FIELD OF THE INVENTION
The present invention relates to moulding unit for manufacturing of biscuits and to a
process for the manufacture of biscuit involving moulding of the biscuit wherein the dough
is present in small amounts into the desired size and shape. More particularly, the
moulding unit is adapted to achieve biscuits of required weight with accuracy, involving
selective operation of filling of dough into moulding inserts, scraping of dough from
moulding roller, panning of moulded dough from moulding roller to the extraction
web/conveyor.
BACKGROUND OF THE INVENTION
It is well known to independently handle biscuits dough, which is spongy in nature to
provide accurate weight. It is also known that the provision of moulding units under the
presently available conventional unit basically involves independent handling. This known
unit thus involve strenuous control of such independent unit which in turn affect the
efficiency and desired user friendly devices to carry out the process and unit for moulding
biscuit dough which are difficult to control weight accuracy.
Importantly, it is found that the provision of such independent handling units for biscuit
manufacturing is difficult to maintain desired standards of dough consistency like density,
viscosity especially during moulding operation. It is important to have better control during
moulding of dough more effective and user-friendly process and unit.
US 4,381,697 discloses an apparatus to make cookies, which consists of a drum, shaped
device known as a die roll for shaping the cookies. The drum shaped die roll receives
dough from a feed hopper and deposits the shaped dough on the surface of a transfer
conveyor at a first location. The drum is provided with knurls on its outside surface, which
ensure a positive drive to the transfer conveyor. The transfer conveyor then moves the
shaped dough to a second location, which is adjacent to an oven conveyor. The oven
conveyor receives the shaped dough at the second location and carries the shaped
dough into an oven for baking into cookies or cookie bits.
US 4,349,574 disclose an apparatus to make cookies, which consists of a drum shaped
device for shaping the cookies. The drum shaped device termed a die roll receives dough
from a feed roll, which in turn removes dough from a feed hopper. The die roll then
deposits the shaped dough on the surface of a transfer conveyor at a first location. The
transfer conveyor moves the dough bits to a second location adjacent to an oven

conveyor. As the dough bits leave the transfer conveyor at the second location they are
made to topple onto their side when they are received by the oven conveyor. While they
lay on their side the formerly flat base becomes slightly rounded. After they are baked in
the oven all the baked surfaces are now rounded.
US 2,212,743 discloses an apparatus for handling biscuits of soft sticky dough comprising
a pair of dough-piece forwarding conveyors arranged in tandem, one discharging over a
knife edge or nosing onto the other in combination, a thin rotatable rod extending
transversely of said first conveyor at the point of discharge of biscuits.
The disadvantage of the above mentioned prior art is that the dough dispensed into the
die roll was not of uniform quantity, further there used to be spillage of dough contents
from the cavity, the prior art unit further needed to have a well positioned and well
adjusted scraping knife to uniformly scarp away the excess dough. The unit of the prior
art was unable to fill the biscuit/cookie dough in uniform quantity into the insert cavity die
roller and lastly the different rollers did not have individual drive, which would in turn give
more flexibility in operation for dough with different consistency.
Thus there is a need to provide an improved unit by the way of a selective design
combination of forcing roller positioning, also the design of the forcing roller and the knife
placement mutually cooperative and interactive which would favour the short dough
moulding operation across bakery industry.
The present invention is mainly related to moulding unit for more effective and user-
friendly process and unit to get biscuits of desired size, shape and weight with accuracy.
OBJECTS OF INVENTION
It is an object of the invention to overcome the disadvantages of the prior art.
It is another object of the invention to provide for advancements in unit and process for
moulding the dough with greater accuracy, consistency and desired user friendly
attributes to carry out controlled process, and unit for manufacture of biscuit.
Another object of the invention is directed to the unit manufacture of biscuit dough
involving adjustable rollers and adjustable flanges for filling and moulding dough with
consistent weight with minimal human interventions.

Yet another object of the invention is to provide a unit for moulding of biscuits which
would enable effectively selective combination of drive unit to produce biscuits in the
bakery industry.
A further object of the invention is to provide a process for moulding of biscuits involving
filling of dough into moulding inserts, scraping of dough from moulding roller, panning of
moulded dough from moulding roller to the extraction web/conveyor.
SUMMARY OF THE INVENTION
The present invention provides a flowable paste material moulding unit for
manufacturing bakery products comprising:
an inlet means with adjustable side flanges operatively connected with plurality of
. adjustable roller means such that the flowable paste material is panned to a
endless web/canvas which passes between the plurality of roller means at
minimum leakage; and
a cutting assembly operatively connected with the said roller means at a particular
angle to remove the excess dough.
It is another aspect of the present invention to provide a process for moulding
flowable paste material in a moulding unit comprises the steps of:
i. mixing raw ingredients along with water to form the flowable
paste;
ii. transferring the said flowable paste material to an inlet means;
iii. filling the said flowable paste material into a moulding roller
cavity at an uniform pressure, volume and density by means of
forcing roller placed at a right angle to the said moulding roller;
iv. uniform scraping of the flowable paste material by means of a
cutting means mounted in-between the said forcing roller and the
said moulding roller;
v. dispensing the said flowable paste material in a required quantity
into the extraction web, which passes in-between moulding roller
and the rubber roller.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
Figure 1A illustrates a side elevation view of the complete unit for the moulding unit in
accordance with present invention.
Figure 1B illustrates an elevation view of the knife fixing position unit.
Figure 1C illustrates an elevation view of forcing roller positioning with respect to
moulding roller.
Figure 1D illustrates Moulding Unit - Plan top view
DETAILED DESCRIPTION OF THE INVENTION
The present invention is directed to a process and machinery, which would satisfy the
following needs identified in the background section.
(i) Proper filling of biscuits dough into the biscuit insert cavity.
(ii) Uniform scraping of dough effectively by flexible knife positioning and flexible
adjustment.
(iii) To dispense the dough in uniform and required quantity.
(iv) To make the equipment much simpler, user friendly and easy to operate.
(v) To make the unit with leak proof.
(vi) Individual drive for each roller i.e. for Moulding roller, forcing roller and extraction web,
which is turn, gives more flexibility in operation for dough with different consistency.
The process steps for the moulding of accurate biscuit dough are as follows:
(a) Mixing of raw ingredients like wheat flour, HVO (Hydrogenated vegetable oil), sugar,
along with water to form a dough;
(b) Transferring of the dough in to the stainless steel feeding hopper fitted above the
moulding roller and forcing roller;
(c) Proper filling of the biscuit dough into the insert cavity of moulding roller where the
forcing roller is placed at a particular angle to fill the dough into the insert cavities in a
uniform pressure, velocity and uniform density to get an equal quantity of dough filling;
(d) Uniform scraping of dough effectively by proper positioning and flexibility in
adjustment of the knife that is mounted in-between the forcing roller and the moulding
roller;

(e) Dispense the dough uniformly and in required quantity into extraction web, which
passes in-between moulding roller and the rubber roller.
The biscuit dough thus moulded into.required shape, size and weight are then transferred
to a wire band conveyor which passes through a heating chamber or over for baking. This
is then followed by natural cooling of biscuits followed by packing and stacking.
The nature of the invention, its objects and advantages are discussed in further details in
relation to non-limiting exemplary illustration of the process/unit as per the following
accompanying figures:
Figure 1A shows an elevation view of an embodiment of the present invention the
stainless steel hopper (110), which is mounted above the said moulding roller (120) and
forcing roller (130). The forcing roller (130) is place at a particular angle to fill the dough in
to the moulding roller cavities/insert cavities (190) in a uniform pressure, velocity and at
uniform density to get an equal quantity of dough filling. The forcing roller (130) position
ie.gap between the forcing roller (130) and moulding roller (120) can also be changed to
attain the required density of dough to get the required weight. The forcing roller (130)
and the moulding rollers (120) are adjustable. Side flanges (140) are adapted to reduce
the dough leakage from the dough feeding hopper (110) through the gap between the
dough feeding hopper (110) and the moulding roller (120) and forcing roller (130).
The side flanges (140) of the forcing roller (130) are designed specially, which Is also
adjustable and movable towards the side face of moulding roller (120) to reduce the gap
irrespective of moulding roller (120) width which in turn avoid the spillages of dough from
the end gaps of the moulding roller (120). The adjustable side flanges (140) is to reduce
the dough leakages through the gap between the moulding roller (120), forcing
roller(130) and dough feeding hopper (110).The knife (150) is mounted in between the
above said roller at a particular angle to scrap the excess dough and keep the required
dough at the cavities. The knife (150) position can also be adjusted. Knife assembly (150)
is operatively connected with the moulding roller such that the edge of the knife is always
in contact with the moulding roller (120) surface throughout the width due to simultaneous
horizontal and vertical movement of the said knife (150). The moulded dough in the cavity
(190) of the moulding roller (120) needs to be panned to a endless web/canvas (170)
which passes in between moulding roller (120) and rubber roller (200). The above said
rubber roller (200) is mounted just below the moulding roller (120). The rubber roller (200)
is also adjustable. Rubber roller (200) has a diameter larger than the diameter of the
moulding roller(120) to improve the release of the dough pieces from the insert
cavity(190) and reduce the tapering on thickness of the dough pieces.

The rubber roller (200) can be moved up and down and create pressure in between the
makes the dough to stick on to the end less web / canvas (170) and extract the dough
from the cavity (190). Then the dough piece with required shape, size, and weight is
being panned to the other web or conveyor for further baking, cooling, stacking and
packing. The total above mentioned parts are rigidly mounted on the side frame (210).
Figure 1B shows Swing arm scraping knife - Side elevation view
Scraping knife (150) has been fixed on swing arm so that the position of the knife can be
adjusted. The edge of the scraping knife (150) is to remove the excess dough projecting
out of the mould insert cavity (190) of the moulding roller (120)
Figure 1C shows Forcing roller position - Side elevation view
The forcing roller (130) is mounted at an angle with respect to the moulding roller (120).
Adjustable moulding roller is having a diameter greater than the said adjustable forcing
roller. The gap between moulding roller (120) and the forcing roller (130) can be adjusted.
This is achieved by adjusting the angle between 11 Deg and 30 Deg. This adjustability is
for filling the dough in to the insert cavity (190) with uniform pressure. Hence the pressure
applied for pushing the dough in the moulding roller insert(190) can be accurately set to
achieve the dough piece weight.
Figure 1D shows Moulding Unit - Plan top view
The Adjustable side flanges (140) are for reducing the leakage of the dough through the
gap between dough feeding hopper (110) and the ends of the moulding roller (120) and
the forcing roller (130). It reduces the dough leakage from the hopper through the gap
between the hopper side plates and the rollers.

We Claim:
1. A flowable paste material moulding unit for manufacturing bakery products
comprising:
an inlet means with adjustable side flanges operatively connected with
plurality of adjustable roller means such that the flowable paste material is
panned to a endless web/canvas which passes between the plurality of
roller means at minimum leakage; and
a cutting assembly operatively connected with the said roller means at a
particular angle to remove the excess dough.
2. The flowable paste material moulding unit as claimed in claims 1 wherein
the said roller means are moulding roller means, forcing roller means and
rubber roller means.
3. The flowable paste material moulding unit as claimed in claim 1 wherein
the forcing roller means and the moulding roller means are placed at a
particular angle to fill the flowable paste material in the said moulding roller
cavities and pass the said flowable paste material between the said
moulding roller cavities and the said rubber roller means.
4. The moulding roller and the forcing roller as claimed in claim 3 are placed
at an angle to each other.
5. The cutting assembly as claimed in claim 1 wherein said cutting assembly
comprises a knife assembly mounted in-between the forcing roller and the
mounting roller.
6. The cutting assembly as claimed in claim 4 wherein said knife assembly is
operatively connected with the moulding roller such that the edge of the
knife is in contact with the said moulding roller surface throughout the width
due to simultaneous horizontal and vertical movement of the said knife.

7. The flowable paste material moulding unit as claimed in claim 1 wherein
the said side flanges are adapted to reduce the dough leakage from the
said inlet means.
8. A process for moulding flowable paste material in a moulding unit
comprises the steps of:
a. mixing raw ingredients along with water to form the flowable paste;
b. transferring the said flowable paste material to an inlet means;
c. filling the said flowable paste material into a moulding roller cavity at
an uniform pressure, volume and density by means of forcing roller
placed at an angle to the said moulding roller;
d. uniform scraping of the flowable paste material by means of a
cutting means mounted in-between the said forcing roller and the
said moulding roller;
e. dispensing the said flowable paste material in a required qua'ntity
into the extraction web, which passes In-between moulding roller
and the rubber roller.