Introduction to small biscuit production line:
The DTS225 roller-cutting automatic biscuit production line is developed by our company by digesting and absorbing Japanese technology. The equipment has novel design, compact structure and high degree of automation. It is fully automatic from feeding and calendering, forming, waste recycling, drying, oil injection and cooling. Completed at one time, our company provides users with hundreds of molds and dozens of process formulas. By changing the molds and process formulas, various high-end biscuits popular in the market can be produced, such as cream biscuits, sandwich biscuits, ultra-thin biscuits, and soda biscuits. Crackers, animal crackers, multi-dimensional crackers, vegetable crackers, etc.
Process composition:
1. Dough mixer
2. Molding host
3. Control cabinet
4. Oven
5. Fuel injection machine
6. Cooling machine
Production line technical parameters
Parameters/Model | Small biscuit production line |
voltage | 380V/50HZ |
Total installed capacity | 28.5KW |
impression roller | Φ205×205mm |
Baking temperature | 200-300℃ |
working width | 200mm |
production capacity | 50Kg/h |
Production line size | 18×0.6×1.5m |
Production line technical parameters
model | 225 | 280 | 400 | 600 | 1000 |
Total installed capacity(kw) | 28.5 | 56 | 120 | 200 | 300 |
Baking temperature(℃) | 200-300 | 200-300 | 200-300 | 200-300 | 200-300 |
production capacity(kg/h) | 50 | 100 | 200 | 500 | 1000 |
Dimensions(L×W×H)(mm) | 18000×600×1500 | 28000×800×1500 | 48000×1000×1500 | 76000×1200×1750 | 103000×1850×2450 |
1. The structure of the machine is composed of:
It consists of dough mixer - molding host - oven - fuel injection machine - cooling belt.
2. Machine process flow:
Preprocessing of raw materials - dough preparation - rolling dough - pressing into cake embryo - baking - oil spraying - cooling - packaging.
3. Relevant knowledge:
The main raw material of biscuits is flour, in addition to sugar, starch, oil, dairy products, eggs, flavors, leavening agents and other auxiliary materials. The above-mentioned raw materials and auxiliary materials are mixed into dough through a dough mixer, then rolled into dough sheets through a rolling machine, pressed into biscuit blanks through a forming machine, baked in an oven, and cooled to become crisp and delicious biscuits. Sweet biscuits can be divided into two categories, namely tough biscuits and crisp biscuits. Whether it is tough biscuits or crispy biscuits, although the formula, feeding sequence and operation method are different, the basic process flow is similar.
(1) Pretreatment of raw materials
1. Pretreatment of flour:
To produce tough biscuits, it is appropriate to use flour with a wet gluten content of 24-36%; to produce crispy biscuits, it is appropriate to use flour with a wet gluten content of 24-30%.
Currently, it must be sieved before use. The purpose of sifting is not only to form small particles of flour and remove impurities, but also to mix a certain amount of air into the flour, which is conducive to the proliferation of yeast when fermenting the dough, and the biscuits made are crisper. Magnets need to be added to the screening device to remove magnetic impurities. The humidity of flour should be adjusted according to the season.
2. Pretreatment of sugars:
Generally, granulated sugar is ground into powdered sugar or dissolved into syrup.
In order to remove impurities and ensure fineness, the ground sugar powder must be sieved. Generally, a 100-hole/25.4mm sieve is used. If the powdered sugar is ground in the workshop itself, the temperature after crushing will be high and should be cooled before use to avoid affecting the temperature of the dough.
Dissolve the sugar into syrup. The amount of water added is generally 30-40% of the sugar. When heating and melting, control the temperature and stir frequently to prevent scorching and fully dissolve the sugar. Boil to dissolve, filter, and cool before use.
3. Pretreatment of grease:
Ordinary liquid vegetable oil, lard, etc. can be used directly. Butter, margarine, hydrogenated oil, coconut oil and other fats have higher hardness at low temperatures. They can be heated over a slow fire or stirred with a blender to soften them before use. This can speed up the mixing speed and make the dough more uniform.
When heating and softening grease, the temperature must be controlled and it should not be completely melted. Otherwise, its milky structure will be destroyed, the quality of the finished product will be reduced, and the biscuits will "leak out". Whether cooling is required after heating and softening should be determined based on the temperature of the dough.
4. Pretreatment of dairy products and eggs:
When using fresh eggs, they must be inspected, washed, disinfected and dried. When beating eggs, be careful to remove the bad eggs and eggshells. When using ice eggs, place the ice egg box on the sink to allow the ice eggs to melt before use. Milk needs to be filtered. Put milk powder and egg powder in oil or water and stir evenly before use.
5. Pretreatment of leavening agent and salt:
The leavening agent and salt must be mixed evenly with the flour. The leavening agent used in biscuit production, such as baking soda, ammonium bicarbonate and salt and other water-soluble raw materials and auxiliary materials, must first be sieved before being dissolved in water. If there are any hard lumps It should be crushed and sieved to form small particles that can be dissolved in cold water. Do not dissolve it in hot water to prevent the chemical leavening agent from being heated and decomposing part or most of the carbonic acid gas, reducing the leavening effect.
(2) Preparation of dough:
Dough preparation is a key process in biscuit production. Whether the dough is properly prepared or not is not only related to the normal operation of the machinery, but also is the dividing line between the quality of tough biscuits and crisp biscuits. The production processes of crisp biscuits and tough biscuits are different, and the methods of preparing dough are also quite different. The crispy dough of crisp biscuits adopts the cold powder crisping operation method, and the tough dough of tough biscuits adopts the hot powder toughening operation method.
1. Hot powder toughness operation method:
Dough temperature 38-40°C. Generally, oil, sugar, milk, eggs and other auxiliary ingredients are first mixed with heated water or hot syrup in a dough mixer, and then flour is added to prepare the dough. If an improver is used, it should be added when the dough is initially formed (about 10 minutes after preparation). Then add leavening agent and flavor successively during the preparation process. Continue to prepare the dough for about 40 minutes or more to form a tough dough. After the tough dough is prepared and matured, in order to reduce the viscosity and elasticity of the bread and maintain stable dough properties, it must be left for more than 10 minutes before rolling.
2. Cold powder crispy operation method:
First, pour sugar, oil, dairy products, eggs, leavening agents and other auxiliary ingredients and an appropriate amount of water into the dough mixer, stir evenly to form an emulsion, then pour flour and starch into the dough mixer, and prepare for 6-12 minutes. The essence should be added at a later stage when the emulsion is prepared, or when the flour is put in, to avoid excessive evaporation of the fragrance. Due to higher temperatures in summer, the mixing time can be shortened by 2-3 minutes.
The dough temperature should be controlled at around 22-28°C. For dough with high fat content, the temperature should be controlled at 20-25°C. When the temperature is high in summer, the dough can be prepared with cold water to lower the temperature of the dough. If the wet gluten content in the flour is higher than 40%, the fat and flour can be mixed into a pastry-style dough, and then other auxiliary ingredients can be added, or part of the flour can be removed from the formula and the same amount of starch can be added.
(3) Rolling
The prepared dough should be rolled into dough sheets with uniform thickness, smooth shape, smooth surface and fine texture to prepare for shaping.
1. Rolling of tough dough
The tough dough needs to rest for a period of time before rolling. The purpose is to eliminate the internal tension formed by stretching the dough during mixing, reduce the viscosity and elasticity of the dough, and improve the technological performance of gluten and the quality of the product. The length of resting time depends on the temperature of the dough. Generally, the dough temperature is high and the resting time is short; the temperature is low and the resting time is long. If the dough temperature reaches 40°C, it should be left to rest for approximately 10-20 minutes.
The number of rolling times of tough dough is generally 9-13 times. During rolling, it is folded and rotated 90° multiple times. The dough is rolled and pressed into a certain thickness.
2. Rolling of crispy dough:
Crispy dough contains a lot of oil and sugar, and the rolled dough is soft and easy to break, so it should not be rolled multiple times, let alone 90° turns. Generally, 3-7 times of one-way reciprocating rolling is enough. Depending on the specific situation, one-way rolling can also be used.
Crisp dough does not need to rest for a long time before rolling. The thickness of the rolled dough is about 2cm, which is thicker than the dough of tough dough. This is because the crispy dough is easy to break and is relatively soft. It can reach the thickness required for molding after passing through the rollers of the molding machine.
(4) Forming
The dough sheets rolled in the rolling process are made into biscuit blanks of various shapes by the forming machine.
(5) Baking
Tough biscuits should be baked at a lower temperature and for a longer time. After the prepared biscuits are put into the oven, under the action of high temperature, the water contained in the biscuits evaporates, the starch is gelatinized by heat, and the leavening agent decomposes to increase the volume of the biscuits. Proteins are denatured by heat and coagulated. Form a porous and crisp biscuit product.
Baking temperature and time vary with cookie variety and block size. Generally, the baking temperature is kept at around 230-270℃ and should not exceed 290℃. If the temperature of the baking oven is higher, the baking time can be shortened appropriately. If the oven temperature is too high or too low, it will affect the quality of the finished product. If it is too high, it will easily burn, and if it is too low, the finished product will be undercooked and white in color.
(6) Cooling
The temperature difference between the surface layer and the center of the baked biscuit is very large. The outer temperature is high, the inner temperature is low, and the temperature dissipates slowly. In order to prevent the biscuits from shrinking and cracking, they must be cooled before packaging. In summer, autumn and spring, natural cooling method can be used. To speed up cooling, blowers can be used, but the air flow rate cannot exceed 2.5 meters/second. If the air flow rate is too fast, the water will evaporate too quickly and the biscuits will break easily. The suitable cooling temperature is 30-40℃, and the indoor relative humidity is 70-80%.
(7) Packaging
Packaging materials: tinplate, cardboard, polyethylene plastic bags, wax paper, etc., 500g, 250g.
It should be pointed out that although biscuits are a food that is shelf-stable, storage conditions must also be considered. The suitable storage conditions for biscuits are low temperature, dryness, air circulation, clean air, and avoidance of sunlight. The storage temperature should be around 20°C, and the relative humidity should not exceed 70-75%.
(8) Biscuit pictures:
The uses and characteristics of multifunctional biscuit production line
The biscuit production line has a novel design, compact structure and high degree of automation. From feeding to calendering, molding, waste recycling, drying, oil injection and cooling, it is fully automated and completed in one go. By changing the mold and process formula, various high-end biscuits popular on the market can be produced, such as cream biscuits, sandwich biscuits, soda biscuits, animal biscuits, vegetable biscuits, etc.
