Biscuits, Cookies & Crackers

Biscuits, Cookies and Crackers

Baker Perkins has the largest installed base and the widest range of
equipment for the supply of biscuit processing machinery worldwide.
For over 100 years, we have been supplying Our commitment:
equipment to biscuit manufacturers all over the
world. Building on this unrivalled experience, ● Innovative – Consistently improving existing
today’s process technologists and engineers are products and processes whilst developing
now developing the latest in innovative, flexible new technologies appropriate to the market
and technologically advanced equipment.
● Accessible – Global resources delivered at a
With a comprehensive range of equipment,
local level
from mixers to sandwiching machines, we offer
hygienic and easy to operate designs which lead ● Reliable – We pride ourselves on meeting
the industry. all of our commitments to our customers –
from contract implementation to after-sales
service

● Flexible – Working with customers to

develop solutions which meet their specific
requirements

● Tight Process Control – Equipment,

sensors and control automation to maximise
quality and efficiency

Offices, manufacturing facility

and Innovation Centre at
Peterborough, UK

Biscuit Cookies Crackers | PAGE 2

Innovative Processes – Value Added Products
The key to profitability in the biscuit industry lies in process efficiency and
differentiated products. As well as offering ‘best in class’ equipment for
each key process stage, we invest in development of new end
products and processes.
There are Innovation Centres located in the UK
and USA. Equipped with a range of pilot scale
forming equipment and multimedia ovens, they
can facilitate:

● New product development

● Validation of process scale-up

● Production of samples for test marketing

● New forming and baking technologies

● Training of operators and engineers

● A more scientific understanding of the

processes which we rely upon

Multi media oven at the

Grand Rapids Innovation Centre, USA

Biscuit Cookies Crackers | PAGE 3

 Mixing and Dough Feeding
The importance of consistent doughs, appropriately fed to the forming
machines, is often underestimated. We offer a wide range of mixing and
dough feed solutions to suit all requirements in terms of dough type
and layout.
The High Speed Range Other mixer options available from Baker
Perkins include:
● High speed blade action gives thorough
mixing and rapid development ● Vertical spindle mixers

● Tilting bowl and shaftless blade for ● Horizontal soft dough mixers
efficient discharge

● Batch sizes from 550kg to 1100kg

● Automatic operation for low running costs

● Variable speed mixing option

Two Roll Feeder

The high speed mixer can

discharge directly through
the floor for a very simple
High Speed Mixer feed system.

The ‘live bottom bin’ system suits

most dough types and can be
extended to provide
dough resting.

Biscuit Cookies Crackers | PAGE 4

A Tradition of Biscuit Forming Processes
Many of today’s most popular products are made using well established
processes where flexibility, long term cost effectiveness and hygiene
are the key criteria for new equipment.
The 540 Series Sheet Forming and Cutting The Wirecut machine is traditionally used for
Machine comprises a number of units that very soft dough including the classic chocolate
sheet, gauge and then cut dough pieces. chip cookie. For flexibility and high output the
Conventionally used for crackers and hard Wirecut has no peers with speeds up to 300
sweet products, the range is finding increasing strokes per minute and angled versions for
application for both baked snacks and soft improved band loading. The filler block ensures
dough products. Solid gauge rolls and dough is carried straight from the feed rolls to
accurate speed cascade ensure high output and the cut off wires or knife to give unequalled
unrivalled weight control. weight control. There is also a deposit version
for swirl-type products.

The Rotary Moulder is used for soft dough

products. Close control of size and weight
make it ideal for chocolate coated or cream
sandwich products and the moulding process
enables an infinite variety of 3-dimensional
patterns and characters to be embossed onto
the product.

540 Series Sheet Forming

& Cutting Machine
Wirecut

The Rotary Moulder

Biscuit Cookies Crackers | PAGE 5

 Forming Technology
Investment in new technology is at the heart of our commitment to the
biscuit industry and nowhere is this more apparent than in the current
range of forming equipment.
The 540 Series Vertical Cut Sheet
Laminator has been designed to meet market
requirements for a laminator that is compact
and easy to operate, combined with good
access for cleaning and maintenance. The
range includes a conventional laminator and a
combination arrangement for maximum
production flexibility. This arrangement
produces both a laminated and sheeted
product from a single unit eliminating the cost
and complexity associated with traditional
combination plants.
The Gauge Roll is available in 300mm or
400mm diameters. Made from solid steel with a
hard stainless surface, this is designed to
achieve less deflection than any other
comparable Gauge Roll unit. Independent drives
and precise temperature control can add further
process refinement.
540 Series Vertical Laminator
Biscuit Cookies Crackers | PAGE 6
The 540 Rotary Moulder can be configured to
suit many production requirements. In its most
popular format the discharge web is separately
driven ensuring control of tension at the point of
extraction. This helps to allow the widest range
of dough types to be effectively
produced at speeds up to 40m per minute.
The EM 390 Rotary Moulder has an extended
range of standard features and options that
make it ideal for production of moulded and
sandwich cookies, bars, mini cookies and pet
treats. It combines the virtues of simplicity,
reliability and durability for a competitive
capital outlay. High productivity with versatility
and optimum sanitation ensure an attractive
cost-of-ownership.
Gauge Roll
540 Rotary Moulder
 The Dualtex Extruder is specifically designed
to produce the new generation of filled bars.
Fillings of fruit, jam and sweet and savoury
creams can be handled. The Dualtex shares
many features with the Wirecut machine and
consequently benefits from excellent weight
control. A key hygiene feature is the ability to
open up the ‘clam-shell’ rolls for easy cleaning.
EM 390 Rotary Moulder
Dualtex Extruder
The Frozen Dough Wirecut offers the
capability of entering the expanding market for
cookies, "baked at point-of-sale". The filler block
allows highly accurate weight control and a
special version of this machine has also been
developed which can handle larger
inclusions.
Ancillary equipment such as jelly toppers, ink
printers, egg wash and sugar sprinklers can be
integrated to add extra value to your products.
Frozen Dough Wirecut
Biscuit Cookies Crackers | PAGE 7
 The World’s Leading Oven Range
Baker Perkins offers a comprehensive range of ovens to accommodate
the widest possible range of products, fuel types and customer
preferences.
The Direct Gas Fired Oven is the most The Cyclotherm Oven uses indirect heating
popular type of oven because of its combination with burner gases passing through the baking
of excellent baking characteristics and chamber in radiant tubes. This promotes gentle
flexibility. A series of strip burners mounted texture development and distinctive highlights
above and below the band supplies radiant heat on the surface of the biscuit. Bake times and
whilst turbulence improves the rate of heat efficiency can be improved by the addition of
transfer and moisture removal. turbulence.

The Jetcirc Convection Oven provides The EM Recirc uses longitudinal heating
TM

a dependable and stable airflow within the
baking chamber for precise regulation of the
baking process. The Jetcirc is available in three
versions – direct and indirect convection, and
re-circulating. All offer savings in capital costs
and bake time.
ducts that can be set to create a fully convective
or a fully radiant bake - or any combination in
between. This unique flexibility makes the EM
Recirc ideal for all kinds of soft dough products.
A Hybrid Oven combines the best of the
available options – radiant heat from DGF or EM RecircTM
Cyclotherm in the early part of the bake
followed by convection heating for efficient
drying and colouring in the latter stages.

Jetcirc Convection Oven

Flexiflame Ribbon Burner

All ovens are modular and are normally

supplied in ‘‘fully factory finished’
format. This means that modules are
assembled, pre-wired and tested before
shipping to site for construction.
This minimises installation and commissioning
time, whilst ensuring the highest possible
standards of build quality.

Biscuit Cookies Crackers | PAGE 8

The Science of Baking . . .
Continuous investment in research allows us to gain an unrivalled
knowledge of the baking process.
The Thermal Performance Research Oven
(TPRO) enables replication of tunnel oven
baking whilst applying sophisticated
monitoring and logging techniques.

Computational Fluid Dynamics (CFD) is a

technique which harnesses the power of
modern computers to mathematically model the
temperature distribution and air
movement within the baking chamber.

Computational Fluid Dynamics

TPRO with Wonderware Software

Biscuit Cookies Crackers | PAGE 9

 The Preferred Solutions for High Output,
Value Added Sandwiching
We have designed, manufactured and supplied cream sandwiching
equipment for over half a century. We have the broadest range of
machines, including innovative technologies which allow new product
and packaging options. Systems are supplied from cream feed through
to multiplication.
The High Speed Creamer is available in 2, 3, The Co-Deposit Stencil is another patented
4, 5 or 6 lane configurations and can be development introduced by Baker Perkins. Two
supplied with a range of infeed and outfeed deposits can be made simultaneously whilst
options to form complete sandwiching maintaining the reliability and efficiency of the
systems. conventional system. The process opens the
way for the production of unique, highly
– Each lane has its own pump allowing fine differentiated products.
control of weight accuracy
– Wash down in the product area The Full Width Creamer is an in-line
– Integrated PLC control of cream and sandwiching system where the number of lanes
cream feed is equal to the number of lanes of biscuits on
the oven. This means that no lane reduction or
The Pile Pack Creamer uses a unique, multiplication systems are required and makes it
patented system to form piles of two particularly suitable where secondary
sandwiches such as those commonly found in processing (e.g. enrobing) is employed.
vend packs. The unique feature is that the two Automatic washdown is available as an option.
sandwiches are formed one on top of another
during the creaming process and fed straight to
a wrapping machine. The Pile Pack Creamer
and wrapper thus form a single seamless unit
reducing both cost and complexity.

Pile Pack Creamer

Full Width Creamer Co-Deposit Stencil Stripping Belt Feeder

Biscuit Cookies Crackers | PAGE 10

Don’t just take our word for it . . .
Kraft Nabisco, USA
The record for the cream sandwiching
operation with the highest output in the world
belongs to Kraft Nabisco in the USA. Four BP4
machines are producing a total of 16,000 sand-
wiches per minute from a single plant, a figure
yet to be equalled anywhere in the world. With
our equipment, Nabisco were able to reduce the
number of machines required to handle the
oven output resulting in significant capital and
operating cost savings.
Campineira, Brazil
Part of the Danone Group, Campineira are
currently running the High Speed Creamer 24
hours a day, 5 days a week. Easy to operate
and maintain, reliable and efficient, our
equipment supply requires no stoppages
throughout the working week for maintenance
and its unique design means no need to stop
for cleaning either.
BP6 with Multiplier
Austin Foods, USA
Manufacturers of the Austin Foods range of
peanut butter and cheese sandwiches were
looking to install a show-piece plant to cream
and wrap their vend packs. Efficiency and
accuracy of deposit were key criteria, along with
ease of maintenance, operation and hygiene. To
be certain of buying the best machine available,
a Pile Pack Creamer and its principal competitor
were run side by side over a trial period. The
result was an
outstanding success.
McVitie’s, UK
McVities had been running a full width
creamer for several years and, following the
relaunch of their popular Penguin biscuit,
required another machine to handle the
increase in demand. They needed a machine
that would deposit the cream very accurately
and position it right up to the edge of the shell
to eliminate bubbles. It also had to
provide exact top and bottom shell alignment.
All of McVitie’s stringent standards were met by
our full width creamer.
Biscuit Cookies Crackers | PAGE 11
Baker Perkins Ltd Baker Perkins Inc
Manor Drive 3223 Kraft Ave SE
Paston Parkway Grand Rapids, MI
Peterborough 49512-2027
PE4 7AP USA
United Kingdom

T: +44 1733 283000 T: +1 616 784 3111

F: +44 1733 283004 F: +1 616 784 0973
E: bpltd@bakerperkinsgroup.com E: bpinc@bakerperkinsgroup.com
I: www.bakerperkinsgroup.com I: www.bakerperkinsgroup.com