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Sandwiching Machine: The Ultimate FAQ Guide

All information you’re looking for about sandwiching machine is right here.

Whether you want to learn about features, components, or working principle, you will find all information you’re looking for here.

Keep reading to learn more.

What is a Sandwiching Machine?

You use a sandwiching machine to make biscuits sandwiches with cream filling. You can sandwich both hard and soft biscuits using a sandwiching machine.

This biscuit processing machine encompasses different units that result in the formation of a biscuit sandwich. You prepare the cream for the sandwiches in the creaming section, where you mix the ingredients.

Sandwiching Machine

 Sandwiching Machine

Where do you Use Sandwiching Machine?

Sandwiching machines find use in the food industry to make biscuit sandwiches or wafer sandwiches. Using sandwiching machines, you can make biscuits with cream fillings of different flavors.

The commercial application of sandwiching machines allows large production of different biscuit sandwiches for the mass market.

What are some of the Advantages of Using a Sandwiching Machine?

When making biscuit sandwiches, a sandwiching machine offers you the best commercial option to meet your needs. Using the sandwiching machine as an industrial producer of food affords you the following benefits:

  • You achieve a higher production output when using a sandwiching machine.
  • The sandwiching machine is less messy thanks to the advanced engineering designs implemented, reducing your sanitation needs.
  • Using a sandwiching machine increases the efficiency of your biscuit production line.
  • When working with a sandwiching machine, you experience reduced downtimes which typically hamper the production process.
  • You benefit from reliable quality processes with the sandwiching machine.
  • Many sandwiching machines are automatic, thus reducing your labor needs and hence your production costs.
  • Conducting changeovers when using the sandwiching machine is simpler, requiring very few protocols.

What are the Methods of Cream Application when Using a Sandwiching Machine?

The sandwiching machine’s methods of the cream application describe how you attach the cream filling used between the biscuits. There are several methods you can use to apply the cream, including:

       i.          Stenciling Method

The stenciling method has been in existence for a long time and prevalent with manual and automatic machines. With this method, you stencil the cream on a biscuit surface before adding another biscuit over it.

You use a flat metal piece with a depth similar to the cream’s desired thickness to make a stencil. You cut this metal piece in the desired shape of the cream and considering the size of the biscuit.

You attach the bottom biscuit below the stencil under the cut-out design before filling it out and leveling. Thereafter, you transfer the biscuit with cream to another section where you add the top biscuit.

      ii.          Using Depositors with Multiple Nozzles

You find two constructions of these depositors with multiple nozzles, with one made mobile and the other secured permanently.

The mobile depositor head can move vertically and laterally, following the biscuits in their path while applying the cream.

The depositor’s head moves downwards towards the biscuit while simultaneously releasing a fluid cream onto a biscuit.

The cream stream breaks off as you raise the nozzle, and the filled biscuit moves along the line.

    iii.          Use of Extruders and Wire Cutters

Here, a hopper deposits cream on the biscuit via a nozzle in the desired shape. You use the wire cutter to cut off the cream stream from the nozzle.

The extruder and cutter work in continuity such that an extrusive operation immediately precedes a cutting operation.

The biscuits move in a rotation where another moves in its place as soon as a biscuit fills up.

After the creaming station, the biscuit moves to another station where a pin pushes the top biscuit over the cream.

Subsequently, a wedge or roller presses the two biscuit pieces together to form a sandwich.

Cream Biscuit Sandwiching Machine

Cream Biscuit Sandwiching Machine

What are some of the Features of Using an Extruder and Wire Cutter in Sandwiching Machines?

Features you identify when using an extruder and wire cutter in the cream application process supports their use:

  • You can adjust the conveyor chains’ position such that their location is far from that of the depositors.
  • You can increase the breadth of the machine to accommodate more rows.
  • You can also alternate the creaming process such that you deposit cream on one biscuit and skip the next.
  • You achieve high production speeds with this method with reduced complexities in terms of cooling and packaging.
  • Using an extruder and wire cutter allows you to adjust the weight of the cream.
  • You find it difficult to produce biscuits with irregular shapes and forms using this approach on a sandwiching machine.

How do you Mix and Handle Creams in a Sandwiching Machine?

There are two ways you can mix the cream with a sandwiching machine including:

·       Batch System

Plasticized fat is the basis of a batch system and typically begins with a chunk or an impelled amount.

When handling plasticized fat in bulk with sharp gradients of melting, you require specialized control processes.

Adding sucrose and additional ingredients causes the temperature to reduce compared to that of the cream mix.

You follow the addition of ingredients by blending the products using a whipping action.

You whip the cream ingredients until you acquire a desirable consistency with the appropriate density and temperature.

You can alter the batch processing by selecting fat and the type of machine you employ for creaming purposes.

·       Continuous Mixing Systems

A continuous system typically begins with fat that is entirely melted, giving it a warm feel. Additionally, the mixer regulates aeration in the cream and channels it to the creaming unit via a pumping mechanism.

You attain adequate fat temperate by employing a heat exchanger to initiate a steady cooling process.

Using icing sugar in the desired quantities poses a problem when done continuously and basing on weight rather than volume.

You need to maintain a steady speed of the continuous mixer during operation. Also, ensure the delivery path of the cream mix is circular with take-offs at respective creaming stations.

Why is the Cooling of a Creamed Biscuit in a Sandwiching Machine Important?

When making filled sandwiches, you contain them in a cooling channel to eliminate excess heat after the sandwiching process.

Cooling also allows the cream filling to harden before you package the biscuits or turn them over for additional processing.

When you don’t cool sandwiches, you can expect the sandwich’s deformation as it is held during packaging or transportation.

Avoiding cooling causes the biscuits to be malleable, making them succumb to the pressure applied during sealing.

It is important to cool your biscuit sandwiches to apply their physical structure and extend their shelf life.

You need to ensure the cooling process is optimal such that when exposed to high temperatures later, the cream remains firm.

What Causes the Splitting of Creamed Sandwiches made by the Sandwiching Machine?

Splitting of a sandwich occurs when the cookies disintegrate while in storage. You can attribute splitting to several reasons as its cause is not apparent.

Some of the common reasons for splitting include:

  • Breakdown of the molecular forces holding the biscuit together during the sandwiching process.
  • The hygroscopic nature of biscuits when exposed to the atmospheric moisture content.
  • Impediment of the movement of the fat crystals weakening attachment.

What Biscuit Shapes can you Make Using the Sandwiching Machine?

You can achieve the following biscuit shapes when using the sandwiching machine including:

  • Biscuits in conventional shapes such as round biscuits, square biscuits, and rectangular biscuits.
  • Biscuits in non-conventional shape such as jig-shaped biscuits, concave biscuits, and those resembling 2D animated characters.

Furthermore, when using a sandwiching machine, you can present your biscuit such that they take varied forms, including:

  • Mini sandwiches
  • Two-layer cream fillings
  • Biscuit sandwiches with three tiers, and
  • Customized shapes

4-Lane Sandwiching Machine

 4-Lane Sandwiching Machine

How do you Classify Sandwiching Machines?

Classifying sandwiching machines allows you to ascertain its predominant feature and, as a result, its production capacity.

Some of the aspects you find to use to identify sandwiching machine type include:

  • Number of lanes or rows it accommodates, and
  • Method of cream application.
  • Capacity of production

What are some of the Factors you Consider when Purchasing a Sandwiching Machine?

Some of the factors you consider when purchasing a sandwiching machine are:

  • Cost of the Machine
  • Level of Automation
  • Volume of Production
  • Machine’s Design
  • Ease of Operation
  • Speed of operation

Why is an Automatic Sandwiching Machine Preferable to a Manual Machine?

An automatic sandwiching machine uses programmed information to control the sandwiching process without human control.

A manual machine requires human guidance for the successful execution of the sandwiching process.

When using an automatic sandwiching machine, you can start and stop the process easily with the touch of a button.

Furthermore, an automatic sandwiching machine has an elaborate sensor system that closely monitors the sandwiching process.

When using an automated sandwiching machine, you require fewer labor requirements. Therefore, using an automatic sandwiching machine is hassle-free and cheaper in the long run.

How Many Biscuit Sandwiches can a Sandwiching Machine Produce in a Day?

The quantity of biscuit sandwiches the sandwiching machine can produce in a day defines the machine’s production capacity.

You find several factors that influence the number of biscuit sandwiches a sandwiching machine can produce daily.

Some of these factors influencing the production capacity include the number of lanes in the machine and operation speed.

A higher speed and lane count allow you to increase your production output when using the sandwiching machine.

Why is Cleaning a Sandwiching Machine Important?

When using the sandwiching machine, you find the creaming process to be particularly messy, especially when the cream is very fluid.

When the cream leaks, it gets into contact with the chain below the sandwiching platform that enables movement.

The sugar content in the cream causes it to be abrasive with the capacity to induce deterioration. Therefore, the cream can cause wear of the chain resulting in performance inefficiencies.

Consequently, you need to clean the sandwiching machine frequently to prevent wear and hampered performance.

Some machines have collector trolleys below the creaming section to collect the leaking cream.

What is a High-Speed Cream Sandwiching Machine?

A high-speed cream sandwiching machine has a high operational speed and yield with enhanced efficiency and reduced production costs.

You use this machine to make biscuit sandwiches of regular shapes such as round and rectangular.

A high-speed cream machine with compatible pitch size reduces chances of breakage and required handling hence saving costs.

While you can manually feed the machine, many high-speed sandwiching machines have automatic feeding systems.

Furthermore, you find high-speed cream sandwiching machines with controls supporting HMI in the form of a touch screen control panel.

In this case, you can centrally direct the processes of the machine, increasing the operational efficiency.

What are the Features of a Pile Pack Cream Sandwiching Machine?

A pile pack cream sandwiching machine allows you to produce sandwiched biscuits in piles consisting of two biscuit sandwiches each.

You can group piles into packs with up to six piles for each pack hence the name pile pack sandwiching machine.

Biscuit sandwiches you make by this machine are typically rectangular or circular, employing single filling and co-depositing.

You find these biscuit sandwiches appropriately suited for vending machines.

The pile pack machine employs a single lane configuration with a sequential creaming process. Besides, the pile pack sandwiching machine is simple in construction and design and doesn’t require sophisticated equipment to merge lanes.

When using the pile pack machine, you don’t have to cool the biscuits, thereby shortening the production time.

Also, this sandwiching machine has reduced production costs due to its simplicity and low waste.

The pile and pack sandwiching machine also has a firm chain build-up that offers stability throughout operations.

Additionally, having a soft start and soft stop minimizes interruptions and downtimes during production.

How Many Colors can you Use in a Sandwich Using a Sandwiching Machine?

When filling a sandwich, you can use a single deposit stencil, a sequential stencil, or a co-deposit stencil.

Using a single deposit stencil, you apply only one filling, whereas the sequential and co-deposit stencil allows you multiple fillings.

You can achieve up to a three-color sandwich using the same or different fillings.

Typically, the limitation to the colors you can use is the number of tiers you furnish your biscuit sandwich.

You find making biscuits with a filling with one color is common and cheaper.

However, you can use two different fillings, such as cream and jelly, and achieve different colors without using additives.

 Biscuit Sandwiching Machine

Biscuit Sandwiching Machine

What are Cream Feed Systems in Sandwiching Machines?

Cream feed systems are hoppers but with a unique design allowing you to deliver cream to the sandwiching machine.

Cream feed systems have increased accuracy and precision in delivering appropriate weights every time.

When operating a sandwiching machine, the speed of the cream feed systems is relative to that of the machine.

You find this allows the cream feed system to precisely deliver cream to match the production process.

What is Lane Multiplication when Using a Sandwiching Machine?

Lane multiplication involves furnishing more lanes for the output than there was in the input. You find lane multiplication useful for machines employing the cooling process which precedes packaging.

You use ratios to determine the number of lanes for your output relative to the input lanes. Consequently, you can have up to twenty-four lanes for your output where you have between two and six input lanes.

How do you Employ the Co-Deposit Stencil?

The co-deposit stencil allows you to deposit two cream fillings on a biscuit simultaneously in a concentric manner.

With a co-deposit stencil, you achieve differentiated biscuit sandwiches that are more attractive.

When you employ a co-deposit stencil, you achieve an appropriate mesh of the cream filling pair. You find this is possible because you release the fillings from one nozzle and at the same time.

Nonetheless, you find aligning the two layers using sequential stencils difficult.

On the other hand, you encounter no such problem when using a co-depositing stencil.

You can employ two different filling types with a co-deposit stencil.

Some of the substances you can use for your filling alongside cream include peanut butter, jelly, and cheese.

How Many Biscuit Pieces do you Need to make a Sandwich Using a Sandwiching Machine?

Making a biscuit sandwich using a sandwich machine involves applying a filling to a biscuit surface and covering it with another biscuit.

Therefore, you need at least two biscuit pieces to make a sandwich using a sandwiching machine.

You can also use three biscuit pieces to make a sandwich, with two separate fillings layers.

In this configuration, you apply a filling between the first and second biscuit and another between the second and third biscuit.

Your biscuits in a sandwich can be squared, circular, or rectangular with cream, jelly, butter, cheese, or chocolate for filling.

Therefore, you can configure your sandwiching machine to make sandwiches with either two or three biscuit pieces.

What are Some of the Equipment Used with a Sandwiching Machine?

The sandwiching process involves biscuits and fillings, which you have to make before sandwiching separately.

Therefore, you employ different equipment in processing the biscuits and sandwiches you use in your sandwich.

Some of the equipment applied in the sandwich-making process include:

Dough Mixer

A dough mixer is a piece of electrically powered equipment you use to knead the dough for making biscuits.

A dough mixer typically has a centrally positioned bar-like feature that rotates, thereby conducting the kneading process.

Oil Sprayer

An oil sprayer is a device you use to administer the oil to the dough for the biscuit-making process.

The oil sprayer disseminates oil through a nozzle with a pipe connecting it to a tank of oil.

Soft/Hard Biscuit Forming Machine

When making hard biscuits, you use a material recycling device to harden the biscuits before baking them in an oven.

In forming soft biscuits, you skip the hardening process by employing the forming machine and undertaking a monitored oven baking.

Tunnel Baking Oven

A tunnel baking oven is a continuous feature you employ to bake the biscuits under set temperatures on conveyors.

You employ different heat sources and methods in a tunnel baking oven to achieve your desired bake.

Cooling Conveyor

A cooling conveyor eliminates heat from your baked biscuits in preparation for the sandwiching process.

You find cooling conveyors employ a series of fans that use forced air to eliminate excess heat.

Cream Mixer

You use the cream mixer to prepare ingredients for your cream filling in the sandwiches.

A cream mixer has a whisk furnished on a rotating device that beats the mixture into a homogenous state.

Packaging Machine

You use the packaging machine to seal the sandwiches in food-secure wrappings to preserve freshness and prevent contamination.

Packaging the sandwiches also allows you to extend the shelf life of the sandwiches.

Biscuit Sandwich Production Line

 Biscuit Sandwich Production Line

What are the Advantages of Using Flow Wrap Packaging when Using a Sandwiching Machine?

You find the following benefits when you employ flow wrap packaging for your sandwiches:

  • Using flow wrap packaging is highly convenient with its reliable performance features.
  • You minimize packaging errors by using the flow wrap as you can control the frequency and change aspects.
  • Flow wrap packaging is highly effective as it employs automated controls that hasten the process and reduces errors.
  • You can track color marks for packages of highly sensitive photoelectric property with this packaging method.
  • The flow wrap packaging is not dependent on temperature allowing you to package sandwiches with food-grade plastic without harm potential.
  • Flow wrap packaging is a cheap alternative that doesn’t employ a tray approach and minimizes pollution incidences.

What are Some of the Technical Parameters for a Sandwiching Machine?

You find several specifications provided for a purchase of a sandwiching machine.

These parameters inform you of the characteristics of the sandwiching machine that indicates its performance capacity.

Some of the parameters attached to the sandwiching machine include:

  • You can have sandwiching machines with either a single row or double rows.
  • A sandwiching machine’s production capacity for a single row can be up to 250 sandwiches per minute. You can achieve a double that rate when using a double row sandwiching machine.
  • You can have sandwiching machines with power ratings between 2.2 kW and 3 kW.
  • The weight of a sandwiching machine can exceed half a ton depending on the production capacity.
  • You can achieve baking temperatures between 190 0C and 240 0
  • A variety of applicable shapes, including round, square and rectangular.
  • Single and multiple sandwiching layers with up to three layers of cream filling.
  • A packaging speed of over two hundred biscuit sandwiches per minute.

How does the Sandwiching Machine Make a Biscuit Sandwich?

The sandwiching process entails the deposition of cream or jelly, or other glutinous substance between biscuit pieces.

You deposit the biscuit pieces manually or automatically to a vibrating conveyor.

The conveyor delivers the biscuits to the sandwiching machine under no pressure ensuring the biscuits don’t disintegrate.

The conveyor transfers the biscuit piece to the creaming section, where you deposit the fill over a stencil.

The delivery of the cream from the cream mixer to the depositor is via a pumping system.

The respective pumps allow you to deposit cream precisely in the required weight for each lane.

After depositing the cream on the biscuit shell, you top the cream with another biscuit piece to form a sandwich.

A pressing section applies pressure lightly on the biscuit surfaces to increase adherence.

What is a Cookie Capper Machine?

A cookie capper machine is a sandwiching machine that achieves sandwiching across its width. You transfer biscuits directly from the cooling process with a capper machine after baking to the sandwiching table.

The capper machine arranges the biscuits in rows, after which it turns over biscuits alternately.

Besides, the machine follows this operation with cream deposition on the flipped biscuits.

Immediately following is the topping process where the robotic arms position the unturned biscuit over the cream filling.

You note that you complete a single sandwich at a station with a capper machine before you process another.

What is the Cost of a Sandwiching Machine?

There are several different types of sandwiching machines available to suit your biscuit sandwich production needs.

Classification of sandwiching machines includes automation, the volume of production, and the sandwiching process employed.

Manual sandwiching machines cost considerably less than automatic machines when taking into account the level of automation.

In the same breath, sandwiching machines with a large production capacity are more expensive than small-scale machines.

Complete sets of sandwiching machines will cost you a few thousand dollars to hundreds of thousands of dollars.

The higher the cost of the machine, the more the capabilities in terms of automation and production.

Automatic Sandwiching Machine

Automatic Sandwiching Machine

What Packaging Material do you Use with a Sandwiching Machine?

You need to package your biscuit sandwiches to retain freshness and extend the shelf life. Providing safe packaging that is not hazardous to health is an FDA requirement for manufactured food substances.

When packaging biscuit sandwiches, you can use polythene packaging, cellophane, and aluminium certified as food grade.

Some of these materials include OPP, PE, PVC, OPP/CPP, PT/PE, and KOP/CPP.

These materials have to be capable of being heat sealed and prevent the later entry of air. Additionally, you can use laminated film of two layers as packaging material with a thickness between forty and fifty micrometers.

What are Some of the Major Features of a Sandwiching Machine?

You find many sandwiching machines available from different manufacturers with different unique features.

When purchasing a sandwiching machine, it would be helpful to consider the following features.

  • Sandwiching machine with a stainless steel frame is less susceptible to cream and cleaning exercises adverse abrasion effects.
  • Machine with a servo-driver system and HMI control panel has enhanced efficiency levels.
  • You need to select a sandwiching machine whose production instructions are programmable and PLC controlled.
  • The cream depositing process of your sandwiching machine should have a high accuracy level.
  • Where your sandwiching machine executes the cream deposition, sandwiching, and packaging processes in consecutive action, you experience higher efficiency.

How do you Maintain a Sandwiching Machine?

Some of the cleaning and maintenance actions you can undertake are:

  • You can use compressed air via a blower to eliminate small particles of material such as dust and crumbs.
  • Brushing allows you to remove dirt particles stuck onto surfaces such as the seal. You can use an oil strain like silicon to remove these particles.
  • Moving parts such as the machine’s gear systems and chain links require greasing to offer lubrication from friction.
  • You also need to grease parts such as the seal, where their continuous operation increases frictional force.
  • You need to ensure the chain and belt are tight to be effective in their driving performance especially concerning speed.
  • When carrying out the maintenance of sandwiching machines, ensure the screws and nuts are well fastened.
  • Equally important during maintenance protocols is fine-tuning the braking system for the rollers used in packaging.
  • A good maintenance schedule also involves checking the sandwiching machine’s electrical connections, ensuring correct polarities and values.
  • When examining the sandwiching machine, you can identify parts where repair rather than a replacement will suffice.

What are the Safety Features of Sandwiching Machine?

When using the sandwiching machine, you find the following safety features:

  • You have an emergency stop button to accommodate sudden machine shutdowns.
  • An array of sensors in automatic sandwiching machines detects errors and inconsistencies instigating appropriate responses.
  • The sandwiching machine has guard rails to restrain projectile movement.
  • The sandwiching machine has the conveyor belts and other moving parts hidden from reach, preventing roping from free clothing.

At SaintyCo, we design and manufacture high performance sandwiching machine in the market.

Our machine come in different designs depending on your unique requirements and specifications.

Contact us today for all your sandwiching machine needs.

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