We often get amazed when we hear how so much different process and steps are involved in making a simple looking thing. The same is true for Biscuits. A lot of different factors get involved in biscuit making in a large scale. Even a tiniest looking thing will result into defective biscuits.
Biscuit manufacturing can be divided into various sections broadly as pre baking and post baking.
First comes the premixing section where all the ingredients get mixed together and poured in the mixer. Here at this stage what really matters is the type of ingredient, its order of mixing, quantity and temperature. Each ingredient has its own importance and action. The variables among the ingredients are water and ammonium bicarbonate (ABC). Where water is used for dough making, ABC is used to increase height of biscuits.
Second step starts with dough formation known as mixing stage. Here first creaming is performed in this process all the liquid materials are poured and mixed with sugar to make an evenly mixed liquid, then flour is poured and mixed with the creamed contents the more you mix the harder the dough becomes, less mixing results in short dough. Generally, all cookies are short dough biscuits were as crackers are of hard dough fermented type. After mixing dough with the creamed ingredients dough is formed which is fed to the moulder.
Moulding is the third step in biscuit manufacturing it is a very critical place in terms of biscuit finishing and weight. As a manufacturer point of view large weight results in losses in terms of extra weight given to the buyer. This extra weight which gets packed so as to maintain the written weight is known as giveaway. In a moulder there is a knife placed in between a forcing roller and a die. There are two controls present 1st knife control in all four directions up down forward and back, and press control in both left and right side of the roller.
Post moulding comes baking. We are generally confused weather biscuits are fried or baked? The reality is biscuits are always baked. Baking consists of a number of chambers known as zone each zone is an independent oven with its own temperature setting. The large the plant capacity larger will be the number of zones. Biscuit travels in a mild steel continental wire mesh inside the oven. Raising, puffing and colouring occurs in a sequence with overlapped boundaries inside an oven. Finally, after the oven what is needs to be checked is weather the biscuit is fully baked, even texture, required height, and colour. Biscuit needs to be golden brown to dark chocolaty depending upon the variety.
Post baking sandwiching is done for cream biscuits whereas other varieties are sent to packing after passing through a cooling tunnel/conveyor.
Sandwiching is the process in which a layer of cream is poured between two biscuits and a delicious cream biscuit is produced. Bourbon is one such sandwich biscuit with a large acceptance.
In packing there are various types of machines which pack the biscuits according to the pack weight i.e 50g, 100g, 150g etc. and then after complete packing in corrugated fiber carton (CFC) they are sent for loading in trucks. Then only they get supplied to your nearest shop or malls.
so what do you think???