D. Maldari & Sons

Contact: Sales Manager

PO box 159016
557 Third Ave.
Brooklyn, NY 11215-9016
U.S.

Phone: 718.499.3555
Fax: 718.449.6071

Website

E-mail

Introduction
  
D. Maldari & Sons, Inc., established in 1903, has grown to be the largest macaroni Die manufacturing firm in the western hemisphere.
 
Incorporated in the State of New York on March 15, 1958 under the title of D. Maldari & Sons, Inc., the company has continued to expand, applying it's experience, resources and new Die concepts to the cereal, snack, chocolate and animal-food industries as well.
 
Maldari takes pride in both its engineering staff and skilled craftsmen. Our talented and skilled employees are dedicated to the progress of the food industry. It is a Maldari policy to use only pure, virgin materials, proven for durability and superior quality.
 
Because our industry is subject to constant improvements, innovations and the preferences of individual manufactures, this website can merely present and illustrate samples of standard food designs with a limited number of specialties. We are fully equipped, however, to manufacture practically any extrusion Die in accordance with special designs and specifications.
 
Materials
Until about 1955 macaroni Dies were manufactured almost exclusively of bronze alloys. Subsequent research and experimental work resulted in the development of Teflonized Dies.
Today our Die designs combine the density, color and  texture advantages of bronze with the smoothness and increased production advantages of Teflon. Special materials are used for other Dies in accordance with processes and foods to be extruded. The choice of material is left to the specifications of the food processor.
 
Specifications
Specifications for Dies are dependent upon the extruder to be used . Dimensions for all Dies should be taken from the extruder manufactures drawings, and not from an old Die. In applicable cases definite advise relative to the rotation of the knife should be supplied.
 
Delivery
We are in a position to make shipments in the shortest time possible, as we have the largest, as well as the best equipped plant in the United States devoted exclusively to the manufacture of extrusion Dies for the food industry.
All agreements are contingent upon causes beyond our control.
All shipments travel at the purchaser's risk. Shortages and/or damage caused in transit should be reported immediately in order that necessary action may be initiated as soon as possible and proper claims be made.
 
Packing
Shipments are securely packed with no extra charge to the purchaser. This includes export shipments.
 
Insurance
Export shipments are fully insured, adding the premium to the cost of the shipment. Domestic shipments are guaranteed by the transportation companies up to the full specified value.
 
Prices
All prices are net 30, f.o.b., Our Plant, Brooklyn, New York.
 
Orders
To avoid errors or misunderstandings in ordering, we request that samples be submitted, or reference be made to the numbers of the products as found on the following pages, or pertinent Die outlet specifications be furnished.
 
Guarantee
All Dies are fully guaranteed against defects in workmanship or material by D. Maldari & Sons, In

Services Home

Maintenance Service
Preventive Maintenance on Dies revolves itself into both quality and quantity control of products. For improved quality we strive to control obvious flaws ion appearance such as dough rings, roughness, splits, breakage, collapsing, color, uneven wall thickness, raggedness and shape. For increased and continuing production we strive to control hidden difficulties which may be encountered in drying, packaging and handling.

In view of the many variable factors involved in production, and the highly complex equipment necessary for the close adherence to high standards of controls, it is recommended that Dies be returned for reconditioning at regular intervals of from 3 to 6 months. This will insure trouble-free operations and maximum production output.

Our facilities stand ready to make all necessary repairs as expeditiously as possible.

A Lesson in Proper Die Maintenance
 
To control product quality and quantity, eliminating flaws such as dough rings, roughness, splits, breakage, collapsing, uneven wall thickness and poor color and shape, dies should be returned for repair and reconditioning at intervals of 3 to 6 months.  End result, trouble-free operation and maximum production output.

Preventive maintenance on Dies resolves itself into both quality and quantity control of your products.  In the first category, we strive to control obvious flaws in appearance such as roughness, splits, breakage, collapsing, color, uneven wall thickness, and shape.  In the second category, we strive to control hidden difficulties which may be encountered in drying, packaging and handling.

Product flaws are danger signs which demand immediate investigation and correction.  The source of difficulty is not always easy to ascertain, and a wide diversion of opinion may result.

Under normal circumstances, we become conscious of Die wear through.....

Go to our web site to continue reading  the Lesson in Proper Die Maintenance

Three Innovative Generations of Extrusion Die Making 

Retrospective in Die Making Technology

When Felice and Donato Maldari came to Little Italy,  New York City in 1903 from Southern Italy and started the first pasta die making plant in the United States, pasta dies were made the old-fashioned way -- by laboriously punching holes in thick copper discs, and by chiseling and filing the excess metal of the outside diameter.  After three generations, the Maldari's, while maintaining their facilities in Brooklyn, are still making dies for the pasta industry, but they are no longer relying on the power of strong arms.  Modern technology, creative thinking and business savvy are key elements to their continued success.  A few decades ago, there were about seven or eight pasta die makers in the United States.  Today, D. Maldari & Sons, Inc. is the only one left.  Dan and Chris respectively the president and vice president and grandsons of the founder have maintained the success through constant innovation.

Maldari's survival from the very beginning has been driven through constant innovation.  The hand-punching methods were replaced by hand-driven drill presses in 1905.  Two years later, power-driven drill presses and lathes were drafted into service.  As copper, with its property of malleability was unable to withstand the greater pressures of the rapidly improving pasta extruders, the problem was to find a material which was not too difficult to machine, yet strong enough to withstand the factors brought on by increased production.  This was solved by the selection of a bronz alloy, still widely used today.

Pasta makers, however, demanded a better material with a higher yield point to prevent bowing under the higher pressures, and stainless steel was selected subsequently followed by aluminum bronze.  While stainless steel was more wear-resistant than bronze, its low coefficient of thermal conductivity retained heat, generated during operation, extruding a product with poor texture, and a whitish appearance.  To overcome this characteristic, in 1955, Maldari started to make inserts of bronze alloy for the dies, a milestone in the industry.  That same year, Maldari introduced the use of a Teflon lining in the inserts, as a way of producing a smoother texture more pleasing to the eye of the consumer.  Incidentally, Maldari first started using Teflon in 1953 when it developed a die for a Kellogg's dog food in the form of a steak.  It was not a very auspicious beginning because the course product took a heavy toll on the Teflon, and it was discontinued.  For pasta, however, Teflon turned out to be almost perfect.  This innovation was copied shortly by the Italians, and became universal. 

In an effort to reduce production costs and improve quality, the company acquired three automated and fully computerized pantograph machines.

Today, D. Maldari & Sons is flexible enough to cope with any contingencies.  State of the Art equipment stand ready to operate around the clock to meet any emergency which may arise.  Should any problem require personal attention at its source, Maldari personnel stand by ready to meet with all concerned individuals.

Supported by continuing advanced technology and three dimensional CAD CAM stations, computer programmers have the capability of designing varying configurations and immediately draw up required programs which are transmitted directly to the NC (numerical control) equipment  Simulated tool path generation assures both accuracy and quality with the finished products.

For almost a century, Maldari has made it a policy to keep pace with the most modern developments in automated equipment, machinery and design processes, providing customers with prompt dependable service and products precisely machined to extremely close tolerances.

Cutting Edge Technology
 
From its humble beginnings, D. Maldari & Sons rode the wave of industrial modernization and technological advance into the new millennium.  They quickly adopted new methods of metal-working and installed new machinery and equipment in relentless pursuit of ever higher standards of quality and customer service.

Today, the Maldari factory is a model of high-tech automation and cutter-edge innovation; state of the art manufacturing facilities and stringent quality control procedures.  Computer-aided design and computer-driven equipment ensure precise calibrations and infinitesimal tolerances.  The net result is optimization of production efficiency and better quality products.

But growth and success did not result from quality production alone.  The Maldari family has always prided itself on enviable customer problems and needs, fast reliable service and old-fashioned personal attention.
And remember, D. Maldari and Sons is right here in the United States......
 
Design and Performance of Pasta
 
Extrusion dies are used to extrude products in many different shapes and sizes.  More than 250 configurations are possible, including dies for snacks, cereal, and animal feed.  In a broader sense, extrusion dies can be used for metal and plastic products.  This article traces the development of present-day dies and discusses considerations in designing dies for pasta production and some factors affecting die performance.

History of Pasta Dies in the United States

In the early days of the pasta industry in the United States, there was a conspicuous absence of mechanized equipment.  Dies were manufactured entirely by primitive hand methods.  The first pasta dies in the United States were made of copper because of its physical properties bowed to human strength.  Holes were hand-punched through a maximum thickness of 1 inch, and the outside diameter of the die was obtained by chiseling the excess metal and filing.  These manual methods required a malleable material soft enough to yield to hand-punching......

Maintenance Service
Preventive Maintenance on Dies revolves itself into both quality and quantity control of products. For improved quality we strive to control obvious flaws ion appearance such as dough rings, roughness, splits, breakage, collapsing, color, uneven wall thickness, raggedness and shape. For increased and continuing production we strive to control hidden difficulties which may be encountered in drying, packaging and handling.

In view of the many variable factors involved in production, and the highly complex equipment necessary for the close adherence to high standards of controls, it is recommended that Dies be returned for reconditioning at regular intervals of from 3 to 6 months. This will insure trouble-free operations and maximum production output.

Our facilities stand ready to make all necessary repairs as expeditiously as possible.

 
 
A Lesson in Proper Die Maintenance
 
To control product quality and quantity, eliminating flaws such as dough rings, roughness, splits, breakage, collapsing, uneven wall thickness and poor color and shape, dies should be returned for repair and reconditioning at intervals of 3 to 6 months.  End result, trouble-free operation and maximum production output.

Preventive maintenance on Dies resolves itself into both quality and quantity control of your products.  In the first category, we strive to control obvious flaws in appearance such as roughness, splits, breakage, collapsing, color, uneven wall thickness, and shape.  In the second category, we strive to control hidden difficulties which may be encountered in drying, packaging and handling.

Product flaws are danger signs which demand immediate investigation and correction.  The source of difficulty is not always easy to ascertain, and a wide diversion of opinion may result.

Under normal circumstances, we become conscious of Die wear through.....

Copyright © 2001 D.Maldari & Sons, Inc.