Based on its rigorous monitoring processes, Molino Gaetano Roccasalva choose the best raw grains in the Italian market and the most valuable ones from abroad. At the beginning of the milling process the produce is assessed for its protein content, gluten quality and purity.
All products have the following certifications: IFS, BIOAGRICERT.
The production cycle is divided into four main stages
When the raw grain arrives at the Mill, once is weighted and analysis and testing inspections are passed, it is stored in silos or large bins. The silos vary by size to accommodate different types of wheat: Wheat is stored according to protein levels and other quality considerations.
Once the quantities of wheat needed for the production of different types of semolina have been decided, the silos are opened in order to ensure a balanced mix of the different varieties of wheat.
In order to remove foreign bodies, the grains must repeatedly undergo a cleansing process: they pass through aspiration systems and are then cleansed and analyzed by an optical selector. The impurities are then separated from the grains and removed. Lastly, the wheat is soaked in water to facilitate the separation of outer bran layers from the grains. The length of the hydration process, and the subsequent storage period in silos (from 12 to 48 hours) depend on the type of wheat.
The wheat kernels are now ready to be milled into flour. The modern milling process involves the gradual reduction of wheat kernels through a process of grinding and sifting. At the beginning of the grinding process, the grain passes through a series of rollers with rough surfaces. These revolve at high speed in opposite directions causing the kernels to break down. The produce then further ground down by machines to gradually reduce the thickness.
At each phase of the grinding process, an oscillating sieve retains the larger fragments (bran), releasing the finer ones to make rough semolinas. The remaining product is again grinded and sifted. Depending on the type of process, it is is possible to obtain numerous products: semolina, regrinded semolina, fine bran, and middlings etc. Once the sifting process has finished, a rigorous series of quality checks is undertaken and the produce is then stored in silos before it is packaged.
Packing and Distribution process
The flour and bran are collected in different batches and from a number of different machines. These are finally gathered either in bulk storage bins or packing stations. The flour is then packaged into 1kg, 2kg or 25 kg paper bags. Flour is also dispatched to large or small bakeries at nationally and internationally.