How does an automatic biscuit production line work?

The journey of a simple mixture of flour, sugar, and fat into a perfectly baked and packaged biscuit is a fascinating testament to modern food technology. An automatic biscuit production line is a highly synchronized system designed for efficiency, consistency, and high-volume output, minimizing manual handling and maximizing hygiene.

Here is a look at the sequential stages of this remarkable process:

      1. Ingredient Dosing and Dough Preparation

The process begins with precision. An Automatic Dosing System accurately weighs and transfers raw materials—flour, sugar, fats, and other auxiliary ingredients—into large-capacity Dough Mixers. The mixer is crucial, blending and kneading the ingredients to achieve the exact texture and consistency required for the specific type of biscuit (hard/cracker, soft/cookie, or sandwich biscuit). The quality of the dough at this stage fundamentally determines the finished product's texture and mouthfeel.

      2. Sheeting, Laminating, and Thickness Control

Once mixed, the dough is automatically conveyed to the Sheeting and Laminating section. For layered biscuits like crackers, a Laminator repeatedly folds and rolls the dough to create layers, which gives the final product its characteristic flakiness. For other types, a series of Gauging Rolls flatten the dough into a continuous, uniform sheet of the precise thickness required. This consistent thickness is vital for uniform baking.

      3. Forming and Cutting

The uniform dough sheet then moves to the Forming stage, where it is transformed into individual biscuit shapes.

• Rotary Cutters are used for hard or semi-hard biscuits (like crackers), utilizing molds that stamp out the shapes and simultaneously recycle the scrap dough back for re-sheeting.

• Rotary Moulders are used for soft biscuits (like cookies), pressing the dough into engraved molds that shape and release the biscuits directly onto the baking conveyor.

      4. Baking in the Tunnel Oven System

This is often considered the heart of the biscuit production line. The formed biscuits travel on a long, continuous wire mesh or steel band through a Tunnel Oven. These ovens are highly sophisticated, often modular, with multiple zones that allow for precise temperature and moisture control throughout the baking cycle. This controlled environment ensures:

• Uniform Texture: The heat profile is managed to achieve the desired moisture removal and structural setting.

• Consistent Color and Flavor: Optimal time and temperature are maintained across every batch, ensuring every biscuit is perfectly golden and fully developed in flavor.

      5. Oil Spraying and Cooling

Upon exiting the oven, some biscuits (especially crackers) pass through an Oil Sprayer to enhance flavor, texture, and visual appeal with a glossy finish. Following this, the biscuits enter the Cooling Conveyor system. Gradual cooling is essential, as rapid temperature change can cause the newly baked, fragile biscuits to crack or warp. The cooling zone prepares them for the next critical step.

      6. Stacking and Automatic Packaging

The final stage ensures the product is ready for consumers.

• Stackers gently align and group the cooled biscuits into neat piles.

• The aligned stacks are then fed into highly efficient Flow Wrapper or Packaging Machines. These units automatically wrap the product, seal the package (often including inert gas for preservation), print expiration dates, and prepare the units for boxing.

Throughout the entire biscuit production line, advanced PLC (Programmable Logic Controller) systems and sensors monitor every step—from ingredient weight to oven temperature to packaging speed—ensuring the highest standards of quality, safety, and efficiency are consistently met. This complete automation is what makes it possible to deliver millions of perfect biscuits to consumers globally.