Trouble shooting in Biscuit Industry

samar vir singh Problems 1 Shrinky Causes Too strong flour Too strong flour Higher mixing time Too much creaming time Dough temperature above 85 deg F Mix too dry Incorrect panner web speed Incorrect rubber roller speed Less leavening agent Less fat Less sugar Too weak flour Too weak flour Too little mixing time Too little creaming time Mixing too soft Incorrect Baking profile Mix too soft Mix too soft Excessive ammonia Excessive sugar Spaces between biscuits too less Mixing time insufficient Weak flour

2 Spready

3 Flat Biscuits

Leavening agent insufficient High steam pressure on top at the entrance of the oven Heat profile incorrect Fat in liquid condition Strong flour Mixing time too much Stron flour Leavening agent too much Low steam pressure on top in oven 5 Blisters Heat profile incorrect Uneven heat profile Undissolved chemicals

4 Blowy biscuits

S.M.P not dispersed well during creaming 6 Black specs Caused by sugar Caused by milk powder Uncleaned oven band Carbon particles falling in the oven Colour variation linewise Wrong weighment of sugar Inversion insufficient Poor baking Variation in dough pieces weight linewise

7 Pale biscuits

Bran & ash content high in flour less sugar in recipe

8 Dark biscuits

9 Poor impression

Fat too less Improper baking Improper uneven spacing of dough pieces on baking band Moulder checking Incorrect/too soft mix Premature or delayed release of dough piece from cavity Wornout rubber roller Oily dough New moulder Lean recipe

10 Rough surface

11 Taper biscuits

Dough too dry Dough overmixed Higher dough temperature Knife too tightly pressed against moulder Sugar too coarsed Warn die roll bearing High bran & ash content Incorrect mesh size of flour particles Dough too soft Excessive rubber roller pressure Rubber roller too soft/hard

Tailing of bisucits 12 on web

Rubber roller too soft

Higher scrapper blade position Higher extraction roller position New moulding apron Too low feed roller pressure Extreme pressure of extraction roller Improper dough feeding 14 Cut biscuits Cavity not getting filled completely Too much rubber roller pressure Knife position too low Premature release of dough pieces cavity Too soft dough Dry biscuits 15 forming lumps in mouth

13 Half filled cavity

Improper baking Creaming insufficient Low leavening fat Dry mix Insufficient invery syrup

Rapid discolouration of biscuit crust colour Germ oil very high in flour Higher pH of baked biscuit Packing & storage condition unsatisfactory Baking time too little Loss of flavour & 17 aroma 1. Flavour not heat sealable 16 1. Immediatelyafter baking 2. Dough too alkaline 3. Reduing agent added such as SMBS 4. Flour or fat has its own odou suppressing the flavour & aroma biscuit 5. Baking time too little 6. Baking profile incorrect 7. Incorrect dosate of salt in recipe 2. Over a period of 1. Packingn material having insufficient time barrier property 2. Storage condition unsatisfactory

Weight variation linewise from 18 working side to nonworking side Moulder bushing/bearing wornout Moulder setting incorrect Uneven rubber roller pressure Uneven feed roller pressure Wornout knife Uneven knife setting Uneven temperature linewise Weight variation 19 unevenly Non uniform die cavity Detoriated rubber roller Damage knife Unclean knife Creaming insufficient Knife springs tension insufficient 20 Extracted matter Contamination from outside sources

Checking (inherent cracks) Poor baking Sudden cooling Parting of cream 22 sandwiches Cream too flowy Biscuits too warm during sandwiching 21 Coarser sugar particle size Drying agent insufficient in recipe

Incorrect viscosity of cream Oval or distorted 23 shapes Strong gluten stresses Insufficient standing time Cutting die alignment not proper Excessive extract roller pressure Too soft rubber roller Positioning of docker pins not proper Insufficient extraction roller pressure Insufficient bottom heat in the first zone Insufficient docker pins Docker pins penetration insufficient Flour or fat has obnoxious odour Infestation of flour

24 Deep cut

Docker holes not 25 cleared Crackers not fully 26 developed 27 Blowy crackers 28 Bad odour

29 Biscuit too soft

Cross odour contamination due to bad storage of materials/finished goods Overbaked biscuits Incorrect baking profile & time Improper handling and storage before packing Too rapid baking Enzymatic activity in flour high High ash content High ash content in flour Excessive soda in the recipe Powder flavour not properly mixed or ethyl vanillin high Rancidity onset in fat, lecithin or biscuit dust Germ oil very high in flour Bad fat/lecithin Rancid or over burnt biscuit dust Moisture pick up before and after packing is high Germ oil very high in flour Infested/ too old flour Contamination by metallic oxide Exposure to direct heat & sunlight to finished goods Onset of rancidity due to ingredient in recipe Milk powder of bad quality Seperation of mixture of oils used fat on storage Emulsion of fat & water improper Extreme variation in ambient temperature during day & night Water in recipe added at the end of mixing Too solid bottom heat & too little top heat New moulding apron

30 Floury taste

31 Bittery taste

32 Rancid taste

33 Soapy taste

34 Fat bloom

35 Hollow bottom

Poor band 36 impression on bottom of biscuit

Oven band choked with carbon particles Biscuit curling concave upward or 37 downward on oven Incorrect top & bottom heat profile in band first zone

Position of fibre scrapper knife too low Surface texture of 38 cookies do not saw cracks Incorrect baking profile Steamy oven Flour too strong Sugar particles size too fine Lack of surface 39 sheen on cookie crust

Creaming insufficient Mixing time insufficient Emulsifier insufficient

Bran & ash content high in flour

e shooting in Biscuit Industry

Solutions feed small dough pieces uniformly along the length of the hopper Try Blending of flour (1:1) Reduce mixing time Reduce creaming time use cold water/ice for mixing A. Increase water in the recipe B. Try water spray Adjust conveyor speed Adjust rubber roller speed Increase ammonia Increase fat Increase sugar Try strong flour Try Blending of flour (1:1) Increase mixing time Increase creaming time Reduce mixing water Increase bottom heat in first zone Avoid water spray Give standing time to the dough Cut down ammonia Cut down Sugar Increase spacing of dough pieces on band Increase mixing time Try strong flour A. Try blending of flour B. Add corn starch A. Increase ABC B. Increase SBC C. Increase Fat Adjust damper of first extract chimney Increase bottom heat in first zone Use plastic aerated fat Try weak flour Reduce mixing time Try Blending of flour (1:1) A. Reduce ABC B. Reduce SBC A. Close damper in first chimney B. Introduce water spray Readjust top/ bottom heat in the first zone adjust oven temperature for removal of heat spots Disperse chemicals in water by mechanical agitation + Sieve before addition

Make milk solution 1:1.5 & add to creaming Check for undissolved sugar crystals Pulverize sugar finely Disperse milk powder in water, free of lumps, sieve & use Clean the band Clean & decarbonize ducts & chimney. Correct line damper & check proper heat profile Check weighment of powdered sugar, invert syrup & liquid glucose Change the invert syrup/increase the quantity Check the heat profile A. Change knife setting B. Readjustnmoulder & feeder roller adjustment C. Adjust rubber roller pressure Change in flour A. Increase powdered sugar B. Increase invert syrup C. Increase dextrose sugar D. Add corn starch Increase fat in recipe Check & correct heat profile Reduce spacing between dough pieces on band Clean the moulder Make correct mix by adjusting water & mixing time 1. Adjust rubber roller speed 2. Adjust direction of moulder web by adjusting the position of guide roller Change the extraction roller 1. Use called water for mixing 2. Reduce mixing time Clean moulder with wire brush, clean & run moulder idle with LOD 1. Use teflon coated moulder 2. Increase fat/emulsifier in the recipe Use softer mix or water spray Reduce mixing time use cold water/ice for mixing Reduce dough pressure at the nip of the moulding roller User finer particle size (60 mesh) sugar Change moulder bearings Change the flour Reject the flour Correct dough consistancy Run moulder with minimum rubber roller pressure & condition the moulder web with fat & flour or with steam Use extraction rubber roller with 65 moh hardness - use nitrile rubber or EPDM rubber for coating roller Correct dough consistancy

Lower the knife position Reduce rubber roller pressure to minimum required for extraction Condition the web with fat & flour or put waterbath below web for easy release of dough pieces from cavity Adjust gap between feed roller & moulder to 1/4" + 1/32" reduce rubber roller pressure to release biscuits from cavity & moulding apron with minimum tailing Break the dough into small pieces and feed evenly along the length of hopper Feed small dough pieces uniformly along the length of the hopper Adjust gap between feed roller & moulder Adjust rubber roller pressure to minimum just enough to extract dough pieces Adjust knife position Avoid oily dough Reduce mixing time & use cold water for mixing reduce water in the recipe

Increase biscuit moisture Increase creaming time to entrap air Increase leavening fat & use it in plastic condition Take softer mix Increase invert syrup

Reject the flour Adjust the recipe to correct pH of biscuit between 6.5-7.6 Improve packing material & storage condition Increase baking time Use flavour with more heat stability

adjust recipe Eliminate reducing agent

Reject flour or fat with obnoxinous flavour Increase baking time Improve baking profile Correct salt level in the recipe Select better packing material & construction Improve storage condition

Replace bushing/bearing reset moulder in position Adjust rubber roller pressure Set feed roller parallel to moulder Regrind/replace knife Set knife correctly Correct line damper setting Reengrave cups or replace the moulder Replae rubber roller or take grinding cut if shore hardness of rubber O.K. Regrind/replace knife Clean knife Use fat in plastic condition & increase creaming time Change the springs Sieve flour, use magnet in sugar grinder & flour sifter, sort biscuit scraps in polybags/drum only Sieve all material before use Keep away maintenance tools, nut bolts & other materials littering around the shop floor. Give good bottom baking Cooling gently-cooling time - 1.5 times baking time Store cream in cold room to set Allow biscuit to cool before sandwiching Sugar not pulverized to correct mesh size. Use 100/120 IS mesh sieve size Use SMP & Corn starch in recipe Correct mixing time so that specific gravity of cream is 0.92. Use soyalecithin as emulsifier in recipe according to ambient temperature. If required use gum-acacia in recipe Condition the dough. Mellow it by use of chemical or enzymes. Give more standing time & use relaxing conveyor before cutting Adjust panner web conveyor speed Cutter to be adjusted/reset to avoid deep-cut Reduced extract roller pressure Use rubber roller with 75 moh hardness Docker pins to be realigned/reset Readjust rubber roller pressure Preheat the returned band and increase baking temperature in the first zone Change the cutter die Increase extract roller pressure Reject flour or mask the odour with extra butter flavour Reject flour

Improve storage condition Improve baking profile Correct baking profile & increase baking time Pack biscuits as fresh as posssible from oven. Store biscuit trays in hot room or dehumidified room. Improve packing material & storage condition Change baking profile & time Reject flour Reject flour change the flour reduce or neutralize excessive soda Use powdered flavour in the form of vanilla sugar Reject rancid ingredient in recipe Reject the flour Reject fat/lecithin Reject the biscuit dust used for recyling Check moisture before packing and reject if found high. Improve packing & storing condition and packing material. Reject the flour Reject the flour Avoid direct contact of iron surface with dough Add anti-oxidant blend to emulsion paste. Reject rancid ingredient Change the milk powder Used hydrogenated fat constituted of single oil desirably 1. Follow the procedure for making emulsion carefully 2. Used Poly-sorbate as emulsifier store biscuit in cooled dark place Add all water in recipe at solution stage before adding flour Correct baking profile

1. Condition the web with flour & fat mixture 2. Used steam for conditioning moulding apron 1. Clean oven band with rotary wire brush rollers 2. Apply petroleum jelly on band and heat the band to 450 deg C for half and hour and clean band mechanically with wire brushes

Correct top & bottom temperature in first zone

Correct position of fibre knife on oven band.

Correct the baking profile Increase opening of chimney dampers of first zone 1. Use soft flour & added corn starch 2. Use phosphated starch in recipe Use sugar with coarser particle size and replae part of powder sugar by S-30 size sugar granules

Increase creaming time Increasing mixing time Increase emulsifier in recipe Add dextrose sugar in recipe Increase corn starch in recipe Incorporation cotton seed flour in recipe Increase milk powder in recipe Change the flour