Easier Imagined Than Moulded

One of the most important things in designing a mould for a new biscuit is to understand the idea of the customer and get it feasible.

It sounds simple but it is not, the conception of a new mould goes through several steps and not everything you imagine can be easily translated into a mould. Good thing that Padovani s.r.l. is always available to provide assistance with the development of new projects, which always represent a challenge we happily deal with!

Let us have a look together to the main phases in the design process of moulds for a new biscuit shape.

PROJECT ANALYSIS

A new biscuit shape may originate in different ways, depending on the context in which the project develops and on the final target product.

Sometimes the idea takes shape in the form of a simple sketch, often the customer takes inspiration from other products existing in the market and finally, in still other cases, the projects are linked to a logo or iconic subjects taken from franchise, global or local events and festivities.

Once all details are clarified with the customer, our team examines the project both from the viewpoint of technical engraving and from the viewpoint of the final resulting product.

Quite often the dough intended to use is being examined as well, for determining the material to use and the right type of engraving to do.

In case it’s clear from the beginning that the idea is not doable, we immediately inform the customer and propose alternative ideas and solutions, otherwise the technical department usually prepares a technical drawing for approval.

DRAWING

The realisation of technical drawings is the core activity of our technical department. It is the moment when it happens the first impact between ideas and reality.

Here at Padovani s.r.l. our technical department makes use of advanced and specific computer-aided design software to prepare accurate and clear drawings, which allow an easy review and feedback from the customers.

In case of doubts regarding the details of the requested shape, it’s advisable to send a 3D rendering of the biscuit, thus enabling the customers to have a true look at how the final biscuit will be and clear up any question.

The traits and graphic elements of the biscuit to-be are depicted taking into account various aspects:

- the transfer from idea to reality has some limits imposed by the practical engraving; for example the concentration of the graphic pattern must allow enough space for the engraving tool.

- the fact that the new shape must be released from the mould and, at the same time, avoid breakage issues after baking and feeding problem with the machine. In this respect there are many things to analyse, for example: depth of the engraving, release angle, radius, chamfers, presence/absence of docker pins and dimensions of the shape.

In this job not only the technical experience is relevant, but our technical team must use also aesthetic understanding and creativity helping the customers to propose something unique.

TRANSLATION INTO A PROGRAM

In this phase the drawings are converted by our skilled engineers into programs using a computer -aided manufacturing software. Starting from the drawing, it creates a series of instructions in a language that the engraving machines understand.

At this step we often create a first hand-model of the shape, so that we can see for the first time if what has been designed is technically feasible. This allows the necessary final corrections to be made before the final engraving.

ENGRAVING ON THE MOULD

The CAM programs provides the instructions to our advanced CNC machines, enabling the engravings of many models of the shape onto the mould.

Since we are talking about new biscuits to launch in the market, it’s generally advisable to start with some test rings, which allows to carry out internal tests and also to test the market.

The engraving is a delicate phase and it must be performed in the presence of expert manufacturing professionals, this is the moment when the initial idea finally turns into reality!

Domain expertise and particular attention to detail, along with the care for our customers have always been distinctive features of our company; Padovani s.r.l. is always ready to work alongside the customers, to provide complete assistance in all the development phases of new biscuits.