The collective imagination in the Nordic Countries links Christmas period to the production of special cookies, the „gingerbreads“ whose shapes are linked to the world of Christmas. However, this tradition has developed more and more not only at a geographical level (today we can find cookies with Christmas shapes in several Countries), but also at a thematic level: celebrations such as Halloween, Valentine’s Day, Easter … up to the promotion of events such as movie releases with cartoon or comic characters. However, the marketing activity has gone even further, expanding the proposal not only to traditional consumers (people) but also to their most faithful friends, (cats and dogs in particular) who are offered biscuits with various Christmas or Easter shapes in such occasions! It goes without saying that for particular doughs linked to tradition (such as gingerbread doughs), a special technology and materials are required that Errebi Technology offers promptly. And not only that: if seasonal products see the use of molds for a few weeks a year, this is not the case for products linked to an event: in this case Errebi Technology offers a construction technology that allows to regenerate the mold that is not more used with a new shape or design, thus saving costs and avoiding waste!

We can say that one of the current trends is to spend a little more to have an „extra and guilty pleasure” while some time ago the priority was towards cheap even if lower quality products. However, this does not mean that no attention is paid to costs. On the contrary, biscuit factories are very careful about cost calculations that a product entails. The ideal research therefore focuses on competitive products in terms of price, trying not to compromise their quality. An example is that of „industrial confectionery and pastry“, once made with various production processes (dropping machine, wire cutter, rotary moulder), and which can now be re-proposed by using the simple rotary moulder and, of course, on the basis of a particular design of the rotary moulding roller (which remains the heart of the line!). Errebi Technology has in fact developed a particular design that allows the production of various products with a single rotary moulding roller, once made with different processes. The result is an assortment of biscuits that does not have the costs of a traditional pastry, yet faithfully reproducing all its characteristics and features. Thanks to the study of design, release, weight control, Errebi Technology is able to propose solutions based on the most varied needs and requests.

It is true that much has been created and invented over the centuries in all areas, so much so that we are often faced with unlikely proposals with extreme innovations. This is a bit in all fields (from the visual arts to  music,  to the culinary and food). In our beloved world of biscuits, the search for novelty is often closely linked to one’s past and traditions, as if not wanting to dare to exaggerate. The history of the market basically teaches us how the most traditional products are the ones that hold the most while the extreme proposals are often simple flashes of straw … In other words, the design of new products and biscuits mainly focuses on the search for unusual dimensions (generally a reduction in sizes but also, even if more rarely, design of XXL sizes). This “resizing” has led Errebi Tecnology to real challenges with the design of products with extremely small dimensions (up to 4-6mm in diameter). Our role is in fact essential to find the most suitable material and profile of the cavities for a perfect performance and release of the products. The production of these biscuits must take into account some precautions such as the passage of the belts and the cooking diagram to avoid falls and burns. The purpose of such an unusual production is basically to offer an alternative product to something that already exists (corn flakes for example). Errebi technology once again plays a fundamental role so that ever greater and impossible challenges are successfully overcome.

Tradition  sees us consuming biscuits by munching them, but often also dipping them in tea or milk … and we speak of a real „art of dunking biscuits„. In fact, there is a relationship between the time in which the biscuit is dipped in the liquid and is tasted. This time must not be too long (risk of too much absorption and therefore breakage of the product) nor too short (risk of not absorbing the liquid at all). In short, it is a question of calculating the exact moment before the biscuit melts but has already absorbed the liquid by combining this marriage with the liquid that is then placed in the mouth: a technique in which the biscuit plays a fundamental role (as does the temperature of the liquid that the hotter and faster dissolves the biscuit). We only remember „en passant“ how „Dunking“ is important to recognize the flavors released by the product, as well as the consistency of the product itself; as well as plays an important role (especially historically) to soften the ancestors of biscuits (the first biscuits needed to be very hard in structure to be kept for long months …). The literature itself has very clear references to this technique: one quote above all: Marcel Proust’s “madeleine” which evokes childhood memories in the narrator. We at Errebi Technology want to emphasize how the dunking biscuits have recently also become a tool for mixing our coffee: the teaspoon that is increasingly being proposed as a nice combination between „tool“ and food, or tool to be eaten. Of extreme importance is the design of a spoon cookie which must have the right proportions (in length, width and depth) to avoid breakage, the right structure so that it absorbs but without exaggerating in order to be used as a real spoon to „taste“. The role of Errebi Technology and of a good technologist for the dough are therefore essential for the development of this kind of product.

It is often thought that the rotary line offers greater possibilities and a greater production range than a printed line. In reality, even the printed line allows a certain flexibility at the production level. This is above all thanks to the decades-long study of Errebi Technology, a pioneer in the development of rotary cutters with a particular technology allowing you to create special products such as biscuits with inclusions (dried fruit, chocolate chips) or with wide passing holes (for making sandwiches for example), up to to products with a scrapless configuration or for the production of potato-type snacks, once the prerogative of processes other than this.

Errebi Technology rotary cutters are made with non-toxic materials that comply with food regulations and in particular have a bronze body which may or may not be Teflon coated and / or plastic.

Both types of cutters (twin and single stage) provide different construction options: with interchangeable rings, or cups, or solid construction, all customized solutions based on individual customer needs.

Great attention is paid by Errebi Technology to details such as the radius, release angle, cutting height, the configuration of the docker pins, etc. … all parameters that our engineers take into consideration when designing a new cutter.

 

We can identify two types of rotary cutters:

 

Single stage rotary cutters and twin cutters, both used to cut a sheet of laminated dough. In both cases, Errebi Technology team of technicians pays close attention to the cutting dimensions that must compensate for the elasticity of the sheet, its tension and shrinckage.

When to choose one type of cutter rather than the other? In principle, the single stage rotary cutter is recommended for simple products without details (Ritz, Agua), while it is preferable to have twin cutters in the case of products with many details (special Petit Beurre, Marie, Zoology) for better performance and release. In addition, the twin cutters allows greater flexibility in terms of sheet thickness, providing for the possibility of adjusting the gap between embossing roller and cutter roller, which would not be possible with a single stage rotary cutter where it is necessary to know the thickness of the dough sheet from the beginning in order to accurately design the cutting thickness or cutting height. Last but not least, the twin cutters allows you to make different products, using the same cutting roller and possibly providing different embossing rollers based on the different engravings you want to make.

 

Once again the long experience of Errebi Technology is ready to listen carefully to the different requests, offering customized solutions for a wide range of markets.