Precision Double-Filling Solutions for Consistent, High-Output Bakery Production

In modern industrial bakeries and food factories, product differentiation and filling accuracy are becoming key competitive factors. Products with double fillings, such as filled buns, stuffed cookies, energy bars, and premium pastries, require a stable structure, precise ratios, and high production consistency.

The OC-1000S Two-Hopper Encrusting Machine is designed specifically for these demands, enabling accurate dough wrapping with two independent fillings while maintaining stable output in continuous production environments.

Why Double-Filling Technology Matters

Compared with single-filling products, double-filled products face more challenges:

• Unstable filling ratios
• Filling leakage or mixing
• Irregular product shape
• Difficult manual control and low efficiency

The OC-1000S solves these issues through independent motor control, precise ratio adjustment, and a short filling path design, ensuring each product meets the same quality standard.

Core Applications of the OC-1000S Two-Hopper Encrusting Machine

1. Double-Filled Bakery Products

The OC-1000S is widely used for producing:

• Double-filled buns and pastries
• Filled cookies and mooncakes
• Energy bars with layered fillings
• Innovative bakery products with core + secondary fillings

Both filling hoppers operate independently, allowing precise control of inner and outer filling ratios without cross-interference.

Application value:

• Stable filling distribution
• Clean product appearance
• Reduced product defects

2. Flexible Dough-to-Filling Ratio Control

Using the touchscreen control system, operators can:

• Adjust dough, main filling, and secondary filling ratios
• Modify product size from 10–100g
• Store multiple recipes for quick product changeover

This flexibility allows one machine to handle multiple SKUs, reducing downtime and improving production efficiency.

3. Stable Output for Continuous Production

With a production capacity of 60–120 pcs/min, the OC-1000S supports medium to large-scale production lines. Independent motors drive molding, filling, and cutting, reducing mechanical stress and ensuring long-term stability.

German-imported cutting blades and food-grade UPE nozzles ensure clean cutting and uniform product shape.

Key Design Features Supporting Industrial Use

High-Hygiene Construction

• All food-contact parts are made of 304 stainless steel and food-grade plastics
• Fully detachable filling hoppers for easy cleaning
• Short filling pipes reduce residue and waste
• Fully compliant with food safety and hygiene standards

Typical Production Line Integration

The OC-1000S is commonly installed:

• After dough mixing and pre-forming
• Before baking, steaming, or freezing

It integrates smoothly with mixers, conveyors, ovens, and cooling systems, forming a highly efficient workflow with minimal manual intervention.

Payback Example: ROI Analysis for a Two-Hopper Encrusting Line

Scenario:

A bakery producing double-filled buns and cookies upgrades from manual or semi-automatic filling to the OC-1000S Two-Hopper Encrusting Machine.

Production Output

• Output speed: 90 pcs/min
• Operating time: 6 hours/day × 250 days/year
• Annual output: approx. 8.1 million pieces

Investment

• Machine investment: USD 22,000 (reference configuration)

Labor Savings

• Manual reduction: 2 operators
• Average labor cost: USD 30,000 / operator/year
• Annual labor savings:≈ USD 60,000 / year

Product Yield & Quality Savings

Reduced filling loss and rejection rate

Estimated 2% product loss reduction

Assuming:

• Average product value: USD 0.5 / piece
• Annual product savings:≈ USD 81,000 / year

Total Annual Savings

• Labor savings: USD 60,000
• Product savings: USD 81,000
• Total savings: approx. USD 141,000 / year

Payback Period & ROI

• Estimated payback period: 2 months
• 3-Year ROI: 600%+

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