Views: 298 Author: Wenva Machine Publish Time: 2026-05-15 Origin: Wenva Machine
Industry: Bakery & Snack Food Manufacturing
Country: Indonesia
City: Jakarta
Project Type: Capacity Expansion & New Product Launch
A well-known food manufacturing company based in Jakarta, Indonesia, has built extensive expertise in the baking industry over the years. Its product portfolio has expanded from traditional biscuits to include a wide range of items such as hard biscuits, soft biscuits, and crackers. With a strong export presence, the company serves markets across China, the United States, Australia, numerous ASEAN countries, and the Middle East, demonstrating robust global reach.
To meet growing global demand for savoury snacks, the client decided to introduce a new product line: potato crackers. However, the initial attempt to use an existing domestic production line (from a local brand) turned into a year-long struggle. The line could not achieve stable, continuous production for potato crackers – the dough consistency, forming, and baking profile were incompatible, leading to frequent breakdowns, uneven thickness, and poor shaping.
The client faced three critical issues with their previous equipment:
Process incompatibility: the machine was originally designed for hard biscuits and could not handle the specific dough rheology and baking curve required for potato crackers, resulting in inconsistent thickness and frequent cracking.
Extended commissioning time: after more than 12 months of repeated adjustments, the line remained unreliable, with frequent stops that delayed the market launch.
Insufficient technical support: the original supplier lacked the baking expertise needed to resolve the complex process issues, and response times were slow.
The client’s core requirement was clear: a complete, ready-to-run production system that could start stable mass production of high-quality potato crackers without lengthy trial-and-error.
Wenva Machine proposed a tailored solution based on our Standard Type-2 Production Line (Model 1200), specifically optimised for thin cracker products.
Dough mixing & forming section: customised mixers and sheeting machines ensure uniform dough consistency and extensibility, combined with precision rotary cutting and embossing systems to control thickness and shape from the very start.
Intelligent baking system (tunnel oven): a 160-metre long tunnel oven with zone-controlled temperature profiles allows precise setting of each zone’s heat and humidity, achieving the ideal golden colour and crispy texture for potato crackers.
Post-baking treatment: an in-line oil sprayer and an efficient cooling conveyor ensure optimal oil distribution and prevent cracking before packaging.
The project was not without challenges. After initial installation, the line showed minor instability and occasional forming interruptions after a few months. Our technical team, together with sales engineers, made **multiple on-site visits** to diagnose and fine-tune the parameters. Eventually, **within just two weeks of formal commissioning**, the line achieved 24/7 stable production – a stark contrast to the client’s previous year-long struggle.
Achieved capacity: stable output of 800 kg per hour, fully meeting the design target.
Rapid start-up: from commissioning to stable mass production in only two weeks, dramatically faster than the client’s previous experience.
Product quality：the potato crackers are uniformly thick, evenly coloured, and delightfully crispy, meeting all export quality standards.
Reduced skill dependency： the user-friendly control interface makes parameter adjustments easy, so operators can be trained quickly, reducing reliance on specialised technicians.
The most compelling aspect of this case is the dramatic turnaround: after the client had struggled for an entire year with an alternative solution, Wenva’s system resolved all production issues within 14 days of final commissioning.
This demonstrates our deep process expertise in specialised snack foods like potato crackers and our ability to deliver reliable, “plug-and-produce” lines that minimise downtime and maximise efficiency. For any food manufacturer facing new product challenges, choosing the right equipment partner is far more effective than repeated trial-and-error.
Credibility：a real-world example of overcoming persistent production bottlenecks.
Expertise：showcases our knowledge in adapting standard lines to challenging products.
Reliability：proves our commitment to on-site support and rapid problem-solving.
If you are looking for a dependable solution for your bakery or snack production, contact us today for a customised proposal tailored to your needs.
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