How are wafer cones made? The process of making wafer cones involves several key stages, starting from the preparation of the batter and ending with the final product.
As a staple product in the global ice cream industry. The production of wafer cones is inseparable from automatic machinery. In this blog, we will take a detailed look at the process of making wafer cones in the factory.
1. Raw Material Preparation
- The process begins with mixing the core ingredients: flour (typically wheat or a gluten-free alternative), water (to bind the batter), vegetable oil (for crispness), leavening agents, etc.
- In industrial settings, ingredients are precisely measured using automated systems to ensure consistency. Large-scale mixers blend the batter into a smooth, lump-free liquid, often at controlled temperatures (20–25°C) to maintain viscosity.
2. Baking: The Heart of Wafer Cone Production
- The batter is poured into specialized wafer cone baking machines, which shape and bake the wafer cones. Here’s how it works:
- Batter Depositing: A pump deposits a precise amount of batter onto heated, cone-shaped molds. Industrial machines feature multiple molds for simultaneous baking.
- Baking Process: The molds close and apply heat (150–200°C) for 1–2 minutes. This cooks the batter, evaporates moisture, and creates the wafer cone’s signature crispy texture. Advanced machines use non-stick coatings to prevent residue buildup.
3. Shaping and Cooling
Freshly baked cones are soft and pliable. To harden them: The shaped cones move through a cooling tunnel (10–15°C) for 2–5 minutes. This step locks in the structure and prevents sogginess.
4. Quality Control
Automated systems inspect wafer cones for defects like cracks, uneven thickness, or discoloration. Rejected units are removed, while approved ones proceed to packaging.
5. Packaging
To preserve freshness, cones are: Stacked vertically or horizontally; Wrapped in moisture-proof film or paper; Boxed for bulk shipping, many factories use nitrogen-flushed packaging to extend shelf life.
Advantages of Industrial Wafer Cone Machine
- Speed: It is several times faster than manual operation and very efficient.
- Consistency: Wafer cones are uniform in size, texture and quality.
- Hygiene: Reduced human contact minimizes contamination risks.
- Scalability: Easily adjust output to meet market demands.
In summary, how are wafer cones made? The entire process from batter to cone forming and packaging is achieved through automated equipment. For businesses looking to enter this market, investing in reliable equipment is key to the large-scale wafer cone production.