Processing of Sprouted Barley Noodles

Ingredients Composition

• Sprouted Barley Flour – 90%

• Tapioca Flour – 10% (for binding and chewiness)

• Cluster Beans Powder – 0.3% (for improved elasticity and noodle structure)

• RO Treated Water

Processing Steps

1️⃣ Selection & Cleaning of Grains

• Select high-quality whole barley grains free from husk, stones, and impurities.

• Clean thoroughly to remove dust, foreign particles, and broken grains.

• Wash using RO-treated water to ensure hygiene and purity.

2️⃣ Sprouting Process

Soaking:
Clean barley grains are soaked in RO-treated water for 10–12 hours to activate enzymatic processes.

Germination:
The soaked grains are drained and incubated at 25–30°C with ~75% humidity for 24–36 hours until sprouts emerge.

Drying:
Sprouted grains are dried at below 50°C using a tray dryer or solar dryer to retain nutrients, enzymes, and improve digestibility.

Sprouting helps reduce antinutrients like phytic acid and enhances bioavailability of minerals and B-vitamins.

3️⃣ Milling & Blending

• The dried sprouted barley grains are stone-ground or hammer-milled into a fine flour (100–150 micron particle size).

• The flour is blended with tapioca flour and cluster bean powder to improve noodle texture and structural integrity.

Since barley naturally contains gluten proteins, the dough gains better elasticity and extrusion properties compared to legume flours.

4️⃣ Dough Preparation

The blended flour mixture is combined with:

• RO-treated water

The mixture is kneaded thoroughly to form a smooth and firm dough.

The dough is then rested for 20–30 minutes to allow proper hydration and gluten development, improving noodle elasticity.

5️⃣ Extrusion & Noodle Formation

• The dough is fed into a cold extrusion machine or pasta extruder.

• It is passed through a thin perforated die plate to form noodles.

• The noodles are cut into 15–20 cm strands.

6️⃣ Steaming & Pre-Drying

• Fresh noodles are steam-cooked for 3–5 minutes to stabilize structure and enhance elasticity.

• They are then air-dried for ~30 minutes to remove excess surface moisture.

7️⃣ Drying for Shelf Stability

The noodles are dried in a tray dryer at 45–50°C until the moisture content falls below 10%, ensuring good shelf stability.

8️⃣ Packing & Storage

• Dried noodles are packed in moisture-resistant biodegradable pouches or vacuum-sealed packs.

• Stored in a cool, dry place.

Shelf Life: Approximately 6–8 months under proper storage conditions.

Approximate Nutritional Profile (per 100 g Dry Noodles)

Nutritional Highlights

✅ High in Beta-Glucan Fiber – supports heart health and cholesterol balance
✅ Rich in Dietary Fiber – aids digestion and improves satiety
✅ Sprouting Enhances Mineral Bioavailability
✅ Sustained Energy Grain – slow-digesting carbohydrates
✅ Naturally Low Fat & Clean Label

Recipe Ideas Using Sprouted Barley Noodles

1️⃣ Garlic Pepper Barley Noodles

Ingredients

• 1 cup sprouted barley noodles

• 1 tsp coconut oil

• Crushed black pepper

• Garlic

• Rock salt

• Curry leaves

Method

Boil noodles for 2–3 minutes, drain.
Sauté garlic, curry leaves, and pepper in coconut oil.
Toss noodles and serve warm.

2️⃣ Lemon Herb Barley Noodles

Ingredients

• Boiled noodles

• Lemon juice

• Roasted cumin powder

• Turmeric

• Rock salt

• Fresh coriander

Method

Lightly sauté noodles with spices and finish with lemon juice for a refreshing meal.

3️⃣ Coconut Vegetable Noodle Bowl

Ingredients

• Coconut milk

• Mixed vegetables

• Turmeric

• Curry leaves

• Cooked barley noodles

Method

Simmer vegetables in coconut milk and spices.
Add noodles and cook for 2 minutes.