The BISKAID Project

“Biscuits are the first and best convenience food”

  • Low cost
  • Nutritious / high energy
  • Require no preparation
  • Have a shelf-life of up to 12 months
  • Ideal use of WHEAT FOOD AID

Our proposal is to provide a production facility to deliver up to 8 tonnes of biscuits per day (on 2 shifts) to feed people in a disaster zone or refugee camp.

THE PRODUCT 

A biscuit formulated to provide energy and protein and carrying minerals (iron, calcium) and vitamins. The formulation and mineral / vitamin supplements may be adjusted to suit each community. Typical fortifications include: iron, calcium, zinc, iodine, magnesium, sodium, Vitamins A, B6, B12, E, K, folic acid, thiamine, niacin…….

Typical nutritional values per 100 g

Energy (kcal)               459.55

Protein (g)                    7.06

Carbohydrate              76.65

Fat (g)                           14.38

THE PRODUCTION AND DELIVERY

 Factory

 

A non-insulated temporary building that provides excellent protection for production and ambient storage. The buildings are quick and easy to transport, install, dismantle, relocate, modify and extend. Buildings have a high re-usability.

Aganto – Temporary Building Specialists   www.aganto.co.uk

  • Roof: Single skin industrial grade flame retardant PVC – easy to clean, durable and transmits natural light
  • Walls: single skin steel cladding that is robust, standing up to the harshest weather
  • Services: doors, lighting, guttering, power distribution, flooring
  • Strong and durable aluminium frame with a 10 year guarantee
  • Snow and wind loadings to BS6399
  • All roof, wall and floor systems conform to British Fire & Safety codes
  • Temporary buildings are anchored down to level hard standing without needing foundations
  • A temporary storage structure is easy to extend, modify, dismantle or relocate
  • PVC roof provides high degree of natural light

Production equipment

The proposed biscuit line is the simplest semi-automatic production line based on a tunnel oven. The mixing and forming machines are suitable for moulded doughs, allowing a wide variety of shapes and recipes to be made. The process is widely used for nutritional biscuits in Asia, including the very popular “Biskuat” in Indonesia and “Parle G” in India, which claims to be the world’s biggest selling biscuit.

The biscuits are baked on a tunnel oven with 3 heating zones separately controlled for process control of biscuit structure, moisture level and colour. The oven is heated either by diesel oil or gas.

 

Dough mixers                                        Rotary moulding machine                 Baker Pacific Indirect Radiant Oven

http://www.dsm-mc.com   

The production line is semi-automatic. Labour is required for weighing ingredients and feeding them to the mixer tub. The dough tub is portable and after mixing the dough is taken to the moulding machine and is fed manually. The baking and cooling are continuous and automatically controlled. Biscuits will be packed manually.

The proposed production line will produce 500 – 600 kg per hour.

Packaging

Biscuits have very low moisture contents, typically around 2%, which ensures a long shelf life. For immediate consumption, biscuits can be delivered directly from lined cartons. For biscuits which will be stored and transported, simple packaging is required, to ensure the shelf life, particularly in humid climates. Suitable materials are polypropylene, coated paper or various laminates.

After baking the biscuits are cooled to around ambient temperature on conveyors. The conveyors are arranged to “penny stack” the biscuits on to a packing table from where they are picked up by the packing staff.   The biscuits may be packed directly into cartons, or transferred to the infeed conveyors of simple Flowpack wrapping machines

 

 

 

 

 

 

 

Qingdao Nissin Food Machinery  www.nissinpacking.en.made-in-China.com

On edge biscuit wrapping machine – 60 packs/min.

 

 

Installation and start up

(estimated time following local provision of a concrete floor and services, actual time will depend on labour and services available on site)

Services                                                                   (depends on the local capability)

Building                                                                  10 days

Installation of production line and start up    60 days

The building and production equipment would be “portable”, able to be rapidly dismantled, packed in containers and moved to a different site.

 Service requirements for biscuit production line                                     

Total estimated maximum power:     75 kW

Diesel oil fuel for baking:                    19 kg/hour (23 litre/hour)

Compresssed air:                                    6-8 bar, consumption negligble

Ingredient usage

Ingredients required             kg per hour    kg per shift (8 hours)

Flour                                        356.1               2849

Dough fat                                114.3               914

Sugar                                        88.5                 708

Malt                                          26.4                 211

Milk powder                            3.1                   25

Lecithin                                   1.9                   16

Ammonium bicarbonate      1.9                   16

Salt                                            3.8                   8

Water                                        32.0                 256

Total                                    628 kg           5003 kg

Production staff required

Ingredient store                                                  4

Weighing and measuring of ingredients        2

Dough mixing                                                      2

Feeding dough to the rotary moulder             2

Baking oven                                                          1

Cooling / stacking                                                2

Packing (Flowpack) machine                             6

Carton packing                                                     5

Finished goods store / despatch                       5

Engineer / supervisor                                          2

Total                                                                     31         

Disclaimer

The information for ‘The BISKAID Project’ has been prepared by Baker Pacific Ltd from various sources. Baker Pacific Ltd has made reasonable efforts to ensure the accuracy of the information. Baker Pacific Ltd, however, does not accept any liability for the accuracy or authenticity of the information or for any errors, omissions or misinterpretation of the information. Baker Pacific Ltd does not accept any responsibility for any consequences arising from the use of information contained in this manual.

   For more information, technical support, training programs, please contact

 bakerman@bakerpacific.com.hk

                               

 

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