The Indian biscuit and crackers industry is one of the more developed segments in the bakery industry worth over ₹ 45,000 crores, and is progressively rising because of lifestyle changes and urbanisation and increased demand for convenient foods. Though the market is largely based on traditional glucose and cream biscuits, there are a range of digestive biscuits, multigrain biscuits, protein biscuits, sugar-free biscuits, artisanal crackers and premium biscuits as well.
With consumers becoming increasingly health and functionally conscious, as also desiring more indulgent snacks, manufacturers of biscuits and crackers market will encounter technological barriers, regulatory barriers, and barriers with developing products that can address consumers’ needs; here come the food consultants like Frontline Food Consultants and Engineers (FFCE) to assist companies to reformulate, scale-up, and produce within constantly changing regulatory requirements.
Technical Aspects of Biscuit and Cracker Production
Production of biscuits and crackers may seem simple to the user, but from a technical standpoint, it is a matter of meticulous engineering of formulation, process, and quality control.
1. Science of Formulation
- Selection of Flour
- Soft wheat flour (7-9% gluten, low gluten) is ideal for the manufacture of a short, crumbling biscuit. For the manufacture of crisp stackable crackers, hard wheat flour containing more gluten (10-12%) should be used.
- Blending of flours makes for proper dough rheology.
- Fat Systems
- Hydrogenated fats are being replaced by palm fractions, sunflower oil, or interesterified fats to achieve acceptable melting properties while meeting trans-fat free regulations.
- Specialists assist in making choices of fats that maintain a balance between texture, spread ratio, and shelf-life.
- Leavening Agents
- Sodium bicarbonate + ammonium bicarbonate used to generate CO₂ for lightness and porosity.
- Precision in dosing is paramount — too little causes biscuits to be hard, too much creates bitter aftertastes.
- Sugar Systems
- White sugar, invert syrups, or malt extract are used depending on the degree of sweetness and browning needed (Maillard reaction).
- Polyols (erythritol, maltitol) and natural sweeteners (stevia) are part of healthy formats.
- Functional Enrichments
- Whey protein and soy protein isolates are instances of protein enrichment.
- Chicory inulin, resistant starch, and oats are some examples of fiber enrichment.
- As per FSSAI fortification guidelines, micronutrient fortification consists of iron, calcium, and B vitamins.
2. Process Engineering
- Dough Mixing: Hydration and gluten formation through controlled mixing. Baking shrinkage due to overmixing.
- Sheeting and Cutting (Crackers): Blister-free sheeting and docking to prevent blistering on baking.
- Forming (Biscuits): Rotary moulding or wire-cut machines for uniform shape and weight.
- Baking Parameters
- In order to make perfectly baked biscuits, a temperature range of 180 to 240 degrees Celsius is ideal, followed by the time of 5 to 20 minutes, which is completely dependent on the thickness, dough and type of biscuits to be baked. As far as moisture control is concerned, a minimum of 3% moisture is considered ideal/
- Packaging & Cooling: cooled to avoid condensation following baking. Packaging utilized laminates that are oxygen and moisture barriers to maintain crispness. The consultants approach and modify these settings for energy efficiency, consistency and saving costs.
3. Quality Control and Shelf-Life
- The greatest issue is movement of moisture which can result in soggy crackers and stale biscuits.
- Also, rancidity due to oxidation of fat must be controlled with antioxidants (such as tocopherols and rosemary extract).
- Microbial safety: Although low-moisture, spoilage may happen with improper processing during cream sandwiching or packaging.
- Shelf life testing accelerated: Consultants conduct shelf life studies under simulated Indian climatic conditions (30–45°C, 65–85% RH).
Regulatory & Labelling Aspects
The following nutritional content must be declared for biscuits and crackers, according to FSSAI regulations:
- Energy, Carbs, Fat, Sugar, and Protein per 100 g.
- Percentages of added sugar and trans fat.
- Allergen statements (for gluten, milk, soy, nuts).
Fortification with logos for the micronutrients
Experts like FFCE can assist manufacturers in label conformity, claim substantiation (e.g.: “source of fibre” or “no trans-fat”), and comprehension of front of pack labelling regulations (FoPL).
Evolutions in the Indian Market
- Health & well-being biscuits
- Crispo’s functional protein cookies, diabetic cookies, gluten-free products
- Utilization of ancient traditional grains (such as ragi, jowar, amaranth)
- Artisanal and premium products
- Butter biscuits, gourmet crackers that include cheese, herbs or seeds
- Urban buyers, exporting as a market.
- Functional & Fortified Products: Biscuits fortified with minerals, vitamins, and probiotics.
- “Immunity booster” crackers after COVID.
- Localized Flavors: Masala biscuits or jeera crackers or possibly ajwain khakra in formats.
- Green Packaging: Employ recyclable laminates and biodegradable films.
Food Consultants such as FFCE’s Role
- Food consultants bridge the technical know-how and business implementation gap for startups as well as established firms.
- Product Development: Formulation design, achieving the taste, health, and cost balance.
- Process Scale-Up: Scaling up from pilot plant runs to full-factory implementation.
- Machine Selection: Rotary moulders, laminators, tunnel ovens, and packaging line selection advice.
- Regulatory Compliance: Products satisfying export regulations, Codex, and FSSAI requirements.
- Shelf-Life Extension: Guidelines on packaging films, storage environment, and antioxidant systems.
- Market Strategy: Consultancy on new-generation categories like protein biscuits, artisan crackers, and export SKUs.
Conclusion
Indian biscuit and cracker industry is transforming from plain glucose biscuits to functional and indulgent snacking foods.
Opportunities are:
- Protein-enriched biscuits for gym-going individuals and adolescents.
- Export of premium crackers with Indian spice blends.
- Vegan and plant-based solutions.
- Hybrid formats (probio-fortified cookies, functional herb multigrain crackers).
As with more and more discerning consumers, innovative companies that are capable of fulfilling technical as well as regulatory needs will benefit — and working with experienced consultants like FFCE guarantees that they do so in a successful manner.
