How is a Sandwich Biscuit Manufactured in Factory?

There are many steps in the production of a sandwich biscuit, and they all need to be done properly to make them taste delicious. In this article, we will discuss the Production stages and Ingredients involved, and how these factors affect the final product. We will also discuss the different thicknesses of the shell and the cream formulations. After reading this article, you’ll have a better idea of how to make a sandwich biscuit.

Ingredients

The primary process in making sandwich biscuits is mixing the ingredients together in a mixer. The type of ingredient, the quantity, and the temperature of the dough all play important roles in preparing the sandwich biscuits. Water is a variable ingredient in dough making, while ammonium bicarbonate is added to improve the crispness of the biscuits. After the mixture is completed, sandwich biscuits are packaged and sold. Often, the sandwich biscuits are stored outside the factory.

The sandwich biscuit is made of two layers of jam or cream, separated by the top shell. The first layer of biscuit is fed by hand from a packing table. Vibrating conveyors are also used to ensure pressure-free feeding. A chain conveyor moves the bottom biscuit shell under a stencil and then the cream is deposited on it. The top biscuit shell is then placed on top of the cream-filled sandwich biscuit.

Production stages

The process of making sandwich biscuits includes several stages: dough molding, baking, and cooling. It requires a large investment to begin and maintain a sandwich biscuit production line. Materials for sandwich biscuits include approximately 350 tons of wheat flour, 60 tons of vegetable fat, eight tons of liquid glucose, yeast, flavoring, and packaging materials. Managing and coordinating workers is another important aspect of the manufacturing process. Here are some tips for success in manufacturing sandwich biscuits.

The first stage involves mixing ingredients. The order of ingredients, the amount, and temperature are all important. Different types of ingredients are used for different processes. Some are moist while others are dry. Water, ammonium bicarbonate, and other ingredients are common, but the quantity of each varies depending on the recipe. Water is used for dough making, and ammonium bicarbonate is used to make the biscuits taller.

Cream formulations

There are several key factors that affect the final precision of a biscuit and the cream formulation used in sandwich biscuit manufacturing. The weight variation in the pack after creaming and cooling reduces the overall precision of the biscuit. As a result, special process control attention is required for the addition of cream. The cream itself contains fat crystals which are responsible for adhesion between the biscuit shell and cream. A biscuit that contains too little cream may fall apart during cooling.

Traditional sandwich lines require physical labour to transfer the heavy cream. This process can cause muscle and joint injuries. This problem was eventually addressed by labour unions through fines imposed for failure to eliminate this risk. Since then, cream sandwich manufacturing lines have become highly automated, featuring the TFT RotoTemp system that cools the cream prior to filling. It also feeds a partially crystallized filling to the stencil shaft to ensure ideal SFC.

Shell thickness

The most common problem with enrobing sandwich biscuits is that they lose their crispness during storage. The reason for this is that the ingredients of the creamed biscuits are volatile and lose their flavour over time. The best solution is to lock the flavour into microencapsulated material that is resistant to moisture. This will prevent the flavour from migrating to the other side of the biscuit, but it also means that the finished product will not have a strong odor. The chocolate is then cooled in tunnels that are designed to maintain precise temperature. This process results in a smooth, glossy surface for the product.

Sandwich biscuits manufactured in factory may have irregular shell thickness. This is due to the irregular application of filling. The thickness of the shell may vary between 0.1 and 6 cm. The thickness of the shell can be greater than one centimeter if the relleno is applied in layers. If the shell is too thick, the cookie may not have the desired appearance or may have an unpleasant taste. The thickness of the shell can also affect the overall size of the cookie.

Natural products used as filler

Creamed biscuits are a popular filler in assorted packs of biscuits. However, they are susceptible to flavour migration during storage. Fortunately, these ingredients are typically locked in some way to limit their smell and release their flavour when masticated or dissolved in water. Besides using natural products, biscuit manufacturers can also use other ingredients as fillers in savoury sandwich biscuits, such as ground biscuits.

The cream filling in sandwich biscuits affects their eating qualities, as well as the process. A good cream filling should be firm at ambient temperatures and maintain its shape when hewed. The cream should also melt quickly when hewed to release the sugar and other ingredients. Natural products used as filler in sandwich biscuits are increasingly becoming a popular ingredient for these biscuits. A recent study showed that half of all sandwich biscuits contain a significant proportion of natural products in their filling.