An encrusting machine feeds the outer dough and the filling into the machine at the same time, extrudes them through a concentric nozzle, and cuts and seals them with a shutter. It can make everything from red bean buns, mooncakes, and mochi to croquettes and tangyuan, and it plays a different role from a forming machine, which only shapes the product.
An encrusting machine meters the dough and the filling separately, brings them together in a concentric double-layer nozzle, and extrudes a continuous rope with filling in the center and dough around the outside, which a shutter then cuts. Feeding them separately is what makes the ratio adjustable and the weight consistent.
An encrusting machine pushes the dough and filling into the nozzle, most commonly with twin screws plus a vane pump for metering, though roller feeding and cycloid flow regulators are also used. Different feeding methods suit materials of different hardness and elasticity, and the quality of the design directly affects gluten and weight.
After the filled rope is extruded from the nozzle, a shutter made of several blades arranged in a ring closes like a camera iris, pinching off the rope and gathering the dough to cover the cut. The conveyor below moves up and down in sync to support the bottom, so the product comes out round without leaking filling.
The dough-to-filling ratio on an encrusting machine is adjusted through the speed ratio of the two feed systems for dough and filling. RHEON's KASEIJIN series lists a ratio from 1:0 to 0:1, but extremely thin dough and very high filling content are still limited by the dough's extensibility, the firmness of the filling, and sealing conditions.
Whether each piece from an encrusting machine weighs the same depends on whether the feeding mechanism fills completely every time, whether the ingredients are uniform, and whether the control system can compensate. Microcomputer control turns speed and timing into stored numbers, making it easier to reproduce the same conditions than with mechanical adjustment.
Rheology is the study of how materials flow and deform. Dough has both the elasticity of a solid and the viscosity of a liquid, and an encrusting machine must make the dough and filling flow together under pressure yet gather closed when cut. RHEON's company name comes from this very science.
Encrusting machines most often make balls; lengthening the shutter interval produces tawara (bale) shapes and bars, and skipping the cut produces a continuous cylinder. Changing shapes usually starts with adjusting settings, then changing nozzles or adding peripherals as needed; two-color and three-layer products rely on special nozzles and triple-encrusting units.
Feeding a third material in addition to the dough and filling is called triple encrusting; wrapping whole strawberries, chestnuts, or egg yolks requires a solid-ingredient feeder. Both are encrusting machine options, each with its own requirements for material firmness and placement.
An encrusting machine mostly produces round balls. Turning them into flat cakes, half-moons, or pleated buns relies on forming conveyors, rollers, stamping dies, and pleating machines connected downstream. Understanding what each secondary forming device does helps the production line run smoothly.
Dusting flour keeps dough from sticking to the shutter, conveyor, and hands, but too much affects texture, appearance, and cleaning. From flour dusters and brush-type flour removers to non-stick cutting mechanisms and water or oil alternatives, here is how to make non-sticky products with as little flour as possible.
Do machine-wrapped products taste worse? The key lies in the recipe, whether the dough gets overworked, and whether the machine is properly tuned. Machines excel at consistent weight and volume production, while hand wrapping still has the edge for small batches of varied, uniquely shaped products.
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