Advantages of hard biscuit manufacturing plant:
- The automatic control system allows maintaining a stable supply of dough into the extruder, regardless of a capacity of the line and product it makes.
- The design of the laminator allows getting 8 to 16 layers of dough according to the classical technology, in which the dough after each rolling on the stage of lamination passes the process of maturation for tension removing.
- Adjustment of the number of layers is simple and convenient, it is made from the operator’s panel and does not require mechanical regulations.
- New design of forming unit of the hard biscuit manufacturing line allows the quick and convenient replacement of rotor in case of switch to the other product.
- It is possible to install additional equipment for sprinkling of product with bulk ingredients.
Hard biscuit plant operation video
You get a full range of services:
• development of project of equipment layout in customer’s premises, including supply pipelines plan; • visit of specialist to the company; • installation and adjustment of equipment; • staff training; • spare parts delivery and service maintenance.
Additional equipment:1. Conveyor system for maturing and feeding of dough into the laminator. 2. Bulk ingredients sprinkling device (salt, for example). 3. Oil sprayer. 4. Cooling and accumulation conveyors, stacker.
The line consists of:
Dough batcherDough batcher is intended for dough feeding process automation. Batcher performs the function of receiving, preliminary rolling, uniform distribution along the width and feeding of dough into the bunker of extruder for maintenance of continuous operation of the line. The automatic control system allows maintaining a stable supply of dough into the extruder, regardless of a capacity of the line and product it makes. The increased volume of the receiving hopper reduces the number of operations for the loading of dough. Preliminary rolling allows obtaining a uniform structure and density of dough on the initial stage, what has a positive effect on product quality. Dough distribution along the width ensures a uniform filling of the extruder’s hopper, what guarantees the high quality of dough ribbon at the output.
Fermentation chamber1*. Intended for the automation of the dough fermentation process. Chamber provides receiving of dough, optimal conditions for its fermentation, dough dividing for the portioned pieces with the following feeding of them into extruder for dough ribbon forming. Due to creating and stable maintenance of temperature and humidity parameters the process of fermentation is very close to natural, what allows producing the highest quality product with a minimum use of chemical additives. Fermentation chamber is indispensable in terms of high-capacity production and production with strict requirements to the presence of additives.
Extruder is intended for the forming of dough ribbon of the required thickness. Special three-shaft design of the extruder provides the uniform dough ribbon at the output, at the same time compacting it at maximum and removing the air. Working width of the extruder could be from 600 mm to 1200 mm, it is defined by a capacity of the line and by a length of tunnel oven’s baking chamber. Reinforcement of separate units’ design significantly increases durability of equipment.
Automatic horizontal laminator is intended for imparting a flaky structure to the product. Quality of the final product, its brittleness and friability are defined by the correct dough lamination. The design of the laminator allows getting 8 to 16 layers of dough according to the classical technology, in which the dough after each rolling on the stage of lamination passes the process of maturation. Maturation provides more elastic dough structure, what enables an easier rolling, dough retains its shape better, has a uniform porosity in the break and, as a result, the appearance of the finished product is improved. Adjustment of the number of layers is simple and convenient, it is made from the perator’s panel and does not require mechanical regulations.
Three-modular rolling machine is intended for the delicate rolling of dough ribbon down to the required thickness with maintaining the obtained dough structure. At the same time due to multiple rolling the quality and plasticity of dough are increased and internal tensions, connected with dough processing, are removed.
Rotary cutting machine
Rotary cutter is intended for getting the pieces of biscuits out of the dough ribbon. The forming rotor provides the fulfillment of this process by cutting down the pieces of a set shape, size and surface pattern. Additionally, forming rotor has pins for dough pieces puncturing, it punctures them through, providing the coming out of gases formed during baking, thereby preventing swelling. New design of forming unit allows the quick and convenient replacement of rotor in case of switch to the other product. Pneumatic system of pressing of dough ribbon to the rotor ensures a stable quality of dough pieces. After cutting a separating of dough pieces and dough offcuts (appeared during the forming of dough pieces) is made and then dough offcuts are fed into a hopper of the extruder for the repeated use by the conveyor system. If necessary, after the forming dough pieces are dusted with bulk ingredients (salt, for example) before feeding into the tunnel oven.
Tunnel oven is intended for the baking of biscuits. Hearth of the oven is made of wire mesh. Width of hearth depends on the dough ribbon width. In case of L-shaped placement of equipment width of hearth could be up to 2 m.
Rotary conveyor, conveyors, stacking
Cooling of final products and preparing them for the packaging is made on the system of conveyors. It could include cooling and accumulation conveyors, final product stacking devices and other components. Size and configuration of conveyor system depends on the room planned for placement of equipment, type of packaging and wishes of customer.
Hard biscuit production technology on biscuit plant workflowRolling, maturing and creating a flaky structure are made in the automatic horizontal laminator. In it two dough ribbons are put on each other and rolled together several times with providing the maturing on the conveyor between rolling processes. After that dough ribbon is put by layers on the output conveyor with the turning of folded layer for 90°, hereby creating flaky structure. After the laminator dough ribbon gets to another biscuit equipment - three-head rolling machine where rolling down to the thickness 2,5 - 4,0 mm (depending on type of product) is made. Dough pieces for hard biscuit are produced on the rotary cutting machine, on which a quick-changing forming rotor cuts the pieces of the dough ribbon. Dough offcuts are separated from dough pieces and returned to the extruder. If necessary, after the forming dough pieces are sprinkled with bulk ingredients (salt, for example). The baking of biscuits is made on the tunnel oven. Modes, temperature and baking time depend on qualities and sizes of product as well as on the hearth fullness. Biscuit manufacturing plants by UkrTechnoFoods can be customized according to individual manufacturer needs. Directly after baking spraying of product with oil or other fatty product could be made, what is required in production of some types of biscuit. After the exit of the oven the ready product is being cooled on the system of conveyors and fed to stacking and packaging.
UkrTechnoFoods also provides automated lines for soft biscuit production, you can find additional information by contacting us