China unique ZPW-4-4 Rotary Block Press (compressed biscuit making machine)

1.How compressed biscuits originate? What is the history of a compressed biscuit?

The compressed biscuit is traditionally used food for the army’s continuous operations.
Previously, during the war fights, there was no time to cook food (rice, vegetables, meat). Therefore, portable, and nutritious compressed biscuits remained considered the best option.

In 1959, the compressed biscuit recipe was developed by Oscar J. Kambly. These biscuits were tasteless that replaced military biscuits ‘federal brick’ and goods with cheese, sausages, etc.

During The War Of Resistance Against Japan, eating cooked potatoes was a general practice. Because the cooked potatoes didn’t intrude continuation of the war and were easy to eat. But it was noticed that such food had caused disadvantages too. For instance, shortage of storage, unable to consume after deterioration, and calorie intake.

So, if you see the photographic record you’ll notice soldiers were malnourished and weak. This was all because of poor nutrition

That’s why in the new era, the army has developed emergency and nutritious items in the form of a compressed biscuit. Since 1959, compressed biscuits are widely distributed about a million serving in the army every year in many states. Furthermore, these biscuits are much different than civilian biscuits as it has a longer shelf life of at least 3 years.

2.What is a compressed biscuit?

A compressed biscuit is a convenient, hunger resistant, and high-energy food significantly known for ‘High Energy Military Ration’.

Because they are:

• non-absorbent and soft.
• nutritious and capable of fast-recovery of physical strength.
• suitable for long-term storage and perfect for transportation.
• accessible with a pleasant flavor that can adapt to consumption in the special environment as well.

They are produced by a dedicated machine known as compressed biscuit making machine,whose  key device is compression die where raw material pressed to form a hard stack.

3.Why are compressed biscuits anti-hunger?

Compressed biscuits are anti-hunger,but do you know why?

Then you may get the reasons as below:

Ⅰ.Poor Water Absorption

This is so apparent,they improve the feeling of fullness due to variation in the water absorption. These biscuits have poor water-absorbing properties that are why they longer time to digest in the gut.

In order to understand well the anti-hunger effects, you can soak a compressed biscuit and a regular biscuit in water separately. After some time, examine the changes in both biscuits.

You’ll find a regular biscuit in pasted form instead of a compressed biscuit. Similarly, if you put a compressed biscuit in boiled water for 30 minutes, it may result in pasted form.

This demonstrates the structural tightness and poor water absorption. Hence, these properties induce anti-starvation effects in the body.

Ⅱ.High Starch Content

Secondly, you must have heard about starch (polysaccharides). The starch content in compressed biscuits is comparatively higher and available in compressed form with a tough texture. To digest starch, your salivary enzymes first break starch into maltose (monosaccharide).  Hence, this process in the body takes a longer time to digest. Furthermore, the presence of dried fruit also improves satiety.

Ⅲ.Compression Process

A compressed biscuit has a lot of materials that are mixed under a high temperature and compression. A compressed biscuit making machine is used to make biscuits in a compact form with additional content such as nuts, and dried fruits. This firm compression results in material compactness.

4.What are important applications of compressed biscuits?

Besides military purposes, compressed biscuits are regularly used by:

Rock Climbers

When going rock climbing or hiking with friends, having compressed biscuits back in your pocket is suitable to refuel yourself.

Desert Crossing

Compressed biscuits are firmly vacuum-packed and long-lasting food good to take when crossing the long desert.

Snow Climbers

When climbing snow intense physical activities are involved for days to weeks. Compressed biscuit high-energy bars are ideal to carry and replenish your body.

Muscle Compacting

Compressed biscuits are the preferable choice for athletes, bodybuilders, sportsperson as it helps to fuel your performance, nutritional balance, and muscle compactness.

Curing Constipation

A compressed biscuit is a good source of constipation remedy as its composition includes whole grain, nuts, and healthy fiber that may improve the frequency and consistency of bowel.

Walking Tour

A compressed biscuit is an excellent nutritional choice for walking tours as it keeps you active and energetic all day.

Weight Reduction

People who do exercise and try to lose fat, have extremely high eating requirements. Ordinary snacks can’t fulfill such needs while dieting is not a solution. At this time, compressed biscuits replenish your meal requirement without gaining weight and feeling hungry.
A leisure farm compressed biscuits are the best helper for fighting hunger and body fats.

5.What is the composition of a compressed biscuit?

The prime composition of a compressed biscuit is:

• Wheat flour
• Palm oil
• Sugar content
• Syrup
• Salt
• Sodium bicarbonate
• Dried fruits

With time advanced modifications are implemented in their formulation to make them more and more nutritious with enhanced properties. These biscuits are heat-treated but it does not seem to be baked. Moreover, the energy content of compressed biscuit is listed below:

	Per 100g
Energy	1988kJ
Protein	7.1g
Fat	19.4g
Carbohydrate	67.6g
Sodium	238m

6.Are compressed biscuits different from other biscuits?

Yes, compressed biscuits are different from usual biscuits. Discussed below are the following assessment points.

Common biscuits

Nutritional Value

Compressed biscuits are non-absorbent, high-energy, enriched nutritional bursts that will improve your physical strength and make you extremely energetic. Whereas other biscuits are of various nutritional value with improved crunchiness, high-amount carbohydrates, low fiber, and high unhealthy fats.

Feeling of Fullness

Compressed biscuit enhances the feeling of fullness after eating that’s why they are preferable to military food. Whereas other biscuits are soft, light, that manages hunger, their unconscious eating ultimately results in weight gain, diabetes, etc.,

Long Term Storag

Compressed biscuits are easy to transport and ideal for long-term storage in military and civilian-run. Whereas other biscuits are light, required suitable storage conditions, and are prone to break down.

Texture

Compressed biscuits are high and tough textured biscuits whereas other biscuits are light and soft textured biscuits.

7.What is a compressed biscuit-making machine?

AIPAK compressed biscuit making machine

A compressed biscuit making machine is an ideal equipment for manufacturing a compressed biscuit. This machine is widely used to form an elongated or rectangular-shaped bar with the help of strong binding and compression die/mold.
It is easy to operate due to photoelectric tracking and a pneumatic hydraulic system. Also, it uses biscuit scraps as a raw material where mixing and high compression leads to compact them.

8.What are the industrial applications of a compressed biscuit making machine?

Compressed biscuit machines are increasingly employed in many industries from food to chemicals for making biscuits and bars. With a shifting trend towards health-promoting foods, compressed biscuits machines are the most sought-after machines.

Below are some applications of compressed biscuit making machines, which might interest you.

Ⅰ.Food Industry

Compressed biscuit making machines are extensively utilized in food industries for making various sweet, coated, savory, and crackers kinds of biscuits. Many customers find biscuits convenient to eat because of their nature.

These machines are used to make both high-calorie and low-calorie biscuits that are desirable to both civilian and military personnel. These compressed biscuits are preferred by hikers, travelers, and soldiers.

Ⅱ.Nutraceutical Industry

Compressed biscuit machines are also found their use in the nutraceutical industry for manufacturing healthy and nutritious protein bars, snack bars, energy bars, and fiber bars. These machines compressed various grains like rice, oats, and millets into bars.

Nutritional bars have various supplements, micronutrients, proteins, and carbohydrates for quick energy.

Ⅲ.Agriculture Industry

In the agriculture industry, compressed biscuit machines are used to manufacture various kinds of organic and inorganic fertilizer biscuits. These fertilizer biscuits are of prime importance for the growth of plants.

Ⅳ.Chemical Industry

Compressed biscuit machines have their applications in the chemical industry to produce detergent and disinfectant bars. These products are used to disinfect drinking water, water pumps, swimming pools, and dishwashers.

Ⅴ.Veterinary Industry

Compressed biscuit machines are used to produce different kinds of animal feed biscuits. These biscuits are rich in fibers, have high protein content, and provide an immediate energy boost.

These machines are commonly used for manufacturing nutrient-rich energy bars for pets.

9.What are the major components of a compressed biscuit making machine?

It is necessary to know about the various parts present in a compressed biscuit making machine and their functioning to smoothly operate this machine. If you have information regarding the components of a machine, then you can easily deal with the fault in the parts of the machine.

Some important parts are discussed below:

Ⅰ.Hopper

The dough is placed into the hopper, which then goes into the pressing unit. It is a cylindrical or funnel-shaped part that holds the dough before processing.

It is placed at an elevated position for easy flow of the material.

Ⅱ.Compression Station

This unit is composed of die and punches. Blend or dough goes inside the die channel and then punches are moved to press this blended mixture into a compact biscuit shape. The pressure to compress the dough in biscuit form is provided by punches.

These biscuits are of various shapes and sizes depending upon the type of die and punches used. These tooling also decide the thickness and diameter of biscuits.

Ⅲ.Motors

Motors provide the necessary force to drive different systems of the compressed biscuit machines. These motors impart power for the movement of punches.

Ⅳ.PLC and Electric Control Unit

Compressed biscuit making machine has PLC unit that constantly displays the state of input, output devices, data, programming and storage. Furthermore, an electrical panel has various switches for powering and shutting down the machine. This board also has emergency and safety buttons.

Ⅳ.Photoelectric Tracking Sensors

These sensors track the movement of dough and biscuits during machine operation. Operators are notified if there is any interruption in machine operation by these sensors.

Ⅴ.Discharge Chute

This component receives compressed biscuits after these are ejected from the die cavity. The final product is collected in the collection bin.

10.How will you benefit from acompressed biscuit making machine?

A compressed biscuit making machine is an ideal purchase and benefits your business in a wide variety of ways. Some of the advantages are discussed below:

Ⅰ.Cost

A compressed biscuit making machine is a cost-effective purchase, saving you from labor expenses. This machine reduces your manufacturing cost as this machine has low maintenance.

There is low human intervention in operating this machine so there is less chance of product waste which also lowers your expenses.

Ⅱ.Hygienic Construction

This machine is made of stainless steel which prevents the growth of microbes thus reducing the risk of product contamination and making it fit for human consumption.

Ventilating the system with vacuum pumps or compressed air also stops dust accumulation.

Ⅲ.Versatility of Products

This machine can produce a huge amount of versatile products having various shapes, sizes, and designs without changing the main parts of the machine.

Ⅳ.User-Friendly Operation

The compressed biscuit making machine is operated effortlessly without requiring intense training and skill.

Ⅴ.Durability

Compressed biscuit making machine is made with superior quality materials that are long-lasting and durable. These materials can withstand harsh weather conditions and intense operations.

11.What are the types of compressed biscuit making machines?

Based on automation, there are three kinds of compressed biscuit making machines which are:

• Automatic Compressed Biscuit Making Machine
• Semi-automatic Compressed Biscuit Making Machine
• Manual Compressed Biscuit Making Machine

Ⅰ.Automatic Compressed Biscuit Making Machine

An automatic compressed biscuit making machine is fully programmed. In this type of machine, the machine itself carries out various biscuit pressing steps.

It is equipped with intelligent controls and safety sensors for accident-free machine operation. Troubleshooting and maintenance of these machines are easily carried out.

An automatic compressed biscuit making machine is proficient and has more production capacity than other types of compressed biscuit making machines. These are large-sized machines and are used in mass-producing businesses.

AIPAK automatic compressed biscuit making machine

Ⅱ.Semi-Automatic Compressed Biscuit Making Machine

Semi-automatic compressed biscuit making machine

A semi-automatic compressed biscuit making machine is generally used in medium-sized production plants to manufacture compressed biscuits.

In a semi-automatic machine, steps like the feeding of dough and removing compressed biscuits are performed by the operator while the rest of the functions like pressing of dough are performed automatically by the machine.

This machine consumes more power than manual compressed biscuit making machines, but machine operation is less demanding than the latter one.

Ⅲ.Manual Compressed Biscuit Making Machine

Manual compressed biscuit making machine

A manual compressed biscuit making machine is a small-sized machine used in houses and small-scale bakeries.

In a manual compressed biscuit making machine every function- from filling to compression is performed by the user. First dough is filled inside the die cavity. Then the lever is pressed to move the punch downward.

The compressed biscuit is expelled out of the machine by the movement of the punch.

A manual compressed biscuit making machine is available at a reasonable rate, occupies small space, is portable, and consumes little to no power.

This machine has a low production capacity and is labor-intensive.

12.How does a compressed biscuit making machine work?

Compressed biscuit making machine operates in a sequential manner in four steps. These steps are:

Ⅰ.Filling

In the first step, the blend or dough is filled into the hopper. This dough is formed with the help of rollers and mixers. These machines aid in the production of a homogenous blend.

From the hopper, the material move to the die channel.

Ⅱ.Dosing

In this step, the excess material is expelled from the biscuit press machine by a lower punch. This step is necessary to measure the precise weight of dough for compression.

The position of the lower punch is adjusted to calculate the accurate volume of dough to create biscuits.

Ⅲ.Compression

This is the main step in biscuit making. The upper and lower punch or die come in close contact with each other and exert the compression force on the dough to form biscuits. The distance between two punches determines the hardness and thickness of the biscuit.

If punches are near to each other, biscuits formed would be harder and thinner.

Ⅳ.Expulsion

Biscuits are removed from the machine after compression. In this step, the upper punch is lifted while the lower punch moves upward which forces the biscuit to top of the die.

Scarpers impel compressed biscuits from the die to the collecting unit.

13.How do you troubleshoot a compressed biscuit making machine?

Do not panic as problems are part of routine compressed biscuit making machine operation.

You can easily rectify these problems by following below mentioned remedies.

Ⅰ.Biscuit Hardness

The biscuit breaks into the piece when it is ejected or removed from tooling.

Cause

• The size of particles in the dough is not homogeneous
• The expulsion blade is damaged or worn out.

Remedy

• Amplify the compression pressure.
• Check the expulsion blade and replace it with a new one.

Ⅱ.Cracking

Small cracks are seen on the sides of the compressed biscuits

Cause

• The temperature of the dough is low.
• Biscuits expand due to air entrapment during expulsion.
• Poor formulation recipe and quality of ingredient

Remedy

• Adjust the machine temperature
• Use conical-shaped die tooling
• Adjust the recipe of dough
• Use good quality ingredients and properly measure them

Ⅲ.Sticking on Die Tooling

Sometimes the dough sticks to the face of the upper and lower punch.

Cause

• The dough is not entirely dried
• Compression force is not accurate
• Dough temperature is high
• The surface of punches is rough
• Inaccurate amount of oil

Remedy

• Fully dry the dough
• Apply accurate compression pressure
• Polish the exterior of punches
• Lower the dough temperature
• Use proper amount of oil

Ⅳ.Resistance during Machine Operation

Sometimes you see that machine parts get jammed or stuck

Cause

• High friction in machine parts
• Unclean machine parts

Solution

• Properly lubricate machine components
• Maintain the proper cleaning schedule

Ⅴ.Varied Biscuit Sizes

Increased variations in the size of compressed biscuits

Cause

• This is caused by the abnormal movement of punches

Solution

• Check the size of the punches.
• Adjust the punch depth
• Replace the tooling with a new one.

14.What is the future perspective of a compressed biscuit making machine?

With improvement in the living style of people, compressed biscuits are high in demand because of their ease of consumption. Today, compressed biscuits are available in a variety of flavors and shapes.

These are seen in all major markets and are consumed by all walks of life. With the increase in demand for compressed machines, there is also an expansion in the market of compressed biscuit making machines.

Manufactures are committed to making compressed biscuit making machines that are equipped with smart technology, modern pneumatic system and electrical components. These machines have high production efficiency.

There is always a chance for improvement so future compressed machines will be intelligent robots that will lower human interference. New materials, image sensors, and microelectronics will be used in future biscuit making machines.

Future machines will have high flexibility and efficiency due to having the latest digital controls, power load, and CNC systems. These machines will be operationally independent and will have maximum precision.

Conclusion

The compressed biscuit making machine not only delivers healthy foods but provides comprehensive utilization and economic benefits. AIPAK compressed biscuit making machine is a robust operational machine that can produce compressed biscuits via automatic operation except loading material. Their manufactured compressed biscuit machine can not only save your material wastage but promises profit margin and progressing your business. Contact  Us right now to get more guidance support and Equipment Quotation.