Food Industry

Flour Shifter
Flour for making biscuit dough normally contains impurities. The commercially available wheat flour has to be refined before making biscuit dough. The quality of wheat flour is judged by its sew size. The recommended size of the sew is 180 microns.

Flour shifter used in biscuit making plant is provided in order to get quality flour. The flour is processed in this unit before making biscuit dough. This unit is consisting of AC induction motor , flywheel and wire mesh . The wire mesh is made out of stainless steel. The wire mesh should be cleaned after regular interval.

Sugar Grinder
Sugar grinder is used for making sugar powder and to grind waste biscuits. The sugar has to be grind before making sugar syrup. The quality of the sugar has to be controlled for getting proper colour for the biscuit. The sugar has to be grounded very fine before adding to the syrup mixer and to the dough.

Syrup Mixer
The syrup mixer unit is consisting of AC induction motor with DOL starter, stirrer motor and electric heater with thermostat. In this unit the sugar powder will be converted in to syrup form to easily mix with biscuit dough. The temperature and water quantity to be controlled to get required quality of sugar syrup.

Biscuit Dough Mixer
The unit is having AC induction motor with gear box to drive sigma blade and another motor for tilting the unit to take out the dough. The unit is having DOL starter for both the motor.

The unit is provided for making biscuit dough. The dough is produced from the ingredients like flour, water, sugar syrup, fat, flavour and salt. The ingredients varies depends upon the biscuits to be manufactured.

Laminator Unit
Laminator unit is produces dough sheets from biscuit dough by means of two roller unit. These units have laminator machine and sliding machine. Unless preceded by a Die Unit, the laminator unit is the first machine in Biscuit plant.

Laminator
Two gauging unit with two sets of Roller for each machine. The roller is coupled with AC induction motor with gear box. The motor will rotate both the roller by means of common chain coupled. The motor is controlled by AC frequency control unit installed in the remote control panel. The Roller is made out of M.S pipe, plated with hard crome.

There are two handles for adjusting the gap between the rollers. The rollers are supported with ball bearing on either side to reduce load on the motor. To feed bulk dough to the rollers, hopper (loading tray) is provided on the top of the roller. Dough should move by its own weight towards the rollers and it should not be pressed manually. For this, the dough should be soft enough to go into the roller gap. Depends upon the Quality of the biscuits to be produced, the roller gap has to be adjusted. The biscuit dough will be converted into continuous compact dough sheet from the compressed roller gap.

Sliding Unit
It consists of AC induction motor, and gear box with automatic forward and reverse starter control. The motor is controlled by AC frequency control unit. The automatic forward and reverse movement is achieved by means of limit switches mounted in the unit corners. Two numbers for forward motion and two numbers for reverse movement. The control unit is housed below slider supporting channel. The slider is made out of angle iron frame and covered with stainless steel sheet to provide smooth surface for the dough sheet. The slider is covered with canvas conveyor to move dough sheet to the gauging unit no. 1.

Three Stage Gauging Unit
This unit consists of conveyor, roller top and bottom, and AC induction Motor. The motor is controlled by the AC frequency converter installed in the AC drive panel. Each stage will have individual canvas conveyor to shift Dough sheet from one gauging unit to another. The conveyor and roller, top and bottom, is driven by common motor, which is coupled with gearbox. The canvas conveyor to be aligned properly with roller, so that dough sheet can pass through roller to the next conveyor without any problem.

The bottom roller is coupled with motor by means of ¾ inch MS double chain. The other end of the bottom roller has gear arrangement and it is coupled with top roller gear. This is to change the direction of rotation of top roller. These alignment should be done very carefully in order to avoid any damage to the roller gear and to the roller. The top and bottom roller is MS hard crome plated. After installing the laminator unit, the gauging section to be installed and aligned for free flow of the dough sheet from one stage to other.

Rotary Moulding Unit
This unit consists of die roller, bottom roller and canvas conveyor. In this unit the conveyor is driven by motor coupled with gearbox. The bottom roller is made out of MS and surface is covered with hard rubber liner. The surface is smooth and aligned properly with die unit.

The die unit rotates along with conveyor. Bottom roller and die unit gap adjustment is carried out by means of hand wheel provided in front side. The canvas tension can be adjusted by means of the conveyor roller by rotating hand wheel. This is to be carried out to maintain free movement of dough sheet into die. Die unit roller should be adjusted in order to get required contact pressure between conveyor and the die.

Biscuit Gap Adjuster
This unit is provided for adjusting the gap between the biscuits coming from die unit. The distance between biscuits have to be maintained uniformly before entering into oven. It is important to maintain the gap in order to avoid uneven baking of biscuits during the process. This unit is consisting of canvass conveyor and AC induction motor with gear box. The AC induction motor is controlled by AC variable drive installed in main control panel. The speed of the conveyor should be matched with rotary moulder unit speed.

Electric Baking Oven
The baking oven is constructed in 4 sections with MS Sheet. The outer surface is covered with fibre glass insulation to reduce heat loss due to radiation. The fibre glass is packed by SS sheet. Inside the oven there is free space for the conveyor that carrnes the biscuit coming from die unit. In between the conveyor heaters are provided. The heating coils are covered with SS tube to increase surface area of the heating source and to give uniform heating to the biscuit. The conveyor is driven by AC induction motor. The motor is controlled by AC variable drive installed in the main control panel. The speed and temperature should be adjusted for proper baking of biscuits, which depends upon the type of biscuit.

The speed and temperature (speed of conveyor) can be set by trial and error basis. There is no specific speed requirement for any type of biscuit. The oven temperature can go upto maximum of 3000C. The maximum temperature requirement for any type of biscuit is 2600C. The oven temperature is controlled by control panel provided at remote distance. In the oven thermocouples are provided in each zone to control the temperature. In each zone inspection covers are provided to monitor on line process of baking.

In the Oven, MS Wire mesh conveyor is provided for biscuit movement. The wire mesh type conveyor is having advantage for release of aerating gases and steam from the base of the products during baking.

Turning Table (Optional)
Baked biscuits are collected in the turning table. Turning is provided to change the direction of flour of the baked biscuit movement as special case. This arrangement provides the manufacture unit to reduce the length of the unit and is aligned in parallel with Oven. By this way length of the plant is reduced.

The turning table speed is to be adjusted slightly above the oven conveyor speed. This ensures that baked biscuit will not fall over and above the baked one.

Oil Spraying Unit
This unit bakes as per the variety of biscuit to be manufactured. This unit is required only for manufacturing of Cracker biscuits. This unit consist of heater with thermostat, oil sprayer; conveyor and two motor pump.

The Oil Sprayer Unit have nozzle to spray heated oil. The oil is heated in oil tank and it is pumped to nozzle. The pump and nozzle is connected by means of pipe. The new oil should be filtered and to be poured into the tank. The oil tank with heater is provided on the top of the unit. In first stage, the oil will be sprayed on one side of the biscuit. Then the biscuit moves along the conveyor and in the second stage the biscuit is reversed and the oil is sprayed.

Cooling Unit (2 Tier)
This unit is required for Hard & Soft biscuits. The cooling unit have two tier canvass conveyor and AC induction motor with gear box. The motor is controlled by AC variable drive unit installed in control panel. After the baking process the biscuit is allowed to cool down to the room temperature before entering into stacker unit.

Stacker Unit
The unit consists of biscuit guide strip, biscuit pushing arrangement, canvass conveyor and AC induction motor with gear box. The motor is controlled by AC variable drive installed in control panel. After cooling process, the biscuits are moved to the stacker unit. The biscuits is collected from here for packing. The biscuits is pushed one after the other by means of pushing unit and it is moved in between biscuit guide strip. The number of strip to be fixed have to be decided before starting the process.

Main Operating And Control Panel
The panel is provided for main power control, power supply distribution and synchronisation of drive motor and its speed indication. The panel consists of main incomer, one oven main control MCCB, drive control panel power supply MCB and power factor control capacitors.

In addition to the above a separate micro processor based production control unit is provided. All the motors speed are controlled by this panel.