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Hello Everyone,
I have recently launched a wafer production facility in Lebanon and am looking for technical guidance to optimize my production. I am currently operating a 30-plate wafer oven and am facing challenges in three specific areas:
1. The Mix (Batter Formulation): I am seeking a balanced industrial recipe that works well with the local flour available in the Middle East (typically medium-protein). My current wafers are sometimes too "flinty" or hard rather than having a light, crispy "snap." I need advice on the ideal starch-to-flour ratio and the best sequence for adding emulsifiers (Lecithin).
2. Manufacturing & Crunchiness: Despite adjusting oven temperatures, I am struggling with consistency.
My current cycle time is 2-2.5 minutes.
I need help with calibrating the plate gap and gas burner pressure to ensure a uniform "shatter" crunch across all 30 plates.
I am also looking for tips on the "Specific Gravity" of the batter to ensure proper aeration.
3. Shelf Life in High Humidity: Operating in a Mediterranean climate (high humidity), my wafers lose their crunch faster than expected. I need recommendations on:
Ideal moisture content (%) upon exiting the oven.
Post-bake cooling protocols for a 30-plate scale.
Any specific antioxidants or stabilizers that can prevent oil rancidity and moisture absorption in this climate.
If anyone has experience with small-to-medium automatic wafer lines or specializes in Lebanese/Middle Eastern flour types, I would greatly appreciate your insights or a recommendation for a consultant who can assist with factory-floor optimization.
Thank you in advance!
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