Our process

Baia Pasta is:
  • Well-kneaded with cold water to create a compact fragrant dough that maintains all the original integrity of the flour
  • Extruded gently in small batches through brass dies giving the pasta a rough surface to create a good al dente texture and to help absorb sauce
  • Dried at low temperatures (never over 105ºF) to preserve the original protein and gluten content of the wheat and maintain its great flavor.
Mix - Extrude - Dry: seems easy isn't it? Well, there are so many little facets to the process, from how wet and well mixed the dough is to how cold and slow the extrusion is performed. Last but not least, drying is the most tricky step, the real bottleneck of our workstream.
We have used a modestly sized Italian Dominioni P55 from the very beginning, specifically to be able to control more closely all of  these conditions. Think small 25lbs batches, and a total daily production of 250-300lbs. Now we have upgraded to a Parmigiana RZ100 and we still do everything by hand (no conveyor belts or shakers). Our daily capacity is now 500-600lbs, thanks to the addition of a second dryer, and no compromises will be taken on the extrusion side. It needs to be gentle, and accurate to maintain all the great features of wheat. Taste first.
The next step is to be able to dry pasta slowly, without excessive heat, to allow even moisture distribution throughout the process. Like an excellent soup, time is required to develop flavor and and a steady long drying is key to achieve superior texture.