Factory production of biscuits involves a series of carefully controlled steps to ensure consistent quality, taste and texture. Here is an overview of the process:
1. Ingredient preparation
High-quality raw materials such as flour, water, salt, oil and leavening agents are carefully selected and measured. These ingredients are essential in determining the final taste, texture and shelf life of the biscuits.
2.Dough Formation through Mixing
To create a uniform dough, the ingredients are combined in large industrial mixers. This mixing step is crucial for developing the gluten structure, which impacts the dough's flexibility and texture. Achieving the desired consistency relies on carefully managing the mixing time and speed.
3.Resting the Dough
Following the mixing process, the dough typically undergoes a resting period. This stage allows the gluten to relax, making the dough more malleable and easier to work with during the shaping phase. Additionally, resting activates any chemical leavening agents, contributing to a lighter texture in the final biscuits.
4. Sheeting and cutting
The rested dough is then sheeted using a series of rollers. The thickness of the dough sheet is carefully controlled to ensure uniformity. Once the dough reaches the desired thickness, it is cut into the desired biscuit shapes using a rotary cutter or punch press.
5. Baking
The cut dough pieces are transferred to the oven for baking. The temperature and duration of the baking process are carefully controlled to ensure that the cookies achieve the right crispness and color. The heat drives off moisture, sets the texture, and develops the cookies' characteristic flavor.
6. Cooling and Drying
After baking, the cookies are cooled on a conveyor belt to stabilize them. This step is important to prevent the cookies from cracking or becoming soggy as they cool.
7. Seasoning (optional)
For seasoned cookies, seasoning is usually applied immediately after baking while the cookies are still hot. This ensures that the seasoning adheres well to the surface of the cookies.
8. Packaging
Finally, the cooled cookies are packaged in individual or bulk packages. The packaging material is designed to protect the cookies from moisture, air, and physical damage, ensuring that the cookies remain fresh and crisp until they reach the consumer.
9. Quality Control
Throughout the production process, quality control checks are performed to ensure consistency in taste, texture, and appearance. Samples are tested regularly to ensure compliance with the factory's standards and regulatory requirements.
This streamlined process allows the factory to efficiently produce large quantities of cookies while maintaining high quality and consistency standards.