In forming sections the dough is passed through several rolls to form sheets , these sheets are then converted into One uniform sheet of desired thickness it is normally 6-5mm.
Moulders and cutters are used to cut sheet or convert dough into desired shape and size
Stages in forming
laminators : Dough after mixing in tipped into laminators hoppers r with some mechanical /pneumatic tilting . There are two type of laminators.
Horizontal type laminators : If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done. The lamination and the controls are visible . Changing webs and rolls are very easy .Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronised with rest of the plant .11-14 sheet per batch
Vertical type laminators : Vertical type of laminators have been there for very long its useful if space is aconstraint.Dough is passed through three stage rollers and after lamination of sheet it cut into sheets which are then carried to rollers through inclined webs .
Gauge roll stands . Reduction in sheet is achieved through numerous gauge roll s stand . Popular are three stand gauge rolls or four stand gauge roll . Reduction are achieved in stages as not to create too much stress on the sheet , webs are provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet.Best results are achieved through four stand gauge rolls . These gauge roll are of different dia depending upon the plant capacity could be as small as 6" ,8"' , 10" , 12'' and 14'' . Speed are set as per plant and cutter rpm . Guage roll speed has to be increased in every stand so as to maintain the flow of sheets .
Dough sheet conditioning : Dough sheet conditioning is done as per the ambient conditions in the plant .
Steam spray - to moist the web surface
Blower : to dry the dough surface.
Flour dusting : to dry the wet surface of the dough .
Above process is mainly for cutting Variety .
Toppings : Toppings are done through mechanical, vibratory or sprays . means where a hopper is placed above the plant line after the cutter . The toppings could be milk , salt , sugar or cashew , pista bits .
Rotary cutter :
Rotary cutter consists of cups which are a attached to the cutter shell.This shell is then fixed to the shaft and drive mechanism . Two types of rollers are popular One is complete on mould shell where cups are attached in the cavity designed for the cups with dowel pins .
Second concepts is also very popular when shell has several rings fitted over it .
This helps in easy removal of damaged part and also very helpful in taking various trials .
Cuter is coupled with rubber roller of shore hardness approx -80-85 . Rubber roller or the pressure roller helps in releasing wet biscuit .
RPM : Rotary cutter speed is set as per plant capacity and baking time , Variety .
Band coverage efficiency : It is ratio of total surface area of cutter -moulder / no biscuit cups
Moulding Roller :It is applied for short dough ,The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to The hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on The die roller surface . These die roller have dies engraved into it . Dough pieces are then released by feed roller which pushes The dough into The dies.