Proform has outlined a series of automation and process-control measures designed to improve the efficiency of high-speed sandwich biscuit and cookie production lines.
Published on 25 August 2026, the manufacturer’s technical guidance focuses on cookie capper systems, where accurate biscuit handling, filling deposition and top-biscuit placement must be closely synchronised at production speed. Proform says improved coordination between these stages can help bakery and snack manufacturers reduce product waste, maintain filling consistency and avoid unnecessary production stoppages.
The Turkish machinery manufacturer supplies equipment for biscuit, snack and chocolate-coated product lines, including cookie cappers, enrobers, cooling tunnels and continuous aeration systems.
Improving deposit accuracy
A key issue highlighted by Proform is the management of irregular biscuit spacing as products travel from upstream equipment towards the filling and capping station. Missing or incorrectly positioned biscuits can result in cream or other fillings being deposited directly onto the conveyor.
To address this, the company recommends optical detection systems incorporating a “no biscuit, no deposit” function. Sensors identify empty positions and prevent the depositor from operating where no base biscuit is present.
Multi-axis servo drives can also synchronise the movement of the depositing head with conveyor speed, improving the positioning of creams, marshmallow and other fillings.
Proform also identifies filling consistency as an important factor in maintaining accurate deposit weights. For aerated creams and marshmallow-based fillings, its approach combines cookie capping with continuous aeration equipment designed to control product density.
Vacuum-assisted suck-back nozzles are used to minimise dripping and filling tails after each deposit, helping manufacturers maintain cleaner production and more consistent finished products.
Supporting flexible production
Production flexibility is another consideration for bakeries and snack manufacturers running multiple biscuit sizes, formats and recipes on the same line.
Proform recommends quick-change guide rails and depositor manifolds, combined with stored PLC recipes that can adjust parameters such as stroke length and indexing timing when switching between products.
These features can help reduce manual intervention during changeovers while improving repeatability between production runs. Tool-less belt removal and cleaning arrangements can also simplify sanitation and maintenance procedures.
The company also highlights the importance of integrating cookie capper output with downstream equipment, particularly where biscuits move directly into chocolate enrobing or cooling processes.
Matching conveyor speeds across the line can help prevent product accumulation, damage and interruptions, while regular checks of suction cups, seals and belt tension can support more consistent operation.
For bakery and snack producers investing in higher levels of automation, the guidance shows how sensing, servo control, filling management and line integration can improve overall production performance without relying solely on higher machine speeds.
