Last Updated on January 8, 2024 by Umer Malik

In the world of snack manufacturing, biscuits, crackers, and cookies are beloved treats enjoyed by people of all ages. Behind every delicious bite, there’s a complex web of machinery working tirelessly to create these delectable snacks. However, like any advanced equipment, biscuits, crackers, or cookie production lines are not immune to routine issues that can disrupt production. In this blog, we will look into some common problems faced in the production process and the preventive measures that you can take to keep your manufacturing line running smoothly.

Without further ado, let’s take a deeper look into the most common issues of biscuit machinery and their preventive measures:

1. Dough Consistency Issues

One of the fundamental challenges in biscuit and cookie production is achieving the perfect dough consistency. Dough that is too dry or too wet can lead to various issues, including irregular shapes and sizes, uneven baking, and even machine jamming.

 Preventive Measures:

  • Routine Maintenance: Regularly check and calibrate the dough mixer to ensure consistent water levels.
  • Quality Control: Implement a rigorous quality control process to monitor dough consistency at different stages of production.
  • Recipe Optimization: Work closely with food specialists to fine-tune your recipes for consistent dough texture.

2. Uneven Baking

Achieving uniform baking is essential for producing high-quality biscuits, crackers, or cookies. Uneven baking can result in products with inconsistent texture, taste, and appearance.

Preventive Measures:

  • Temperature Control: Maintain precise temperature control throughout the baking process with regular maintenance and calibration of ovens and heating elements via the HMI Panel.
  • Belt Alignment: Ensure that conveyor belts are properly aligned to guarantee even exposure to heat.
  • Rotation and Timing: Regularly inspect and adjust the rotation and timing mechanisms to promote even baking.

3. Jamming and Clogging

Biscuit machinery jamming and clogging are common issues that can disrupt the biscuit production line, leading to downtime and increased maintenance costs.

Preventive Measures:

  • Regular Cleaning: Implement a strict cleaning schedule to prevent the build-up of dough or batter residues.
  • Lubrication: Keep all moving parts well-lubricated to minimize friction-related issues.
  • Employee Training: Train your staff to identify early signs of jamming and take corrective action promptly.

4. Inconsistent Product Weight

Inconsistent product weight can result in packaging issues and customer dissatisfaction. This problem often arises due to variations in dough thickness or improperly calibrated cutting and moulding equipment.

Preventive Measures:

  • Equipment Calibration: Regularly calibrate cutting and moulding equipment to ensure consistent product weights.
  • Quality Assurance: Implement weight checks at different stages of production to catch discrepancies early.
  • Operator Training: Train biscuit machinery operators to monitor product weight and make necessary adjustments.

5. Packaging Problems

Packaging is the final step in the biscuit or cookie manufacturing process, and issues at this stage can result in wasted products and increased costs. Common problems include misaligned packaging, damaged goods, and seal failures.
Preventive Measures:

  • Quality Assurance: Implement strict quality control measures to catch packaging issues before they leave the production line.
  • Operator Training: Ensure that packaging operators are well-trained in the correct procedures for loading and sealing packages.
  • Regular Maintenance: Maintain packaging machinery to prevent malfunctions that can lead to packaging problems.

Important Closing Recommendations

In the world of biscuits, crackers, and cookie manufacturing, routine issues can disrupt production and compromise product quality. However, with proactive preventive measures, these issues can be minimized or even eliminated. Regular maintenance, employee training, quality control, and process optimisation are all key components of a successful preventive maintenance program & keeping your biscuit machinery healthy.
By investing in the health and reliability of your production lines and educating your workforce on best practices, you can ensure that your biscuit, cracker, or cookie production line runs smoothly, efficiently, and consistently. For best results and perfectly baked biscuits, crackers & cookies with machines that have minimum downtime, switch to New Era Machines, masters of biscuits production lines since 1965. Their turnkey equipment can meet your needs in a reliable, effective & consistent manner with utmost efficiency. Give them a try & bake your success story.