSTOMISATION

Pasta moisture %
100 S1 26
TWO HOURS 80 A2S2 A2 S2 A2 S2
We know how precious
energy is, this is why our 60 The climatic zones are areas in the dryer that are The drying diagram is completely customisable.
physically separated from one another; they can be This simplifies the changeover between pasta shapes
lines take less than 2 hours 40 managed and configured independently but are also with different drying requirements or different
to dry short-cut pasta
and less than 5 hours for 20 12,5 intelligently interconnected. ingredients.
long-cut pasta. Lower 0
energy consumption and
0.00 0.30 1.00 1.30 2.00 2.30 3.00
more compact systems
Time hh.mm.
AIR TEMPERATURE RELATIVE HUMIDITY OF AIR PASTA MOISTURE
DRYING SOLUTIONS
A system that is able to adapt to and react to all conditions
STRATEGIC AIR FLOWS

The air flows inside the dryer are managed so that the and humidity conditions and reacts strategically, using
masses of hot and moist air are moved where required. them as operating tools.
The automated system recognises the temperature
VENTILATOR AND AIR

JET CONTROL
DRYING ZONE
A1
STABILISATION ZONE
S1
DRYING ZONE STABILISATION ZONE

A2 S2
Cross section of 11-tier short-cut pasta dryer

Air flow circulation
AIR JET
HIGH PRODUCTIVITY, GREAT RESULTS IMPROVED DRYING WITH CLIMATIC ZONES
The TAS technology involves accelerated drying and allow for optimal drying of pasta, preserving the The climatic zones are the technological core of finished product. Hot and moist air masses are used
stabilisation stages that take place in physically product's properties and reducing process times. the TAS drying process. They are comprised of to accelerate or stabilise the drying process, using
separate zones inside the dryer. These areas Excellent quality and maximum efficiency. physically-isolated independent sections in which an intelligent ventilation system that provides ideal
provide temperature and humidity variations that the temperature and humidity are controlled in order control over the conditions in each zone.
to optimise the process and provide an excellent
MAXIMUM THERMAL INSULATION
High performance insulation, a shield against energy waste
®
STRATOS
Increased energy savings
INSIDE
DRYER
The high levels of insulation are
achieved using multi-layer panels
made from insulating materials
such as polyurethane foam and
rock wool.
OUTER LAYER
1 mm 30 mm
Stainless steel sheet Horizontal fibre rock
wool
CROSS SECTION OF PANEL

70 mm 1 mm
Polyurethane foam Stainless steel sheet
CLOSURES COMPLETE
ACCESSIBILITY
Every single detail has
Pavan dryers are
been made with great designed and built to
care, using durable be easily accessible
materials such as for maintenance and
cleaning operations
stainless steel
DRIVE SYSTEMS
A mechanical system designed to last
RELIABLE
MECHANICS
The innovative concept
in the mechanics of
the drive parts ensures
complete mechanical
reliability
The innovative concepts used in the mechanics of the The chains are generously oversized with respect to the
moving parts, based on the high precision manufacture imposed standards and the Niploy surface treatment
of the individual parts, ensures that the systems are provides excellent resistance to corrosion.
fully mechanically reliable.
Every mechanism is also equipped with electronic
With the aim of minimising maintenance times monitoring and redundant safety systems.
and increasing efficiency, unique applications were
designed such as heat exchangers in the main
reducers to lengthen the life of the oils, the use of new
generation lubricants and high service factors in the
mechanical parts.
INFLATABLE SEALS
Protection against heat dispersion
0.8 bar 32 N/mm

Made from a special VMQ compound which following event of complex geometries.
a vulcanisation process at 200°C acquires excellent This feature is essential from a technological point of
resistance to high temperatures, humidity and tearing. view, as it allows the relative humidity of the air to be
The internal chamber is pressurised with air at 0.8 bar, kept to maximum levels.
ensuring adhesion to the contact surface even in the INTERNAL TEAR
PRESSURE RESISTANCE
To guarantee complete The seals are resistant to

isolation between the outside wear and stress
and inside environments
PASS
®
ADAPTIVE
PAVAN AUTOMATION & SUPERVISION SYSTEMS SYSTEMS
Pass® is the integrated automation and supervision system developed by Pavan The production systems
are able to recognise
problems and react
by implementing the
necessary measures
IMPROVED SUPERVISION REMOTE ASSISTANCE

MOBILE READY Pavan's technological and software
The entire plant is monitored in
support service is available 24/7;
real time and the software system
PASS® has been it is also able to solve issues
records every piece of data in order developed to be remotely.
to measure efficiency and compare accessible from all
power consumption against historical mobile devices
data.
- High speed data archiving and - Smart Alert System
retrieval - Flexible planning
- Power consumption analysis - Compatible with mobile systems
- Easy recipe management
Full automation Power consumption analysis
Real time control Historical data analysis
Recipe management Compatibility
QUALITY REPEATABILITY EFFICIENCY SIMPLICITY COMPATIBILITY

Quality ensured in Standardised Increased system Simple to use, The system
the end product execution of best efficiency implement and integrates with all
practices configure the main operating Production plant Customer terminal Pavan Assistance Centre
systems The sensors detect The operator views the Pavan technicians are
an incoherent signal message and asks for able to connect to the
help system and provide
support
A COMPLETE RANGE
OF ADVANCED
SOLUTIONS
SHORT-CUT PASTA LINE DRYER
This machine is divided into technologically independent

areas for drying and stabilising the product. The entire
structure is made of stainless steel. Each process zone is
separated by panels and equipped with automatic heating
and ventilation stations, heat exchangers and independent
air extraction units in order to ensure accurate temperature
01
and humidity control.
Dosage and Press 04 05

TAS HP
In the mixing tank the slowly rotating paddles mix
the ingredients until optimal hydration is achieved, dryer Cooler
allowing the gluten matrix to form. The whole process This machine is enhanced by TAS technology, and by a This machine is equipped with automatic air
from dosing to extrusion takes place under vacuum at ventilation system designed to allow air to flow through cooling units that lower the temperature of
a temperature of 40-45°C. the product layer. The dryer is completely isolated from the pasta to 20-25°C and prepare it for the
the outside environment and all air inflow and outflow packaging stage.
is strategically managed to improve the production
process. The maximum temperature reached is
115°C with stabilisation zones at 77°C and an average
residence time of 120-145 minutes.
02 03 EXTREMELY HIGH
TEMPERATURES
DRYING
CYCLES
TAS
TECHNOLOGY
ADAPTIVE
SYSTEMS
The strategic management The drying process takes Production changeover
Efficiency and of the drying cycles place via alternating is optimised and takes
Cutting units Shaker pre-dryer
extremely high improves the cooking stabilisation and place dynamically
temperatures for the performance of the accelerated drying zones without the need to stop
This machine cuts all short-cut pasta shapes and The pasta is surface-dried
finished product the drying process
is suitable for the installation of the PENNAUT with hot, dry air in order shortest possible drying
device for cutting “penne” pasta shapes; this is to prevent sticking. The times and superior
equipped with an automatic centring/positioning temperature of the pasta is
quality pasta
system for the cutting discs. raised to 70°C.
BELTS
Strong and secure: guaranteed long life
260°C 0.1%
Pavan has chosen PEEK as the material 400
for its dryer belts; a technical polymer
Strength maintained %
100
with high levels of thermal and mechanical PEEK 160°C
Cycles to breakage
90 300
performance. The belt is not subject to any 80 PPS 100°C
mechanical stress as it is never fully under 70
PET 200 30°C
60
tension. Resistant to high temperatures, 50
humidity and wear, it is not subject to M-ARAMID
40 100
structural modifications or alterations. 30 THERMAL RESISTANCE
The geometry of the belt allows the air to 20 RESISTANCE TO ABRASION
10 10 MAXIMUM OPERATING MOISTURE
permeate perfectly through the layers of After seven days TEMPERATURE ABSORPTION
pasta. The hot and humid air masses pass 50 100 150 200 250 300 PEEK PPS PET PA
of exposure to
over the product in a controlled way without Temperature °C steam Single filament on abrasive rod 2.5 times higher than the operating Environmental moisture
the obstacles typical of other systems. temperature of the dryer absorption almost nil
MULTI TIER
LONG-CUT
PASTA LINE
The solution for producing
high quantities of
long-cut pasta in the
smallest possible space
LONG-CUT PASTA LINE After the pre-drying stage the pasta enters the dryer, which has either
three or five tiers. These tiers are physically separated from one another
and house the technological core of the Thermo Active System. The pasta
MULTI-TIER passes through accelerated drying and stabilisation zones in which the
temperature and humidity parameters are programmed in order to achieve
perfect drying.
01 04 05 06
TAS HP Cooler Stripper saw unit
dryer
Dosage and Press
The drying process is enhanced by thermo- This machine is equipped with automatic Removes the pasta from
Low-shear stainless steel compression active climatic zones. The structure is made ventilation units with cold water heat the sticks and cuts it to the
screw. The variable pitch and broad diameter up of physically separate process tiers for exchangers that bring the pasta to an ideal desired length.
of the screw, combined with an ideal rotation maximum humidity and temperature control temperature before the packaging stage.
speed, allow for gradual compression and a at every point.
more homogeneous dough.
CROSS SECTION OF PRE-DRYER | Air circulation diagram
EFFICIENT
02 03 PRE-DRYING
There is no need to
inject steam during
CENTRALISED
MOVEMENT
TAS
TECHNOLOGY
COMPACT
LINE
the pre-drying The movement of sticks The drying process takes Space is optimised
Multiple spreader Pre-dryer process because the always remains in phase place via alternating because the line is built
system is designed to thanks to the centralised stabilisation and up in height over several
Spreader with sticks up to The pasta is surface-dried maintain the correct driving device accelerated drying zones drying tiers
2500mm in length, with a device with very hot air flows before temperature and
for collecting the trimming entering the final dryer. humidity conditions
scraps, mincing them and
returning them to the press.
CONVEYOR STICKS
A simple and effective system
350
The product conveyor sticks have an AISI 304 Made from high-strength extruded HIGH RESISTANCE
Deformation index
300
oval cross-section and offer excellent AL 6060 stainless steel rods, the ends of the rods TO DEFLECTION
resistance to mechanical stress. They are 250 are attached to conveyor chains.
made from AISI 304 stainless steel, which 200
guarantees optimum process hygiene with Stainless steel sticks have a deformation
150 DEFORMATION INDEX
respect to conventional aluminium sticks, trend of 1/3 that of conventional aluminium
100 With equal loads and
which due to surface micro-porosity can sticks with the same cross section; this
cylinder cross-sections,
capture particles of the product. 50 translates into increased solidity.
the deformation index of
0 AISI 304 steel sticks is 1/3
0 1 2 3 4 5 6 7 8 9 10 that of AL6060 1500mm - 2000mm - 2500mm
Load index aluminium sticks
SINGLE TIER
LONG-CUT
PASTA LINE
Effective technology for
optimum results.
The single tier solution
LONG-CUT PASTA LINE The production line is characterised by a single-tier dryer, expressing
the full potential of TAS technology. After extrusion the pasta is pre-dried
and then sent to the dryer. Following successive accelerated drying and
SINGLE TIER stabilisation stages in the dryer, the product then arrives at the cooler with
the correct humidity percentage and excellent organoleptic properties.
01 04 05 06
TAS HP
Dosage and Press dryer Cooler Stripper saw unit
Stainless steel tank with dough level sensor. Each section of this machine is Lowers the temperature This device removes
The process takes place under vacuum at low equipped with ventilation units, of the pasta before the the pasta from the
temperature. Thanks to the slow rotation of heat exchangers and air extraction packaging stage. It can be sticks and cuts it to
the mixing paddles, the gluten matrix is not stations in order to ensure accurate accessed from both sides the desired length.
subjected to mechanical stress and the product temperature and humidity control at to facilitate maintenance
maintains excellent elasticity. every point in the dryer. operations.
CROSS SECTION OF PRE-DRYER | Air circulation diagram
DRYING
02 03 AREAS SIMPLE
The line extends in
TAS
TECHNOLOGY
The drying process takes
RELIABLE
The single drying tier
Drying takes place in length over a single place via alternating production line is reliable
Spreader Pre-dryer segments in which production tier. Simple, and easily accessible for
stabilisation and
climatic conditions with all Pavan's accelerated drying zones maintenance
Single or multiple spreader with sticks The pre-dryer eliminates the water are kept constantly technology inside
1500, 2000 or 2500mm in length. All from the outermost layer of the
under control
versions include a device that captures pasta and prepares the product for
the scraps and reintroduces them into the subsequent drying stage.
the mixing tank.
NEST
SHAPED
PASTA LINE
Making pasta is an art
that requires knowledge
and imagination
NEST-SHAPED PASTA LINE
CUPS & BELTS
This mixed system features a pre-drying stage in which the just-extruded nests are placed in cups where they
remain until they exit the pre-dryer. They are then deposited onto belts that transport them through the entire
drying process.
01 03 04
Dosage and Press Lower pre-dryer Upper pre-dryer
and TAS dryer
The nests sent to the
Low-shear stainless steel
pre-dryer in cups are subjected This machine is comprised of two sections.
compression screw. The variable
to strong ventilation to achieve During the first stage the nests are
pitch and broad diameter of
the ideal shape and prevent pre-dried still in their cups until they
the screw, combined with an
sticking. reach a suitable rigidity. During the second
ideal rotation speed, allow for
stage the nests enter the main dryer on a
gradual compression and a more
conveyor belt.
homogeneous dough.
02 05 TAS CUPS
Nest forming machine Storage
TECHNOLOGY
The drying process takes Made from stainless
place in alternating steel with a mesh
Laminating roller unit positioned under the This area acts as a buffer with loading and stabilisation and bottom, these ensure
extrusion head; removable for the production of unloading stages regulated by automatic accelerated drying zones breathability for
directly extruded products. Nest making device sequences based on presets that can be improved drying
with 12 or 24 tubes installed directly under the programmed by the operator to adapt to
press die. With conveyor tubes in transparent different packaging requirements or to manage
food grade material for checking the length of the production of different types of nests.
the pasta strips.
CUPS LINE
The nests travel in cups
from the beginning to
the end of the process to
prevent scraps
NEST-SHAPED PASTA LINE
NIDOMATIC
The “Nidomatic” solution employs a different method for conveying the nests during the drying stage.
Following extrusion, the pasta is placed into cups where it remains until the end of the process.
This system reduces scraps to zero and facilitates packaging in trays.
01 04
Dosage and Press Pre-dryer
05 06
In the mixing tank the slowly Stainless steel structure with ventilation units TAS dryer Unloading units
rotating paddles mix the specifically designed to keep the nests in
ingredients until optimal their ideal shape. Equipped with independent Divided into three independent sections: the The nests are unloaded in groups of 4, 6 or 8
hydration is achieved, allowing controls for automatically regulating pre-drying stage continues in the first zone, units for arranged packaging in trays or
the gluten matrix to form. temperature and humidity. in the second area the main drying process heat-sealed film. After unloading the empty
takes place and the third section is used for cups are returned to the nest forming
stabilisation. machine to repeat the cycle.
02 03 CONTROLLED
DRYING NIDOMATIC NO PRECISE
The cups move SYSTEM SCRAPS PACKAGING
Nest forming device Weight check The nests remain in their Conveyance in cups The method of conveying
through climatic cups from the beginning reduces scraps and the nests in individual cups
Laminating roller unit positioned under the Situated under to the end of the process risk of damaging the allows for the precise
extrusion head; removable for the production of the nest-forming zones and air passes
product to nil management of the
directly extruded products. Nest making device machine, this device over them in a packaging process
with 12 or 24 tubes installed directly under the checks the weight of
press die. With conveyor tubes in transparent the nests.
controlled way
alimentary material for checking the length of
the pasta strips.
The data provided in this brochure may be subject to
changes aimed at improving the solutions shown.
The reproduction and use of the data and images

contained in this brochure, in full or in part, is strictly
forbidden unless expressly authorised by Pavan srl.
For information and requests, please contact the
Corporate Marketing Department: marketing@pavan.com
44 DRY PASTA | Pavan cutting edge technology

Pavan Group
Headquarters
Via Monte Grappa, 8
Galliera Veneta - PD
Italy
info@pavan.com
www.pavangroup.com

Pavan Dry Pasta ENG

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DRY PASTA PROCESSING

Cutting edge technology developed by pioneers

TOTAL VACUUM TAS TECHNOLOGY ADVANCED RESEARCH

EXCELLENT PASTA FROM ANY TYPE OF RAW MATERIAL

The technology developed by Pavan facilitates the use of any type of

DRY PASTA | Pavan cutting edge technology 1

THE FOUNDATIONS OF QUALITY

TAS - THERMO ACTIVE SYSTEM AND HIGH TEMPERATURES

Colour Texture Hygiene

HIGH PERFORMANCE TECHNOLOGY TAS

A1 GREAT FLEXIBILITY, MAXIMUM SCOPE FOR CUSTOMISATION

AIR TEMPERATURE RELATIVE HUMIDITY OF AIR PASTA MOISTURE

STRATEGIC AIR FLOWS

VENTILATOR AND AIR

DRYING ZONE STABILISATION ZONE

Cross section of 11-tier short-cut pasta dryer

HIGH PRODUCTIVITY, GREAT RESULTS IMPROVED DRYING WITH CLIMATIC ZONES

CROSS SECTION OF PANEL

0.8 bar 32 N/mm

To guarantee complete The seals are resistant to

IMPROVED SUPERVISION REMOTE ASSISTANCE

Real time control Historical data analysis

Recipe management Compatibility

QUALITY REPEATABILITY EFFICIENCY SIMPLICITY COMPATIBILITY

This machine is divided into technologically independent

Dosage and Press 04 05

CROSS SECTION OF PRE-DRYER | Air circulation diagram

The reproduction and use of the data and images

44 DRY PASTA | Pavan cutting edge technology

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