Those who are not „professionals“ might taste a biscuit without paying attention to the fact that it often has small holes. But for a biscuit manufacturer those holes are not always dictated by  aesthetic. In fact, during cooking biscuits and crackers develop and assume an open and light structure. This is because with the cooking process in the oven the humidity in the dough comes out of the product. Now if this steam finds a way out through these holes, our biscuit will have an even surface, essential above all for the automatic packaging of the biscuits and the stacking. Otherwise, if the steam cannot escape, we are faced with structural problems of the product, in particular „checking“ phenomena and / or bubbles on the surface of our cookies.

The presence of the docker pins in the moulds is therefore essentially dictated by one or both of the following factors:

1. a) Indispensability: if they need to completely pierce the biscuit for cooking needs on steel band ovens thus avoiding the „craters“ on the underside of the biscuit and the bubbles on the top of the biscuit. Also important to prevent the biscuit from falling out of the cavity before reaching the band causing a breakage or deformation of the product.
2. b) Decoration: if they have a pure aesthetic function: normally, in fact, with cooking on a net oven band they are not indispensable and if they are present they have a purely decorative function.

Errebi Technology’s attention to detail could not fail to focus on the research and development of this small detail that is part of the mould. Height of the docker pins (which differs between a rotary moulding roller and a rotary cutter), arrangement and configuration on the biscuit, material (stainless steel or plastic material), profile of the docker pins and radius, half-conic, flat, rounded head, etc. are some of the fundamental elements to be taken into consideration according to the biscuit to be developed.

To complete its production, Errebi Technology has now its own internal production of docker pins with automatic insertion of the same on the moulds, to guarantee accuracy and precision both in the application and in the height of the docker pins. This is thanks to the investment in computerized machinery that allows these processes. In Errebi Technology we know that detail should never be underestimated and it makes the quality difference of a product!

During these days there has been a lot of talk about the „recovery fund“, a very topic expression that is more current than ever, if not of historical significance. In Errebi Technology if we replace the word „fund“ with „scraps“ we can say that the expression „recovery scraps“ is very familiar and we can say that we are still talking about economy … In fact with „recovery scraps“ we mean to recover dough scraps making it possible to produce perforated products not only for soft biscuits but also for hard products. Perforated products are an interesting alternative in order to reduce production costs. In fact it is a question of proposing the same classic shapes, or new shapes, but with the addition of passing holes allowing to obtain a biscuit with the same size as the original product, but lighter, with less dough, and with a consequent greater margin of profit for the biscuit manufacturer. In other words, an „elegant“ way to reduce costs, by reducing the quantity without reducing the quality of the product. Now, if for a soft biscuit process  the presence of passing holes is not a problem, in a hard biscuit the creation of passing holes would not be possible without an adequate technology that allows the recovery of scaps, the „recovery scraps“ actually. Errebi Technology has designed simple and innovative solutions that allow to be applied to any type of cutting line, without particular interventions or adjustments on the existing line. If you think about creating something new allowing you at the same time to reduce your production costs, Errebi Technology team is available to find the best solution with you!

The world has restarted and with him also the world of biscuits. Errebi Technology, always first-hand witness to the evolution of the market thanks to its privileged position as a collaborator with most of the biscuit factories worldwide, can confirm that there is once again a great desire to start again with new projects. Current market trends? Same products but with new recipes that know how to combine health with taste. Same products but with recipes that can surprise us with unusual combinations such as combinations of sweet and savory. New shapes, new designs almost to exorcise the drama of the past months. But what is most trendy is the resizing of old products in terms of measures (generally a reduction of the measures or, paradoxically, XXL measures). We then talk about „resizing“ to offer similar products but which allow you to save on the amount of dough. Or we talk of „restyling“ because we must always look to the future with an eye to the past. So the „historical“ shapes are revised eventually with the addition of passing holes: an idea to propose something new but which is lighter in terms of unit weight. This is especially done with the purpose of containing production costs: in fact, to reduce costs, the most immediate thing to do is to reduce quality or quantity. But with the revisiting of the resized shapes we have a reduction of costs without affecting the quality of the product. Errebi technology once again plays a huge role in ensuring that the challenges consisting of thinner and thinner biscuits, very abrasive recipes difficult to be released from the mould, so that all these challenges can be overcome once again thanks to the study of angles, materials and designs that allow you to overcome ever greater obstacles.

It is a fact, the world is starting up again, even if step by step, slowly and with all precautions. In these months of lock down, the cookie industry has not been immune from the COVID-19 pandemic. And if from one side there has been an increase in the production of biscuits due to the shut down of coffee bars, with the only alternative to have breakfast at home, it is also true that most of the new projects of biscuits have been frozen „till better times „. As Errebi Technology, from our position, we  have witnessed first-hand closures of entire production lines to consecrate to only certain types of products with more traditional consumption in times of crisis. The same network of international markets and exports has suffered greatly.

However, we can now say that, little by little there is a restart, even if the world will probably not be the same as before. But, as Darwin says, „the strongest is the one who best adapts to change.“ So the restart must find us prepared. Thus, the recovery of projects left on stand-by for weeks. Biscuit factories wish to start again from where they left off, trying to adapt everything to the new needs that the new reality has faced us. New recipes are once again the subject of study by R&D in biscuit factories trying to surprise the consumer with new flavors and sensory taste experiences. Healthy, vegetarian, vegan, diet products, but without forgetting the taste. New shapes, new sizes at the very possible limit for a biscuit production process. However, all of this needs to be tested before investing in a complete mould. And here is how, once again, Errebi Technology knows how to suggest the best solution to be able to carry out those temporarily abandoned projects: test rings to be mounted on existing rollers allow you to directly test in production weight, thickness, engravings, release, simulating 100%  the final production. And based on the results, Errebi Technology technicians will be able to calculate all the proportions necessary to arrive at a final mould without surprises. A test in production is different from a manual test giving only a rough idea of ​​the result. Without forgetting that often, in order to carry out manual tests, the same consistency of the dough will be necessarily different especially in terms of humidity, and this falsifies the validity of the test from the start. Last but not least, the tests carried out with test rings allow to produce a sufficient quantity of sampling for market research purposes. it goes without saying that only decades of experience in ring construction can allow a guarantee of accuracy and precision otherwise not found. And Errebi Technology can rightly afford to be a leader in this sector: do not trust appearances: it is only in production that the difference of Errebi Technology is noticed. And in fact, a mould for Errebi Technology is the result of long experience and technical studies, a tool to be exploited in its various possibilities, always with the accuracy and precision that make Errebi Technology different from any other mold manufacturer in worldwide …

Need for flexibility has become very topical in a world where everything is changing all the time. And it is even more topical nowadays when incertitude impacts with our habits and forces us to  change often our plans. And this happens also in our beloved world of biscuits: following media, social trends, novelty or cartoons themes (we all know children’s power in the market  to convince their parents to buy a trend mark rather than another one, influenced by what’s going on for them in terms of movies for example). Beside, also the so called “traditional or classical” brands making the story of a Company might need some restyling and / or some resizing. Or again, the “seasonal” products (Halloween, Christmas, St.Valentine, Easter …).

More and more there are cookies celebrating a season or cookies promoting an event or a movie. But their production life is quite short.

So, if from one side we have a trend toward short life cycles, from the other side, there is the request for re-designing existing shapes. And to facilitate this rapidity in changes, biscuit producers demand more and more fast track route from conception to production. No matter of saying that #Errebi technology is ready once more to play a proper role on this. A special construction permitting you flexible changes married with a performance looking like a solid construction in terms of accuracy and precision.

In other words, if our rollers look like made in a piece only, they are actually made with interchangeable rings and this means “flexibility”

• In terms of continuity in production, because the easy change allow you to replace the damage ring with the spare one
• In terms of accuracy and precision when testing a new product: a trial ring can give you a 100% precise test in production

But “flexibility” with Errebi Technology is even much more than this: the possibility of regenerating your roller once they are worn or once a cycle of products is over and you don’t produce such a cookie any more. And this allow you to save costs.

And last but not least, a consideration on cookies traditionally made with a different process (wire cut, hard, soft), which might be made with a similar appearance but with a different process. The purpose for this? To save money in the process or to produce something similar but with the available machines…

A biscuit roller here in Errebi Technology is not a simple tool for giving shape to a piece of dough. It’s much more than this. It is the result of long experience and rational considerations to offer you a special tool which can be exploited in different possibilities, always with the accuracy and precision which make Errebi Tecnology different from any other die manufacturer worldwide…