On-site Planning
Installation & Commissioning
Automated & Energy Efficient
Client Name: Big D Food Industries Sdn. Bhd.
Country: Malaysia
Region: Rawang, Selangor – Northern Klang Valley industrial belt, a core area for Halal food certification in Malaysia
Core Products: Chocolate-coated donuts, coconut pandan donuts, durian custard donuts, mini glazed donuts
Equipment Configuration: Hadof custom fully automatic batter injection molding + dual-zone oil bath frying line (capacity 6,000 pieces/hour, including automatic glazing/icing system and pillow packaging integration)
Commissioning Date: Q1 2024
Malaysia is a global center for the Halal food industry and a major consumer of desserts in Southeast Asia. Big D Company, based in Selangor, had been known for over a decade for its handmade traditional Malay fried dough (Kuih Keria), primarily sold in night markets and morning markets. With the younger generation's growing enthusiasm for Western-style donuts, Big D decided to launch a new brand, "Big D Donuts," to enter modern supermarkets and convenience store channels. However, in the industrial production of donuts, they encountered challenges that traditional processes could not overcome:
Inconsistent shape and fluffiness: Hand?formed donuts varied in size, leading to different expansion rates during frying. Some products collapsed or remained undercooked, failing to meet the standardization requirements of supermarket chains.
Excessive oil absorption, greasy texture: Traditional fried donuts had an oil content exceeding 28%, conflicting with modern consumer preferences for healthier snacks. Moreover, Halal certification imposes strict requirements on oil quality.
Glaze and decorations easily fall off: Chocolate, icing, and other glazes tended to peel off or stick to the packaging during transportation, affecting product appearance and resulting in a return rate exceeding 10%.
Strict Halal certification requirements: Malaysia's JAKIM Halal certification imposes stringent regulations on equipment cleanliness and oil sourcing. Incomplete cleaning during product changeovers could jeopardize certification.
Mohd Firdaus, the second-generation operator of Big D, had examined donut equipment from Japan and Europe but found that Western machines were not suited to the wet ingredients commonly used in Malaysia, such as coconut milk and pandan. Through a recommendation from the Malaysian Food Industry Association, they initiated joint R&D with Hadof. Over five months, we developed this industrial donut frying line specifically designed for "Southeast Asian flavors + Halal standards."
1. Servo?controlled batter injection molding + automatic flipping system – weight tolerance <2g per donut
To achieve uniform shape, we designed a servo?driven batter injection molding machine. The batter is de?aerated through a multi?stage process and then precisely injected into ring molds, with weight tolerance controlled within ±1.5g. An automatic flipping arm inside the fryer rotates each donut 180 degrees after 30 seconds of frying, ensuring uniform golden color on both sides and eliminating the appearance inconsistencies caused by manual flipping.
2. Dual?zone gradient frying + centrifugal de?oiling – oil content reduced from 28% to 19%
We designed the frying section with a front?high, rear?low dual?temperature zone: Zone 1 at 185°C for rapid expansion and crust formation, sealing in moisture; Zone 2 at 165°C for slow dehydration. After exiting the fryer, a centrifugal de?oiling unit uses centrifugal force to remove excess surface oil. The finished product achieves a stable oil content below 19%, nine percentage points lower than traditional processes, resulting in a light, non?greasy texture and successfully passing JAKIM's clean oil certification.
3. Constant temperature and humidity glazing/icing system – chocolate and sugar coatings adhere firmly without flaking
To solve the glaze adhesion problem, we added an infrared pre?heating unit before the glazing stage, raising the donut surface temperature to a stable 35°C before applying chocolate coating, increasing adhesion by three times. After glazing, the donuts enter a 10?meter gradient cooling tunnel, where the temperature slowly drops from 35°C to 20°C, allowing the chocolate to crystallize uniformly with a smooth finish. Simulated transport vibration tests showed a reduction in glaze detachment from 12% to below 1%.
4. CIP self?cleaning + Halal?dedicated filtration system – meets JAKIM's strict changeover requirements
To comply with the stringent cleanliness demands of Malaysian Halal certification, we designed an online CIP cleaning system. The fryer oil tank is equipped with high?pressure rotary spray heads, and a food?grade cleaning agent circulates for thorough rinsing. The oil filtration system uses dual stainless steel screens combined with magnetic traps to remove micron?level carbonized particles. Changeover cleaning time was reduced from five hours to one hour, completely eliminating the risk of non?Halal ingredient residue.
Capacity and Quality Leap
Daily capacity: Increased from 3,000 pieces/day on the manual line to 60,000 pieces/day on the automated line (two shifts), capable of running continuously for 20 days without quality fluctuations. Total production in the first half of 2024 exceeded 8.5 million pieces, with the product qualification rate rising from 83% to 98%.
Channel Breakthrough
The low oil content, standardized appearance, and Halal certification enabled Big D Donuts to enter 700 MyNews convenience stores and 300 KK supermarkets across Malaysia, as well as becoming a designated supplier for Petronas service station convenience stores. In August 2024, the first batch of coconut pandan donuts was exported to Singapore and Brunei, establishing Big D as an emerging exporter of Halal donuts in Southeast Asia.
Economic Benefits
Return on Investment: The production director of Big D stated: "The manual line required 22 people per shift; now the entire line operates with just three. We save over 600,000 Malaysian ringgit annually in labor costs alone. Combined with lower oil consumption and reduced reject rates, the actual payback period is under 15 months."
Product Premium: The uniform color and flawless glazing achieved through automation allow Big D donuts to be priced 50% higher than traditional fried dough in convenience store outlets, with a repeat purchase rate of 45%, making it the fastest?growing brand in Malaysia's Halal snack market.
"Hadof's equipment taught us that true industrialization does not mean abandoning traditional flavors. It means presenting Malaysian tastes like coconut and pandan to the world with international standards. Now, our donuts can proudly carry the label 'Made in Malaysia – Halal' and sit on shelves in Singapore and Brunei."
—— Mohd Firdaus Bin Abdullah, CEO, Big D Food Industries Sdn. Bhd.
