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Configuration of Double-Layer Biscuit Production Lines And Key Equipment Selection

Views: 0     Author: WENVA machine     Publish Time: 2025-12-01      Origin: Site

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Double-layer biscuits have gained strong momentum in global snack markets due to their richer textures, layered structure, and expanded flavor possibilities. For factories planning to upgrade to double-layer products or build new production lines, proper configuration and equipment selection are crucial. Compared with traditional single-sheet biscuits, double-layer products require stricter control over dough extensibility, lamination precision, heat distribution, and moisture removal.

This article breaks down the entire industrial production flow—from mixing, sheeting, coating/lamination, forming, baking, post-bake adhesion, cooling, to packaging—and highlights the key equipment requirements at each stage. Integrated Wenva Machine solutions are also introduced to provide a complete and practical reference for factories seeking a reliable turnkey line.

Double Layer Biscuits machine

1. Dough Mixing: The Foundation of Double-Layer Stability

Double-layer biscuits require both sheets to share consistent dough extensibility and gluten development. Any mismatch creates shrinkage differences during baking, resulting in misalignment or layer separation.

Key Requirements

Uniform gluten development

Stable dough temperature (18–22°C ideal)

Precise ratio control

Wenva Machine Mixing Solutions

Variable-frequency mixers for controlled gluten development

Jacketed cooling bowls to prevent temperature rise

Automated ingredient dosing for high-capacity plants

Synchronization with downstream sheeter loading

These features ensure the dough's elasticity and handling characteristics remain consistent between both layers.

2. Sheeting System: Controlling Thickness and Tension

The sheeting process is one of the most crucial stages for double-layer biscuits. Consistent sheet thickness, minimal tension fluctuations, and proper edge stability are essential for smooth lamination and accurate forming.

Wenva Five-Roller Sheeting System

±0.1 mm thickness precision

Servo-driven gap adjustment for fast product switching

Automatic edge guiding and sheet alignment

Hygienic stainless-steel polishing rollers

Wide-width options: 800 / 1200 / 1500 mm

Wenva's sheeters are widely used in Southeast Asia, the Middle East, and South America due to their stability in long-duration, high-capacity production.

3. Coating & Lamination: The Core Value of Double-Layer Biscuits

Double-layer biscuits often incorporate flavor coatings or intermediate layers such as butter slurries, sugar films, malt syrup, savory paste, or powdered seasoning.

3.1 Coating System

Wenva coating units support a wide variety of materials.

Features

Coating thickness 20–200 μm

Compatible with low- and high-viscosity compounds

Heating/insulation modules for butter or viscous slurries

Quick-release structure for rapid cleaning

3.2 Laminating System

The laminator combines two continuous sheets with precise positioning and pressure.

Wenva Lamination Advantages

Dual-servo synchronous driving to avoid misalignment

Automatic web guiding

Optional three-layer lamination module

Wide-width compatibility: 800/1200/1500 mm

Wenva's modular lamination design is especially suitable for manufacturers with fast product turnover or multiple SKUs.

4. Forming: Precision Rotary Cutting for Layered Dough

After lamination, the sheet enters the rotary cutting system for shape punching and embossing. For double-layer biscuits, the cutter must maintain stability to prevent slippage between layers.

Wenva Rotary Cutter System

One-piece copper forming rolls for high wear resistance

Digital pressure adjustment

Rapid tooling change for product diversification

Accurate synchronization to prevent layer displacement

This system is proven effective on high-capacity lines up to 1,000 kg/h.

5. Tunnel Baking: Heat Transfer and Moisture Removal for Dual Layers

Baking double-layer biscuits is more demanding than single-sheet products due to the need for uniform moisture release and balanced top-bottom heat.

Wenva Tunnel Oven Options

Steel belt ovens for thin, crispy double-layer biscuits

Wire mesh ovens for high-fat or coated products

Core Features

3–5 independent heating zones

Adjustable top/bottom heat ratio

High-efficiency moisture exhaust to prevent delamination

Auto-tracking and tensioning system for belt stability

Wenva tunnel ovens are customizable from 25 to 60 meters depending on required throughput.

6. Post-Bake Adhesion: Creating Complex Multi-Layer Structures

Some double-layer products require additional filling after baking, such as:

Cream layers

Syrup or caramel films

Powder seasoning layers

Wenva Adhesion & Depositing Systems

Precision cream depositing valves

Thin-layer spreading modules

Pressure-controlled lamination conveyors

Shock-free conveyors designed for fragile double-layer biscuits

These systems help maintain product integrity and minimize breakage.

7. Cooling: Stabilizing the Structure Before Packaging

Uneven cooling leads to moisture gradients, warping, softened texture, or layer separation.

Wenva Cooling Solutions

Multi-tier cooling towers for space-saving layouts

Full-channel forced-air cooling

Optional dehumidification for tropical climates

Controlled outlet temperature within ±3°C of ambient

Wenva cooling systems ensure structural stability before packaging.

8. Packaging: Designed for Fragile Double-Layer Biscuits

Double-layer biscuits require gentle handling to avoid chipping or cracking.

Wenva Packaging Line Integration

Metal detection + checkweigher

Buffer conveyors for shock absorption

Horizontal/vertical high-speed flow wrapping

Multi-pack and carton packaging systems

This ensures premium presentation and reduces downtime from product jams.

9. Capacity Planning, Footprint, and Factory Retrofit Guidance

Capacity Recommendations

500–600 kg/h: Medium-size plants, 800–1200 mm width

1000–1500 kg/h: Large plants with 1500 mm sheeters + long steel-belt oven

200–350 kg/h: Lab or regional specialty lines

Typical Footprint (1000 kg/h Line)

Length: 50–80 m

Width (with operator aisles): 6–8 m

Total area: 350–600 m²

Retrofitting Older Facilities

Wenva Machine frequently upgrades older factories by:

Replacing old sheeters with servo-driven systems

Adding lamination modules (requires 3–6 m additional length)

Enhancing oven exhaust for double-layer moisture removal

Re-optimizing production flow and layout

Wenva's engineering team provides complete layout drawings and on-site assessments.

10. Choosing the Right Supplier: What to Look For

Double-layer biscuit lines require unified integration across sheeting, lamination, forming, baking, and cooling. Factories should prioritize suppliers with:

Proven double-layer project experience

Full line integration (avoiding multi-brand mismatches)

Local service capability and spare parts support

Strong oven commissioning and process optimization expertise

In-house mold design and manufacturing

With over 40 years of biscuit machinery experience, Wenva Machine has delivered complete double-layer biscuit lines across Southeast Asia, the Middle East, Africa, and South America. Wenva provides end-to-end services from engineering consultation to commissioning, operator training, and recipe support.

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Our Business Team: Over 12 Years of Industry Expertise – Understanding Equipment and Your Needs Even Better
 
Choosing biscuit production equipment is not just about selecting a product, but a partner who can solve practical problems. Every member of our business team has more than 12 years of industry experience; they are "all-round consultants" who understand technology, master processes, and are familiar with the market.
 
From production line planning for start-up factories to equipment upgrades for large enterprises; from optimizing the texture of shortbread biscuits to adapting processes for sandwich biscuits – they have seen thousands of production scenarios, and can accurately interpret your capacity needs, budget range, and quality goals. There’s no need for you to struggle to explain industry jargon; with a simple description of your requirements, they can quickly match you with an equipment solution, and even anticipate potential problems in production (such as the impact of raw material characteristics on equipment, or suggestions for optimizing workshop layout).
 
12 years of accumulation bring not only experience, but also a deep understanding of "customer success": They will communicate with you armed with production line debugging manuals, case data, and process parameter sheets, making no exaggerated promises but instead providing solutions that can be verified on-site. Whether you need an initial consultation or follow-up services, they are like an old friend who is well-versed in the industry: professional, hassle-free, and able to help you avoid the majority of detours.

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