about biscuit and manufacturing

1. BISCUITS
BY
SAMSEENA U
DEPT .FOOD TECHNOLOGY
MSTM COLLEGE
PERINTHALMANNA

2. BISCUIT

3. BISCUIT
• The term ‘Biscuit’ refers to the small round bread leavened with baking
powder or soda and covers a large variety of sweet, salted, filled and
coated biscuits.
• The word biscuit is derived from the Latin word “Bis coctus” which means
twice baked.
Types of biscuit
• Classification of biscuits based on chemical composition and processing
methodology is difficult due to overlap. These are manufactured in
varieties covering sweet, salted, filled coated biscuits.

4. • a) BIS Classification (IS 1011:2002)
• The varietal differences of biscuits can be easily distinguished
based on sensory attributes. This standard broadly classified the
biscuits on the sensory basis into the following five
types:
Type I Sweet
Type II Semi-sweet
Type III Crackers
Type IV Cookies
Type V Speciality Biscuits

5. • b) UK Classification: Biscuits are classified based on the formulation as
follows:
• 1. Hard dough biscuit
Dough used is similar to bread dough
 Mixing of flour is more to maximize gluten development
 Dough is elastic and extensible due to well developed gluten network
during mixing
Very low fat and sugar content relative to flour
Example: Crackers, sweet and semisweet biscuits

6. • 2. Short dough biscuit
Dough more closely related to cake dough however water used is
lesser than cake dough
 Mixing of flour is very little to minimize gluten development
 Higher fat or shortening than hard dough resulting into lower
extensibility of gluten and hence easy breaking of biscuits
 Higher sugar in the formulation
Soft dough biscuit: A subgroup of short dough biscuit with a more soft
consistency which can be attributed to its higher sugar and fat content.

7. • c) USA Classification: This classification of biscuits is based on the method of processing
• and, in particular on the basis of the way biscuits are shaped.
1) Sheeting or cutting type:
• Here the dough is passed through laminators to produce sheets. These multilayer sheets are
then fused into single sheet of desired thickness. This sheet is then passed onto cutter of
various shape and sizes of cups/dies. The examples are cream crackers, puff crackers, marie
gold, salt n sugar cracker, fifty fifty, krackjack, monaco etc.
2) Rotary molding type:
• The dough is in short crumb form and is directly fed in to rotator moulder with dies of various
shape and size. The examples are Good day, Glucose chocochips biscuit etc.

8. 3) Wire cutting type:
• Here soft short dough is passed through holes in extruders and these doughs
are then wire cut in pieces which are directly dropped into oven band.
• Two three types of dough can be co-extruded from the die where the central
dough could be jelly or jam .These ropes can be cut after or before baking.
Examples are butter cookies, chocolate cookies.
4.Depositing type:
• Here the soft pourable short dough is passed out from extruder
and directly laid on baking bands.
• The depositor may rotate to make swirls and twists on to the
products.
• Cream treat biscuits are made by this method.

9. CRACKERS.
Type of biscuits which are neutral or less sweet in taste.
Thinner and crispier than the other type of biscuits.
Prepared from unsweetened dough which may be leavened or
unleavened.

10. WAFER.
Crisp,often sweet, very thin, flat, light and dry biscuit.
Often used to decorate icecream and also used as a garnish on some
sweets.

11. COOKIES.
Heavy,rough and crispy biscuits loaded with things such as nuts, raisis,
chocolate etc.
Soft and sweet and have a more complex flavour due to their toppings.

12. INGREDIENTS.
Flour
Sugar
Salt
Shortening agent
Leavening agent
Milk or Water
Egg
Milk Powder.

13. BISCUIT MANUFACTURING
PROCESS
The process of manufacturing of biscuits
mainly involves the following three steps:
1.mixing
2. shaping or forming
3. baking

14. Mixing
Mixing is commonly defined as a
process designed to blend different
ingredients into a uniform, homogenous
mixture.
The major ingredients are flour, fat,
sugar and others as per the desires final
one would like to have.
All ingredients are put together in right
proportion for dough formation.

15. These are then fed into mixers where mixing is done,
and dough is prepared for moulding/cutting. There
are three types of mixers being used for mixing of
ingredients
a) Vertical spindle mixer
b) Horizontal mixer
c) Continuous mixer

16. Mixing can be done in two methods :
1. Creaming Method
2. All in one Method.
CREAMING METHOD.
This method is generally used for short dough biscuits
(Sweet or Soft dough Biscuits).
It can be :
a) Two Stage Method
b) Three Stage Method

17. TWO STAGE METHOD.
•All the ingredients except flour and acidic ingredients
are mixed first at a gentle speed.
•The mixing time is around 10-15 minutes.
•This results in a formation of white semi stiff cream.
•The flour is then added to the cream and mixing
proceeds until uniform dispersion of flour takes place

18. THREE STAGE METHOD.
•Fat, sugar, emulsifier and a part of water are mixed
around 10-15 minutes.
•A suspension of salt, alkaline chemicals, flavours,
colours and the remaining water is mixed to obtain a
smooth cream
•Finally, the flour and acidic chemicals are added to
smooth cream and mixed until a desired consistency is
obtained.

19. ALL IN ONE METHOD.
•Rarely used for short dough biscuits and mainly used
for hard dough biscuits.
•All the ingredients including sugar are placed in the
mixture.
•Here long mixing time is required, so it causes longer
gluten development.
•Hence the dough will be dense and tuff

20. DOUGH RELAXATION.
After mixing doughs are left to relax or ferment for 30-45
minutes for cookie dough and 2-3 hours for chemically
leavened cracker dough.
DOUGH MACHINING AND FORMING.
The dough is dumped into hopper for machining or forming.
According to finished products properties, the dough can be
machines by three methods :
1. Sheeting and Cutting.
2. Rotary Molding
3. Extrusion

21. •SHEETING AND CUTTING.
•The formed dough is first sheeted by using a pre
sheeter.
•The pre sheeter having 1 or 2 cylinders rotating in
opposite directions. The dough is compressed by the
smooth cylinders through which they pass. This set of
cylinders called “Compression chamber.”
•Then it passes through a number of rollers to obtain fine
thickness.
•The process of converting the dough into sheets of fine
thickness is called lamination.

22. Lamination is done to :
•To build flaky or layered structure in biscuit
•To give uniform surface of the dough
•To control shape of the biscuit.
•Done more work on gluten making it more
suitable for baking.

23. oIn this lamination process the dough sheet from the first
roller is either folded or cut by reduction roller and laid one
top on the another, then passes into the next roller i.e.,
Guage Rollers to obtain the final consistency.
oReduction and Gauge rolls : Consists of 2 or more cylinders,
with the first pair being referred to as “Reduction rollers” and
the final pair is “ Finishing or gauge rollers”
o Each pair of rollers is fitted with scrapper knives to clean
dough from the roller surface
oThe dough is transported between each set of rollers

26. RELAXATION.
As the dough passes through different rollers the
repeated working on the dough introduces stress on
the dough
 If the dough sheet is subjected to cutting at this
stage, it results in deformation of the biscuit
Hence the dough sheet need to be relaxed before
cutting
CUTTING
The biscuits cut into the desired shapes are formed
with separation of the dough piece from the scrap

27. ROTARY CUTTER / MOULDER
•The cutter rolls over the dough sheet and dough get
cut with the support of a rubber roller, which is placed
below the canvas
•In the case of moulder, there will be 3 rollers in which
one will have moulds, other presses the dough
towards the molder & so the dough fill in the moulder
without any air gap and then third roller replaced
below, to support these rollers

28. •Rotary cutter

29. Extrusion method:
In this method of dough forming, the dough is
extruded through a row of dies which is cut by a wire
or blade mounted on a frame that moves through the
dough just below the die nozzle outlet.

31. TOPPING.
To give a better presentation over the surface of the
biscuits.
Usually flour sugar salt etc. will be sprayed over the
surface.
BAKING
Baking is a process by which the raw ingredients are
subjected to cooking and drying along with
development of texture, colour and flavour so that the
final product made it palatable.
Baking temperature : 450℉ for 10-15 minutes

32. Changes during baking :
1. Formation of a film on the crust on the biscuit.
•On entering the oven, the outside of the dough piece
soon becomes coated with a film or crust
• The thickness of which develops as moisture is
evaporated from the outside skin
• This crust formation starts at low temperature at 80
ºF and proceeds rapidly at around 100 ºF

33. 2.Melting of fat in the dough
The aggregates of fat particles melt as soon as their
immediate area in the dough piece reaches the
melting.
3. Gas expansion
The carbon dioxide formed by chemical reaction
within the dough piece, under the influence of
increasing the temperature, will increase the volume
and stretch the dough piece.

34. 4.Water converted to steam
The expansion of the dough piece due to formation of
steam is much greater than the expansion due to
carbon dioxide and or ammonia.
5. Escape of carbon dioxide, other gases and steam
As these are removed the dough piece becomes
reduced in overall volume.
Too great a loss, too soon, will cause the structure to
collapse resulting in hollowed tops and cracked
surfaces

35. 6. Starch Gelatinization
If starch be mixed with cold water, swelling occurs
Removal of the water leaves the starch practically in its
original state
However, if the starch water mixture is heated above
130º F gelatinization occurs , it play an important role
in producing biscuit structure during baking.
7.Protein changes
Proteins begins to coagulate at temperature from 145
ºF upwards ,which imparts strength to the biscuit
structure
It around 165º F the proteins undergo an irreversible
denaturation

36. 8.Caramelization of sugar
This is accompanied by the formation of melanoidins
9. Dextrination
At temperatures slightly higher than 300 ºF the starch
begins to become converted to dextrin

37. COOLING
During cooling the flexible structure becomes rigid as sugar
and fats solidifies
Cooling should be extended if period as possible and the
humidity of cooling atmosphere must be controlled. There are 2
systems of cooling : -
In the atmospheric multi-tier conveyor: - The biscuits from the
oven band travel on a canvass web having single, double or 3
tiers. The biscuits on these are cooled by surrounding
atmosphere
The forced draft-cooling conveyor: - Forced draft cooling is
used. Filtered air is blown against the direction of travel of
biscuit coming out of the oven on the cooling conveyor there by
cooling the biscuits earlier than the normal time

38. PACKAGING.
To protect from environmental hazards and spoilage.
Should be sterile, gas proof and moisture proof

39. faults and remedies
 Dough is too sticky to roll if it has too little flour. Cover
and chill dough.
 Dough becomes too dry if it contains too much flour.
Dribble in water until the dough reaches desired
consistency.
 Cookies crumble and become too dry and hard if the
dough is excessively mixed. Stop mixing when the dough
is just mixed. Do not overdo it.
 Excessive liquids and salt make cookies hard. Use suitable
measuring cup or spoons for measuring ingredients and
follow accurately. Level the dry ingredients with a flat
edged knife or scale.

40. Too less fat results in hard cookies. Over baking also makes
cookies hard
Over mixing of the dough, over baking, too much water or
a lack of fat or excess of dry fruits/coconut.
Excessive salt can also cause your cookies to be hard.
When dry fruits are to be used, soak them in little water for
few minutes to prevent moisture pick up from the formula.
Cookies stick to baking pans if they are still hot from the
oven. Let the cookies cool on the pans for a few minutes
before transferring to wire racks.
Use cookie or parchment paper to line pans. Light grease
application can also be followed but cookies spread more on
greased sheets and therefore some people prefer parchment
paper.

41. Cookies bake unevenly if dough is not rolled or portioned
to a consistent thickness or size.
Cookie dispensers are useful in maintaining the size of
cookies besides giving attractive shapes.
Cookies appear oily if not enough flour or too much fat is
used. Do not substitute shortening, or margarine for
vegetable oil.
Cookies become too flat, spread and thin out while baking:
Use shortening instead of butter. Make smaller cookies,
they’ll puff better.
Chill dough, form cookies and then chill on pans before
baking.

42. oBake cookies a few minutes longer than suggested and
immediately remove them to wire racks to cool to make crispier
cookies. Use more white sugar than brown to give more
crispiness. Use a little bit more liquid in the batter, that will help
cookies to spread more, and thus be thinner and crispier
oCookies break if removed still when hot. Allow the cookies to cool on
the pans for a few minutes before transferring to wire racks.