If you’re wondering how your favourite chocolate biscuit is made, you’re not alone. The process is very similar to making bread: ingredients are measured out using a computer system and stored in bulk. The mixer is manned by a worker who controls the amount of each ingredient. One machine, a mixer, can turn out as much as 800kg of dough every 18 minutes, creating 600kg of baked goods. The finished dough drops onto a laminator machine, which rolls it into sheets and places them on top of each other.
Caca
A Cacao biscuit factory makes chocolate-based foods and treats. The ingredients are refined and ground to a fine powder, before the biscuits go through the conching process. The purpose of conching is to increase the fat content in chocolate, while reducing the moisture content. Most biscuit factories do not manufacture chocolate, as the focus is on delivery. In addition, these factories produce chocolate-based confections for private label markets in Europe and Asia.
The cacao tree is native to the Amazon rainforest and was domesticated more than five thousand years ago by the Olmecs. In addition, it contains significant amounts of magnesium, iron, and calcium. These compounds are part of the reason that cacao is widely believed to have health benefits. Flavonoids, which may have beneficial effects on cardiovascular health, are also found in cacao. Theobromine, a compound found in cacao, is the active ingredient in Hershey’s chocolate bars.
Cooking
The process of manufacturing chocolate biscuits involves two steps: the initial baking phase and the second baking stage. In the first baking stage, the dough piece undergoes a series of physical and chemical changes. These changes occur at varying temperatures and time intervals. After the dough has reached a specific temperature, the process of browning begins, during which high temperatures help to release latent heat and change the biscuit’s colour. During the second baking stage, the temperature of the biscuit is increased, and the colouring is applied.
The next stage is the final baking stage. The dough is mixed in a mixer, and the ingredients are measured and combined in the correct proportions. Several factors determine the final cookie’s texture and shape, including the temperature at which they are mixed. When the dough is sufficiently mixed, the dough reaches a baking temperature of 60o-70oC. At this temperature, the starch begins to gelatinise. However, the amount of water present in the dough is too small to fully gelatinise the starch. Biscuits baked at 70degC are well formed and stable, and the gelatinisation process may continue until the biscuit reaches a temperature of 95degC.
Packaging
How chocolate biscuit is packaged in factory? It is a continuous, in-line process, during which the biscuits are delivered to the enrobing machine. After being cooled down to 25 degrees Celsius, the biscuits are transported through a wire mesh conveyor and then covered with chocolate. Chocolate is then cooled off in tunnels equipped with accurate temperature control. This process ensures a glossy surface for the products.
The production of round biscuits causes the most pollution and has the highest potential for global warming. This is attributed to the high demand for water, electricity, and other raw materials. Chocolate-coated biscuits have the greatest impact, particularly when palm oil is used. Despite the debate on this ingredient, there is little doubt that the production of chocolate-coated biscuits is not very friendly to the environment. However, the process of packaging and manufacturing them is an important part of the overall process.
Delivery
Delivering chocolate biscuits manufactured in a factory is not a simple task. Packaging machines pack chocolates and then send them to the final destination. Despite the tight deadlines, the project was completed on time and under budget. Moreover, it ensured that the chocolate biscuits remained as fresh and tasty as they were when they were first produced. Read on to learn more about the delivery process of chocolate biscuits manufactured in a factory.
Conveyor belt
A conveyor belt for manufacturing chocolate biscuits is a common piece of equipment in a factory. This belt transports the biscuits between ovens and can be designed to transport large batches of product. A typical belt is made of food-grade cotton and durable fibers. It is used to extract the shapes of the biscuit dough from rotary molding drums, which have been standard since the advent of mass-production of biscuits. A conveyor belt helps a factory produce large batches of product in a relatively short time. The belt is made in the UK by Arville, a textiles company that invested in P&S to achieve ISO 9001 standards.
Typical cooling conveyors have numerous transfer points, making it difficult for them to achieve uniform positioning of the product. The longer the cooling conveyor, the more transfer points there are. A longer conveyor also means the biscuits are subject to more jumbling. Ultimately, a properly orientated product can be packaged without damage. Conveyor belts are a common feature of factory production and help keep products uniform and clean.
Creamy chocolate biscuits
Nestle is a major manufacturer of chocolate biscuits. They are also available in low-fat and low-sugar versions. This study compares the environmental impact of biscuits and their ingredients. It found that chocolate-coated biscuits are the least sustainable and have the highest energy consumption. Low-fat and sugar biscuits are the least affected, with the lowest energy demand. All biscuits are manufactured in factories.
The production process involves several steps. The first step is the enrobing process. It is an in-line process, where biscuits are delivered to a machine after they have been cooled to 25 degC. Depending on their size, biscuits may be fully coated with chocolate or only partially covered. The remaining steps involve cooling the chocolate in tunnels equipped with accurate temperature controls and air/water cooling systems. This process ensures that the biscuits have a glossy finish.
