Flow chart for Biscuit Manufacturing

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Biscuit Manufacturing Process Flow Chart: Step-by-Step Industrial Guide

The biscuit manufacturing process is a carefully controlled sequence of operations designed to ensure consistent quality, taste, texture, and food safety. From raw material preparation to final packaging, each stage plays a critical role in determining the shelf life and consumer acceptability of biscuits. Understanding the biscuit manufacturing flow chart is essential for bakery owners, production managers, quality control teams, and food technology students.

This article explains the complete biscuit manufacturing process step by step, strictly following the standard industrial flow diagram used in commercial biscuit plants.

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1. Pre-Mixing Stage in Biscuit Manufacturing

The biscuit manufacturing process begins with the pre-mixing stage, where all raw materials are prepared and conditioned before dough formation. This stage ensures uniformity and reduces variability during mixing.

Key Pre-Mixing Operations

• Ingredient addition: Flour, sugar, fats, leavening agents, emulsifiers, salt, and minor ingredients are weighed accurately as per formulation.

• Sugar solution preparation: Sugar is dissolved in water to achieve uniform sweetness and proper dispersion.

• Milk solution preparation: Milk solids or liquid milk are mixed to improve flavor and nutritional value.

• Flour preparation: Flour is sieved to remove foreign matter and lumps.

• Fat preparation: Fats and shortenings are softened or melted for easy mixing.

• Additives preparation: Colors, flavors, enzymes, and preservatives are prepared separately.

• Flour sifters and sugar grinders: Used to achieve uniform particle size and remove contaminants.

Proper pre-mixing directly impacts dough consistency and final biscuit quality.

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2. Mixing Process in Biscuit Production

The mixing stage is where all prepared ingredients are combined to form biscuit dough. This step determines dough structure, aeration, and machinability.

Equipment Used

• Horizontal or vertical mixers

• Creaming mixers for fat and sugar blending

Mixing Parameters

• Mixing time: Must be controlled to avoid over- or under-mixing

• Water addition: Determines dough softness

• Creaming: Fat and sugar are creamed to incorporate air

• Dough consistency: Adjusted based on biscuit type (hard dough or soft dough)

Uniform mixing ensures even baking, proper spread, and consistent texture in the finished biscuits.

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3. Forming Process: Shaping the Biscuit Dough

After mixing, the dough is transferred to the forming section, where it is shaped into biscuits of desired size and design.

Forming Equipment

• Laminators: Used to sheet and layer dough

• Gauge rolls: Control dough thickness

• Sheet reduction units

• Cutter moulds: Cut biscuit shapes

• Moulders and embossers: Create surface designs and logos

Key Functions

• Maintaining uniform thickness

• Accurate weight control

• Consistent shape and appearance

Proper forming ensures visual appeal, even baking, and standard packaging dimensions.

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4. Baking Process in Biscuit Manufacturing

Baking is the most critical stage in biscuit production, where dough is transformed into finished biscuits with desired color, texture, and flavor.

Baking Equipment

• Baking ovens (gas, diesel, or electric)

• Continuous tunnel ovens

Baking Parameters

• Baking time: Depends on biscuit type

• Temperature zones: Controlled heating across oven length

• Steam injection: Used for surface texture and shine

• Heat distribution: Ensures uniform baking

During baking:

• Moisture is reduced

• Starch gelatinizes

• Proteins coagulate

• Biscuit structure is set

Incorrect baking can lead to burnt, under-baked, or cracked biscuits.

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5. Cooling Process After Baking

Once biscuits exit the oven, they must be cooled properly before packaging. The cooling stage stabilizes biscuit texture and prevents condensation inside packs.

Cooling System

• Cooling conveyors

• Ambient or forced air cooling

Cooling Parameters

• Cooling time: Sufficient to reach room temperature

• Moisture stabilization

• Handling strength development

Inadequate cooling can cause soggy biscuits, microbial growth, or packaging defects.

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6. Packaging Process in Biscuit Manufacturing

Packaging is the final stage in the biscuit manufacturing flow chart and plays a crucial role in shelf life, food safety, and branding.

Packaging Operations

• PPM (Planned Preventive Maintenance) checks

• Metal detection: Ensures product safety

• Stackers: Arrange biscuits uniformly

• Cream sandwiching (if applicable)

• Horizontal flow wrap machines

• Vertical form-fill-seal (VFFS) machines

• Printing: Batch number, manufacturing date, expiry

• Carton sealing

Packaging Objectives

• Protect from moisture and contamination

• Maintain freshness

• Provide regulatory information

• Enhance shelf appeal

Proper packaging ensures biscuits reach consumers in perfect condition.

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Importance of Biscuit Manufacturing Flow Chart

A well-defined biscuit manufacturing flow chart helps bakeries:

• Maintain consistent product quality

• Improve production efficiency

• Reduce wastage

• Ensure food safety compliance

• Train operators and supervisors

• Meet FSSAI, GMP, and ISO requirements

It also serves as a reference document for audits and process optimization.

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Quality Control in Biscuit Manufacturing

Quality checks are integrated at every stage:

• Raw material inspection

• Dough consistency checks

• Weight and thickness control

• Baking color and moisture testing

• Metal detection and packaging integrity

Following the flow chart systematically minimizes defects and customer complaints.

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Conclusion

The biscuit manufacturing process is a scientifically designed sequence that converts raw ingredients into safe, tasty, and shelf-stable products. From pre-mixing and mixing to forming, baking, cooling, and packaging, every step must be carefully controlled to achieve consistent results.

By following a standardized biscuit manufacturing flow chart, bakeries can improve productivity, ensure regulatory compliance, and deliver high-quality biscuits that meet consumer expectations. Whether you operate a small bakery or a large industrial plant, understanding and implementing this process is essential for long-term success in the biscuit industry.

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