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Better Than Spaghetti?

Inside a three-year search for the perfect pasta shape

By Andrew Klein
From the May/June 2023 Issue

Learning Objective: Students will explain how a food podcaster used the engineering design process to create a new kind of pasta.

Lexile: 760L; 530L
Guided Reading Level: S
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From spiral swirls to long spaghetti strands, there are about 350 different shapes of pasta. All have their uses in different recipes. But does one noodle stand above the rest?

That was a question asked by Dan Pashman. He hosts a food podcast called The Sporkful. In 2018, he began thinking about how noodle shapes affect the way people enjoy different pasta dishes. Some pastas hold sauces well. Others are satisfying to bite into or easy to eat with a fork. “Most pastas do one of these things well,” says Pashman.

But could one pasta do all of these things? To find out, Pashman began a search he called “Mission: ImPASTAble.”

There are about 350 different types of pasta. Noodles come in every shape, from swirls to long strands. All have their uses in different recipes. But does one noodle stand above the rest? 

That was a question Dan Pashman asked. He hosts a food podcast called The Sporkful. He began thinking about noodle shapes in 2018. He wondered if pasta shape affected the way people enjoy different dishes. Some pastas hold sauces well. Others are pleasing to bite. Some are easy to eat with a fork. “Most pastas do one of these things well,” says Pashman. 

But could one pasta do all of these things? Pashman began a search he called “Mission: ImPASTAble” to find out.

Food Features

COURTESY OF DAN PASHMAN/SCOTT GORDON BLEICHER

Dan Pashman

First, Pashman studied different noodles. He created criteria, or standards, to judge the noodles by. One was “sauceability,” how well sauce sticks to the pasta. Another was “toothsinkability,” how enjoyable it is to sink your teeth into it. The last was “forkability,” how easy it is to stab a noodle with a fork.

Pashman also thought about the pastas he liked best. He loved the ruffles on lasagna edges and the tube shape of ziti. These features hold sauce and make noodles chewy. Pashman decided to create a shape that combined them. 

Pashman spent weeks sketching pasta designs. He showed his ideas to experts at a company called De Mari Pasta Dies. The company makes metal pasta dies, or molds. Pasta dough is squeezed through the molds to make different shapes.

De Mari told Pashman that his first designs were too complicated. After working for months, Pashman finally had a shape De Mari said might work: a long half-tube with two ruffled edges. De Mari got to work creating the die.

First, Pashman studied different noodles. He created criteria. He judged noodles using these standards. One was “sauceability.” It was how well sauce sticks to the pasta. Another was “toothsinkability.” It was how pleasing pasta is to bite into. The last was “forkability.” It was how easy pasta is to pick up with a fork.

Pashman also thought about the pastas he liked best. He loved lasagna’s ruffled edges. He also loved ziti’s tube shape. These features hold sauce and make noodles chewy. Pashman decided to make a pasta noodle with both of these features.

Pashman spent weeks drawing pasta designs. He showed his ideas to experts. They worked at a company called De Mari Pasta Dies. The company makes metal pasta dies, or molds. Pasta dough is squeezed through these molds. That makes different shapes.

De Mari told Pashman that his designs were too complex. Pashman worked with De Mari for months. Finally, they had a shape that might work. It was a long half-tube with two ruffled edges. De Mari got to work making the die.  

Perfecting the Pasta

Pashman worked with Sfoglini (sfo-LEE-nee), a pasta maker in New York. Sfoglini used De Mari’s die to produce prototype pasta. But when Pashman boiled the noodles, they fell apart! The pasta needed to be shorter and thicker to hold up while cooking.

De Mari created a new metal die to increase the thickness, and Sfoglini cut the dough shorter. The new pasta met all of Pashman’s criteria! He named his creation cascatelli. That’s a play on cascata, the Italian word for “waterfall.”

In 2021, Sfoglini sold 3,700 boxes of cascatelli online in two hours! Today other stores sell the pasta too. “Some food fads are done just to look cool,” says Pashman. “I wanted to make something that was actually good to eat.” Mission accomplished!

Pashman worked with Sfoglini (sfo-LEE-nee). It’s a pasta maker in New York. Sfoglini used De Mari’s die to make prototype pasta. Pashman boiled the noodles. They fell apart! The pasta needed to be shorter and thicker. Then it would hold up while cooking.

De Mari made a new die that made thicker pasta. Sfoglini cut the dough shorter. The new pasta met all of Pashman’s criteria! He named his creation cascatelli. Cascata is the Italian word for “waterfall.”

Sfoglini began offering cascatelli online in 2021. It sold 3,700 boxes in two hours! Today other stores sell the pasta too. “Some food fads are done just to look cool,” says Pashman. “I wanted to make something that was actually good to eat.” Mission accomplished!     

Activities (3)
Answer Key (1)
Activities (3)
Answer Key (1)
Step-by-Step Lesson Plan

1. ENGAGE: Activate prior knowledge about pasta

  • Show a photo of different pasta shapes. Ask students to think about the following questions: Which kinds of pasta shown have you eaten? Which do you like best, and why?
  • Have students discuss in pairs before reconvening. Note that people probably have different personal preferences for their pasta. Have students share their ideas with the class. Were there traits that their favorite pastas had in common?

2. EXPLORE: Identify qualities of pasta that could be improved.

  • Ask students to describe any difficulties they’ve had with eating pasta (e.g., the pasta falls off the fork, it drips sauce, or it doesn’t hold sauce). List their ideas on the board. Ask: How do you think someone could create a better pasta shape? Discuss their ideas. Then tell students they’re going to read about a food fan who did just that.

3. EXPLAIN: Read about the invention of a new pasta design.

  • Read the article aloud. Discuss the “Investigate It!” questions (p. 11) together. Or have student pairs answer them, recording their answers on the Investigate It! skills sheet.

4. EVALUATE: Summarize the engineering design process in a comic strip format. 

  • Work together to list the design steps Dan Pashman followed. (He identified a problem, created criteria to judge his success, evaluated existing pasta shapes, brainstormed new shapes, created prototypes, evaluated his prototypes, improved his design, and continued testing and improving until his design met his criteria.)
  • Preview the Create a Comic Strip skills sheet. Ask students to think about Pashman’s point of view: How might he have been feeling at different points in the process? What could have made him persevere, or not give up? Allow students to work alone or in pairs to create their comics. Discuss what key parts of the engineering design process each student or pair included.

5. EXTEND: Evaluate pastas and propose a new pasta design.

  • If you choose to do this activity, follow your school’s food policy to ensure students with food allergies can safely participate. Emphasize to students that this pasta is not for eating.
  • Tell students they are going to use parts of the engineering design process to brainstorm their own pasta design. Preview the Pasta Proposal skills sheet. Provide groups with small samples of two different cooked pasta shapes on plates, such as spaghetti and elbow macaroni. Demonstrate how to test the plain pasta safely and responsibly for criteria like how well it stays on a fork.
  • Have students design their pasta and then share pasta designs in a gallery walk. Have small groups present their improved pasta to the class.

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