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Biscuit Production: From Hand to High-Speed Production

Biscuit Production: From Hand to High-Speed Production


The humble biscuit, a timeless treat loved by generations, requires a precise process to achieve its signature flaky layers. While bakery shop bakers meticulously form dough by hand, large-scale production relies on sophisticated machinery to ensure consistency and efficiency.


Modern biscuit production lines are designed to be versatile, accommodating a wide range of biscuit shapes, sizes, and patterns. Quick-change systems enable seamless transitions between different products, catering to the growing demand for customization in the market. This flexibility is essential for manufacturers to adapt to changing consumer preferences and market trends.


The Production Line Journey:


Mixing: Large mixers combine flour, sugar, fats, and other ingredients according to carefully measured recipes. The mixing time and speed are crucial to develop the desired dough texture without overworking it.


Gauging: For hard biscuits, the dough passes through gauge rollers, further reducing its thickness into uniform thickness.  This is an essential step to ensure uniformity in the biscuit's size and texture. Modern sheeters are equipped with advanced controls that allow for precise adjustments, catering to the specific requirements of different biscuit types. To create distinct layers, laminating can be extra. This process helps achieve the characteristic dense texture and crisp bite.


Dough Conditioning: Depending on the biscuit type, the shaped dough may undergo conditioning, which allows for relaxation and development of the gluten network, further contributing to a light and flaky texture.


Decoration and Toppings: For some biscuits, automated systems can apply toppings like sugar sprinkles, sesame, or others before baking.

Cutting and Molding:

Cutting and molding are the defining stages of biscuit forming. The dough sheet is passed through a rotary cutter or a rotary molding machine, shaping the biscuits into their final form. The design of the cutting tools dictates the biscuit's shape, whether it's a simple round or a complex pattern. Molding equipment ensures that the biscuits maintain their structure and appearance.


Scraps Recycling: Leftover dough scraps are collected and fed back into the sheeting process, minimizing waste and maintaining production efficiency.


Baking and Cooling: The shaped and decorated dough is conveyed to tunnel ovens for baking. Temperature and timing are precisely controlled to achieve the perfect golden brown color and internal consistency.


Secondary processing: Some biscuits can be secondary processed to sandwiched biscuits, chocolate coated biscuits.


Packing and Distribution: After cooling, the baked biscuits are automatically counted, packed, and distributed for retail.


Benefits of Automatic Biscuit Line:


Increased Production Capacity: Automated systems can produce thousands of biscuits per hour, significantly exceeding the capacity of manual dough forming.

Improved Consistency: Precise controls ensure consistent dough thickness, shape, and final product quality.

Reduced Labor Costs: Automation reduces the need for manual labor, leading to cost savings and increased profitability.

Enhanced Hygiene: Automated systems operate in controlled environments, minimizing the risk of contamination.

Versatility: Production lines can be customized to accommodate various biscuit shapes, sizes, and recipes.

The Future of Biscuit Production Line:


Technological advancements continue to shape the biscuit industry. Automation is becoming increasingly sophisticated, incorporating advanced sensors and control systems for even greater precision and efficiency. Additionally, research is exploring the use of innovative ingredients and techniques to further optimize dough formation and achieve superior biscuit quality and texture.


While the art of hand-forming biscuit dough remains a treasured tradition, automated production lines play a vital role in bringing this delightful treat to millions around the world. From mixing and shaping to baking and packing, these technological marvels ensure the consistent quality and deliciousness that makes biscuits a timeless favorite. If you are interested of this article, please follow our Facebook. We will share more interesting knowledge about biscuit production line.

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