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How To Transform A Traditional Single-Line Biscuit Factory into A Double-Layered Biscuit Production Line: A Practical Upgrade Guide

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

>> Key Components to Inspect

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

>> Common Layout Models

>>> Parallel Layout

>>> Vertical/Stacked Layout

>>> L-Shaped Layout

Step 4 — Implementing the Lamination and Bonding Process

>> Lamination Bonding Methods

>> 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

>> Recommended Adjustments

Step 7 — Update Cooling, Handling, and Packaging

>> Cooling Improvements

Step 8 — Conduct Testing, Calibration, and Quality Validation

>> Trial Run Checklist

Step 9 — Train Operators and Engineers

>> Key Training Topics

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.

Understanding the Requirements of Double-Layer Biscuit Production

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

Double Layer Biscuits1

Why Double-Layer Production Requires Major Adjustments

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.

Double-Layered Biscuit Production Line1

Step 1 — Assess Your Existing Single-Line Factory

Before purchasing equipment or redesigning layouts, conduct a comprehensive audit of the current production line.

Key Components to Inspect

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.

Step 2 — Identify Upgrade Requirements and New Equipment

A double-layer system requires two dough-sheeting systems and a reliable lamination station.

Equipment That Must Be Added

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

Equipment That Can Usually Be Reused

Mixers

Ingredient dosing systems

Tunnel oven (if wide and flexible enough)

Cooling conveyors

Metal detector

Packagers (depending on biscuit height changes)

Step 3 — Designing the Layout of a Double-Layer Production Line

Upgrading to double-layer biscuits often requires redesigning the physical layout.

Common Layout Models

Parallel Layout

Two dough-sheeting lines placed side-by-side merging into one laminated sheet.

Vertical/Stacked Layout

One sheeter placed above the other; the top sheet drops onto the bottom one.

Saves floor space but requires structural reinforcement.

L-Shaped Layout

Suited for factories with irregular floor plans.

Double-Layered Biscuit Production Line2

Step 4 — Implementing the Lamination and Bonding Process

This is the core of the upgrade. Lamination must produce a consistent, stable, two-layer dough sheet.

Lamination Bonding Methods

Mechanical compression using rollers

Water mist adhesion

Starch slurry or sugar solution coating

Oil/fat-based bonding

Critical Parameters to Control

Top and bottom sheet thickness

Sheet speed synchronization

Bonding pressure

Adhesive dosage

Step 5 — Adjust the Forming and Cutting Process

Double-layer dough behaves differently from single-layer dough during cutting.

Forming Technologies That Work Well

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.

Step 6 — Recalibrate Tunnel Oven Settings

Double-layer dough requires different thermal profiles.

Why Baking Must Be Adjusted

Upper and lower layers expand at different rates

Moisture reduction must be even

If heat balance is incorrect, layers can separate

Recommended Adjustments

Modify top vs. bottom heat ratio

Lower initial zone temperature

Increase drying zones

Adjust conveyor speed for optimal moisture release

Step 7 — Update Cooling, Handling, and Packaging

Cooling is more delicate because laminated dough can warp or separate.

Cooling Improvements

Longer cooling conveyors

Balanced airflow fans

Adjustable product guides

Gentler stacking mechanisms

Packaging machines may need height adjustments due to thicker product structure.

Step 8 — Conduct Testing, Calibration, and Quality Validation

Trial Run Checklist

Dough texture consistency

Lamination stability

Forming accuracy

Oven curve calibration

Moisture final measurement

Breakage rate after cooling

Package sealing integrity

Step 9 — Train Operators and Engineers

Double-layer production requires new skills:

Key Training Topics

Speed synchronization

Lamination alignment

Bonding agent management

Oven heat balancing

Troubleshooting layer separation

Cost Planning and Investment Outlook

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.

FAQ

1. Can any factory upgrade to a double-layer biscuit line?

Not all. Space constraints and old equipment may limit feasibility.

2. Must the two dough layers use different recipes?

Not mandatory, but differentiation improves consumer appeal.

3. Does double-layer production slow the line?

During early calibration yes, but final speed can match traditional lines.

4. What is the most common technical failure?

Delamination caused by poor bonding or inconsistent sheet thickness.

5. Does the tunnel oven need to be replaced?

Usually no, as long as it offers adjustable heating zones.

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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).
 
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