Chocolate Wafer Biscuit Production Flow
1. Batter Making
Batter making is the first step for producing chocolate wafer biscuit. First of all, calculate the water volume according to the flour weight, then mix and stir them, and the stirring time is usually within 3-3.5 minutes. After stirring the mixture for about 1 minute, palm oil, ammonia powder, baking soda, edible salt and other ingredients should be added and stirred together. After fully stirring, the batter is placed into the storage barrel, and it is ready to be delivered to the batter container on the baking oven.
Batter mixer cleaning: After production for each shift is complete, 1/3 barrel of water is added into the mixing barrel, and clean water is used to remove flour or batter that sticks to the inner wall. Press the Manual Stir button on the control panel for about 30 seconds, and then drain the water from the ball valve that is set on the behind. After the mixing barrel is cleaned, it is turn for the storage barrel. 1/3 barrel of water is put into the mixing barrel first, and then it is transferred into storage barrel. Or, you can directly put water into the storage barrel. Then, clean the storage tank in the same way as mixing tank.
Maintenance: After cleaning, the batter mixer must be dried in case water flows into electric box which can lead to short circuit. The surrounding water needs to be cleaned with the help of mop, and make sure that there is no water leaking into electric box and motor.
Caution: The mixing tank and storage tank mustn’t run without any batter.
Equipment: Batter mixer
Power supply: 3 phase, 380V, 50Hz
Motor power: 5.5kW
Motor current: 12.62A
Stirring speed: 1420r/min
Centrifugal pump capacity: 4m3/h
Mixing tank capacity: 235L
Storage tank capacity: 235L
2. Batter Delivery
There are two delivering modes which are manual mode and automatic mode, and this selection can be realized on the control panel. For the manual mode, someone needs to keep an eye on the batter container which is on the baking oven during transportation, and the batter should not over 4/5 of the container in case the batter flows out, and the money is wasted. On the other hand, if automatic mode is selected, the batter will be transferred into the container automatically. When the lower detection probe doesn’t receive signal, it means that the batter level is lower than the lower probe, and the batter mixer will automatically carry the batter into container until the batter level reaches the upper detection probe. When the batter is in contact with upper probe, the delivery stops immediately. This process is cycled again and again, and the batter is successfully transferred.
Delivery pipe cleaning: The pipe end on the batter container of oven needs to be closed off by washer and hoop, and select the manual mode to make the clean water flow back into the storage tank. In this way, the cleaning is finished.
Caution: If the pipe is blocked during delivery, the delivery must be stopped at once, or press the Emergency Stop button on the control panel. Then, disassembly the hoops on both ends of the pipe and remove the stuck object. Make sure that it can transfer batter normally before start production.
3. Batter Feeding and Baking
Check the coal gas, valve for compressed air as well as parameter setting on the control panel, and then start the baking oven if there is no problem. The speed is usually set at 15 pieces/min, and make sure that the machine is in normal condition. Then, start the heating fan and heating device, and wait until the plate temperature reaches up to the preset value. Then, install the batter feeding pipe onto baking oven, and fix it. Start feeding, and the batter flows through the pipe to the designated area on the plate evenly. The plate folds automatically and moves into baking tunnel, and the wafer biscuit is made after 90 seconds of baking.
Maintenance: After the production for a shift is finished, batter and other foreign objects inside the oven should be removed, otherwise, these objects will be deposited which may lead to short circuit or damage of the electrical parts.
Caution: During batter feeding, if there are any undesired things near the plate, please use the air gun to remove them.
Equipment: Baking oven
Power supply: 3 phase, 380V, 50Hz
Compressed air: 0.9m3/min, 0.8Mpa
Baking time: 90 seconds
Control panel: Mitsubishi, Japan
Positioning control for feeding: Delta encoder
Proximity switch: ROKO
4. Demoulding and Discharging
The plate will be automatically opened when it moves to the discharge port of baking oven, and the wafer drops down on the wafer receiver slightly, then it is carried to the conveyor. Meanwhile, there is a brush on the top of conveyor of sheet receiver, and it can automatically clean the waste material near the wafer edge during transportation.
Equipment: Wafer sheet receiver
Power supply: 3 phase, 380V, 50Hz
Motor power: 0.18kW
Motor current: 0.58A
Motor speed: 1320/129r/min
Conveyor: PU orange belt
5. Automatic Air Cooling
The wafer biscuit moves to our cooling machine, and it is cooled naturally by air to lower its temperature. So, the biscuit won’t be too crisp, and this can avoid cracking problem which is caused by collision during laminating process.
The running speed of the conveyor is the same as the demoulding speed of baking oven. The wafer moves in a direction that is vertical to the conveyor, so the horizontal length is short, but the delivering time is quite long. In this way, our machine won’t take up too much space.
Caution: During the transportation, if the wafer position is deviated, please fix it as soon as possible.
Equipment: Cooling machine
Power supply: 3 phase, 380V, 50Hz
Motor power: 0.81kW
Motor current: 2.78A
Motor speed: 1360/20r/min
Conveyor: PU belt
6. Wafer Checking
The wafer shape is automatically detected, and if there is a missing corner, the wafer will be picked out and disposed. There are two photoelectric switches on top of the conveyor, one is on the left and the other is on the right. These two switches are used for inspection, and the picking out precision can be adjusted. There are two corners on one side of the wafer, if any one misses an area that reaches the preset value, the conveyor will automatically descend to carry the unqualified wafer to the recycling container that is set under the conveyor. In addition, this function can be enabled or disabled.
Under the condition that the coating process is in disorder, press the Reset button to descend the conveyor, and the wafer is delivered to the recycling container to avoid miss operation.
Caution: Please check the connecting pipe for cylinder in case it is in the wrong way. Meanwhile, the recycling container should be cleaned in time if it is full of wafer.
Equipment: Wafer picking machine
Power supply: 3 phase, 380V, 50Hz
Motor power: 0.18kW
Motor current: 0.58A
Compressed air pressure: 4kg/cm2
Conveyor: PU orange belt
7. Cream Coating
The cream spreader is designed to coat cream on the wafer and then laminate the cream-filled wafer. When the wafer moves to the belt of cream spreader, and the pre-determined delay time which is detected by the photoelectric switch is met, the belt rises, and cream is coated on the wafer surface by the coating roll. In addition, the cream thickness can be adjusted by the digital display hand wheel which is set behind the cream tank.
After coating, the wafer will be carried to the rotary laminator to finish the lamination process. Then, the wafer biscuit is transferred to the cooling cabinet to finalize its shape.
Cream spreader cleaning: After the production for a shift is finished, the cream tank needs to be cleaned with water, but the water should be kept away from control cabinet. Waste material and broken wafer inside the rotary laminator must be collected, and use clean water to wash the machine.
Caution: The stirring function must be used for the cream tank, and it can maintain the flowability of cream.
Equipment: Cream spreader
Power supply: 3 phase, 380V, 50Hz
Motor power: 3.59kW
Motor current: 13.51A
Compressed air pressure: 4kg/cm2
Laminated layer: 2-10 layers
Control panel: Mitsubishi, Japan
7.1 Production of Chocolate Coating
According to the recipe, shortening, sugar, cocoa powder and other ingredients are put into the mixing tank, and stir them until the chocolate coating expands. Then, deliver the chocolate coating to the cream tank that is set on the cream spreader. With the help of cream spreader, the chocolate can be coated on the wafer, and its thickness is adjustable.
Equipment: Cream mixer
Power supply: 3 phase, 380V, 50Hz
Motor power: 5.05kW
Stirring speed: 61r/min
Total volume for stirring: 242L
Effective volume: 190L
8. Cooling and Shape Forming
The semi-finished wafer biscuit is delivered to the cooling cabinet to form its shape.
Equipment: Cooling cabinet
Refrigerating power: 10HP
Refrigerating capacity: 1818kcal/h (5°C /35°C)
Humidity: 60%
Centrifugal fan capacity: 6000m3/h
Wind pressure: 580Pa
9. Delivering
When the wafer is detected by the photoelectric switch that is set on the conveyor before cutting machine, the cylinder will automatically descend to block the following wafer. When the previous wafer moves to the cutting channel through opening-closing plate, the cylinder resets and rises, allowing the entrance of next wafer. The electromechanical control and power supply of the conveyor are supplied by the electric control box of the cutting machine, and the PLC is adopted to automatically control the electric parts.
Equipment: Conveyor
Power supply: 3 phase, 380V, 50Hz
Motor power: 0.18kW
Conveyor: PU orange belt
10. Wafer Cutting
When the semi-finished wafer moves into the cutting channel, the cutting machine automatically pushes the wafer to the first cutting tool. After processing, the wafer is carried to the second cutting tool by the pushing device, and then the cutting is finished. During this period, the opening-closing plate is closed tightly, and it won’t open until the pushing device moves to the starting position.
Caution: Please lubricate the main shaft frequently.
Equipment: Cutting machine
Power supply: 3 phase, 380V, 50Hz
Motor power: 0.75kW
Control panel: Siemens
Cutting mode: Steel wire or stainless steel blade
| Model of Automatic Wafer Production Line | Tastes Available | Filled Layer Number |
| 27 Mould | Chocolate, vanilla, strawberry, lemon, cream, peanut, strawberry and chocolate, other desired taste | 2-10 layers |
| 33 Mould | ||
| 39 Mould | ||
| 45 Mould | ||
| 51 Mould | ||
| 65 Mould | ||
| 75 Mould |
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