Biscuit Production Line Assembly

For  more description  check  biscuit production line
Biscuit  Making Process
Indian Biscuit Industry Review

Biscuit Production Line

Biscuit production line consists of following equipments with brief  description

Mixers
All  ingredients are mixed into mixers  to prepare  dough  with desired characteristics . Normally two stage mixing is done  in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer .

Dough Elevator or Dough Tipper

Dough bowl  are either taken to tippers where dough is decanted into mixer bowl  which is beneath the tipper at level lower  to the tipper  or  dough bowl is  carried to certain height  and then tilted to decant the bowl into laminator hopper .

Dough Laminator

Laminator main function is to reduce the  mass of dough into uniform sheet or laminate for further reduction in gauge roll . Laminators have sets of roller where this dough is acted upon  and are converted into dough sheet .

Gauge Rolls

These gauge rolls have set of cylindrical rollers which rotates in reverse direction so as to  give  push to the next gauge rolls . Three stand to four stand of gauge rolls are used in normal biscuit  production line . Speed of rolls ae set as per the baking time and increases  as we proceed further .

Moulding /or  Cutter Unit

These are equipment  which cuts the dough sheet into desired shape and size . Plant out put are calculated as per the design of the moulder or cutter . These cutters or moulders have dies , cups or inserts which are fixed on the cavities or  surface of the moulder or cutter .
Now days engraved moulders and cutters are available . Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cups .

Moulder are used for short dough  where as cutters are used for hard dough variety

Scrap return conveyor

These conveyors  returns the  scrap dough back to mixers which are again used for production thus minimising waste .

Swivel Panner
Swivel panner  is  installed at the feed end of oven where it centres the dough piece entrance on baking oven band  it has swivel arrangement on which it balances the  web or centres the web  so that wet dough pieces enter s oven in straight line .

Baking Oven

Dough pieces then enters oven  and travels on wire band for baking . Burners generates heat which is circulated through ducts or pipelines  to bake wet  dough pieces . length and width of oven are designed as per the capacity required . Oven speed is adjusted as per the standards baking time for particular variety


Stripper Conveyor

Stripper conveyors are provided  at  the delivery end of oven so that  baked biscuit are cooled and doest not come into contact of any surface when hot . Stripper conveyors has wire mesh which carries these hot baked biscuit .


Cooling Conveyor

These conveyors  are provided in biscuit production line to   bring down temperature of   hot biscuits which comes out from oven . normally they 1.5 -2 times of  oven length .


Magnetic Stacker

Stacker are used to  distributes and   arrange biscuits  in a line and are thus could be stacked easily for packing process . These biscuits  are made to pass of plates which acts as guides which makes these biscuits to fall into space between the guides .


Packing Table

Biscuit s travels into guidelines on packing table where either they are fed into  into  packing machine automatically or are fed into feeding chutes  manually by operators .


Packing Machine
Biscuits are fed into packing  machine for packaging   there are various types of biscuit packing such as pile type , on the edge  and cream sandwich type . Horizontal flow wrap machines are  mostly used to pack with flexible packaging .

Biscuit  Process Flow Diagram 
Bread Process  Flow  Diagram 
Accesories & Additional Equipments For  Biscuit Production

Automated biscuit manufacturing process - Video

Automated biscuit manufacturing process consists of following steps







Types of dough

Hard dough  and Short dough

Type s of biscuit

Glucose biscuits , Crackers , Cream biscuits , Coconut , Choco chips , Milk ,Sweet , Salty , Sweet n Salty

Premixing

Mixing

Forming

Baking

Cooling

Packing

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 .

Additional equipments required for biscuit production line

Apart from basic equipments such as biscuit oven , mixers , laminators , packaging machine which are used by large biscuit manufacturers in their automated biscuit production line there are certain equipment requirement specific for certain varieties . We can call them accessories to the main biscuit production line .These are either permanently installed on the line or can be fitted on the production line during change overs .Varieties like Crackers , Cream , Nice , Milk and for additives like cashew , pistachio and other nuts would require these additional equipment on the biscuit production line.

To make your plant truly versatile you need to ask your biscuit plant and machinery manufacturer to make the plant for hard dough and short dough variety or in other words biscuit plant which can produce cutting and moulding variety .

Following equipments are

• Oil spray unit
• Milk spray unit
• Flour dusting unit
• Cashew or Nut sprinklers
• Salt Sprinklers
• Sugar Sprinklers
• Biscuit Grinders
• Sugar Grinders
• Creaming Unit
• Depositors
• Milk Storage and preparation unit

When installing biscuit production line check for above mentioned equipments and make arrangement for them .