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Love eating cookies? Have you ever wondered how much technology is poured to the manufacturing process of biscuit and cookies? How the same great taste is ensured while making cookies or biscuits?

Overall Steps Followed at a Typical Biscuit or Cookie Manufacturing Plant

Dough making and mixing Process

• Mixing of all the ingredients can be done through single or multiple stages depending upon the type of biscuit to be manufactured. The mixing temperature and dough consistency play important role to the quality of biscuits.

 

Machinery required in this stage:

• Dough mixer: It mixes the ingredients to make dough. Based on the orientation and the rotation pattern, the dough mixer can be horizontal, vertical, spiral and planetary types.

 

Doing fermentation Process

• The fermentation plays important role in the manufacturing biscuit, cookies and all other types of bakery products.

 

• Fermentation is happen in presence of Yeast, so, the dough has to be mixed with yeast and keep it for 20-26 hours to ferment.

 

Machinery required in this stage:

• Dough mixer itself can mix yeast with the dough. After the fermentation, the dough is placed on hoper connected to the conveyor and the journey of manufacturing cracker starts.

 

Giving shape Process

• The soft dough is first made flat to make sheets out of the dough.

 

• The dough sheets then compressed under series of rollers.

 

• The compressed dough sheets now conditioned to make it hard enough to apply toppings above it.

 

• Toppling of creams or other materials are added over the sheets.

 

• The sheet then fed into the rotary cutter. The rotary cutter, a rotating roller with cups attached around it, is used then to get the desired shaped biscuits ready to bake.

 

Machinery required in this stage:

• Laminators: Laminator performs the rolling operation to flatten the dough. Laminator can be of horizontal or vertical types.

 

• Gauge roll stand: This machine compresses the flat dough to make it little thin and hard. Here again the flat dough is passed under series of rolls pairs.

 

• Rotary cutter: It has a pair of rollers with the desired shaped cups attached surround it. The machine can convert the dough sheet in to biscuits.

 

Baking the raw cookies Process

• The biscuits from the rotary cutting machine are supplied to the oven for baking it in desired temperature for desired durations.

 

Machinery required for this stage:

• Oven: The ovens can be of gas fired, coal fired, electrically heated to primarily categorize it. It can also vary based on the production rate. Basically an oven consists of conveyor and the heating sources.

 

Cooling and testing Process

• The hot biscuits need to be cooled before it can be tested or packaged. The cooling is done over the conveyor itself. After the cooling, samples of the cookies are tested to ensure quality and tests.

 

Machinery required for this stage:

• Testing laboratory: Apart from manual testing different other testing are also performed using the reagents in the laboratory.

 

 

Packaging and supply

Process: The conveyor is connected to the weighing and packing machine after the cooling.

Machinery required for this stage:

• Weighing and packing machine: Automatic weighing and packing is done here.

 

The manufacturing process of biscuits or crackers or cookies described here is the typical one, lots of developments is happening in the machineries and processes of this industry. Leave comments if you would like to share some thing on the subject.


shibashis
Hi, I am Shibashis, a blogger by passion and an engineer by profession. I have written most of the articles for mechGuru.com. For more than a decades i am closely associated with the engineering design/manufacturing simulation technologies. I am a self taught code hobbyist, presently in love with Python (Open CV / ML / Data Science /AWS -3000+ lines, 400+ hrs. )

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