Cookie Capper Machine: The Ultimate FAQ Guide

Through this guide, you’re going to learn how to choose high performance cookie capper machine.

From features, parts, working principle to specifications – you will find all information you need about cookie capper machine.

Let’s dive right in.

What are the Features of the Best Cookie Capper Machine?

The properties of cookie capper machine vary depending on the specific equipment design.

Figure 1 Cookie Capper Machine

Cookie Capper Machine

But some of the most outstanding features include the following:

Hi-tech Controls

Comes with a fully integrated operator interface, timer, and control system package for regulating different ingredient recipes. Also, it features servo, maintenance, and diagnostics settings.

Moreover, this machine has a pivoting touch screen allowing you to have easy control access from either of its sides.

Auto-speed Synch

Monitors product backup, which is vital since it helps to match the incoming rate of product rows.

Solid Frame

It features hygienic and robust design construction in a stainless steel frame without any significant mechanical parts under process area. This makes it easy to clean the machine at all times.

Quick Changeovers

Most cookie capper machines have easy to change parts, which is achievable in 10-15 minutes.

A single system can run over 50 different products with varied sizes, styles, filling, and lanes across with a simple changeover. It only requires pressing a button to accomplish the changeovers.

By-pass Conveyor Mode

This feature allows cookies to pass through the system on all-belt-to-belt transfers. The system makes the main belt easy to be used for pass-through.

Auto-lubrication System

Provides a central lubrication unit regulated from the HMI to all lubrication points. The system uses multiple zone distribution blocks to lubricate all the points simultaneously.

Linear Capping Design

The design is essential in enhancing the equipment’s speed and performance. As such, it makes it easy to attain higher precision for an ideal sandwich at relatively high speeds.

Flexible

This equipment features a system, which can handle different product sizes ranging from a diameter of 20-70mm or more.

Ideally, you can make any type of cookie such as die-cut, wire cut, rectangular or square products among others.

Other notable features of this machine include;

  • Auto-product alignment
  • Crème mixing operation
  • Auto-belt tracking
  • Auto-belt wash
  • No product No dosing function

What is the Typical Speed of Cookie Capper Machine?

It is mainly dependent on the specific design and specifications of the equipment. Ideally, large-capacity cookie capper machines yield higher speeds than low-capacity units.

On average, though, the production capacity of this type of cookie making machine ranges from 3000-21,000 pieces per minute.

The deposition speed, on the other hand, varies from 20-30 strokes per minute depending on the model and other technical specifications.

Figure 2 Cookie Capping Machine

Figure 2 Cookie Capping Machine

How Many Styles and Sizes of Cookies Can you Process with Cookie Capper Machine?

Cookie capper machine is quite flexible; hence you can use it to make a wide range of styles and sizes of your preferred cookies. You can make as many as 50 variations of cookies using this equipment.

Moreover, the sizes would range from 25mm to 125mm in diameter. This machine also allows you to make rectangular, square, and other odd-shaped cookies in different sizes.

The most critical aspect is ensuring you set the machine correctly based on your specific needs surrounding style and size.

Which are the Main Parts of Cookie Capper Machine?

Ordinarily, cookie capper is full-width sandwiching systems.

It uses several parts and components to accomplish its role in the production process of cookies.

Some of the core parts and components of this machine, which you ought to know, include the following;

Motors, Drives, and Gear-box

Primarily, these are like the engine of this device. They are essential in regulating parts movement within the cookie cappers.

You can also control speed of these parts using the control panel and determine the ideal promptness.

Belts

They form part of the conveyor unit ideal for moving the products from one station to another. Belts are also essential since they hold the cookies firmly in position during capping.

Control Panel

It is an integrated computerized system in the machine directing operation of different automated parameters and computer functions.

Shafts and Sprockets

They are vital in transmission of rotary motion between shafts.  These components come in handy where gears are not ideal for imparting linear motion.

Typically, shafts and sprockets assist in the movement of various parts of the machine.

Depositors

These are a series of flow control valves featuring individual nozzles for fine-tuning pressure balance across manifold.

Feeder

It is a component designed to allow the products to flow into the capper right from the cooling conveyor.

Sensors

These are integrated subsystems, devices, or modules in a cookie capper machine designed to detect numerous operational and functional changes and prompts.

Sensors relay signals to the machine’s electronic system to trigger computer unit to respond accordingly.

Indexing Device

It is a unit containing a technically advanced method for flipping each row in the machine to offer alternate rows of tops and bottoms.

Guarding Clamps

Generally, these clamps help in safeguarding machine parts from damage. They hold and join different parts, and some of these clamps include guarding hinges and handles among others.

Gripper Discs

As the name suggests, the essence of these parts is to enhance the holding grip of the cookie crapper. These discs increase holding strength and torque to prevent any form of misplacement or spillage.

Chutes

They are designed to hold the cookies in place while on the capper. Chutes utilize different principles to guarantee a continuous replacement of the cookies appropriately.

What are the Materials Used in the Construction of Cookie Capper Machine?

Different parts of a typical cookie capper machine are made using a variety of materials.

However, the main body parts are usually designed using stainless steel material.

This material is more stable and can withstand different harsh mechanical, environmental, and operational conditions.

Moreover, stainless steel has better heat resistance, displays incredible tensile strength, and it is somewhat appealing to the eye.

Stainless steel features anti-bacterial elements, and it is easy to clean, which makes it an ideal consideration for this equipment.

There also other parts made using different types of thermoplastic and rubber materials.

Depositor manifold dosing pipes, for instance, are made using thermoplastic materials.

Other materials also used in making different parts of this machine include copper, titanium, and aluminum among others.

Which are the Equipment in Cookie Capping Line?

Depending on the specific design of the cookie capping machine, the production line can feature different equipment.

The most common ones in both short and long versions include the following;

In-feeder

It is a special endless conveyor belt with many features for unscrambling and receiving cookies in the machine.

The In-feeder section also places the product into lanes, accumulates, and properly synchronize the product into the indexing device.

You can always align and space products accordingly with easy changeover of customized parts.

Figure 3 Cookie Capping Infeed System

Cookie Capping Infeed System

Flip-slide Device

A versatile and efficient technique in cookie capping line is flipping every other row to provide alternate rows of tops and bottoms.

The flipping speed of this equipment often varies depending on design specifications. However, it provides ability to switch to a bypass or conveyor mode with a mere button press.

Deposit Manifold

It accomplishes depositing of different ingredients on the cookies. Mostly, they are mounted onto traveling platforms for effortless removal and cleaning.

Capper

This is the specific equipment where sandwiching operation occurs. It features a vacuum jet, which picks up top cookie to a particular programmable position.

This clears the approaching cookie with deposited filling then placed at the bottom to form a precise sandwich.

How Does Cookie Capper Machine Work?

Ideally, cookie capper machine is a full-width sandwiching system.

The working principle of the equipment is a bit straightforward since it is designed for a specific function in the cookie production line.

Essentially, the cappers take the cookies directly from the end of a cooling unit’s conveyor. Cookie capper then takes complete control of the product straight from the oven band.

Individual cookies are oriented, indexed, and flipped in every other row.

Once flipped, the products, amounts of filling are applied accurately, followed by positioning of tops onto bottoms automatically at a set speed per minute.

The sandwiched cookies are then conveyed for enrobing, packaging, or any further processing requirements.

Primarily, most of the operations of a cookie capper are automated and takes effect immediately there are setting adjustments.

What is the Output of Cookie Capping Machine?

Numerous variables determine the exact output of a cookie capping device. For instance size, a bigger cookie capping machine is likely to have a higher production output than a smaller unit.

Secondly, the specific technical and design specifications also determine the exact production output of this machine. Latest models are integrated with advanced technology, which plays an essential role in enhancing the overall production capacity.

Power and pressure ratings also influence the particular capacity a capping machine can produce.

Changeover parts is another fundamental determinant of cookie capping machine output. A unit that supports quick changeover has a higher production output than one with a slower conversion.

In essence, the exact output is dependent on various factors, as mentioned above. However, a typical cookie capper would endeavor to yield an average production capacity of between 3000-21,000 pieces per minute.

And this is great since it gives you flexibility to determine your preferred equipment based on these factors. Moreover, you can constantly adjust the speed based on various factors such as size and shape of the cookies.

How Many Lanes Does Typical Cookie Capper Machine Have?

A typical cookie capper machine has lanes ranging from 2-6.

Depending on the equipment setting, and type of product, each of the multiple lanes may produce between 200-800 cookies per minute.

Generally, the cookie capper is often followed by a lane multiplier. This is vital in increasing the number of lanes of sandwiches to feed on the cooling unit.

Does Cookie Capper Machine allow Integration with other Machines?

Yes, the general production of a cookie entails a manufacturing line, which features different sets of machines.

All these machines, including the cookie capper, are integrated and synchronized to ensure they work simultaneously in the production line.

Some machines integrated with cookie capping equipment include indexing devices, magazine feeder, placing device, depositing manifold, etc.

What is the Difference Between Cookie Capper Machine and Biscuit Sandwiching Machine?

Ideally, cookie capper machine features a full-width system where the products are taken directly from the end of a cooling conveyor.

This equipment aligns cookie rows, flip over alternate rows, align and deposit fillings onto alternate rows.

Systems of cookie capper machines are versatile and available with different depositing systems to handle varied ingredients.

Also, the several depositors in a typical capper allow for application of different fillings.

Moreover, a cookie capper can be organized to feed cookies directly to ingredients enrobing line.

Conversely, a biscuit sandwiching machine is a multi-lane device of up to six lanes, each producing between 200-800 sandwiches per minute.

Biscuit sandwiching machine automatically sandwiches the product with a jam or cream or two ingredients.

Biscuits are often fed manually from the packing table to a set of vibratory conveyors.

It features vibratory conveyors to guarantee a pressure-less feed to the sandwiching equipment. In essence, it prevents biscuits from breaking.

A lane multiplier often follows this machine to increase the number of lanes of sandwiches to feed a cooling unit.

How do you Control Cookie Capper Machine?

A typical cookie capping device has a wide range of control options you may choose for various operational functions.

The most commonly used ones include the following;

Fully Integrated HMI

It is a control system, which entails human intervention during most parts of the cookie capping process. This system of control displays real-time data regarding the manufacturing capping process of cookies.

Nonetheless, you can manipulate information on HMI by pressing different buttons when adjusting varied parameters of the equipment.

Figure 4 HMI for Cookie Capper Machine

 HMI for Cookie Capper Machine

Touch Screen PLC Panel

Often features a Programmable Logic Controller (PLC) and is designed to utilize computerized information to relay its functions.

Data is fed into the computerized system of the machine and synchronized with the respective buttons. Primarily, the input on this unit is what determines the output of the equipment.

Automatic Belt Alignment System

This control system features an advanced cookie alignment device. It tracks wandering of products due to the incoming conveyor’s belt tracking system.

Servo Control System

It is a control system that features a rotary actuator unit allowing for precise regulation of capping process of the equipment. The servo control unit has a motor and sensors serving as its core components.

Which are some of the Safety Features of Cookie Capper Machine?

Some of the cookie capper machine safety features include:

  • Highly Automated Functions: Reduces human operation aspect of the machine, making it relatively secure. Essentially, it facilitates human-machine interaction since most parameters are automated.
  • Alarm System: Raises attention if there is a fault, malfunction, or misuse of a particular functional parameter.
  • Immobilizer: Reduces or limits the machine’s efficiency in case of an emergency, fault, or any pressing issue that requires attention.

Does Cookie Capper Machine have Belt Tracking Management System?

Yes, modern cookie cappers are integrated with a hi-tech and efficient auto-belt tracking system.

In this case, there is a tracking roller offered to alternate the angle in response to a special tracking valve. This valve monitors the edge of the belt.

How Many Deposition Fillings can you Use with Cookie Capper Machine?

Quite a number depending on your preferred ingredient taste. The most common options, however, include the following;

  • Cream
  • Jam
  • Marshmallow
  • Jelly
  • Chocolate
  • Caramel

Which are the Feeding Options of Cookie Capper?

There are two major feeding options you can always use on a cookie capping machine, and they include the following;

Automatic Feeding

In automatic feeding, the prompts are directed from the central control unit. Once set, the machine continuously feeds the product straight from the cooling conveyor to the respective lanes.

It is more efficient, reliable, and quite faster, thus an ideal option in large-scale production where high production capacity is necessary. Moreover, automatic feeding is more cost-effective since it hardly requires human input.

Manual Feeding

It is a method, which entails placing the cookies by hand immediately they leave the cooling conveyor. In many instances, this is often a way of regulating the specific designs and quantity of cookies you want to be capped.

Manual feeding is considered primarily on small-scale production where production capacity is not necessarily high.

What are Some of the Tips of Maintaining Cookie Capper Machine?

Ideally, nearly all the functionalities of cookie capper machine are automated. As such, it will require meticulous routine maintenance to enhance the efficiency, reliability, and durability of the equipment.

Some of the ideal maintenance tips you may consider include the following;

  1. Always do a thorough cleaning of the machine after use. The design construction of the framing component makes it easy to clean this equipment even during operation.

Moreover, the fully automated units are integrated with cleaning mechanisms to assist in efficient real-time maintenance.

  1. Make sure you replace worn-out and broken parts and components of the cookie capping machine. You can always run a computerized diagnostic test to determine the particular parts or components that are worn out.

It is also a suitable technique to figure out the specific parts of this machine, which require repair, whether light or in-depth.

  • Lubricating all the moving parts of a cookie capper machine should be a routine.

Most modern units have a central lubrication system regulated from the HMI to various lubrication points simultaneously.

  1. It reduces friction, which is vital in enhancing durability of the machine.

Can you Optimize Design of Cookie Capper to Integrate Cleaning in Process (CIP) System?

Yes, with the automation system, it is easy to integrate and synchronize CIP system.

Essentially, CIP system cleans the interior surfaces and components of this equipment without necessarily disassembling it.

All feed piping and hoses extending to deposit manifolds are integrated with the cookie capping machine.

The cleaning water, in this case, returns to the system to complete the loop. This is imperative since it makes it easy for you to maintain high hygiene levels on the machine.

What is the Standard Dimension of Cookie Capper?

Standard dimension for a typical cookie capping machine is 5800mm long by 1000mm wide by 1800mm high.

Of course, these dimensions may vary from time to time based on the specific manufacturer of the equipment.

Figure 5 Cookie Capping Line

Cookie Capping Line

Which are the Types of Conveyor Belt System of Cookie Capper Machine?

Generally, this type of machine uses an endless conveyor belt system.

But this design feature different types depending on the specific type of machine you are using in cookie capping;

However, the main types include the following;

  1. Unscrambling Conveyor Belt – This is designed to restore the products as they get into the infeed section of the machine.
  2. Receiving Conveyor Belt – its role is to receive the cookies as they get from the cooling conveyor.
  • Placement Conveyor Belt – It is designed to place cookies into different lanes awaiting filling.
  1. Amassing Conveyor Belt– The design of this belt is to accumulate the products together and synchronizing them into the indexing device for subsequent functions downstream.

Is Conveyor Belt of Cookie Capper Made of Food-Grade Material?

Yes, the conveyor belt system comes in contact with the cookies in most instances along the process. It is necessary for the specific material used in making the conveyor belt to be food-grade.

Most quality and safety standards agencies approving suitability of these items usually recommend specific food-grade materials for these conveyor belts.

Are there Sanitary Design Cookie Cappers?

Yes, most modern cookie capping machines feature sanitary designs.

These designs make it easy to maintain the equipment’s system with absolute hygienic operation.

Sanitary design cookie capping equipment are made exclusively of titanium, stainless steel, and anodized aluminum construction.

It also features minimum plate-to-plate contact, welded stand-offs for hoses and wires, and non-tube penetration for mounting the device.

How do you Lubricate Cookie Capper Machine?

Technically, there is a central lubrication system in a typical modern cookie machine.

This system provides auto-lubrication regulated from the Human Machine Interface to all the necessary lubrication points in the machine.

The auto-lubrication process takes place simultaneously to all these points using multiple zone distribution locks.

Are there Custom Cookie Capper Equipment?

Yes, since different users have varied needs, manufacturers often provide customized units.

Ordinarily, getting a custom cookie capper involves coming up with a design blueprint and submitting it to the manufacturer.

The manufacturer approves or recommends alteration of the design where applicable.

In most instances, if the design blueprint meets all the expectations, the manufacturer goes ahead to produce it within a specified timeline.

The best element of getting a custom cookie capper is it allows you to get a particular unit, which meets your specific demands.

What are the Quality Standards for Cookie Capper Machine?

Cookie capping requires a high level of safety, hygiene, and efficiency. As such, the machines involved in such processes must conform to various quality standards, which include the following;

FDA

An abbreviation for Food and Drugs Administration. This agency is responsible for protecting the general public by enforcing efficacy, security, and safety of products and equipment.

cGMP

Refer to rules and regulations practices necessary for conforming to recommended guidelines as stipulated by agencies regulating authorization and certification of devices.

Current Good Manufacturing Practices ensure consistent quality and safety of all the processed products.

CE Marking

It is an administrative marking showing the machine’s compliance to safety, health, and environmental protection standards.

Which are the Key Technical Specifications of Cookie Capper Machine to Consider Placing an Order from China Supplier?

The most fundamental technical specifications to always consider when procuring a cookie capper machine include the following;

  • Torque control
  • Degree of automation
  • Production capacity
  • Diameter of deposited cookie
  • Possibility of integration into an existing line
  • Speed and throughput
  • Self-diagnostic ability
  • Electric power rating
  • Compresses air consumption and pressure
  • Steam pressure
  • Gross weight
  • Dimension

At SaintyCo, we will help you find the best cookie capper machine for your unique production needs and requirements.

Contact us now for any cookie capper machine.

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