In the industrial production of stick noodles, the generation of broken noodle segments is an inherent and unavoidable aspect of the manufacturing process. This broken head, which typically accounts for approximately 10% to 15% of the total feed volume, represents a significant portion of raw material that cannot be overlooked. The efficient and correct processing of this material is paramount, as it directly influences both the final product quality and the overall economic profitability of the production operation. Effectively managing these broken pieces ensures resource optimization, minimizes waste, and contributes to maintaining consistent product standards. The nature and treatment of this broken head are not uniform; it is categorized into three distinct types based on its moisture content and the stage in the production line at which it occurs: wet broken head, semi-dry broken head, and dry broken head. Each type requires a specific and tailored processing method to reintroduce it into the production cycle effectively.

The wet broken head is generated during the initial stages of production, specifically at cutting, hanging on rods, racking, or at the entrance of the drying chamber. Its properties remain very close to those of fresh dough, making its processing relatively straightforward. This material can be promptly collected and returned directly to the dough mixer. Here, it is fully integrated with the new dough through comprehensive mixing, after which the combined mass proceeds seamlessly to the next stages of the production line without significantly altering the fundamental dough characteristics. The semi-dry broken head presents a more complex challenge. This type breaks off during the drying process, typically in the zone where the noodles are perspiring moisture and moving into the high-temperature area. Its moisture content is variable, depending on the precise point in the drying cycle where the breakage occurred, meaning it cannot be simply reintroduced into the dough mixer like its wet counterpart. Two primary methods are employed for its treatment. One method involves soaking the semi-dry pieces in water for a predetermined period to rehydrate them, after which they are added back into the mixer. The alternative method is to divert these broken pieces further along the drying tunnel, pushing them into the high-temperature zone to complete their drying. This process transforms them into dry broken heads, which are then processed alongside the other dry broken material.

The dry broken head occurs after the primary drying phase, usually at the cutting or packaging sections. Its moisture level is nearly identical to that of the finished, packaged noodles, but its physical structure—particularly the damaged gluten network—is vastly different from raw flour. The standard treatment involves a wet process: the dry broken noodles are first cleaned and then soaked in water. This soaking is crucial to allow the brittle, dry pieces to fully absorb water and soften completely. Once rehydrated into a pliable state, this material is blended back into the production process by being mixed with a certain proportion of fresh flour in the dough mixer. This approach is widely favored because it causes minimal disruption to the gluten network integrity, thereby exerting a lesser impact on the overall production technology and the final quality attributes of the noodles. Furthermore, it is an energy-efficient solution compared to other potential recovery methods, helping to keep operational costs low.

Addressing the challenge of broken noodle management requires not just effective methods but also reliable equipment designed for high-volume continuous production. A company with extensive experience in this field is the Zhengzhou Dongfang Naomu Food Machinery Co., Ltd., which has specialized in the engineering and manufacturing of noodle production line equipment for over five decades. Their comprehensive approach ensures that from initial consultation and customized production line design to onsite installation, personnel training, and ongoing technical support, clients receive a complete service system dedicated to maximizing efficiency and productivity, including the optimal handling of by-products like broken noodles.