Processed foods are foods that have been altered from their natural state through industrial processing techniques like canning, freezing or packaging. They often contain preservatives and other chemical additives. Biscuits are a type of processed food made from ingredients like flour, baking powder, sugar and shortening. There are various processes for manufacturing biscuits, including mixing ingredients, shaping the dough through methods like sheeting and cutting, and baking. Different types of biscuits have different recipes and manufacturing processes, such as crackers, hard sweet biscuits, short dough biscuits and cookies. The wafer manufacturing process involves making a batter, baking wafer sheets, releasing and cooling the wafers, optionally adding fillings or coatings, and packaging.

1. Processed
Foods

2. PROCESS
FOODS
Technology used in making processed or packaged foods is
known as the technology of processed foods. Such foods
include cakes and biscuits. Processed foods refers to those
food items that are packaged in boxes, cans or bags. These
foods need to be processed extensively to be edible and are
not found as is in nature. In addition to going through many
complex processing steps, processed foods often contain
additives artificial flavorings and other chemical ingredients.

3. The term ‘Biscuit’ refers to the small round bread leavened
with baking powder or soda. They are eaten by all sections of
people across the board round the year. The basic ingredients
of biscuit are flour, baking powder, salt, baking soda, sugar,
shortening and milk solids.
Technology of Biscuits Manufacture

4. ● The starting point must be an understanding of the
ingredients and the baking process. Biscuits are the
snack food – have a long shelf life, are nutritious and
available in many functional forms.
● Biscuits broadly fall into four categories, distinguished
by their recipes and process: crackers, hard sweet and
semi-sweet biscuits, short dough biscuits and cookies
(including filled cookies).
BISCUITS

5. ● There are various established processes
commercially available and being practiced by
different manufacturers. The process of
manufacturing of biscuits mainly involves the
following three steps: Mixing, Shaping or forming
and Baking. As the mixing and baking steps are
common to manufacture of all types of biscuits the
differences in the finished product arises due to the
different shaping and forming methods.
BISCUIT MANUFACTURING
PROCESS

6. ● Mixing – is a process designed to blend different ingredients into a
uniform, homogenous mixture. The major ingredients are flour, fat, sugar
and others as per the desired final one would like to have. There are
three types of mixers being used for mixing: Vertical spindle mixer,
Horizontal mixer and Continuous mixer.
● • Shaping or Forming – The forming process is specific for each
biscuit, cookie type. There are three processes by which shaping or
forming of biscuits is achieved; Sheeting and cutting, Rotary molding and
Extrusion.
● • Baking- This is the area where we pass these moulded/formed wet
biscuit into baking oven. The biscuits are baked on desired temperatures.
Various type of heating are available now a-days as per the convenience
and cost. Different types of oven are available for baking products.
Process of manufacturing of
biscuits

7. Cracke
rs
• Crackers are a wide range of products
characterized by crispy, open texture
and savoury flavours. Crackers include
soda and saltine crackers, cream
crackers, snack crackers, water biscuits,
puff biscuits, ‘Maltkist’ (sugar-topped
crackers), ‘TUC’ type, ‘Ritz’ type,
vegetable and calcium crackers

8. Cracker
Features
Cracker doughs are doughs which are
leavened and fermented with ingredients
such as yeast, ammonia and sodium
bicarbonate. Doughs generally have a high
water content (15-25%) and are baked to low
moisture contents (1.5-2.5%).

9. Hard Sweet Biscuits
Hard sweet biscuits are characterized
by an even, attractive colour and
texture and good volume. Doughs
have strong, developed gluten which
gives an elastic dough, which is
sheeted and cut. Biscuits are baked to
low moisture contents, around 1.5-
3.0%.

10. Doughs are short with higher fat
and sugar contents than the
crackers and hard sweet biscuits.
Malted milk, Glucose, Lincoln,
Digestive, Nice, Shortbread,
custard cream from Britain, Italian
frollini, Dutch speculaas,
caramelised biscuits, and Tiger
from India.
SHORT DOUGHS
(Molded buscuits)

11. • Texture – open, flaky, short, depending on the product, etc.
•Density/volume-low density gives more volume and a lighter bite
•Bite/mouth feel-crispiness, softness, smoothness,
crunchiness, etc.
•Flavour many flavours and fillings are heat susceptible and the
protection of the flavours and texture of the fillings needs
consideration for the baking process. For example, for a variety of
soft doughs and cookies, a preference will be given for radiant heat,
a longer baking time at a lower temperature
BISCUITS STRUCTURE

12. Evenness of the moisture content from the centre
to the outside of the biscuit requires penetrative
heat and adequate time for baking and cooling. An
important factor in baking doughs with high water
content, such as crackers and water biscuits. Low
moisture content enhances the keeping qualities
of a biscuit.
MOISTURE CONTENT

13. Some products such as Marie require a very even bland
colour; others such as cream crackers and some rotary
moulded designs require colour contrasts and highlights.
These features require different baking systems to
enhance the appearance of the product – see Which
Baking System Is Best For You for more information.
COLOUR

14. Machineries used in Biscuit Manufacturing
Process
For the manufacture of biscuits the following machines are primarily used by the
baking industry:
•Flour Shifter
• Stainless steel mixer
• GMS Churner
• Fat Churner
• Cotton conveyor
• Laminator
• Teflon coated cutting, stamping & punching machine
• Electrically/Diesel operated baking oven
• Cooling conveyor
•Packing & sealing machine

15. ● Wafer are low-moisture-baled-foods. The primary
textual attributes of products, the crunchiness our
crispness is highly affected by the product’s physical
state ( glassy or rubbery). Wafers represent
specialized type of light-textured biscuit, generally
made from cereals.
● The wafer sheet itself is baked from a simple batter
containing little or no sugar.
● Wafer usually serve as the edible carriers of an
added food. However, the crispiness of the wafer
enhances the appeal of added food, making the
wafer more than an inert carrier. Compared to other
biscuits, starch gelatinization in wafer is quite high.
TECHNOLOGY OF WAFER
BISCUITS

16. THE CHARACTERISTICS OF
WAFER
Wafers are baked in different fancy shapes like cones, sheets, sticks etc. The main
features of wafers with respect to other bakery products are:
• Wafers are very thin biscuits: the thickness lies between 1 and 5 mm.
• Wafers often have a typical “wafer pattern” on one or both surface of the
product. The surfaces are smooth and precisely formed with the dimensions,
engraving, logos etc.
• Wafers are cereal based low fat products. They are made of wheat flour,
some times with combination of other flours or starches.
• The product density of wafer ranges from 0.10 to 0.25 g/cm³. The cross
section of product reveals that wafer matrix is highly aerated and primarily
composed of gelatinized starch.
• Wafers by their delicate crisp texture combine well with different types of
coatings and fillings like cream, ice cream, foam etc.

17. CLASSIFICATION OF
WAFER
Wafers may be classified in two basic types:
 No-or low-sugar wafers
 Higher-sugar wafers
Wafer may be following three types:
 Plain wafers: Plain wafers may be hollow or flat or in any
shape desired by the purchase.
 Sandwiched wafers: These types of wafers shall have two
more plain wafers, sandwiched with filling in between. The
filling may be cream, jam, jelly, marsh mallow, caramel,
raisins etc. The fillings shall be not less than 50% by mass
the filled wafer.
 Coated wafers: These types of wafers include both half-
coated and full-coated wafers.

18. INGREDIENTS OF WAFER
The ingredients of wafer biscuit preparation can be classified in two
types:
 Essential ingredients: The essential ingredients for preparation
of batter of wafers are a) Flour and b) Water.
 Optional ingredients: In addition to essential ingredients
following ingredients may be added to wafer batter are a) baking
powder and other leavening agents, b) cereals, c) chocolate, cocoa
powder, coffee extract, d) citric, malic, lactic, tartaric, acetic
acid e) food colours, flavouring essences, flavour improvers and
fixers f) desiccated coconut, dry fruits and nuts, g) fruit and
fruit products, h) salt, dextrose, liquid glucose and sugar
products (gur, jiggery etc.), i) emulsifying and stabilizing
agents, j) preservatives and anti oxidants, k) enzymes -fungal
alpha amylase for dough conditioning, 1) Fat and shortenings, m)
malt products, n) milk and milk products, o) eggs and egg
products, p) spices, condiments and their extracts, q) nutrients

19. MANUFACTURE
TECHNOLOGY OF WATER
BISCUITS
Wafer biscuits preparation
• Batter preparation
• Batter transport and disposition
• Wafer sheet baking
• Wafer release and cooling
• Wafer conditioning
• Creaming and book building
• Cooling and cutting
• Enrobing in chocolate
• Cooling
• Packaging

20. THANK YOU!!