Suzanne Callander reports on the different cookie and biscuit production technologies and solutions that can help bakery manufacturers ensure their production lines continue to meet productivity efficiency and sustainability targets.
The cookie and biscuit industry is in a constant state of evolution – driven by both consumer demand and a growing need for more sustainable production. For many bakeries choosing the right production solution today often comes down to finding a balance between product characteristics, energy efficiency, and long-term flexibility.
From artisanal-style products to high-volume lines producing thousands of pieces per hour, bakeries now have more options than ever when it comes to production equipment and technology available to them.
In recent years, one of the most significant innovations in the biscuit industry has been the introduction of automated production lines which have led to faster and more efficient production when compared with more traditional mostly manual operations. Automated production lines are now able to handle all stages of the biscuit making process – from mixing and shaping the dough to baking and packaging the final product. These increasing levels of automation have significantly boosted production capacity and efficiency, allowing manufacturers to meet the growing global demand for biscuits and cookies.
Key benefits of automated production lines include their ability to produce a wide variety of biscuit shapes and sizes with minimal manual intervention. This level of flexibility allows bakeries to adapt quickly to changing market demands. Additionally, the precision and repeatability offered by automated lines helps ensure consistent product quality, resulting in a more uniform and appealing final product. Overall, the introduction of automated production lines has transformed the biscuit making industry, making it more efficient, flexible, and scalable than ever before.
Energy efficiency
The baking process is a critical stage in biscuit production, and traditionally it has also been an energy intensive process. So, the development of more energy-efficient technologies has been a priority here, to help bakeries reduce their environmental footprint and operating costs. Golden Bake cites, for example, the use of infrared radiation technology in biscuit ovens which has led to significant energy savings through reduced baking times and improved heat transfer efficiency.
According to US-based Bakery Technology Equipment (BTE) the role of energy-efficiency has become key in a world where sustainability is now so much more than just a buzzword. It argued that, as manufacturers strive for greener operations, energy-efficient solutions are not only environmentally responsible but also economically beneficial and integrating more energy efficient equipment onto the production line can have a significant impact. It can, for example, reduce operational costs – according to the US Department of Energy, industrial equipment that utilises less energy can help save up to 20% on utility bills.
Many regions are also implementing more stringent environmental regulations and the adoption of energy-efficient baking equipment can help ensure organisations remain compliant. Also, reducing energy consumption of the production process will have a big impact when it comes to lowering an organisations carbon footprint, and aiding in global efforts against climate change.
Tunnel vision
Traditionally, for smaller-scale biscuit and cookie production, bakeries have relied on deck ovens or rack ovens. These ovens are versatile and are still a good fit today for artisan producers or bakeries where product flexibility is more important than volume. However, as production demands increase, tunnel ovens have become the favoured solution for mid-size to industrial-scale cookie and biscuit production, according to Henrik Tillander, Industrial Sales Manager at Sveba Dahlen.
Now available in gas or electric heating configurations, tunnel ovens are designed for continuous baking. Their conveyor-based design ensures consistent throughput and uniform results. For cookie and biscuit producers, this can result in greater efficiency, reduced labour, and the ability to scale up without compromising quality.
“What makes tunnel ovens particularly suitable for use on cookie and biscuit production lines is their combination of flexibility, energy efficiency and reliability,” says Henrik. “Sveba Dahlen tunnel ovens are available in normal temperature (up to 320°C) or high temperature (up to 500°C) versions to meet specific application needs.” This flexibility allows bakers to handle a wide range of products – from delicate meringues and mooncakes to traditional cookies, biscuits and even bread. “One of the key strengths of our electric tunnel ovens lies in their even heat transfer. For products like meringues, which are highly sensitive to temperature fluctuations, consistent heat is essential to achieving the right texture and avoiding dryness,” he continues. “Sustainability is becoming increasingly important from both environmental and cost perspectives. Electric tunnel ovens have proven to be energy-efficient, with designs that minimise heat loss and optimise energy use.”
The modular design of tunnel ovens also makes it possible to expand the oven with additional zones as production needs grow. This future-proof approach can help bakeries adapt to changing demands without replacing entire lines.
Highlighting another key factor in modern baking solutions, Henrik pointed to usability. “Technology should empower bakers, not complicate their work,” he says. “Our tunnel ovens are designed to be user-friendly, offering intuitive controls and reliable automation. This reduces training requirements and also provides bakers with the creative freedom to focus on product development and quality rather than daily operational concerns.”
Digital monitoring and control systems are also transforming how bakeries manage production. By tracking energy consumption, baking profiles, and output data in real time, it is much easier to fine-tune processes to maximise efficiency and consistency.
Offering an example to highlight the benefits of tunnel ovens, Henrik pointed to a customer specialising in delicate meringue-based products which require extremely stable baking conditions –even minor temperature fluctuations can affect texture, colour, and moisture content. By specifying an electric tunnel oven, the customer was able to achieve the consistency it needed for this product line while reducing energy consumption compared to the previous setup. The result was improved product quality, lower production costs and a more sustainable process.
Tracking solutions for oven belts
Solid steel bake oven belts are known to deliver good performance in terms of bake quality due to their excellent heat transfer and thermal conductivity. However, stability is also key – a solid or perforated steel belt needs to keep its shape and stay flat as it passes through the intense heat of the oven to ensure consistent product quality and easy discharge.
“This performance depends on the belt running straight and true – any movement will impact the smooth running of the oven and the quality and consistency of the bake,” warns Marko Leber, Segment Manager at IPCO. “And the quality of the belt isn’t the only factor that needs to be considered.”
For a belt to track properly, the line and all the parts that touch the belt must be straight and level with gravity and with each other. While a properly designed conveyor will track straight and true, conditions are rarely, if ever perfect – temperature changes alone are enough to cause the belt to track one way or the other – so it is advisable to add some form of tracking to steel bake oven belts.
Guide rollers offer the most basic solution and come in two forms – fixed and spring-loaded. “Generally speaking, fixed guide rollers are not a good solution as they can wear down quickly, risking damage to the belt edge. Spring loaded guide rollers are less prone to wear and easily mounted to a conveyor frame. However, if either type is mounted closer to the drums than 10x the width of the belt, they will be incapable of correcting belt position and, sooner or later, will actually end up causing damage,” said Marko. He pointed to the IPCO Compact Belt Tracking (CBT) system as being able to provide a good solution when active tracking is required on an existing conveyor and a rebuild is not practical or desirable. “Previous CBT models used a physical belt edge detector but the latest system employs an optical sensor instead, eliminating any contact with the belt edge and enabling increased tracking speed and precision,” he says.
The optical sensor is able to continuously monitor the position of the belt edge. Any deviation immediately triggers a corrective action to restore smooth, straight running. The tracking effect is achieved by tilting rollers that cause the belt to move laterally in the appropriate direction. The tracking system can be mounted to an existing conveyor, usually with little modification needed.
Turning to turnkey
In the bustling world of cookie and biscuit production, efficiency is key, and that’s where turnkey solutions can come into play, according to BTE. Turnkey solutions should be perfectly synchronised so that every piece of equipment works together in harmony and it should be provided as a complete package from start to finish. This approach allows bakeries to streamline their whole production process as everything – from the cookie mixing system to the biscuit cooling tunnel – should be designed to ensure smooth transition and minimal downtimes.
“The beauty of turnkey solutions lies in their ability to transform complex processes into streamlined operations,” says a BTE spokesperson. Moreover, these solutions are customisable so bakery manufacturers can opt for specialised machinery such as the rotary moulder for biscuits or biscuit laminating machinery – tailored specifically to their own unique production needs and they don’t need to pay for unused functionality.
Smart packaging
Packaging also plays a crucial role in the biscuit industry, as it not only protects the product but also serves as a key marketing tool. In recent years, the development of smart packaging solutions has been a major innovation that is changing the way biscuits are packaged and presented to consumers. Golden Bake highlighted technologies such as intelligent labels, QR codes, and interactive packaging, which offer new ways to engage with consumers and provide them with information about the product.
For example, intelligent labels embedded with sensors can monitor the freshness and quality of biscuits throughout the supply chain. Similarly, QR codes on biscuit packaging can give consumers access to detailed product information, recipes, and promotional offers, enhancing the consumer experience. These smart packaging solutions not only benefit consumers by providing them with valuable information but also allow manufacturers to track product performance, improve inventory management, and strengthen brand loyalty.
Smart packaging solutions are also helping biscuit makers comply with increasingly stringent regulatory requirements related to food safety, traceability, and sustainability. By leveraging these innovative technologies, manufacturers can demonstrate their commitment to producing safe, high-quality products while building trust and loyalty among consumers. As the biscuit industry continues to embrace smart packaging solutions, manufacturers will have new opportunities to differentiate their products, build stronger relationships with consumers, and drive growth in the market.
Editorial contact:
Editor: Kiran Grewal kgrewal@kennedys.co.uk
