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Semi-Automatic Cookie Plant: Manufacturing Process Of Cookies
Jul 6, 2018·3 min read
Cookies are a part of a daily diet for many, though some people do not consume them on daily basis. But they are the main snacks all over the world, for the people of different age groups.
And talking about the varieties of the cookies, the number is large and generally, vary from region to region. While the cookies manufactured by the major brands are served all over the world. Right from the sweet cookies, to the salted ones and then to the ones stuffed with chocolate, strawberry and fruit creams, there is a wide choice for you.
But do you know how your favourite snack item is manufactured?
Well, these are manufactured at the cookie plants with the help of automatic and semi-automatic cookie machines. It depends on the features of the machines that what type and what size of cookies can be made with it. If you are thinking about the manufacturing process, here we have explained the complete process followed in the cookie plants.
The first step is mixing all the ingredients together for prepping dough. These include flour, sugar, fat and more. All the ingredients are put into the mixers and the dough is prepared once they are mixed properly. The things that matter the most in this part of the procedure are:
- the mixing time
- and the dough temperature
Mixing is done in two or three stages at different mixing speed. The average mixing time is 10–15 minutes, which further changes depending on the characteristics of the flour.
The second step is moulding. In this, the dough is laminated into the sheets and then is passed through the gauge rollers to get appropriate sheet thickness for cutting. It is in this step that the biscuits are given different shapes and are cut into different sizes.
The duration of this step depends on the speed of the cutter or moulder, which further depends on the variety of biscuits.
The moulded biscuits are put into the ovens for baking and the temperature is set accordingly. The different kinds of ovens provide different baking options, like indirect fired, direct fired and hybrid ovens. The particular option is chosen while keeping in mind the convenience, cost and temperature.
The methods used in the ovens include convection, conduction and radiation. And the moisture in the oven is controlled with the dampers lying inside the oven.
The baked biscuits are cooled naturally prior to packing, by placing them on the cooling conveyors. The cookies are cooled until the temperature comes down to the room temperature. Though the choice of forced cooling is also there, the natural cooling helps in maintaining the texture quality of the biscuit.
Once the cooling process is complete, the cookies are then fed into the packing machine. The different types of packaging materials include slug packs, family packs, pouch packs and more. After that, the biscuits are packed into the big cartons for transporting them to the retailers.
So, that was the process for the manufacturing of cookies, which is used in all the plants. Whether you are using the automatic or semi-automatic cookie machines, the process remains the same.
The two basic categories of cakes—foam and shortened—are distinctly different in their preparation. This chapter deals with aspects of cake production as a function of ingredients, mixing methods, and baking requirements focuses on the effect on cake quality. Ingredients play an important role in creating an acceptable product. Flour, liquid, sugar, leavening agent, eggs, and fat are present in a proportion that when properly mixed produce a quality product. A section examines various mixing techniques for forming a batter. Baked goods rely on freely moving currents for the transfer of heat, so it is important to ensure that baking pans are placed on racks in such a way to allow for the efficient flow of air currents.
Cookie Manufacturing Process
Reading Bakery Systems’ expertise, innovative research and development, and range of commercial cookie manufacturing equipment are unrivaled in the industry. We can help you improve your process, reduce labor costs, and produce consistent, high-quality cookie products.
Headquartered in Robesonia, Pennsylvania, Reading Bakery Systems is the world’s leading industry supplier of high volume commercial snack production equipment. Our goal is to help customers perfect their processes and their products with equipment that is specifically tailored to their needs.
Mixing & Dough Handling Solutions
Dough can be mixed on Thomas L. Green Vertical Spindle Mixers that allow the dough to be mixed twice and stay in the same trough throughout the entire process, or with Exact Continuous Mixers that uniformly mix products with a variety of dough moisture levels.
The EX Continuous Mixer, for example, produces low absorption dough for products such as cookies, crackers, pretzels, and bagels, as well as high absorption dough for bread, buns and pizza. This mixer offers dough production rates from 100 to 10,000 kg/hour.
The LDX Continuous Mixer is the ideal two-stage mixer for rotary moulded cookies, wirecut cookies, and crackers. It allows the creme up stage to be automated in conjunction with the dough mixing, and offers dough production rates from 1,500 to 7,500 kg/hour.
The Thomas L. Green Wirecut Machine creates a variety of cookies, biscuits and bar products. It is designed to provide piece-weight accuracy and reliability, and is best for nondescript shapes, with or without inclusions.
The machine uniformly cuts individual shapes at up to 150 cuts per minute, and can be positioned over the transfer belt or oven band and removed from the line without disrupting the conveyor system. It can also be built with an integral conveyor that discharges onto the oven conveyor system.
If your production involves high definition, three dimensional cookies, sandwich cookies, bars or biscuits, the Rotary Moulder features an interchangeable die roll made of engraved brass that can be supplied with segmented rings for multiple shapes.
The cookie industry has trusted Thomas L. Green ovens for more than 120 years. The PRISM OVEN is a flexible single-pass baking platform designed to enhance product consistency. It features:
- Uniform quality, color, taste and texture
- Direct gas fired, convection and emithermic radiant/convection baking zones
- Repeatable control of time, temperature, humidity and type of heat transfer
- Available in full stainless steel to address salt, corrosion and high humidity levels
- Excellent access for cleaning
The PRISM OVEN is available with a full range of control options for optimum performance. “Recipe” settings within the control processor allow for fast and repeatable startups, and controls are provided as easy to use, touchscreen interfaces.
Reading Bakery Systems’ design team engineers the most advanced, customized oven systems using 3D modeling software, oven airflow analyses, thermal imaging and other advanced tools. Our oven mechanics construct these proven designs in pre-built modules for superior quality control and faster plant installation.
Cake production lines
GEA can tailor cake production lines to fit in with your existing plant. From paper cup denesters, mixers and depositors to ovens, injecting systems, depanners and packaging lines, we can offer customized, state-of-the-art technologies that will provide the capacity for processing new products, and for upgrading, optimizing and automating existing processes.
Cake production lines
At the heart of any cake production line is the depositing process. We offer a range of compact and industrial-scale independent volumetric cylinder piston depositors that are highly precise and accurate, and can handle the most delicate or dense batters and mixes. Options and accessories including easy-change and dual-depositing heads, servo-motors, heated hoppers and cleaning-in-place systems make switching between products quick and easy, to minimize manual intervention and production down time.
Installing a depanner at the end of baking automates the process of gently turning out trays or picking products individually.
We also offer a leading portfolio of volumetric piston injectors that can fill products either vertically or horizontally, and models are available for any production scale or capacity.
And for that final touch, a GEA cake decorating system will make your products stand out from the crowd.
At the GEA Bakery Experience Center, our food expert food technologists partner with customers to improve existing recipes, develop new recipes and design and test production processes for new bakery goods, including niche products such as gluten-free or other allergy-specific lines.
GEA technologies are world-renowned for their reliability, robust and efficient operation. We consult with the industry to design and develop highly versatile and configurable technologies that are sustainable, and minimize the use of valuable resources. By choosing GEA technologies, our customers have the backing of world-class service engineers who will keep every item of GEA equipment working efficiently and effectively, throughout its lifespan.
Mixing Process In Biscuit Production
By World Bakers On Feb 25, 2017
Mixing process in biscuit production is crucial, being the first of the four major production steps where all the ingredients are perfectly blended to allow the baker to produce the perfect biscuit.
Biscuits are one of the most popular snacks around the world and liked and enjoyed by people of all age groups. The thing that most people enjoy about a biscuit is that it can be taken with anything from a cup of tea or coffee to milk or just nibbled alone. They can be dunked or eaten as is.
Biscuits come in many shapes and forms but each one, quite simply, needs the right ingredients mixed perfectly to produce the desired end product. There are primarily four stages of making the biscuit in a factory – mixing, forming, baking, and cooling.
In the mixing stage, flour, fat, sugar, water and other ingredients are mixed together in the right proportion in large mixers to form the dough. The mixing time is carefully managed to achieve uniform distribution of ingredients and the right dough consistency.
During this process, all ingredients like flour, fat, sugar are put together in the right proportion for dough mixing and then the mix is fed into the mixers. During this process, the dough temperature and mixing time play an important role.
Mixing time is normally around 15 minutes, depending on factors like flour characteristics.
Biscuits differ, however, from other baked goods like bread in that they have lower moisture content and maintaining this in the mixing process is crucial too.
So, control of the mixing process is important and Reading Bakery Systems reckon its continuous mixing systems allow this. Continuous mixing, the company says, offers bakers an opportunity to provide front-end control to the process.
Reading’s Exact Continuous Mixing System automatically meters ingredients and produces dough continuously to ensure that all dough is processed at the same age, meaning that no single batch has been sitting longer than any other.
Jul 19, 2020
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Dec 17, 2019
Reading Bakery Systems is seen by many as the global leader in continuous mixing technology. RBS offers a variety of Exact Continuous Mixing Systems for the biscuit and cookie, baked snack, cracker, sweet goods, pizza, tortilla and bread and buns industries.
Continuous mixing offers a consistent, uniform dough stream to the production line at the same rate is being used. The continuous mixing process eliminates the problems associated with batch cycles and produces a consistent product all day, every day, says RBS.
Exact Mixer models can produce dough consistently with high production yields and this can be accomplished in an almost employee-free operational environment adding significant cost savings and value.
Results can be fine-tuned and repeated day in and day out while the history of production can be monitored and saved electronically so that manufacturing data from the past can be reviewed and examined.
The LDX continuous mixed from RBS is ideal for low development dough requiring two stages of mixing and is, therefore, ideal for biscuits which are wire-cut or moulded.
Mixing dough for inclusion biscuits requires gentle folding, not the pounding that happens when mixing bread dough. For this purpose, Tonelli Group, Parma, Italy, equips its planetary mixer to handle large inclusions.
“We have specialised mixing elements designed for gentle mixing of gourmet cookies with big inclusions, such as chocolate chips and nuts, so they don’t break up during the mixing process,” noted Kevin Wilkinson, North American sales manager, Tonelli Group.
“Programmable variable-speed drives, from very high RPM to very low, allow bakers to fold in large inclusions gently without breaking.”
Baker Perkins also offers a range of high speed, multi-purpose batch mixers which are suitable for both hard and soft dough types. Thorough mixing is assured by the unique shaftless blade design which gives good dispersion and rapid dough development.
The blade is mounted horizontally and the bowl tilts up to a maximum of 150 degrees to ensure quick and thorough discharge of the mix.
A Detailed Overview of the Biscuit Manufacturing Process
Priti International has transformed into one the best biscuit making firms harbouring the best biscuit making machine in Kolkata. Usage of quality products have contributed to the excellence of the edibles churned out.
Preparation of the dough
The mixing of the dough during the preparation of the dough depends on the type of biscuit that is to be manufactured. The consistency of the dough and temperature at which the dough is prepared is one of the most deciding factors that influence the quality of the biscuit. The prime machinery used during the process is a dough mixer. You can avail a spiral, vertical or horizontal mixer as per your requirements.
The Fermentation process
The entire fermentation process takes about 21 to 26 hours to be completed. The process involves the mixing of the dough with the required amount of yeast. The mixture is then left for it to be get completely fermented.
Giving the cookie the right kind of shape
Initially the dough, made from flour bought from a quality flour mill in Kolkata, is flattened to convert it into sheets which is then followed by the compression of the sheets under a number of rollers. The sheets are then hardened to apply the topping over it. The required materials are then added on to the biscuits. It is after this that a rotary cutter with cups attached to it is used to give the biscuits their desired shape. The entire process involves the usage of a rotary cutter, a gauge roll stand and laminators.
The Baking process
After attaining the desired shape, the biscuits are then transferred to a massive oven where they are baked till perfection in the required temperature. A gas oven or electricity heated or coal fired will suffice the task. The oven comprises of several heating sources and a conveyor.
Cooling and testing of the biscuits
It is essential to cool the biscuits so that they can undergo the testing process. The cooling process of the biscuits is completed in the conveyor itself. It is after this that a few samples of the biscuits are collected and send for a quality check. The testing process is carried out in a specified laboratory for all other testing apart from the manual ones.
Packaging and supply
After the completion of the cooling process, the biscuits are moved on to a packaging machine where the packing process is completed before being finally disposed into the market.
Bakery Manufacturing Process. Manufacture of Bread, Biscuit, Cake, Cookies, Muffins
Baking is a food cooking method that uses prolonged dry heat by convection, rather than by thermal radiation. Heat is gradually transferred "from the surface of cakes, cookies and breads to their centre. As heat travels through it transforms batters and dough into baked goods with a firm dry crust and a softer centre".
Bakery products have become essential food items of the vast majority of population. The present day consumer looks for new bakery products, better appeal, taste and convenience from bakery foods. Bakery industry has also an important role in popularizing wheat in non-wheat consuming region of the World.
With good planning and access to good staff, raw materials and markets, setting up a bakery can represent an excellent enterprise opportunity. The book is invaluable reading for those starting their own baking business or any baker looking to improve their existing business in order to increase profits.
The book covers various aspects related to different bakery products with their manufacturing process and also provides contact details of raw material, plant and machinery suppliers with equipment photographs and their technical specifications. It provides a thorough understanding of the many new developments shaping the industry and offers detailed technical coverage of the manufacturing processes of bakery products. It examines the nature of bakery products, the role of the ingredients in determining their quality, processing methods and their control.
Various bakery products covered in the book are wheat ingredients, other grain ingredients, shortenings, emulsifiers, antioxidants, water and salt, different types of breads and biscuits, cakes, buns, icings, production of cookie and cracker, spices, flavours, colors, leavened and unleavened products, air-leavened products, chemically leavened bread and rolls, chemically leavened sweet goods, Yeast-leavened plain bread, rolls, dough, preservation of bakery products, milk and egg ingredients, fruits, vegetables, nuts and many more.
Food Mixer, Cookie Extruder, Rotary Oven, Biscuit Sandwiching Machine, Tunnel Gas Oven, Flour Mixer, Cookies Rotary Moulder, Bun Divider Moulder, Planetary Mixer, Spiral Mixer, Pillow Packing Machine, Oil Spray Machine are the various equipments described in the book with their photographs and technical specifications.
The book aims to provide comprehensive information on different types of bakery products. The book is aimed for food technologist, scientists, research scholars, as well as for new entrepreneurs and those who are engaged in this industry.