Industry 4.0 in food processing: what actually works
Sensors, AI, predictive maintenance: plenty of promises. Here is what brings concrete results in a food plant, and in what order to put it in place.
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Industry 08
Biscuits and wafers: mixing, baking and coating
A biscuit plant makes or loses its margin on consistency: weight, colour, breakage, and downtime between products. That is our ground.
Plain biscuits, sandwich biscuits, wafers, coated products: each family has its own dough, baking and packing constraints. Lines are long, and every drift upstream is paid for in breakage and waste downstream.
We work with production, quality and maintenance teams to stabilise processes, cut losses and control allergens.
Key process steps
- 01
Dosing and mixing
Ingredient weighing, mixers, dough temperature control.
- 02
Forming
Sheeting, rotary cutting, depositing; wafer sheets.
- 03
Baking
Tunnel oven, temperature profiles, colour and moisture control.
- 04
Cooling and filling
Cooling conveyors, cream, wafer assembly.
- 05
Enrobing
Chocolate enrober, tempering, cooling tunnel.
- 06
Packing
Flow-wrapping, case packing, checkweighing and detection.
The challenges we see
- High breakage and waste
- Variable weight and colour
- Allergen control and recipe changes
- Machine stops in packing
How we help
- Line performance diagnosis and loss-reduction plan
- Standard recipes and baking parameters
- Allergen control plan and HACCP
- Preventive maintenance of ovens and packing machines
- Training for line operators and team leaders
Standards and frameworks
- Moroccan law 28-07 and ONSSA
- HACCP / ISO 22000
- IFS Food, BRCGS
- Allergen labelling rules
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