A Johannesburg biscuit maker needed to fill, sandwich and wrap cream biscuits in one pass. We supplied two lines, each a cream biscuit sandwich machine feeding its own flow wrapper, rated at 600 biscuits a minute and 30 to 180 packs a minute. Both lines are delivered and running.
The customer makes cream sandwich biscuits in Johannesburg: round or rectangular biscuits 3 to 6 mm thick, paired around a layer of cream and sold in flow-wrapped packs, laid flat or stacked two high. Thin biscuits break easily, and the cream has to sit evenly between them, so every biscuit looks the same in the pack.
Each line had to fill, sandwich and wrap the biscuits in one pass, with no handling between the steps.
Deposit a set amount of cream on each biscuit, adjustable for each product.
Close each biscuit two in one, for round and rectangular biscuits.
Wrap the biscuits one to three across, in one or two layers, in printed or plain film.
We supplied each line as a cream biscuit sandwich machine feeding a flow wrap machine, so biscuits go from cream filling to a sealed pack without being handled again. The flow wrapper senses each biscuit and feeds film only when one arrives, a photo-eye keeps printed film in register, and the end seal and cut are made together. Product-contact parts are stainless steel.
The sandwich machine fills and closes each biscuit, and the flow wrapper forms film around it, seals it and cuts it into packs.
| Biscuit shapes | Round, 30 to 55 mm or 55 to 65 mm across; rectangular, 35 to 50 mm or 56 to 65 mm wide and up to 70 mm long |
| Biscuit thickness | 3 to 6 mm |
| Sandwich | Two in one |
| Sandwich speed | 600 biscuits a minute |
| Cream | 30 L tank, rotor pump, adjustable quantity |
| Film | 90 to 400 mm wide, printed or plain |
| Packs | 35 to 160 mm wide, 60 to 300 mm long, products 5 to 50 mm high |
| Pack layouts | One to three biscuits across, in one or two layers |
| Wrapping speed | 30 to 180 packs a minute, depending on pack size |
| Options | Date coding, nitrogen flushing, automatic feeding |
| Power | 380 V; 3.7 kW sandwich machine, 6.25 kW flow wrapper |
| Footprint | Sandwich machine about 2.2 x 0.9 m; flow wrapper about 4.0 x 0.9 m |
Each biscuit goes from plain biscuit to a sealed, wrapped pack in one pass.
Biscuits are fed into the sandwich machine automatically, round or rectangular.
A rotor pump draws cream from the 30 L tank and deposits a set amount on each biscuit.
A second biscuit closes each one, two in one, at up to 600 biscuits a minute.
The flow wrapper forms film into a tube around the biscuits, one to three across in one or two layers, and seals it along its length.
The end seal and cut are made together, with date coding and nitrogen flushing as options.
Both lines are delivered and running in Johannesburg. Each fills, sandwiches and wraps cream biscuits in one pass, with the sandwich machine rated at 600 biscuits a minute and the flow wrapper at 30 to 180 packs a minute, depending on the pack size. These are the machines’ rated speeds; the output the customer achieves on its own biscuits has not been measured for this case study.
Rated speed of each sandwich machine.
Depending on pack size.
One to three biscuits across.
The clip shows a flow wrap machine like the one on these lines, loading, wrapping and sealing packs.
Flow wrappers for biscuit packs and the biscuit lines we have supplied.
Video demonstrations of every machine type we supply, filmed in the workshop and on site.
Start from your biscuit, your pack and the output you need, as this project did.
Top-roll and bottom-roll flow wrappers, with the builds we have supplied.
Flow wrappers for biscuit packs, cream biscuit lines and weigher lines for cookies.
A new cookie factory in Johannesburg, from mixer to bagged cookies.
Send us your biscuits, your pack and the output you need. We will test them and come back with a recommendation or quotation.
