Versatile High-Fat Dough Solution
Industrial Soft Biscuit & Cookie Production Line
Master the art of Short Dough processing. Our modular line integrates interchangeable Rotary Moulder and Wire Cut units, allowing you to produce standard Digestive Biscuits and premium Butter Cookies on a single system.
Mastering High-Fat &
Short Dough
Unlike hard biscuits that rely on gluten, soft biscuits and cookies use high-fat formulas (Short Dough). The challenge lies in processing this sticky, crumbly dough without deforming the intricate patterns.
Loyal’s Soft Biscuit Line is engineered for this specific task. By integrating a high-pressure Rotary Moulder with an optional Wire Cut System, we enable you to produce everything from standard Digestive biscuits to gourmet Butter Cookies on one line.
Achieve premium texture with fat content handling capability up to 40%.
Precision Moulding
Our Rotary Moulder uses an engraved alloy roller to press dough into shapes. The seamless canvas belt extraction system ensures even sticky high-fat dough releases perfectly, preserving the finest logo details and patterns.
Wire Cut Versatility
Expand your portfolio. By adding a Wire Cut Unit, you can produce cookies with chunks (chocolate chips, nuts) or unique extruded shapes. Switching between moulding and cutting takes less than 30 minutes.
Hybrid Baking Profile
Soft biscuits require a delicate balance of heat to remain crumbly yet fully baked. Our Tunnel Oven offers independent top/bottom heat control zones, preventing “burnt bottoms” while ensuring the center is perfectly cooked.
From Dough to Golden Biscuit
A simplified, high-efficiency process. Since Short Dough requires no gluten development, we skip the laminator and move directly to Precision Moulding.
Soft Biscuit Process Flow
01
Horizontal Mixing
Gently blends flour, fat (>20%), and sugar. Low speed ensures ingredients mix without developing gluten elasticity.
02
Dough Feeding
The crumbly dough is tilted into a hopper and crushed by a kibbler, ensuring a consistent feed to the moulder.
03
Rotary Moulding
The Core Step. A feed roller forces dough into engraved molds, forming the biscuit shape and pattern instantly.
04
Wire Cutting (Opt)
Switch to this unit for Cookies. Dough is extruded through nozzles and sliced by a wire for a handmade look.
05
Tunnel Baking
Biscuits travel through a long Tunnel Oven (Gas/Electric). Precise zoning ensures the center cooks before the edges burn.
06
Oil Spraying
Immediately after baking, a fine mist of oil is sprayed to enhance color, gloss, and savory flavor.
07
Cooling Conveyor
Natural air cooling on a long conveyor allows the fats to solidify, setting the biscuit structure for packing.
08
Star Wheel Stacking
Biscuits are automatically flipped and stacked into neat rows (Penny Stacking) for the packaging machine.
Core Machinery for Soft Dough
Processing high-fat dough requires specialized handling to prevent sticking and deformation. Our modular system allows you to switch between standard biscuits and fancy cookies effortlessly.
High Precision Forming
Rotary Moulder Machine
The heart of soft biscuit production. It uses a three-roller system: a grooved feed roller forces dough into the Engraved Mould Roller, while a rubber roller presses the canvas belt against it to extract the formed biscuit. Our “Endless Canvas Belt” design ensures 100% extraction success even for very sticky doughs.
Seamless Canvas Belt
Pneumatic Tracking
Quick-Change Roller
Speed Sync Control
Cookie Versatility
Soft Biscuit Forming Machine
Transform your line into a cookie factory. This unit can be rolled into position to replace the Rotary Moulder. It extrudes dough through custom nozzles and slices it with a high-speed wire (up to 80 cuts/min). Perfect for producing Chocolate Chip Cookies, Butter Cookies, and Jenny Cookies with high fat/chunk content.
Servo Motor Drive
Weight Accuracy ±1g
Touch Screen Recipe
Multi-Nozzle Options
Baking Technology
Hybrid Tunnel Oven
Soft biscuits are prone to spreading if not baked correctly. Our oven features independent top and bottom heat control in each zone. We typically recommend a Direct Gas Fired (DGF) entry zone to quickly set the structure, followed by convection zones to achieve uniform golden color and moisture removal.
PID Temp Control
Auto Band Tracking
Gas or Electric
Safety Flameout Detect
Versatile Product Portfolio
From classic teatime biscuits to premium gift cookies. Our line handles doughs with fat contents ranging from 18% to 45%, giving you the flexibility to adapt to market trends.
Moulded Soft Biscuit
Examples: Digestive, Shortbread, Marie. Characterized by intricate surface patterns, uniform thickness, and a crumbly texture.
Wire Cut Cookie
Examples: Choco Chip, Cranberry Cookies. Rough, handmade appearance with visible chunks (chocolate, nuts) inside.
Deposited / Extruded
Examples: Jenny Cookies, Butter Rings. High fat content allows for 3D extrusion and unique twisted shapes.
Technical Specifications
Our lines are categorized by Working Width. The wider the belt, the higher the capacity. All models support both Rotary Moulding and Wire Cut modules.
| Model | Working Width | Capacity (Soft) | Capacity (Cookie) | Oven Length | Energy Source |
|---|---|---|---|---|---|
| LY-S600 | 600 mm | 100 – 200 kg/h | 80 – 150 kg/h | 20 – 30 m | Gas / Elec |
| LY-S1000 HOT | 1000 mm | 400 – 600 kg/h | 300 – 500 kg/h | 40 – 60 m | Gas / Elec |
| LY-S1200 | 1200 mm | 800 – 1000 kg/h | 600 – 800 kg/h | 60 – 80 m | Gas (LPG/CNG) |
| LY-S1500 | 1500 mm | 1200 – 1500 kg/h | 1000 – 1200 kg/h | 80 – 100 m | Gas (LPG/CNG) |
Space Planning: Biscuit lines are typically long (30m – 120m).
We provide free CAD layout design to fit the line into your existing or new factory.
ROI Strategy: Soft vs Hard Biscuit
Investment decisions depend on your target market. Soft Biscuit Lines offer a lower entry barrier and higher product variety, while Hard Biscuit Lines are built for massive volume production of staple snacks.
High Variety / Premium
Soft Biscuit Line
Ideal for Digestive biscuits, Shortbread, and Cookies. No laminator required means a shorter line and lower startup cost.
Initial Equipment Cost
Lower (No Laminator)
Product Profit Margin
High (Cookies)
Factory Space Required
Medium
High versatility (Biscuits & Cookies)
Shorter ROI period
Recipe (fat content) is sensitive
High Volume / Staple
Hard Biscuit Line
Designed for Soda Crackers and Petit Beurre. Requires complex sheeting and laminating equipment for layering dough.
Initial Equipment Cost
Very High
Product Profit Margin
Low (Volume Based)
Factory Space Required
High (Long Line)
Massive output capacity
Staple food market stability
Huge space & capital needed
Live Factory Operation
See our Soft Biscuit Production Line creating premium treats in client factories worldwide.
Client Success Stories
See why manufacturers trust Loyal for their biscuit and cookie production needs.
“
Bonjour, Je voudrais remercier comlete equipe de LOYAL. Au nom, il m’a bien accueilli pour aujourd’hui. J’ai visité l’unité de production de machine de biscuits et de macaroni. Et je voudrais les commander aussi. Merci bien.
“
The quality and craftsmanship of the equipment are excellent. It exceeded my expectations and it was a perfect transaction.
More Than Just Machinery
Soft biscuit production is an art of balancing fat ratios and baking profiles. Loyal provides the technical expertise to ensure your final product texture is perfect.
Formula Tuning
Short dough is sensitive. We help you adjust the Fat/Sugar/Flour ratio. Whether you want a crunchy Digestive or a melt-in-mouth Butter Cookie, our food technologists are here to guide you.
Custom Mold Design
Your brand logo matters. We provide CNC High-Precision Engraving for your rotary moulder rollers. We can replicate any intricate pattern or logo with sharp definition and perfect release properties.
Energy Saving Oven
The oven is the biggest energy consumer. Our Tunnel Ovens feature High-Density Rock Wool Insulation and heat recovery systems, reducing gas consumption by up to 15% compared to standard models.
Global Installation
From layout planning to final commissioning. Our engineers will fly to your factory to install the line, connect the gas/electric utilities, and train your staff on operation and maintenance.
Frequently Asked Questions
Expert answers about Soft Dough & Cookie manufacturing.
Can I produce Hard Biscuits (Soda Crackers) on this line?
No. Hard biscuits require a Laminator and a series of Gauge Rolls to create dough layers and gluten networks. This line is specifically designed for “Short Dough” (Soft Biscuits & Cookies) which uses a Rotary Moulder directly. If you need to produce both, we recommend a “All-in-One” line configuration (which adds laminators upstream).
How do I switch from Rotary Moulding to Wire Cutting?
Our line is modular. The Wire Cut Unit is typically mounted on wheels. You can simply roll it into position over the conveyor belt or enable it via the PLC if it’s permanently installed. Switching production modes usually takes 20-30 minutes, primarily for cleaning the hopper.
Which oven heating source is better: Gas or Electric?
For commercial production, Gas (LPG or Natural Gas) is highly recommended due to lower running costs and the ability to provide powerful “Direct Fire” heat, which gives biscuits a better color and volume. Electric ovens are cleaner but significantly more expensive to operate unless your local electricity rate is very low.
How long does the factory need to be?
Biscuit lines are long because the baking time determines the conveyor speed. A standard 500kg/h line requires an oven length of about 30-40 meters. Including mixing, cooling, and packing, the total factory length should be at least 60 to 80 meters. We can design U-shape layouts if space is limited.
Do you provide biscuit recipes?
Yes. We provide Basic Starter Recipes for Digestive biscuits, Shortbread, and Butter Cookies. During installation, our engineer can help adjust the fat/sugar ratio to match your local flour characteristics and ensure smooth machine operation.
Need a factory layout drawing?
Send us your factory dimensions (CAD/PDF), and we will design the line placement for you.
Request Layout Design