If you’ve ever wondered how a round biscuit is made, you aren’t alone. Most biscuit manufacturers have their own unique processes for making round biscuits, including pressing the dough into a disc, rolling it, punching it, baking it, and then wrapping it in plastic film. These methods differ from one another, but all share a similar goal – to provide a delicious and affordable treat. Learn more about these processes below!
Cold powder process
Biscuit production line begins with pretreatment of raw materials and mixing of ingredients. This dough is then shaped into flat sheets with a fine texture. Next, the biscuit sheets are fed into a machine that shapes the dough into various kinds of round biscuits. Baking time and temperatures also play a role in biscuit manufacturing. It is necessary to know the baking time and temperature before beginning this process. Moreover, it is essential to understand the biscuit production process thoroughly.
Biscuits are made from wheat flour, sugar, butter, oil, sparse agent, and other auxiliary materials. This process results in a porous, firm biscuit with a good taste. There are three types of biscuits: sesame, cream, and scallion. Each type of biscuit has its own taste, texture, and ingredients. To make the best-quality biscuits, you should invest in this process.
Rolling
The process of rolling round biscuits in the factory involves reducing the thickness of the dough sheet. This stresses the structure of the dough pieces, which will shrink and become misshapen during the baking process. To prevent this problem, a relaxation conveyor is usually employed. It runs at a slower rate than the dough sheet delivered by the gauge roll unit. The dough sheet is fed on to the relaxation conveyor with ripples, which gradually diminish as the stress is removed.
This equipment is widely used to manufacture hard biscuits, sugar biscuits, crackers, and cookies. The UTF-GROUP supplies equipment for the production of all three types of biscuits. The process begins with the preparation of the dough, which is done in a horizontal mixer. In case of hard biscuits, proofing is accelerated with the addition of additives or a separate fermentation chamber. Stamping the dough mass results in the formation of individual sugar biscuit pieces. The size and shape of the surface of the dough pieces are determined by the number of cells in the forming drum.
Punching
The main difference between a traditional machine for punching rounds and a rotary cutter is the number of rolls. A traditional machine has one roll, while a rotary cutter has two rolls. The former has one advantage: adjusting the pressure of each roll separately. Both the cutting and printing rolls have to be adjusted separately to achieve a uniform, clean print and a perfectly round biscuit. The rotary cutter’s phasing adjustment allows the print to be in the centre of the cut dough piece.
Each gauging station adds additional stress to the sheet of dough, and the time between each gauging station is usually insufficient to relieve all of the stresses before the next step. This is particularly true of the way the dough sheet is fed into the gauge roll, which will affect the amount of stress that the dough has. Variable stresses tend to remain after the biscuit is shaped after baking, so careful control is needed.
Baking
To achieve a consistent and high quality biscuit, a number of factors are important to consider. The oven should be able to deliver a rapid heat transfer at the start of the bake, while maintaining a flexible outer skin. The moisture in the dough should be removed effectively, as moisture condenses on the surface of the piece when the temperature is above 70oC. In some cases, it may be advantageous to inject steam into the baking chamber.
Once the dough has been made, it is then placed into a large mixer. The dough must be mixed with the right proportions, which is accomplished using a mixer. The temperature of the dough plays an important role in the mixing process. A high temperature during this step is a good way to achieve the desired shape of the biscuit. Afterwards, the dough must be transferred to the baking oven, where it is baked to perfection.
Palm oil
A decade ago, the United States Food and Drug Administration gave food manufacturers three years to phase out trans fats from baked goods. This was to avoid further damaging the environment. The product had been used in baking, soap, popcorn, and frozen pizza. By 2015, most manufacturers had complied with the deadline and were using palm oil in their production. However, the question is, “What does this mean for consumers?”
There are over 500 substances used in the manufacture of round biscuits, but many of the names obscure the source of palm oil. If you want to find out whether your biscuits are palm-oil free, identify the ingredients by their four-letter roots. If you find a recipe using a word that sounds like “palm oil,” call the company and ask them for more information. Then, they can help you make an informed decision.
Flexible packaging equipment
The round biscuit industry has grown steadily over the past few years, and the rise of ‘fussy’ and ‘over-the-top’ confectioneries has boosted this industry. But what are the key features of flexible packaging equipment for round biscuit manufacturing? The best solutions are modular and can scale as production capacity increases. The key factors include food safety, consumer-friendly features, and single-serve packaging.
The initial stages of the design process involved redesigning a biscuit forming machine and ancillary equipment. A small team of designers was brought in to redesign the machines and plant. The big questions were form and price, and the Drawing Office found itself at a disadvantage when discussing costs. However, the company had hired an Industrial Designer to assist with the redesign and to give input on new ideas. After all, he had no interest in designing the biscuit machine himself.
