In recent years, the global biscuit market has continued to grow, and consumers' demand for product diversification has become increasingly significant.
Hard biscuits are known for their crispness and storage resistance, while soft biscuits are favored for their moist taste and rich flavor. For food manufacturers, can they produce two products at the same time through a mixed production line, saving costs and responding quickly to market demand? This article will explore the feasibility of this solution in depth.
According to Nielsen's 2023 data, the annual growth rate of the soft biscuit category reached 12%, while hard biscuits still maintained a steady growth of 6%.
Single production lines need to frequently switch product types, resulting in increased downtime. Mixed production lines can flexibly adjust production capacity ratios to meet dynamic needs such as holiday promotions and regional customization.
Universal pretreatment: The basic ratio of raw materials for hard and soft biscuits is similar, and compatibility can be achieved through a modular feeding system. Different ingredients) can be accurately added through independent pipelines.
Dough forming technology: Using forming equipment with adjustable calendering rollers and molds, hard biscuits obtain a compact structure through high-pressure calendering, while soft biscuits retain a fluffy texture through low pressure.
Building two independent production lines: equipment procurement, plant space and labor costs increase by about 40%-60%.
The mixed production line can save more than 30% of initial investment through equipment reuse.
Energy consumption reduction: The segmented baking design reduces energy consumption by 15%-20% compared with independent double lines.
Human resource optimization: unified operator training and reduced job redundancy.
Cross-contamination risk
Countermeasures: Design cleaning modules (such as automatic CIP systems) to quickly clean up residual raw materials when switching products; plan production schedules and centralize the production of similar products.
Complexity of process parameter debugging
Countermeasures: Introduce digital control systems (such as MES), preset process templates for hard/soft biscuits, and switch parameters with one click.
Market demand fluctuations
Countermeasures: Establish a dynamic inventory model, adjust the production ratio based on real-time sales data, and avoid unsalable products.
The mixed production line of hard biscuits and soft biscuits is not a simple equipment superposition, but a strategic upgrade achieved through technological innovation and process optimization. For companies pursuing efficiency and diversity, this solution is not only feasible, but may also become the key to seize market opportunities. In the fiercely competitive food industry, only "flexibility" and "efficiency" coexist to be invincible.
Consult industry experts now to get your customized mixed production plan!
