Have you ever wondered how biscuits are made step by step? The factory process is an automated process that combines precision, technology and craftsmanship to create the delicious taste we all love. Let’s take this factory tour of biscuit making!
Step 1: Ingredients Preparation
Exceptional flour serves as the backbone of any biscuit, establishing its fundamental structure and flavor foundation. Sugar infuses the dough with essential sweetness. Fats, whether butter or vegetable oil, introduce a delicious fattiness and satisfying crunch. Meanwhile, leavening agents like baking powder or baking soda enable the dough to expand and rise when exposed to heat, resulting in a delightful light and airy bite.
Salt enhances the flavor, and various spices, such as vanilla, cocoa or fruit essences, give the biscuits their unique taste. These ingredients are stored in large containers and are precisely weighed according to specific recipes.
Step 2: Dough Mixing
Next, the ingredients are transported to a mixing area. Here, they are thoroughly mixed by large industrial mixers. The mixing process is strictly controlled in time and speed to achieve the perfect dough texture.
Under-mixing will make the dough uneven, while over-mixing will make the dough too compact. The result is a smooth and soft dough, ready for the next stage.
Step 3: Biscuit Forming
One common forming method is extrusion, where the dough is squeezed through a special nozzle to form a round, square or other interesting shape. Another method is roller stamping and roller cutting.
The dough is flattened into thin slabs and then shaped using biscuit molds. In the case of filled biscuits, the process involves splitting the dough into two portions – a lower layer and an upper layer. The lower layer is shaped first, after which fillings like fruit preserves, whipped cream, or chocolate are applied. Finally, the upper layer is positioned on top to complete the assembly.
Step 4: Biscuit Baking
The shaped dough is sent to the oven. The factory’s ovens are very large and highly controlled. The temperature and baking time depend on the type of biscuit, but are generally between 180°C and 200°C, with a baking time of 8 to 15 minutes.
As the heat is transferred, the dough expands and the sugars caramelize, gradually transforming into golden, crispy biscuits. The factory’s conveyor ovens slowly move the biscuits forward, ensuring that each side is evenly heated.
Step 5: Biscuit Cooling and Decorating
After emerging from the oven, freshly baked biscuits are delicate and warm, requiring a cooling period before any further handling. They travel along a cooling rack or conveyor belt, where exposure to ambient air allows them to reach a stable temperature. This cooling phase is essential not only to prevent structural damage like cracking but also to optimize their shelf life by removing excess moisture.
Once cooled, the biscuits may undergo a final decorative touch. Options include being coated in chocolate, drizzled with icing, sprinkled with decorative bits, or dusted with powdered sugar. Advanced automated systems handle these processes with precision, ensuring each biscuit receives a uniform and aesthetically pleasing finish.
Step 6: Biscuit Packaging
The final step is packaging. The cooled and decorated biscuits are collected and sorted. They are then packed individually or in batches into larger packages. Modern packaging machines are extremely fast and efficient.
The packaging material is designed to protect the biscuits from damage, moisture and air, preventing them from spoiling. The packages are also attractively labeled with nutritional information, brand logos and barcodes for retail sales.
How biscuits are made step by step? The above steps are the main steps of making biscuits in the factory. The whole process from raw material preparation to biscuit packaging is operated by professional machinery. The whole process is more automated and more efficient. If you want to start this business, feel free to contact us.