Perkenalan: Revolutionizing Biscuit Manufacturing
The global demand for high-quality biscuits is continuously on the rise, driven by consumer preference for convenient, delicious, and affordable snacks. To meet this growing demand while ensuring consistency, kebersihan, and efficiency, A fully automatic biscuit production line has become the gold standard in industrial food manufacturing.
This article presents a comprehensive overview of the modern biscuit production line, detailing the machinery involved, production flow, technical specifications, automation features, and business advantages for biscuit factories around the world.
1. What Is a Fully Automatic Biscuit Production Line?
A fully automatic biscuit production line is an integrated system of machinery designed to process raw ingredients into finished, packaged biscuits through automated operations. It eliminates the need for manual labor across various stages such as mixing, forming, pembakaran, pendinginan, and packaging.
From classic butter cookies to cream-filled sandwich biscuits, this production line accommodates a wide range of product types with high precision and minimal waste.
2. Key Components of a Biscuit Production Line
A professional biscuit production line consists of the following major equipment:
2.1 Dough Mixer
- Mixes flour, fat, water, gula, and additives into a uniform dough.
- Options: Horizontal mixer, vertical spiral mixer.
2.2 Dough Feeding Conveyor
- Transfers the dough to the forming machine.
- Speed-controlled with stainless steel construction.
2.3 Biscuit Forming Machine
- Types: Rotary moulder, rotary cutter, wire-cut, or extruder.
- Custom molds for different biscuit shapes and patterns.
2.4 Tunnel Baking Oven
- Heat source: Electric, gas, diesel, or infrared.
- Uniform baking with temperature zones for precise control.
2.5 Oil Sprayer (Optional)
- Applies oil or glaze for shine and flavor enhancement.
2.6 Biscuit Cooling Conveyor
- Reduces the temperature of baked biscuits before packaging.
- Ensures product firmness and prevents condensation.
2.7 Packaging Line
- Types: Horizontal flow wrapper, vertical form-fill-seal (VFFS).
- Features: Date coding, nitrogen flushing, label application.
3. Technical Specifications
| Parameter | Spesifikasi |
|---|---|
| Kapasitas produksi | 100 kg/h to 2000 kg/jam |
| Biscuit Types Supported | Hard biscuits, soft biscuits, sandwich, cookie |
| Oven Length | 20m–60m (dapat disesuaikan) |
| Heat Source | Electric / Gas / Diesel / LPG |
| Power Requirement | 50 kW – 200 kW (varies by configuration) |
| Operating Voltage | 380V/50Hz 3 Phase (dapat disesuaikan) |
| Control System | PLC + HMI (touch screen panel) |
| Bahan | Food-grade SUS304 stainless steel |
| Moulding Speed | Up to 25–40 molds/min (depending on type) |
| Packaging Speed | 20–120 packs/min |
4. Production Process Flow
Step 1: Dough Preparation
Ingredients are weighed and blended in the automatic mixer.
Step 2: Dough Conveying
The mixed dough is transferred to the forming system without human contact.
Step 3: Biscuit Forming
Biscuits are shaped using a rotary cutter or extruder, forming dough sheets or individual cookies.
Step 4: Baking
The shaped biscuits pass through a tunnel oven with multiple temperature zones.
Step 5: Pendinginan
The baked biscuits cool down uniformly via conveyor fans to maintain their shape and texture.
Step 6: Kemasan
Biscuits are aligned, counted, and packed into bags, trays, or cartons automatically.
5. Types of Biscuits Produced
A biscuit production line can manufacture various biscuit styles including:
| Biscuit Type | Keterangan |
|---|---|
| Hard Biscuits | Low sugar/fat, crispy texture (MISALNYA., Marie, Soda) |
| Soft Biscuits | High sugar/fat, soft texture (MISALNYA., Shortbread) |
| Cream Sandwich Biscuits | Two biscuits with cream filling |
| Cookies | Thick, chewy texture (often wire-cut formed) |
| Wafer Biscuits | Thin layers with cream filling |
6. Otomatisasi & Intelligent Features
- PLC Control Panel – Real-time monitoring and adjustment of parameters.
- Touch Screen HMI – User-friendly interface for recipe setting.
- Temperature Sensors – Multi-zone oven temperature regulation.
- Servo Motor Drive – For precision biscuit forming and alignment.
- Remote Maintenance (Optional) – Support via IoT cloud connection.
7. Advantages of a Fully Automatic Biscuit Production Line
✅ 1. Peningkatan efisiensi
Continuous, high-speed production with minimal downtime.
✅ 2. Consistent Product Quality
Accurate ingredient dosing, forming, and baking ensures every biscuit is uniform.
✅ 3. Labor Cost Reduction
Fully automated operation drastically cuts manual labor needs.
✅ 4. Kebersihan dan Keamanan
Closed processing with food-grade stainless steel equipment meets HACCP and GMP standards.
✅ 5. Energy Optimization
Modern ovens and conveyors are designed for energy efficiency.
8. Factory Layout Consideration
A biscuit factory must be designed based on:
- Kapasitas produksi
- Space for raw material and finished goods storage
- Ventilation and heat insulation zones
- Separate zones for dough, pembakaran, pendinginan, and packaging
- Power and water supply availability
A typical layout may range from 25 meters to over 100 meters in length depending on output and biscuit types.
9. Case Study: 1000 kg/h Biscuit Production Line
Client: Snack Manufacturer in Southeast Asia
Setup Highlights:
- 60-meter gas oven
- Dual rotary cutters for shape variation
- Nitrogen-filled horizontal packaging machine
- 24/7 operasi, three shifts
Outcome:
- Production increased 4×
- Waste reduced by 35%
- ROI achieved in 14 months
10. Common Buyer Questions (RFQ Section)
Q1: What is the minimum capacity available?
A: Our smallest biscuit production line starts at 100 kg/jam, ideal for small and medium-sized factories.
Q2: Can the production line handle different biscuit shapes?
A: Ya, molds can be quickly replaced to support various shapes and patterns.
Q3: Is operator training provided?
A: Ya, we provide on-site or remote training for your staff.
Q4: Can the line integrate with an existing plant?
A: Sangat. We customize layouts to match existing infrastructure.
Q5: How long is delivery time?
A: Standard delivery is 35–60 days depending on customization.
11. Maintenance and Support
- Preventive Maintenance Schedule
Regular checks on bearings, belts, motors, and sensors. - Spare Parts Availability
Fast global shipping for critical components. - Remote Diagnostics
Enabled via industrial routers and PLC diagnostics.
12. Pricing & Investment Return
| Kapasitas | Approximate Price (USD) |
|---|---|
| 100–200 kg/h | $35,000 - - $60,000 |
| 300–500 kg/h | $70,000 - - $120,000 |
| 800–1000 kg/h | $150,000 - - $220,000 |
| 1500 kg/h+ | $250,000 and above |
ROI Period: Typically 12 ke 24 months depending on scale and market conditions.
13. Market Trends & Future Outlook
- Rising demand for healthier biscuits (low sugar, gluten-free).
- Growing investments in smart factories Dan Industry 4.0.
- Increased export opportunities in Africa, the Middle East, and Latin America.
14. Kesimpulan: Build Your Biscuit Factory with Confidence
A fully automatic biscuit production line empowers food manufacturers to deliver high-quality products at scale with consistency, kebersihan, and flexibility. Whether you are starting a biscuit plant or upgrading your facility, investing in modern biscuit production technology is the cornerstone of long-term profitability.
Ready to take the next step? Contact us for a tailored proposal, layout design, and quotation.