TRIBHUVAN UNIVERSITY
INSTITUTE OF ENGINEERING
PULCHOWK CAMPUS
REPORT
ON
BISCUIT MANufACTURING
SUBMITTED BY SUBMITTED TO
MADAN ARYAL CHHABIN POKHREL
079BCH025 DEPARTMENT OF APPLIED SCIENCE
PULCHOWK CAMPUS & CHEMICAL ENGINEERING
JUNE 21, 2025
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Abstract
Biscuit making is a key process in the food industry that transforms simple ingredients like flour,
sugar, fat, and water into delicious, crispy biscuits through a carefully controlled production line.
This report outlines the step-by-step process, from preparing raw materials—such as sieving
flour and cooling fat—to mixing dough, shaping, baking, cooling, and packaging. It highlights
the role of specialized machines and the importance of maintaining optimal conditions like
temperature, moisture, and hygiene to ensure consistent quality and efficiency. Additionally, the
report discusses safety measures, waste management, energy conservation, and modern trends
like gluten-free biscuit production. Overall, this study showcases how food science and
engineering work hand-in-hand to produce biscuits on a large scale, meeting both industry
standards and consumer expectations.
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1. Introduction
Biscuits are one of the most commonly consumed baked products worldwide, enjoyed for their crisp texture,
taste, and long shelf life. They are made primarily from wheat flour, sugar, fat, leavening agents, and water.
The biscuit manufacturing process involves several stages, including raw material preprocessing, dough
mixing, shaping, baking, cooling, and packaging.
Each step is carefully controlled to achieve the desired quality. Preprocessing ensures raw materials are
clean and consistent, while baking causes important physical and chemical changes such as moisture
evaporation and browning reactions that develop the biscuit’s flavor and texture. Maintaining proper
temperature, moisture content, and mixing uniformity is crucial to producing biscuits with consistent quality
and appearance.
This report provides an overview of the key processes and factors involved in biscuit manufacturing,
highlighting how raw materials and process parameters influence the final product.
RAW MATERIALS
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Wheat flour
Sugar
Fat or shortening (such as butter or oil)
Milk or milk solids
Baking powder or soda
Flavours and additives (as required for specific varieties)
Other ingredients: rolled oats, whole wheat flour, glucose, cream, etc
Packaging Materials & Types
Materials:
Plastic films (polypropylene, metallized films)
Paper
Metal tins
Biodegradable materials
Common Packaging Types:
Flexible plastic pouches/bags (sealed for freshness)
Flow wrap packaging (continuous film wrapping)
Pillow packs (sealed plastic bags, often nitrogen-flushed)
Stand-up pouches (flexible with bottom gusset)
Cardboard boxes (for fragile/premium biscuits)
Tin boxes (luxury or gift biscuits)
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Raw Materials and Preprocessing
Raw Material Preprocessing Steps Why It’s Needed (Detailed Explanation)
1. Removes lumps, insects, and impurities for
1. Sieving
Wheat Flour clean input.
2. Aeration
2. Introduces air for better dough texture.
1. Ensures even mixing and smooth dough.
1. Grinding to powder
Sugar 2. Prevents clumping during storage and
2. Moisture control
mixing.
1. Prevents melting or lump formation.
1. Cooling
Fat/Shortening 2. Makes handling and dosing easier during
2. Cutting into blocks
mixing.
1. Removes dust and particles to keep dough
1. Filtering
Water clean.
2. Temperature control
2. Maintains dough softness and consistency.
1. Ensures proper gas formation in dough.
1. Weighing accurately
Leavening Agents 2. Avoids moisture that can reduce
2. Dry storage
effectiveness.
1. Dry storage 1. Prevents spoilage and lumping.
Milk Powder/Solids
2. Rehydration 2. Ensures it blends smoothly into the dough.
1. Separated storage by 1. Protects sensitive ingredients (e.g., liquids
Flavorings/Additives type need cold).
2. Dosing 2. Gives uniform flavor and color.
Equipment: Selection, Reasoning & Operating Conditions
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Operating
Equipment
Equipment Choice Reasons Temperature /
Category
Pressure
Ensures uniform mixing for hard
35–42 °C,
Mixing Horizontal Dough dough; durable stainless steel build;
Atmospheric
Machine Mixer PLC touch screen allows precise
Pressure
control
Ambient
Dough Provides consistent dough flow,
Automated Dough Temperature,
Feeding reduces manual handling, and
Feeder / Conveyor Atmospheric
System maintains uniformity
Pressure
Ambient
Roll the dough to a uniform
Sheeting Dough Sheeter with Temperature,
thickness for a consistent biscuit
Machine Adjustable Rollers Atmospheric
shape and baking
Pressure
Ambient
Rotary Moulder High-precision shaping; integrates
Forming Temperature,
(Automatic Biscuit lamination, cutting, and forming;
Machine Atmospheric
Forming Machine) fully automated
Pressure
Multi-zone controlled baking for 300–400 °C,
Belt Conveyor Tunnel
Baking Oven even product quality; stainless steel Atmospheric
Oven
build; high throughput Pressure
Gradually cools biscuits to stabilize 20–25 °C,
Cooling
Cooling Conveyor structure; prevents condensation and Atmospheric
System
moisture issues Pressure
Ambient
Automated Packing Hygienic and efficient packing into
Packaging Temperature,
Line with Sealing film or boxes; extends shelf life and
Machine Atmospheric
Machines reduces contamination
Pressure
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1. Ingredient Preparation
What Happens: Ingredients like flour, sugar, fat, milk powder, and baking agents are
accurately measured. Flour is sifted to remove lumps and impurities.
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Why It's Done: To ensure clean and correct amounts of raw materials, which helps make
consistent dough.
Key Requirements:
o Precise weighing
o Clean flour (free from stones or metal bits using sifters and magnets)
Output: Clean, properly measured ingredients ready for mixing.
2. Mixing
What Happens: All ingredients are mixed in a large dough mixer to form a smooth and
even dough.
Why It's Done: Good mixing makes sure the dough has even texture and moisture—
important for biscuit quality.
Key Requirements:
o Dough temperature: 35–42°C
o Mixing time: 15–25 minutes
o Speed control to avoid over-mixing
Output: Soft, uniform dough.
Impurity Check: Dough may pass through metal detectors after mixing.
3. Dough Sheeting
What Happens: Dough is flattened into thin, even sheets using rollers.
Why It's Done: To get the right biscuit thickness for baking and shape.
Key Requirements:
o Even thickness
o Clean, smooth dough surface
Output: Flat dough sheets ready to be shaped.
Impurity Check: Sensors or workers check for lumps or defects; rejected dough is
reused.
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4. Dough Forming
What Happens: Dough sheets are shaped using rotary moulders or cutters (round,
square, or designed shapes).
Why It's Done: To give biscuits their final shape and uniform appearance.
Key Requirements:
o Proper cutter alignment
o Consistent size and weight
Output: Shaped dough pieces, ready for baking.
Impurity Check: Metal detectors and visual inspection remove bad or contaminated
pieces.
5. Baking
What Happens: Shaped dough goes through a long tunnel oven where it's baked using
hot air and infrared heat.
Why It's Done: Baking removes moisture and gives the biscuit its crisp texture, golden
color, and taste.
Key Requirements:
o Oven temperature: 160–220°C
o Time and airflow control
Output: Crisp, baked biscuits.
Impurity Check: Badly baked or burnt pieces are rejected.
6. Cooling
What Happens: Hot biscuits are slowly cooled on moving conveyors to room
temperature (~20–25°C).
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Why It's Done: Prevents condensation, sogginess, and breaking. Makes biscuits stable
for packaging.
Key Requirements:
o Gentle airflow
o Clean environment
Output: Stable, cool biscuits.
Impurity Check: Area is kept dust- and insect-free.
7. Packaging
What Happens: Biscuits are packed in wrappers, pouches, or boxes using automatic
machines.
Why It's Done: Packaging protects from moisture, contamination, and breakage during
transport.
Key Requirements:
o Food-safe packaging
o Airtight sealing
o Proper labeling
Output: Finished, packed biscuits ready for sale.
Impurity Check: Metal detectors and quality checks before sealing.
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