Major biscuit moulding roll contract
Date: 05 November 2004
Baker Perkins meets a demanding schedule
Innovative use of state-of-the-art technology enabled Baker Perkins to accelerate the production of a wide selection of biscuit moulding rolls, and meet a demanding schedule for leading manufacturer United Biscuits ('UB').
Baker Perkins won a major contract to supply new rolls for a variety of McVitie's market leading brands, made at UB's factories in Carlisle and Tollcross in Glasgow. Best selling product lines including McVitie's Digestive and Chocolate Digestive, Mini Cookies, Mini Hobnobs, Rich Tea, Shortcake and Ginger Nuts were involved.
UB operates at the highest levels of quality and consistency, and total accuracy in replicating these products is fundamental in the manufacture of new moulding rolls.
Biscuits that have extremely complicated surfaces - particularly those of apparently 'random' design - present a significant challenge when a new roll has to be created for an established product. This was the situation faced by Baker Perkins when asked to produce a roll for Coconut Rings, and was further complicated by the need to get the roll 'right first time' in order to met the tight production schedule.
Baker Perkins utilised scanning technology normally associated with car components such as body panels to help solve the problem successfully and rapidly. An accurate impression of the biscuit, made of dental compound, was scanned to high levels of precision, producing the digitised programme used to engrave the roll.
Ridges and valleys within the biscuit were exact replicas of the original and the resultant roll went straight into production.
A 3D CAD modelling tool was used to solve a similar challenge with a shortcake biscuit, producing a solid, textured product model - and again the project was 'right first time'.
Biscuit moulding rolls consist of an outer sleeve of brass or bronze bearing the biscuit design, mounted on a steel shaft. Baker Perkins provides a comprehensive service in the design and engineering of new and replacement moulds - often replacing an old outer sleeve with a new design, effectively recycling equipment for a second life. Baker Perkins has also developed techniques to ensure that new products can be brought to market as rapidly as possible.
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