Tortilla Production Line in Algeria
Africa Tortilla Production Line

Tortilla Production Line in Algeria

Location
Setif，Algeria
Equipment
PXTA-820 Tortilla Production Dual-line
Application
Tortilla
Project Type
New Project
Main Goal
7000-8000pcs/h

Project Overview

The customer is located in Sétif, Algeria, and has been operating in the local food market for 20 years. The company specializes in tortilla production and has already built a well-known local brand. As market demand continued to grow, the customer planned to expand production capacity, increase market share, and strengthen its ability to handle larger-volume orders. At the beginning of the project, the customer clearly expressed the need for a high-capacity tortilla production line. At the same time, because the available factory space needed to be used more efficiently, layout optimization became an important requirement. The customer shared key product information with PROX, including tortilla sizes of 25 cm and 30 cm, a target output of 7,000–8,000 pcs/h, and specific requirements for space utilization and production flow. Based on the customer’s product specifications, capacity target, and site layout requirements, PROX recommended the PXTA-820 Tortilla Production Dual-line. The dual-line configuration was designed to support higher output while improving space utilization, helping the customer achieve more efficient industrial tortilla production within the available factory area and prepare for further market expansion.

Customer Challenges

Existing Capacity Could Not Support Market Expansion

The customer had been operating in the local market for 20 years and had already built a recognized tortilla brand. As market demand continued to grow, the existing production capacity was no longer sufficient to support brand expansion and larger-volume orders. The customer needed a higher-capacity and more stable production line.

Large Tortilla Sizes Required Higher Line Stability

The customer mainly produced 25 cm and 30 cm tortillas. Compared with smaller products, larger tortillas require better control in dough portioning, hot-press forming, baking uniformity, cooling, and stacking. Without stable equipment performance, issues such as uneven thickness, edge deformation, inconsistent baking, or unstable stacking may occur.

High Output Target Was Difficult for a Standard Single Line

The customer expected an output of 7,000–8,000 pcs/h. For 25–30 cm tortillas, this required strong coordination across pressing speed, baking capacity, cooling efficiency, and stacking performance. A standard single-line configuration would be difficult to match both capacity and product stability.

Limited Factory Space Required Better Space Utilization

The customer needed high output while also making better use of the existing factory space. Planning the dough handling, pressing, baking, cooling, stacking, and packaging connection within the available area became a key challenge in the project design.

Capacity Expansion Could Not Compromise Brand Quality

Since the customer had already built a well-known local brand, capacity expansion could not be achieved at the expense of product quality. Tortilla size, thickness, appearance, taste, and baking performance still needed to remain consistent. For the customer, the goal was not only higher output, but also stable brand-level quality.

PROX Customized Solution

To meet the customer’s key requirements for fast project launch, higher output, and better space utilization, PROX recommended and customized the PXTA-820 Tortilla Production Dual-line solution. The solution was designed to support the customer’s 25 cm and 30 cm tortilla production while improving capacity, layout efficiency, and long-term production stability.

Fast Design, Production, and Delivery to Catch the Market Opportunity The customer wanted to expand capacity quickly to meet growing local demand and capture the market opportunity. After project confirmation, PROX coordinated the design, manufacturing, and delivery process with priority to keep the project moving efficiently.
2. Unique 1+2 Dual-Line Design for Capacity and Space Efficiency Based on the customer’s output target and factory space requirements, PROX designed a unique 1+2 dual-line configuration. In this solution, the front-end sections, including dough chunking, conveying, dividing, rounding, and proofing, are shared. The back-end sections, including hot-press forming, baking, cooling, counting, and stacking, are configured as two independent production lines. This design reduces repeated front-end equipment, saves floor space, and improves overall production efficiency. At the same time, the two independent back-end lines provide stronger capacity and more stable processing rhythm for large-size tortillas.
3. Production Rhythm Optimized for 25 cm / 30 cm Tortillas The customer mainly produces 25 cm and 30 cm tortillas, which require stable forming, uniform baking, and reliable stacking. PROX optimized the line rhythm to better match the shared front-end feeding system with the two independent back-end lines, reducing waiting time, material accumulation, and process imbalance.
4. Higher Output Within Limited Factory Space The customer required high output but also needed to make better use of the available factory area. Compared with installing two completely separate full lines, the 1+2 configuration creates a more compact layout and allows higher output per square meter, helping the customer expand production without unnecessary space waste.

Equipment Configuration

Equipment List

  1. Chunker
  2. Lifter
  3. Divider & Rounder
  4. Proofer
  5. Dough Ball Distributor Table
  6. Press（820*820mm）
  7. Oven
  8. Vacuum Conveyor
  9. Cooler Conveyor
  10. CCD Rejection System
  11. Counter & Stacker

Installation & Commissioning

After the PXTA-820 Tortilla Production Dual-line arrived at the customer’s factory in Sétif, Algeria, PROX arranged on-site installation and commissioning support. Before the engineer’s arrival, we provided the customer with complete preparation documents, including the dual-line layout plan, equipment positioning drawings, electrical connection points, power requirements, compressed air requirements, and gas requirements for the ovens. This helped the customer prepare the site in advance and shorten the on-site installation time.

  1. 1

    Pre-Installation Preparation

    Before shipment and engineer departure, PROX confirmed the factory layout, utility requirements, and installation conditions with the customer to ensure the site was ready for the dual-line setup.

  2. 2

    Equipment Positioning & Line Connection

    After arriving on site, the engineer guided the customer team to position the shared front-end modules and two independent back-end production lines, including pressing, baking, cooling, counting, and stacking sections.

  3. 3

    Commissioning & Trial Production

    After installation, PROX carried out electrical connection checks, mechanical adjustment, line synchronization, parameter setting, and trial production for 25 cm and 30 cm tortillas.

  4. 4

    Operator Training

    During commissioning, PROX trained the customer’s operators on daily operation, line adjustment, production rhythm control, cleaning, maintenance, and basic troubleshooting to help the customer start stable production quickly.

Project Results

PROX completed the equipment design, manufacturing, and shipment in approximately 3 months, helping the customer move faster toward installation, commissioning, and production start-up, while capturing the local market growth opportunity.

Shorter Project Lead Time

For 25 cm and 30 cm tortillas, the PXTA-820 dual-line solution helped the customer increase output while maintaining stable product size, thickness, baking performance, and stacking quality, reducing the risk of quality fluctuation during capacity expansion.

Stable Quality for Large-Size Tortillas

he PXTA-820 dual-line solution was configured around the customer’s main product sizes: 25 cm and 30 cm tortillas. It helped the customer reach the target output of approximately 7,200 pcs/h, supporting their need for larger market supply capacity.

Meeting High-Capacity Demand for 25 cm / 30 cm Tortillas

Project Value Summary

This project shows how a mature food brand can expand production capacity without wasting factory space. For the Algeria customer, the key challenge was not only higher output, but also how to achieve it within the existing site conditions while maintaining stable quality for 25 cm and 30 cm tortillas. The PXTA-820 Tortilla Production Dual-line provided a practical solution. By sharing the front-end dough processing section and using two independent back-end production lines, the customer improved output capacity, optimized space utilization, and strengthened supply capability for future market expansion. For tortilla manufacturers facing growing demand, limited factory space, and pressure to maintain brand-level product quality, this project demonstrates that a well-designed dual-line production system can be more efficient than simply adding another complete production line.

Customer Feedback

We needed a higher-capacity tortilla production solution, but factory space was also a major concern for us. PROX understood our requirements clearly and recommended the PXTA-820 dual-line configuration, which helped us balance output capacity and space utilization. The 1+2 line design was a practical solution for our factory. It allowed us to increase production for 25 cm and 30 cm tortillas without installing two completely separate production lines. PROX also supported the project with fast production and delivery, helping us move forward with our market expansion plan.

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