With the continual rise of consumer demand for biscuits and cookies globally in terms of scale and different varieties, food manufacturers are being pressured to provide high-quality products at low costs and in more adaptable formats. Because of this, the use of specialized biscuit making machines has become a strategic necessity.
Manufacturers can scale production by automating key processes and can achieve consistent output, quality, and cost reductions. The role of well-known biscuit making machine manufacturers that collaborate with food producers to provide scalable solutions (not machines only) is equally important.
Let’s discuss how contemporary biscuit-making machines are becoming a key factor in increasing productivity.
Why Biscuit-Making Machines Matter for Productivity
1. Improving Throughput and Reducing Wastage
With an estimated global biscuit-making machinery market size of US $5.4 billion in 2024 and an approximate growth of US $8.2 billion by 2033, the market is expanding at a fast pace. This expansion indicates a basic fact: food-manufacturing processes investing in high-capacity equipment have the ability to scale more quickly and intelligently. For example, a rotary-cut line for hard dough biscuits can produce far better results as compared to older batch equipment, in terms of both hourly output and dough yield, and also requires less rework.
2. Consistency in Product Quality
Automated equipment guarantees correct portioning, consistent shaping, controlled bake times, and consistent cooling, all of which are important to contributing to consumer expectations and preventing scrap. An example of this is a soft-dough biscuit rotary moulding line, which allows quick changeovers and allows high tolerance control to reduce variation in weight, shape, and texture.
3. Labour and Hygiene Benefits
The food-manufacturing plants are becoming more demanding in terms of hygiene and fewer human contacts. Automated biscuit production lines minimise human intervention, risks of contamination and reduce the overall costs of labour. Also, machine uptime turns out to be a lever of productivity: reduced number of stoppages, repairs, and unexpected downtimes.
4. Adaptability and Responsiveness
Consumer preferences are changing faster than ever. They demand healthier biscuits, high-quality cookies, and that too by using responsible ingredients. Machines manufactured by established biscuit machine manufacturers like New Era are modular and flexible. As an example, the New Era’s cookie production line with wire-cut and deposited cookies can be re-configured to handle new recipes or seasonal production with minimum downtime.
What to Look for in Biscuit Making Machines
Whether you are upgrading or designing a new line, consider these main features for analysing machines:
End-to-end automation and control: Find systems incorporating mixing, sheeting/rolling, moulding, cutting, baking, cooling, and packaging. Biscuit making machines are said to automate the mixing, forming, and baking to increase the capacity significantly.
Precision dough handling: Consistent thickness, regular moulding or extrusion, low amount of waste on scrap pieces is equal to increased yield. In bakery engineering, technologies like the dough sheeting and gauge rollers are tested.
Efficient baking and heat exchange: The essence of efficient baking lies in the baking oven, zones, temperature, conveyor belt design, all influence texture, colour, and throughput. The steam-tight tunnel of the biscuit baking oven makes the whole process efficient.
Energy, hygiene, and maintenance: The total cost of ownership is improved by the stainless-steel body of the oven, ease of cleaning, automation to regulate lubrication, and energy-saving (heat recovery, insulation) methods.
Support from biscuit making machine manufacturers: The machine is just a part of the solution. The difference is made by suppliers who provide turnkey solutions, service, spare parts, training, and global support. NEM is an example, and it is a reputable biscuit making machine manufacturer with 60+ years of experience and turnkey biscuit line solutions.
Key Production Lines for Productivity Gains
To explain how biscuit making machines can be used to enhance productivity practically, the following are the key production lines (of one respected equipment supplier) used in the food-manufacturing environment:
#1 Hard Dough Biscuits Manufacturing Line
Hard dough biscuits have a rotary cut line that provides continuous operation, maximum throughput, and low rework. Handling tough doughs, coating, and ensuring product integrity can be done at high speed by manufacturers. A mid-sized factory could be able to relocate to such a line and become entirely automatic with a throughput of 1,000+ kg/hr instead of manual or semi-automated with a throughput of 300 kg/hr, yielding better and at less labour intensity.
#2 Soft Dough Biscuits Production Line
A rotary-moulding line enables biscuit manufacturers in the soft-dough segment to develop more types of biscuits that are softer, lighter, and provide a higher margin. The change to this configuration allows the quick switching of products (in case of seasonal flavours), enhanced homogeneity, and responsiveness to market demands without significant downtimes.
#3 Cookies Production Line (Wire-cut / Deposited / Extruded)
With cookies, which usually come in more elaborate shapes, toppings, and fillings, a flexible wire cut/deposited/extruded products line is required. This allows manufacturers to introduce new SKUs in a new price line within hours, tailor packaging batches, and cater to high-end snack market needs. This is especially applicable to the food-manufacturing businesses interested in expanding to value-added products, and not only the simple biscuits.
#4 Other Bakery Products Production Line
In addition to regular biscuits, most food manufacturers are looking to venture into related bakery products (crackers, snack biscuits, savoury lines). The fact that a production line is created with the intention of producing other bakery products provides the flexibility to diversify, utilising the same footprint, controls, and hygiene regimes.
Looking for a biscuit making machine manufacturer offering all of these production lines?
New Era is here to help.
Check out their biscuit production lines and boost the productivity of your business.
A major differentiator in food manufacturing is productivity. The manufacturers should expect a step-change improvement in performance by investing in high-speed, flexible, quality, and cost-effective biscuit making machines. It is also of equal significance to select a stable, internationally proven manufacturer of high-end biscuit making machines. At New Era, we have decades of experience coupled with creative engineering and turnkey solutions to make manufacturers achieve their productivity goals.
FAQs1. What are some of the types of biscuits that can be manufactured using biscuit making machines?
They are able to make hard, soft cookies, crackers, and specialty biscuits of different textures and shapes. The production capacities are normally 100kg/hr to 5000kg/hr.
2. To what extent will we be able to increase our productivity by improving our biscuit production machines?The modern automated lines are able to increase throughput, waste reduction, and minimization of energy consumption by 50 percent, as recorded in the projects of the New Era Machines.
3. What contribution do the manufacturers of the biscuit-making machine make besides the supply of the equipment?New Era Machines, among other manufacturers, offer turnkey solutions such as designing, installation, training, and support, which makes sure that there is smooth operation and quick market availability.