Biscuit Grinders –How to reduce waste in biscuit production

Biscuit  manufacturing generates waste in form of 

• Loose biscuits
• Over weight biscuits
• Under weight biscuits
• Unpacked biscuits
• Oven dropping
• Rejection due to color
• Rejection due to ingredients
• Trial  waste
• Packing machine rejections
• Packing defective

These if not recycled can result in huge loss of money labour  fuel and packaging  for the company  . The best way to recover some value is to recycle these biscuits . These biscuits should be collected in hygienic ways in s.s  containers  without being contaminated  and with help of biscuit grinder turned into biscuit powder which can easily  be  used in fresh batch of mixing . Normally 1-2% of batch weight can be biscuit dust without affecting the dough properties . Ensure that  biscuit powder is labeled as per the variety  and is added in the similar variety .Excess addition can affect the quality of the biscuit .

Various type of Biscuit grinders are available in market

• Rotary type   biscuit grinders

• Hammer type  grinders

Principle  of biscuit grinder is that these defective biscuits are put into either pin type or hammer type grinders which on higher rpm reduces these biscuits into fine dust . We can always adjust these elements to increase or decrease  the powder size . Keep these  biscuit powder either in s.s enclosed containers or  food grade  plastic bags . Ensure that Rejected biscuits are screened with metal detectors installed on the feeding conveyor .

Popular Grinders are  from   equipment  International equipment manufacturer

• Stephan Machinery
• Bauermiester

Indian Biscuit Grinders can be sourced from

• Kaps Engineer
• Mangal Machinery

Basic Facts about rotary moulder and cutter - biscuit production equipments

Moulders and cutters are the basic equipments for any biscuit production line . Biscuit plant capacities are  designed with respect to moulder/cutter design .Forming section  or process are the technical name given to the area in which moulder/cutter operates .

Moulders :  These are cylindrical shaped equipments which have dies/cups  holding dough and which imports its design on the dough . These when pressed with pressure roller form the  biscuit shape and size .These are meant for Short Dough  type biscuits /cookies.Its hollow cylindrical pieces with tie rods and shaft.Hardness of  the pressure roller need to checked regularly  and should be  between 70-85 shores

Cutter : These are cylindrical  shaped equipment which  cut laminated sheets of dough in various shape and size of biscuits . Cutter roller has  got cups /dies  which are mounted on the surface of the cylinder .Different shape  and size are  available   for biscuit  production but for optimisation the circular shape is most popular shape of  biscuits.Its hollow cylindrical pieces with tie rods and shaft.Mainly used for  cutting variety ( laminates of dough)  or Hard Dough .




Size : Depending upon plant capacities, baking time  the moulder/cutter are designed . Normally the size is categorised in Diameters the most used diameter are  10"  and 12".

Basic Output of Moulders/Cutter s are calculated as =  Number of rows x Numbers of column s x RPM


Types of Moulder/Cutters -

One piece rollers

Ring type

Metallic rings
FG Plastic rings
Engraved Cutter s

To protect these cutters/moulders in biscuit production line its highly recommended to place  metal detector before dough comes in contact with them .

Weight variations in biscuits  originates from the cutters/moulders   the minor variances in weights can be sorted  out by adjustments in pressure roller/moulders/knife combination.

Major variation in biscuit weights can be sorted out by  skinning of moulders/cutters .

Change over of moulders /Cutters  are major activity in any biscuit production line  following methods are used to reduce the change over time from one variety to another

Chain Hoist Motorised or Manual
Hydraulic Lifter
Movable Unit- Complete Unit
Precaution is required while dismantling and installing these molders/cutters as any accidents can damage the cups/dies of the moulders/cutters.Normally these are wrapped in protective sheets .

Maintenance team has to keep the major load  bearings at the ends  in good condition for  better performance of these moulders and cutters .

Indian Biscuit manufacturing equipment supplier s

List of Major  Indian Biscuit Equipment Manufacturers and Suppliers

SNO	NAME OF THE MANUFACTURER	ITEMS
1	PRIMA ENGINEERING	Biscuit plant and machinery
2	NEW ERA INDUSTRIES	Biscuit Plant and machinery
3	AIFSO	Biscuit Plant and machinery
4	SUNBEAM INDUSTRIES	Biscuit Plant and machinery
5	MANGAL ENGINEERING	Biscuit Plant and machinery
6	SARLA INDUSTRIES	Biscuit palnt and machinery
7	MIRANDA ENGINEERING	Bulk Handling
8	INDCON PROJECTS	Bulk Handling
9	SARLA ENGINEERING	Cooling conveyor
10	KAPS ENGINEER	Sugar Grinder,Biscuit grinder
11	PRAGATI ENGINEERING	Moulders and Cutters
12	ESPEE ENGINEERS	Biscuit palnt and machinery ,erection of Biscuit plants
13	PROMESE ENGINEERS	Erection and Comissioning of Biscuit Plant.
14	G C DUTTA AND SONS	Cotton Conveyors
15	SCANDIA BELTING	Cotton Conveyors
16	AARJAY SYSTEMS PVT LTD	Automation
17	NECON	Automation
18	AVISTAR	Moulders and cutters
19	ACUSHARP	Knifes and blades
20	MULTIPACK SYSTEM PVT LTD	Packing machines
21	BOSCH PACKAGING( INDIA)	Packing Machines
22	KHOSLA PRECISION	Packing Machines
23	NEW INDO PACKING MACHINE	Packing machines
24	ITW SIGNODE ( INDIA)	Taping Machines or carton sealing machines
25	VIBGYOR	Sealers
26	CONTROL PRINT	Printing dry and ink jet
27	BAKSHI ENTERPRISE	Markem Printers
28	ISF	Milk chillers and handling system
29	TECHNOFOUR SYSTEMS	Metal detectors and Check Weighers
30	METLLER TALEDO (INDIA)	Metal detectors and check weigher s
31	HABASIT ( INDIA)	PU conveyors
32	FORECH INDIA	PU conveyors
33	K DHARMALINGAM	Endless Webs
34	VIVEK ENGINEERS	Sugar,flour , salt and Milk sprinkler
37	RAJNI COMBUSTION	Weishaupt burners
39	NARI WIRE NETTING INDUSTRIES	Oven Bands
40	ROSHAN INDUSTRIES	Oven Bands
41	LLYOD INSULATION	Insulation material
42	UP TWIGA	Insulation material
43	RADIX SENSORS	Sensors
44	WESMAN THERMAL	Burners
45	CHADHA SALES PVT LTD	Chillers
46	ADMIR OVENS	Biscuit Plant and machinery
47	FESTO PNEUMATICS	Pneumatics
48	VOLTAS	Air Conditioning
49	BLUE STAR LTD	Air conditioning and cold storage
50	GODREJ MATERIAL HANDLING DIVISION	Pallets and material handling
51	RIECO INDUSTRIES	Bulk Handling
54	SUPER TECH	Knifes and blades
55	SEPERATION ENGINEERS	Vibration gyro screens for flour sifting
58	THERMAX	Vam and Boilers
59	BRY AIR	Humidifier
60	NILKAMAL	Plastic trays and bins
61	SUPREME INDUSTRIES	Plastic trays and bins