1. Dough Preparation
The first step in biscuit production is the preparation of dough. This process involves mixing various ingredients like flour, sugar, fat (such as butter or oil), salt, and other additives like flavorings and leavening agents. The dough must be mixed until it reaches the right consistency and texture to form biscuits that are crispy and delicious.
In an automated production line, this is typically done using a large dough mixer that combines the ingredients quickly and evenly. The quality of the dough is critical to the final product, and it must be consistent to ensure that each biscuit has the same texture and taste.
2. Sheeting and Rolling
Once the dough is prepared, the next step is sheeting, which involves rolling the dough into a thin, even layer. This process is done using large rollers, which flatten the dough to the desired thickness. The thickness of the dough determines the texture of the biscuits. Thinner dough results in crispier biscuits, while thicker dough creates softer biscuits.
The dough is then cut into the desired shapes using cookie cutters or rotary cutters. At this point, manufacturers can choose to produce various types of biscuits, such as round, square, or even more intricate designs.
3. Baking
After the biscuits are shaped, they are transferred to the baking oven. The oven is typically a conveyor belt system, where the biscuits are evenly distributed and baked at a controlled temperature. The baking time and temperature depend on the size and thickness of the biscuits. A precise temperature is crucial to achieving the perfect texture, color, and flavor.
Baking ovens in modern production lines are often equipped with advanced technology to ensure even heat distribution and prevent over-baking or under-baking. This ensures that every batch of biscuits comes out consistently good.
4. Cooling
Once the biscuits are baked, they need to cool down before packaging. This is because biscuits straight out of the oven are too soft and delicate to be handled or packed. Cooling conveyors are used to gradually cool the biscuits, allowing them to firm up without losing their shape.
The cooling process is critical to preserving the quality of the biscuits and ensuring they maintain their crispness. The cooling conveyors are designed to provide optimal airflow to reduce the temperature gradually.
5. Packaging
The final step in the biscuit production line is packaging. Once the biscuits have cooled, they are moved to a packaging station where they are inspected for quality and defects. Automated machines then package the biscuits into boxes or plastic trays, depending on the packaging requirements.
