Biscuit Production Process: An Industry Overview
Biscuits are one of the most popular snacks consumed in the country. On average, nearly every third person in India enjoys biscuits with tea daily. This has helped the biscuit business to boom more than ever before in history. Most biscuits today are manufactured with the help of automated machines. Here is an industry overview for you if you are interested in learning more about how these tasty treats are produced. Let’s go through the process on a step-by-step basis.
Preparing the Dough
The type of dough depends on the biscuit being made, and each brand uses its own recipe. Some use plain flour, while others employ multigrain flour with several dried fruits. The most important factors at this stage are the consistency and temperature of the dough. Most companies use a basic dough mixer for this as it can work up the dough automatically. Some of these mixers come with inbuilt thermal sensors and priming arms that ensure each batch comes out just right. There are spiral, horizontal, and vertical type mixers in the market, and each has its own benefit for a specific type of biscuit.
After the dough has been mixed, it needs to be mixed with yeast. Some brands do this while preparing the dough, while others wait until the dough has been prepared. The fermentation can take anywhere from 21 to 26 hours, allowing the dough to get airy. In most cases, this is a manual process.
Shaping the Biscuit
After fermentation, the dough is sent to the shaping machine. These machines have three major parts – the roller, cutter, and laminator. The dough is first passed through the rollers to get flattened out, which allows for easy cutting. Since the process is automated, the thickness of each cookie remains constant. The sheets are then hardened with the laminator, and some toppings can be applied here. After this has been completed, the laminated sheets pass through the cutter, which precisely cuts the dough into the required shape.
Once the biscuits have been appropriately shaped, they are transferred to a massive oven. This is usually done via a conveyer belt but can also be a manual process. The oven is automated via a microcontroller, ensuring that the temperature is precise and constant for each batch. The oven also has a conveyor belt that transports the cookies away once the baking process is completed.
Once the biscuits have completely cooled down, they are ready to be packaged. The conveyor passes them through the packaging machine, which packs them inconsistent sets. These can then be shipped in large crates and delivered to retail stores for sale.
The manufacturing process may sound a little simple at first glance; however, the most important part here are the machines used. These precise tools allow consistency in every batch to help make a biscuit brand well known. Hopefully, this answers all your questions about the biscuit production process.