Введение: 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, гигиена, и эффективность, а 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, Технические спецификации, automation features, and business advantages for biscuit factories around the world.
1. What Is a Fully Automatic Biscuit Production Line?
А 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, выпечка, охлаждение, и упаковка.
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 Тесто миксер
- Mixes flour, fat, вода, сахар, 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
- Типы: Rotary moulder, rotary cutter, wire-cut, or extruder.
- Custom molds for different biscuit shapes and patterns.
2.4 Tunnel Baking Oven
- Heat source: Электрический, gas, дизель, or infrared.
- Uniform baking with temperature zones for precise control.
2.5 Oil Sprayer (Необязательный)
- 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
- Типы: Horizontal flow wrapper, vertical form-fill-seal (VFFS).
- Функции: Date coding, nitrogen flushing, label application.
3. Technical Specifications
| Параметр | Спецификация |
|---|---|
| Производственные мощности | 100 кг/ч до 2000 кг/ч |
| Biscuit Types Supported | Hard biscuits, soft biscuits, sandwich, печенье |
| Oven Length | 20m–60m (настраиваемый) |
| Heat Source | Электрический / Газ / Diesel / LPG |
| Power Requirement | 50 kW – 200 кВт (varies by configuration) |
| Operating Voltage | 380V/50 Гц 3 Phase (настраиваемый) |
| Система управления | ПЛК + HMI (touch screen panel) |
| Материал | Food-grade SUS304 stainless steel |
| Moulding Speed | Up to 25–40 molds/min (depending on type) |
| Скорость упаковки | 20–120 packs/min |
4. Production Process Flow
Шаг 1: Dough Preparation
Ingredients are weighed and blended in the automatic mixer.
Шаг 2: Dough Conveying
The mixed dough is transferred to the forming system without human contact.
Шаг 3: Biscuit Forming
Biscuits are shaped using a rotary cutter or extruder, forming dough sheets or individual cookies.
Шаг 4: Baking
The shaped biscuits pass through a tunnel oven with multiple temperature zones.
Шаг 5: Охлаждение
The baked biscuits cool down uniformly via conveyor fans to maintain their shape and texture.
Шаг 6: Упаковка
Biscuits are aligned, counted, and packed into bags, trays, or cartons automatically.
5. Types of Biscuits Produced
А biscuit production line can manufacture various biscuit styles including:
| Biscuit Type | Описание |
|---|---|
| Hard Biscuits | Low sugar/fat, crispy texture (например, Marie, Soda) |
| Soft Biscuits | High sugar/fat, soft texture (например, 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. Автоматизация & 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 (Необязательный) – Support via IoT cloud connection.
7. Advantages of a Fully Automatic Biscuit Production Line
✅ 1. Повышенная эффективность
Непрерывный, 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. Гигиена и безопасность
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:
- Производственная мощность
- Space for raw material and finished goods storage
- Ventilation and heat insulation zones
- Separate zones for dough, выпечка, охлаждение, и упаковка
- 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. Тематическое исследование: 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 операция, three shifts
Outcome:
- Production increased 4×
- Waste reduced by 35%
- ROI achieved in 14 месяцы
10. Common Buyer Questions (RFQ Section)
Q1: What is the minimum capacity available?
А: Our smallest biscuit production line starts at 100 кг/ч, ideal for small and medium-sized factories.
Q2: Can the production line handle different biscuit shapes?
А: Да, molds can be quickly replaced to support various shapes and patterns.
Q3: Is operator training provided?
А: Да, we provide on-site or remote training for your staff.
Q4: Can the line integrate with an existing plant?
А: Абсолютно. We customize layouts to match existing infrastructure.
Q5: How long is delivery time?
А: Standard delivery is 35–60 days depending on customization.
11. Maintenance and Support
- Preventive Maintenance Schedule
Regular checks on bearings, belts, motors, and sensors. - Доступность запасных частей
Fast global shipping for critical components. - Remote Diagnostics
Enabled via industrial routers and PLC diagnostics.
12. Pricing & Investment Return
| Емкость | Approximate Price (доллар США) |
|---|---|
| 100–200 кг/ч | $35,000 - $60,000 |
| 300–500 кг/ч | $70,000 - $120,000 |
| 800–1000 кг/ч | $150,000 - $220,000 |
| 1500 kg/h+ | $250,000 and above |
ROI Period: Обычно 12 к 24 months depending on scale and market conditions.
13. Рыночные тенденции & Future Outlook
- Rising demand for healthier biscuits (low sugar, gluten-free).
- Growing investments in smart factories и Industry 4.0.
- Increased export opportunities in Africa, the Middle East, and Latin America.
14. Заключение: Build Your Biscuit Factory with Confidence
A fully automatic biscuit production line empowers food manufacturers to deliver high-quality products at scale with consistency, гигиена, 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.