Bake Wavy Potato Chip Production Line

Golden Bake -Industrial Automatic Biscuit Making Machinery Manufacturer

Baked wavy potato chip

Capitalize on two of the most powerful trends in the snack industry—health-conscious eating and exciting textures—with baked wavy potato chips.

This innovative product meets consumer demand for a "better-for-you" snack without sacrificing the satisfying crunch and premium feel of a ridged chip. The global baked snacks market is a multi-billion dollar industry, projected for significant growth as shoppers actively seek out guilt-free indulgences. By offering a product that is both baked and wavy, you can capture a discerning audience and command premium pricing, ensuring high profitability.

For a company with expertise in biscuit production, manufacturing baked wavy potato chips is a seamless and strategic expansion. Our specialized production lines leverage your existing knowledge of baking technology. The process begins with mixing potato-based dough, which is then rolled into a consistent sheet. The key is our precision forming and cutting station, which imprints the signature wavy pattern onto the dough before it moves through a long, high-capacity tunnel oven. This efficient, automated system bakes the chips to perfection, creating a product with the ideal texture and taste to dominate the modern snack aisle.

How to start a Baked wavy potato chip business?

The process of Baked Wavy Potato Chip typically initiates with Ingredient Staging and Pre-Processing for a Batch of Raw Materials and ends with Packaging.

Baked wavy potato chips offer a satisfying crunch and a healthier alternative to their fried counterparts. They are similar to a cracker in texture but made from potatoes and with a wavy shape. Here are the typical production steps involved in a batch process:

Batch Ingredient Introduction

The production line for baked wavy potato biscuits starts with the preparation of the potato dough. At this stage, ingredients such as potato flour, seasonings(salt, spices, flavor enhancers), and a small amount of fat or oil might be added to create the desired texture and flavor profile.. If the manufacturer pursues a higher-end product, it can also add mashed potatoes. Then the raw potatoes need to go through a series of processes: washing, peeling, steaming, mashing, etc. These ingredients are thoroughly mixed in batches using industrial mixers to ensure a homogeneous dough. The consistency of the dough is critical for the subsequent shaping and baking steps.

Formation, Baking, Seasoning, Packing

After the dough is ready, it will be transported to the forming process. First, it will pass through a series of rollers to press the dough into a specific thickness, then pass through special corrugated rollers to press it into wavy dough sheets, and then use a roller cutter to cut it into the shape of potato chips. The neatly arranged raw potato chips will pass through the oil sprayer and then enter the tunnel oven for baking. The baking process is the next critical step. The oven is precisely controlled for temperature and humidity, with different zones designed to gradually reduce moisture content and achieve the desired crispness without browning or burning. The "wavy" design of the chips can sometimes require slightly adjusted baking profiles to ensure even cooking throughout the ridges. After baking, the baked potato chips are sprayed with oil, seasoned and cooled. Finally, the baked wavy potato cookies are sorted, metal-detected, and packed into bags or boxes in predetermined quantities for distribution. Every step of the process is strictly monitored to ensure the consistency and quality of each batch of products.

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Baked wavy pOTATO CHIP machine

Golden Bake baked wavy potato chips production line includes: Material handling/Silo system, Pre-gauge roll unit, 3-gauge roll unit, wavy-shape/Corrugated forming unit, oil spraying machine, dough sheet relax device, Blowing device on the surface of the dough sheet, Rotary cutter unit, Scrap separator, Scrap residue recycle system, Oil Sprayer, Oil Filter, Oven infeed machine, Tunnel Oven, Powder Sprinkler, Transition conveyor, Handling system, Packing system.

Our baked wavy potato chips production line can produce baked potato chips with clear ripples and beautiful shapes. The whole line has the characteristics of advanced technology, large output, low energy consumption, precise components, and easy operation. It is very popular among users and is an ideal investment choice in the current food machinery investment market.

This special biscuit line has stable production, hygienic and safe, and has the following characteristics:

1)Do not need skilled workers, simple operation, easy to understand

2) LCD touch panel, PLC control, computer memory function, drive part servo motor.

3) Working width reachs Max.1200mm

4) The shell of the machine is made of stainless steel and aluminum, which is easy to clean.

5) Through the optimization of oven design details such as combustion efficiency, insulation and exhaust of the oven, our oven energy consumption is lower

6) The gauge rolls and corrugated roller are made of chilled alloy, which meets food safety and durability. Especially for corrugated rollers, ensure that there is no peeling, no slag, no health risks.

7) Better taste of the product (from customer sharing)

8) The combustion chamber for the 3 convection zone adopt 310S stainless steel imported from Sweden with temperature resistance up to 1200℃

Hourly output of naked biscuits (excluding packaging film and plastic tray):	Actual output 600kg per hour normally at baking time 4min30sec Max.about 650kg per hour at 4min10sec
Main motor reducer	SEW
Pneumatic parts	AIRTAC
Main bearing	SKF
Servo motor	Siemens
Circulating fan	Dongrun fan
Pipe ribbon burners for DGF （zone 1 & zone 2）	Made by D-One, with imported 316L stainless steel ribbon net （900℃ resistant）
Combustion champers for DFC （zone 3,4,5）	Made by D-One, with imported 310S stainless steel.（1200℃ resistant）
Big burners for DFC	Weishaupt, Germany
Oven steel band	Sandvik /sweden
Conveyor PU belt	Shanghai yongli
PLC	Siemens
Touch screen	Siemens
Low-voltage apparatus	Siemens
Inverter	Danfoss
Gas combustion related accessories	RapidFlame, UK
Proximity switch	AUTONICS
Photoelectric eye	SICK
Limit switch	Tend
Power supply unit	WEAN WELL + Siemens
Dough sheet thickness detector	German NOVO displacement sensor
Control cabinet	Combe
Fuse	Chint
Temperature probe	Zhaoyi
Thermocouple	Zhaoyi
Casters and hand wheels	Italy ELESA + GANTER

GOLDEN BAKE Baked wavy Potato chip production line

Customized baked potato chip line solution

1. Initial Consultation & Needs Discovery

First Contact: Engage with the potential client to understand their initial inquiry and general needs.

Exploratory Meeting(s): Conduct in-depth discussions to fully grasp the client's current operations, challenges, specific goals for their biscuit/cookie production, desired output, types of products they want to produce, space constraints, budget considerations, and any existing equipment.

Site Assessment (if applicable): Visit the client's facility to understand the physical environment, utility availability, and potential integration points.

2. Detailed Requirement Gathering & Analysis

Technical Specifications: Work with the client to define precise technical requirements. This includes throughput (e.g., kilograms per hour, pieces per minute), specific biscuit/cookie types, size and weight variations, ingredient handling, level of automation desired, and any special processing needs (e.g., allergens, specific baking profiles).

Solution Design & Proposal Development: Based on the gathered requirements, your engineering and design team will develop one or more conceptual solutions for the production line.

3. Manufacturing & Testing

Fabrication & Assembly: Manufacture the custom machinery and assemble standard components according to the detailed engineering plans.

Internal Testing: Assemble and test the production line (or key sections) in our facility to ensure it functions as designed.

Client FAT: Invite the client to our facility to witness the line in operation, verify it meets the agreed-upon specifications, and provide approval before shipment.

Shipment & Logistics: Carefully pack and prepare the equipment for shipment to the client's facility.

4. Installation & Commissioning

On-site Installation: Our technical team installs the production line at the client's facility according to the agreed layout. This includes mechanical, electrical, and pneumatic connections.

Commissioning: Systematically start up and test each component and then the entire line with actual product to ensure it operates correctly and achieves the specified performance criteria (e.g., output, product quality).

Client SAT: Conduct a Site Acceptance Test with the client to formally demonstrate that the installed line meets all contractual obligations in their operational environment.

Training : Provide comprehensive training to the client's staff on how to operat

5. After-Sales Support

Performance Review: After a set period, review the performance of the solution with the client to ensure it's meeting their expectations and identify any areas for improvement.
Warranty Support: Honor the warranty period for any defects or issues.
After-Sales Service: Offer ongoing technical support, spare parts supply, preventative maintenance services, and potential upgrades or modifications as the client's needs evolve.

FAQ

Q: What types of cookies or biscuits can your production lines handle?

A: Our lines are versatile and can be designed to produce a wide variety of cookies, including chocolate chip cookies, shortbread, sugar cookies, wire-cut cookies, deposited cookies, and more. We can customize the line based on your specific product recipes and desired textures.

Q: What level of automation can I expect?

A: We offer various levels of automation, from semi-automated lines requiring more manual intervention to fully automated solutions that integrate ingredient handling, mixing, forming, baking, cooling, and packaging with minimal labor. The level of automation can be tailored to your budget and operational preferences.

Q: Can the production line be customized to fit our existing facility space?

A: Absolutely. We specialize in designing custom layouts to maximize the use of your available space while ensuring efficient workflow and adherence to safety standards. We conduct site assessments or work with your facility drawings to propose an optimal layout.

Q: Can your production line integrate with our existing equipment?

A: Yes, where feasible and practical, we can design our solutions to integrate with your existing upstream or downstream equipment. We'll need details about your current machinery to assess compatibility.

Q: What materials are used in the construction of the machines, especially food contact surfaces?

A: All food contact surfaces are typically made from food-grade stainless steel (e.g., SS304 or SS316) and other approved materials that comply with international food safety standards to ensure hygiene and durability.

Q: What support do you provide during the installation and startup phase?

A: Our experienced technicians will be on-site to manage the complete installation, commissioning, and startup process. We also provide support to ensure your team is comfortable running initial production batches.

Q: How readily available are spare parts, and what kind of after-sales support do you offer?

A: We maintain a stock of common spare parts and can provide recommendations for critical spares to keep on-site. Our after-sales support includes technical assistance, troubleshooting (remote and on-site if needed), and options for service contracts or preventative maintenance plans.

Bake Wavy Potato Chip Production Line | Golden Bake