Views: 248 Author: Wenva Machine Publish Time: 2026-08-26 Origin: Wenva Machine
A leading Thai bakery and biscuit manufacturer upgraded its ageing 500 kg/h line with a customised automated biscuit production line from Wenva Machine. The new 1000 Series solution combined PLC-based process control, a hybrid tunnel oven, and flexible forming equipment to improve capacity, baking consistency, colour uniformity, and OEM production responsiveness.
| Project Item | Details |
|---|---|
| Customer location | Thailand |
| Industry | Biscuit manufacturing, bakery processing, OEM/contract manufacturing |
| Main products | Hard biscuits, soft biscuits, sandwich biscuits |
| Project scope | New biscuit production line, capacity expansion, product-quality upgrade |
| Original production capacity | Approximately 500 kg/h |
| New design capacity | 800–1,000 kg/h |
| Production line length | Approximately 90 metres |
| Production line model | Wenva 1000 Series |
| Control solution | Full-line PLC centralised control |
| Key equipment | Dough mixer, sheeting machine, laminator, rotary cutter, rotary moulder, hybrid tunnel oven, oil sprayer, cooling conveyor |
| Follow-up cooperation | One repeat order for an additional biscuit production line |
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For biscuit producers serving both branded retail markets and OEM customers, growth is rarely just about increasing output. It also depends on whether every batch can meet the same product standard: consistent colour, stable texture, accurate shape, predictable baking results, and reliable delivery capacity.
This Thailand-based bakery manufacturer had built an established position in the local market and developed a growing international OEM business. However, its existing production equipment had become a constraint. The company needed more than a faster machine; it needed an integrated biscuit manufacturing line capable of supporting product development, improving quality control, and giving the production team greater confidence in daily operation.
Wenva Machine designed and supplied a complete automated biscuit production solution tailored to those needs. The result was a production upgrade that nearly doubled the customer's available capacity while helping create a more consistent foundation for quality-driven biscuit manufacturing.
The customer is a comprehensive bakery food manufacturer in Thailand with many years of industry experience. Its business model combines in-house biscuit brands with OEM and contract manufacturing services for other food companies.
Its portfolio includes several mainstream biscuit categories:
- Hard biscuits
- Soft biscuits
- Sandwich biscuits
- Customer-specific OEM biscuit products
This product mix created both opportunity and operational complexity. The manufacturer needed to maintain dependable daily output for its own branded products while also accommodating different recipes, sizes, shapes, textures, and specifications for OEM customers.
In the increasingly competitive Southeast Asian snack-food market, quality consistency is not a minor production detail. For branded biscuits, visual appearance affects shelf appeal and consumer perception. For OEM projects, stable product quality is directly connected to customer acceptance, repeat orders, and long-term commercial relationships.
The customer therefore identified a strategic requirement: build a more capable automated biscuit production line that could support capacity growth without compromising product standards.
Before working with Wenva Machine, the customer was operating an older biscuit production line with a capacity of approximately 500 kg per hour. While the line had supported the business for years, its limitations had become increasingly visible as customer expectations and order volumes increased.
The existing oven used an outdated control approach. Temperature adjustment depended heavily on operator experience and manual intervention, which made the process more complicated than it needed to be.
In a biscuit factory, baking is one of the most critical stages of the process. Small variations in heat distribution, baking time, airflow, or zone temperature can affect final moisture, crispness, surface colour, shape retention, and product texture. When oven settings are difficult to control accurately, production quality can vary even if the dough formula remains unchanged.
For the Thai manufacturer, the old system placed too much responsibility on individual operators. Experienced staff could often make adjustments based on observation, but this approach made quality stability difficult to standardise across shifts.
The customer also faced product inconsistency within the same batch. Ageing equipment and limited process-control precision made it difficult to achieve stable results on a continuous basis.
The effects were visible in areas that matter to both brands and OEM buyers:
- Uneven baking performance
- Variation in biscuit colour
- Inconsistent appearance between pieces
- Difficulty maintaining a predictable yield rate
- Greater need for inspection and manual adjustment
For an OEM-focused manufacturer, these issues can create operational pressure far beyond the production floor. Inconsistent products may require additional sorting, increase waste, create delivery risk, and reduce confidence among contract-manufacturing customers.
Biscuit colour is often treated as a visual quality standard, but it is also a useful indicator of baking uniformity. If biscuits exit the oven with noticeably different surface colours, there may be inconsistency in temperature distribution, heat transfer, airflow, or residence time.
The customer's old line struggled with uneven colouring between biscuits. This was especially important because the company produced products for external OEM customers, whose quality-control teams may assess product appearance against predefined approval samples.
A more uniform baking environment was therefore essential—not only for appearance, but also for overall production repeatability.
With only one 500 kg/h line, the customer's production capacity was becoming insufficient for growing order volumes. The company wanted to expand its market reach, win more OEM projects, and develop a broader range of biscuit products. However, limited capacity restricted its ability to respond quickly to demand.
The manufacturer needed a line that could deliver greater throughput while retaining the flexibility required for hard biscuits, soft biscuits, and product variations.
Its goal was clear: invest in a modern biscuit production system that could produce competitive-quality biscuits consistently, efficiently, and at a commercially scalable output.
Wenva Machine approached the project as a full production-system upgrade rather than a simple equipment replacement. The solution was built around three connected priorities:
1. Higher capacity for business expansion
2. Better process control for stable product quality
3. Flexible production capability for OEM and multi-product manufacturing
The final solution was a complete 1000 Series automated biscuit production line with a design capacity of 800–1,000 kg per hour.
The supplied line included the core equipment required to support a continuous biscuit production process, from dough preparation through baking, finishing, and cooling.
The main equipment configuration included:
- Dough mixer
- Sheeting machine
- Laminator
- Rotary cutter
- Rotary moulder
- Hybrid tunnel oven
- Oil sprayer
- Cooling conveyor
This integrated configuration allowed the customer to process multiple biscuit types through a coordinated production flow. Depending on the recipe, product design, and process requirements, the line could support the manufacture of both hard and soft biscuits.
The sheeting and laminating sections provide the foundation for controlled dough handling and product formation. The rotary cutter and rotary moulder offer the flexibility needed for different biscuit shapes, patterns, and product styles. After baking, the oil sprayer and cooling conveyor help complete the process before downstream packaging operations.
For a manufacturer handling both proprietary products and OEM orders, this production flexibility was a key part of the investment value.
The tunnel oven was the centrepiece of the quality upgrade. Wenva supplied an advanced hybrid tunnel oven that combines forced hot-air circulation with radiant heating.
This hybrid approach was designed to create a more controlled and uniform baking environment. Rather than relying on a less predictable heat profile, the new oven uses carefully designed baking zones and a more intuitive operating interface to improve temperature management.
The practical objective was straightforward: help the customer produce biscuits with more stable baking performance and more consistent surface colour.
The hybrid tunnel oven contributed to several important production improvements:
- More even heat distribution across the baking zones
- Improved biscuit colour consistency
- Better control of baking conditions
- Reduced dependence on manual operator judgement
- Easier adjustment and daily operation
- Greater repeatability from batch to batch
For the customer's production team, the difference was not only technical. A clearer, more user-friendly oven control system reduced the complexity of day-to-day management and shortened the learning curve for new operators.
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Wenva also integrated a centralised PLC control system across the complete automated biscuit production line. The PLC-based solution connects key production stages, including dough processing, sheeting, forming, baking, oil spraying, and cooling.
Instead of managing each process stage independently through manual experience, the customer could monitor and coordinate key production parameters through a centralised control approach.
This helped the plant reduce the influence of human factors on final product consistency. Real-time monitoring and more standardised settings allowed the production team to establish more repeatable operating conditions across shifts and product runs.
For biscuit manufacturers, automation does not remove the value of skilled operators and process technicians. Rather, it gives them a more reliable platform for managing recipes, observing line conditions, making informed adjustments, and protecting product standards at scale.
The customer's OEM business was an important factor in the line design. OEM biscuit manufacturing requires a producer to respond to changing customer requirements without turning each product change into a lengthy or disruptive production event.
Wenva's technical team therefore focused on flexibility as well as output. The line was designed to accommodate different recipes and product specifications, helping the customer manage a broader range of hard biscuit and soft biscuit applications.
This production flexibility supports several commercial advantages:
- Faster response to customer-specific product requests
- Better adaptability for new biscuit development
- More efficient transitions between applicable product types
- Greater capability to serve multiple OEM customers
- Expanded potential for in-house product innovation
For a company operating in a fast-moving regional snack market, this ability to adapt can be just as important as a high hourly capacity figure.
The new Wenva automated biscuit production line delivered a meaningful step forward in both capacity and manufacturing control.
The original line operated at approximately 500 kg per hour. The new 1000 Series biscuit production line was designed for 800–1,000 kg per hour.
At the upper end of its design range, the new system offered up to twice the previous hourly output. This gave the manufacturer greater headroom to manage higher order volumes, accept more OEM business, and support expansion of its own branded biscuit range.
Importantly, the capacity increase was not treated as an isolated target. The project aimed to combine higher throughput with a more stable and manageable production process.
With the hybrid tunnel oven and centralised PLC control, the customer achieved a higher level of consistency in baking results, biscuit colour, and overall product stability.
The improved temperature control and oven-zone design addressed one of the customer's most visible quality issues: inconsistent biscuit colouring. More uniform heat distribution helped create a more consistent finished appearance, which is particularly important for retail presentation and OEM quality acceptance.
The customer was able to move closer to a production standard where biscuits could be manufactured with more predictable visual and quality characteristics from batch to batch.
The old oven required substantial manual judgement. The new control system and more intuitive operator interface simplified daily use and reduced the degree to which production quality depended on a small number of highly experienced employees.
This is valuable for any food manufacturer seeking stronger process standardisation. When a production line is easier to operate and key parameters are easier to monitor, teams can train staff more efficiently and maintain more consistent procedures across different shifts.
The project therefore improved not only equipment performance, but also the customer's operational resilience.
The new line's ability to handle both soft and hard biscuit production gave the customer more freedom to develop products and broaden its market offering.
For a Thai bakery manufacturer competing in branded and OEM segments, this flexibility provides a practical platform for future growth. The company can explore additional biscuit styles, support different customer specifications, and enrich its product portfolio without being constrained by an outdated single-purpose line.
The customer expressed strong satisfaction with the new production line, especially its ability to consistently produce biscuits that met the company's quality requirements.
This point was especially meaningful because product consistency had been a persistent challenge with the previous equipment. The combination of improved oven performance and PLC-based process control gave the customer greater confidence in the stability of its output.
The production team also positively evaluated the ease of operation of the advanced tunnel oven. A more user-friendly system helped make baking control less dependent on complex manual adjustments and individual experience.
Most importantly, the successful first project led to a repeat order for an additional biscuit production line. For Wenva Machine, repeat cooperation is one of the clearest indicators that a customer has recognised both equipment performance and the value of ongoing technical support.
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This Thai project shows that an automated biscuit production line upgrade can deliver more than higher hourly output. When designed around actual production challenges, it can improve the entire manufacturing foundation of a biscuit factory.
The main outcomes included:
- Capacity increased from approximately 500 kg/h to 800–1,000 kg/h
- Improved baking uniformity and biscuit colour consistency
- More stable product quality across production batches
- Centralised PLC control from dough processing to cooling
- Easier operation and reduced dependence on manual experience
- Greater flexibility for hard biscuits, soft biscuits, and OEM requirements
- A repeat order that confirmed long-term confidence in the partnership
For biscuit manufacturers facing ageing equipment, inconsistent product quality, complex oven operation, or insufficient production capacity, a modern line should be evaluated as a complete system. The best solution is not simply the fastest line available. It is the line that aligns equipment design, process control, product requirements, factory layout, operator usability, and future business strategy.
With more than 40 years of experience in the development and manufacturing of biscuit production equipment, Wenva Machine provides tailored solutions from initial line design through equipment manufacturing, installation, commissioning, and technical support. Our team works with global biscuit and bakery manufacturers to build automated production systems suited to their products, capacity targets, and plant conditions.
If your factory is facing unstable biscuit quality, uneven baking colour, low capacity, difficult oven operation, or growing OEM demand, Wenva Machine can help assess your requirements and develop a customised solution.
Contact Wenva Machine to discuss an automated biscuit production line designed for your product range, factory layout, target capacity, and long-term growth plans.
