How to achieve Industrialized Production of Wheat Tortillas

How to achieve Industrialized Production of Wheat Tortillas

Industrialized Production of Wheat Tortillas – Principles and Key Technologies

1. Overview

Wheat tortillas are thin flatbreads made primarily from wheat flour, water, oil, salt, and leavening agents. 

Widely used in wraps, sandwiches, and quick-service foods, tortillas have become a core category in standardized food manufacturing. 

To meet the demands of large-scale, consistent, and long shelf-life production, 

traditional manual pressing methods have been gradually replaced by fully automated production lines.

2. Tortilla Dough Formula and Characteristics

▲A wheat tortilla typical formula (per 100kg flour):

- Plain Flour: 100kg

- Water: 50–55kg

- Vegetable oil: 4–6kg

- Salt: 1.5–2kg

- Baking powder: 0.5–1kg

- Dried yeast: 0.8–1.2kg

- steep sugar: 1.5–3.0kg Enzyme

- Enzyme: 0.2–0.5kg 

▲Dough characteristics:

- Medium hydration (50–55%), good extensibility.

- Moderate gluten development, avoiding excessive mixing.

- Short high-temperature baking forms distinct brown spots and layered texture.

3. Industrial Production Process

A. Mixing: Automatic dosing and mixing ensure uniform, extensible dough. Water temp 5–15°C; mix 6–8 min.

B. Dough Dividing Rounding: Servo-controlled divider rounder achieves ±1g precision, simulating hand rounding.

C. Resting: Dough relaxes for 8–12 min to improve elasticity.

D. Hydraulic Pressing: Heated plates at 160–180°C press each dough ball for 1–2 sec into 6–12-inch tortillas.

E. Baking: Tunnel gas oven at 210–250°C for 40–45 sec develops flavor and characteristic blisters.

F. Cooling & Packaging: Cool below 30°C, stack 10–12 pcs, vacuum or heat-seal pack for chilled or frozen storage.

4. Main Equipment

| Process | Equipment | Description |

| Mixing | Spiral or Planetary Mixer | Uniform gluten development |

| Dividing | Dough Divider Rounder | High accuracy, non-stick handling |

| Resting | Intermediate proofer | Dough relaxation |

| Hydraulic Pressing | Heated Press | Diameter and thickness control |

| Baking | Tunnel Oven | Consistent color and flavor |

| Cooling & Stacking| Cooling Conveyor+Stacking &counting  Line | Hygienic|

5. Quality Control

- Water temperature and mixing time affect extensibility.

- Pressing temperature/time ensures uniform size.

- Baking uniformity for even color.

- Moisture content: 28–32% after baking.

- Packaging hygiene critical for shelf life.

6. Advantages of Industrial Production

7. Conclusion

Industrial tortilla production relies on precise dough control and highly coordinated automation. 

Dough dividing/rounding, hydraulic hot pressing, and gas tunnel oven baking are key to consistent quality. 

With the rise of smart manufacturing, modern tortilla lines achieve higher efficiency, lower energy use, and better adaptability for global markets.

8. FIVE Global Manufacturers of Wheat Tortilla Production Lines

1. Overview

The global tortilla production line market is dominated by a few specialized manufacturers that 

focus on automated solutions for wheat tortilla production.

These companies provide full processing lines from dough mixing to packaging, 

integrating high-precision servo systems, hygiene design, and energy-efficient technologies.

2. Major Global Manufacturers

A. **Lawrence Equipment (USA)** – Industry leader specializing in flour tortilla, corn tortilla, and pita bread lines. Known for high-speed, servo-controlled presses and tunnel ovens.

B. **Casa Herrera (USA)** – Provides complete tortilla lines from dough feeders to coolers, widely used by large QSR brands.

C. **JC Ford (USA)** – Focused on corn and wheat tortilla lines, offering automation for sheeting, baking, and packaging.

D. **QINLI/Queenly Machinery (China)** – Focused on wheat tortilla lines, offering automation wheat tortilla line from volumetric dough balls dividing, hydraulic hot press, gas oven, cooling & stacking system, Flow packing system.

E. **Rigos Equipment MFG.(USA)**-Specializes in“tortilla snack and baking industry”，offer Hot press machine, gas oven, conveyors,etc.

3. Regional Insights

- **North America**: Market leaders with the most advanced automation and high-speed tunnel baking systems.

- **Europe**: Known for modular, flexible designs suitable for various dough types.

- **Asia-Pacific**: Growing segment; China, India, and Southeast Asia rapidly expanding tortilla demand for QSR and frozen food markets.

4. Conclusion

With increasing demand for high-quality tortillas in the global food industry, manufacturers are focusing on developing efficient, flexible, and hygienic lines. 

Future trends emphasize intelligent control systems, reduced energy consumption, and integrated data monitoring for smart bakery production.

2025-10-27/ 18:37:23