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Fully Automatic

Biscuit Production Line

DSM full-automatic biscuit production Line is a complete set of large scale equipment which can produce hard biscuit, soft biscuit, cracker, sandwich biscuit, etc for industrial purpose, in a minimum capacity of 500kg. All production lines are customized according to the required biscuit output, available space of the plant, the moisture content, baking time control based on the biscuit technology. The overall unit complies with food sanitation and industrial safety standards. An easy operation design, precise data base, accurate system control had resulted in high efficient production and in the greatest extent reduce the number of labors and related cost. The product contact areas are all made of stainless steel or food grade materials. This line has the character of big production capacity, stable running, good-looking surface, easy operation, etc.

MAIN PRODUCTS PRODUCED ON THE LINE

capacity

500 kg-2000 kg/hour

Feature

01.

There are optional capacities of 500 kg-2000 kg/hour upon request.

02.

Standalone machine unit with independent control and cascade control

03.

304 Stainless steel construction

04.

Machine structure adopts food sanitation and safety criteria

05.

Humanization design for easier operation, cleaning and maintenance

06.

Food grade material for the area in contact with the products

07.

Safety interlocks for avoiding injuries during operation and maintenance

08.

Low variation of the baking oven temperature

09.

Equipment complies FM global standard

flow chart

Soft Biscuit

Raw material preparation → mixing → dough feeding → rotary moulding (forming) →baking→cooling→arranging→packaging

Hard Biscuit

Raw material preparation → mixing → dough feeding → pre-sheeting → gauge roll sheeting → dough sheet relaxing→rotary cut→scrap lift and return →baking→cooling→arranging→packaging

Cracker

Raw material preparation → mixing → dough feeding → pre-sheeting → laminating →gauge roll sheeting → dough sheet relaxing→rotary cut →scrap lift and return →baking →cooling →biscuit breaking → arranging → packaging

(This is the basic configuration, please contact us for other special processes.)

Production line composition

The hard and soft biscuit production line consists of material handling system, dough mixer, dough feeding system, roll sheeter, laminator, gauge rolls, relaxing conveyor, rotary moulder, rotary cutter, scrap lift and return conveyor, gas baking oven, cooling and arranging system, as well as series of supplementary equipment such as cream mixer, milk wash, salt&sugar sprinkler, oil spray, seasoning sprinkler, etc.

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Material Handling System
Material handling system is used at the preliminary stage of the biscuit production line. The system weighs and delivers required amount of the ingredient to the mixing section.
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Vertical Dough Mixer
This type of machine is designed in single/double speed mixing, and is ideal for the preparation of dough for crackers or delicate mixtures or the dough especially for preliminary mixing and secondary mixing.
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High Speed Horizontal Dough Mixer
This mixer is used for preparation of hard dough and soft dough. It uses spiral blade with double speeds with programmable control system.
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Dough Feeding System
The dough feeding system is to deliver the dough from mixing section to the forming section of the biscuit production line. It requires dough tub tilter, feeding hopper and feeding conveyors. For hard dough of hard biscuit/cracker/soda, it requires cutting machine to cut the dough into pieces before they transferred to lamination and sheeting.
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Laminator
The machine is to pre-sheet and laminate the dough into multiple layers of dough sheet to form the the special structure of cracker/soda biscuits. It has vertical and horizontal design depending on the length and height of the plant layout. The vertical laminator occupies a compact horizontal space and the horizontal laminator occupies a compact vertical space. Both design share the same function and are equipped with cut sheeting and flour spreading.
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Roll Sheeter
Roll sheeter is used in a rotary cut forming section of a hard biscuits/compound potato chips production line. It is positioned before the gauge roll sets for the pre-sheeting of cut dough pieces. It can be equipped with 3 rolls, 5 rolls or 7 rolls in order to achieve different thickness of the dough sheet.
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Gauge Rolls
This unit is designed and developed to reduce the thickness of a continuous dough sheet, and they are made with a pair of high quality chilled iron casting steel material.
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Relaxing Conveyor
This unit is to relax the dough sheet prior to transferring to the rotary cutter.The relaxing conveyor is to release the tension inside the dough sheet resulted from continuous pressing as to avoid shrinkage inside the baking oven.
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Rotary Moulder
This unit is completed with three independent drives for forcing roll, moulding roll and conveyor. It equips with the adjustments of the pressure of the rubber roll, the position of the forcing roll and the position of the scraper.
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Rotary Cutter For Hard Or Soda Biscuit
Rotary Cutter may have two types: one is single cutter and the other one is double cutters’ system. Both of them may be continuously embossing and perforating the dough pieces.
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Stamping Machine
This machine is used in the forming section of a hard biscuit production line, positioned after the laminator and gauge rolls. It adopts oscillating movement to stamp on continuous dough sheet to form biscuits in different shapes and patterns before it enters the baking oven.
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Stamping Machine
The unit is to separate the engraved dough pieces from the dough sheet and return the scrap dough to the hopper by return conveyor.
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Panner
The conveyor belt is polyurethane coated synthetic material with tensioning and automatic web tracking
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Hybrid Gas Oven
The Hybrid Gas Oven is the combination of two types of baking methods in one production line. The advantages of this oven is good for baking different types of hard and soft dough, especially good for baking crackers and hard dough biscuits.
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Direct Gas Fired Baking Oven
The direct gas fired baking oven is is a type of gas tunnel oven in the biscuit industry. It bakes the product with direct firing inside the baking chamber. It is usually applied in a cracker/soda production to fast develop the structure of the product and achieve a crispy texture. The medium for direct gas fired oven may be LPG, natural gas or coal gas.
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Forced Convection Baking Oven
The forced convection baking oven is a type of gas tunnel oven in the biscuit industry. It bakes the product through indirect firing, by extracting the air of burning. The burning flame will not be in direct contact with the product. It is applicable for producing soft biscuits that require higher water content and longer baking time.
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Indirect Force Convection Section
The indirect forced convection baking oven is a type of gas tunnel oven in the biscuit industry. It bakes the product through indirect firing, by blowing hot air on the surface of the dough. It helps to main the necessary water content of the baked product and provide even coloring of the surface. It is applicable for production of cookies.
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Electrical Baking Oven
This model uses electric elements as a medium to directly fire the chamber and reach the desired baking effect. It has a simple structure and has easy maintenance. It is applicable for hard biscuit for effectively control the require water content.
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Biscuit Cooling Conveyor
This conveyor is used for cooling down the biscuits after baking to enable the products complete cool down for arranging and packaging. The design of this cooling conveyor may be varied subject to the different requirements and site environment.
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Biscuit Curve Conveyor
The biscuits after baking continue their cooling process. Using this curve conveyor to change the conveying direction to practically occupy the site space. This unit is using polyurethane conveyor belt with excellent smooth biscuits transfer.
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Biscuit Breaker
This unit is for breaking and stacking the continuous sheet of soda cracker. After baking, the unit will break the continuous sheet of soda cracker in cross direction. After that, the unit will cut the broken pieces in straight direction to enable the whole piece into individual single piece of crackers. Meanwhile, the crackers will be stacked up to prepare for packing. This will increase the production efficiency.
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Biscuit Packing Table
The packing table is in the after-cooling section of a biscuit production line, its main purpose is to convey the biscuits after arrangement to the packaging machine.
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Auto-feeding System For Sandwich Machine
This is an arranging system for base biscuits of sandwich product such as Oreo. It can automatically align and distribute the biscuits to multiple lanes and divert them to separate sandwich machine/creamer in high speed and minimum breakage rate.
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Sweeper
This machine is mainly used for the auto-feeding of finished biscuit product to the slug packer. It is to be positioned in the after-cooling and after-sandwiching section in a biscuit production line. Its function is to horizontally sweep the biscuits and change the orientation of the biscuits on the main cooling conveyor to each individual packaging machine. This is a customized product that its design could be varied depending on different feeding requirement of the packaging machine.
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PDS For Vertical Packaging Machine
PDS (Product Distribution System) for vertical packaging machine is a biscuit feeding system to vertical packer in the after cooling section. It is used for biscuits that do not need alignment for tray loading. The biscuits are packed in bulk.
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Semi automatic solution

Biscuit stacker

To stack up the biscuits to packing format through differential speed of two conveyors or starwheel rotation to flip up the biscuits.

Packing table

The packing table of biscuit production line is for operators to manually pick up the stacked biscuits and transfer to the packaging machine.

Full automatic solution

Biscuit stacker

To stack up the biscuits to packing format through differential speed of two conveyors or starwheel rotation to flip up the biscuits.

Auto-feeding system for sandwich machine

It can automatically align and distribute the biscuits to multiple lanes and divert them to separate sandwich machine/creamer in high speed and minimum breakage rate.

Auto-feeding system for Horizontal packaging machine

The traditional type of automatic feeding to packaging machine is the combination of biscuit stacker and packing table. By putting full guides on the packing table and have sets of vibration channels to transfer to the separate packaging machines, it reduces the process of operators picking up the biscuits manually from the packing table.

Sweeper

To horizontally sweep the biscuits and change the orientation of the biscuits on the main cooling conveyor to each individual packaging machine. This is a customized product that its design could be varied depending on different feeding requirement of the packaging machine. Specifically for sandwich products because it will change the up and down face of the biscuits.

PDS for vertical packaging machine

It is composed of biscuit diverter and circular conveyor. It has feeding level control and the diverter will evenly distribute the biscuits to separate vertical packer according to the signal provided by multi-weigher of the packer.

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APPLICABLE

LAYOUT

APPLICATIONS

The main ingredients of the biscuits products are flour, sugar, water and fat. The different ratio that each ingredient occupies in the recipe decides whether it is a soft biscuit, hard biscuit or cracker. An end user can choose to adopt a material handling system when there are greater capacity of the plant and need to frequently transfer the ingredients to the dough mixer. Or else, manual delivery of the raw materials will be well enough for one or two production lines. After mixing the ingredients, for soft biscuit, the next step will be directly moving the dough tub to the tub tilter and it will lift up and send the dough to the forming section for rotary moulding; for hard biscuit and cracker, it might require fermentation and second time mixing before going to the next step. The hard biscuit will pass through a pre-sheeter for pressing to dough sheet and enter three or four sets of gauge rolls for continuous sheeting; the cracker share similar process as the hard biscuit, except it has one extra step – the lamination. It is for building the multiple layers and hollow structure inside the cracker for the light and crispy texture. The key process that affects the texture and surface appearance of the final product are mixing, forming and baking. The mixer determines if the dough structure is formed for the expansion and development during the baking; the forming determines the shape and weight of each dough pieces if they are identical; the baking process determines the moisture, coloring and structure development of the final product. Each process are very important and need accurate database and PLC control.

Completion of project testimonials

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