Views: 0 Author: WENVA machine Publish Time: 2025-11-14 Origin: Site
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● Understanding the Requirements of Double-Layer Biscuit Production
>> Why Double-Layer Production Requires Major Adjustments
● Step 1 — Assess Your Existing Single-Line Factory
● Step 2 — Identify Upgrade Requirements and New Equipment
>> Equipment That Must Be Added
>> Equipment That Can Usually Be Reused
● Step 3 — Designing the Layout of a Double-Layer Production Line
>>> Parallel Layout
>>> L-Shaped Layout
● Step 4 — Implementing the Lamination and Bonding Process
>> Critical Parameters to Control
● Step 5 — Adjust the Forming and Cutting Process
>> Forming Technologies That Work Well
● Step 6 — Recalibrate Tunnel Oven Settings
>> Why Baking Must Be Adjusted
● Step 7 — Update Cooling, Handling, and Packaging
● Step 8 — Conduct Testing, Calibration, and Quality Validation
● Step 9 — Train Operators and Engineers
● Cost Planning and Investment Outlook
● FAQ
>> 1. Can any factory upgrade to a double-layer biscuit line?
>> 2. Must the two dough layers use different recipes?
>> 3. Does double-layer production slow the line?
>> 4. What is the most common technical failure?
>> 5. Does the tunnel oven need to be replaced?
Transforming a traditional single-line biscuit factory into a high-performance double-layered biscuit production line is an excellent opportunity to expand your product portfolio, increase market competitiveness, and modernize aging facilities. Double-layer biscuits—whether laminated, composite, or texturally contrasted—require different engineering principles compared to conventional single-sheet biscuits. This guide provides a complete, practical roadmap for factories planning such an upgrade, covering equipment assessment, layout redesign, lamination technology, baking adjustments, staff training, and quality control.
Double-layer biscuits are composed of two dough sheets combined before forming or baking. The two layers may have:
Different formulations
Different dough textures
Different thicknesses
A bonding agent or mechanical compression

Two dough production streams must be synchronized
Laminating requires precise pressure and alignment
Baking performance changes due to different moisture and density
Cutting dies must accommodate multi-layer thickness
Cooling must be more controlled to avoid separation
Upgrading an existing line involves adapting every major processing stage.

Before purchasing equipment or redesigning layouts, conduct a comprehensive audit of the current production line.
Dough mixers and feeders
Sheeting/rolling units
Existing forming section
Tunnel oven length, heating zones, and control performance
Conveyors and cooling lines
Packing systems
Available floor space
Electrical and gas infrastructure
Understanding what can be reused and what must be replaced saves time and investment.
A double-layer system requires two dough-sheeting systems and a reliable lamination station.
1. Second dough sheeting line
Independent rollers
Gearbox-driven thickness controls
Separate dough feeder
Tailored dough handling depending on texture
2. Laminating and bonding station
Compression rollers
Alignment sensors
Water mist, slurry, or fat coating applicator
3. Synchronization control system
Ensures equal belt speed
Prevents wrinkling or drifting
Mixers
Ingredient dosing systems
Tunnel oven (if wide and flexible enough)
Cooling conveyors
Metal detector
Packagers (depending on biscuit height changes)
Upgrading to double-layer biscuits often requires redesigning the physical layout.
Two dough-sheeting lines placed side-by-side merging into one laminated sheet.
One sheeter placed above the other; the top sheet drops onto the bottom one.
Saves floor space but requires structural reinforcement.
Suited for factories with irregular floor plans.

This is the core of the upgrade. Lamination must produce a consistent, stable, two-layer dough sheet.
Mechanical compression using rollers
Water mist adhesion
Starch slurry or sugar solution coating
Oil/fat-based bonding
Top and bottom sheet thickness
Sheet speed synchronization
Bonding pressure
Adhesive dosage
Double-layer dough behaves differently from single-layer dough during cutting.
Rotary cutting for uniform shapes
Punch-and-cut for thicker laminated dough
Wire-cut (if top dough layer is softer)
Uniformity is crucial for preventing separation during baking.
Double-layer dough requires different thermal profiles.
Upper and lower layers expand at different rates
Moisture reduction must be even
If heat balance is incorrect, layers can separate
Modify top vs. bottom heat ratio
Lower initial zone temperature
Increase drying zones
Adjust conveyor speed for optimal moisture release
Cooling is more delicate because laminated dough can warp or separate.
Longer cooling conveyors
Balanced airflow fans
Adjustable product guides
Gentler stacking mechanisms
Packaging machines may need height adjustments due to thicker product structure.
Dough texture consistency
Lamination stability
Forming accuracy
Oven curve calibration
Moisture final measurement
Breakage rate after cooling
Package sealing integrity
Double-layer production requires new skills:
Speed synchronization
Lamination alignment
Bonding agent management
Oven heat balancing
Troubleshooting layer separation
An upgrade typically costs less than installing a brand-new production line. Major investment categories include:
Additional sheeting line
Lamination/bonding system
Conveyor reconfiguration
Control systems
Installation labor
Testing and adjustment
Return on investment is often fast because double-layer products command higher market value.
Not all. Space constraints and old equipment may limit feasibility.
Not mandatory, but differentiation improves consumer appeal.
During early calibration yes, but final speed can match traditional lines.
Delamination caused by poor bonding or inconsistent sheet thickness.
Usually no, as long as it offers adjustable heating zones.
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