For bakers looking to expand their knowledge of international confectionery, the Dorayaki stands out as a unique study in texture and assembly.

While it visually resembles a standard pancake, technically, it is closer to a Castella cake (Kasutera).

Dorayaki (Red Bean & Mochi Filling) by msshiandmrhe.com

Origins and Geography

The Dorayaki is a staple of Japanese Wagashi (confectionery) culture.

The name stems from the Japanese word for “gong” (dora), purportedly because the original shape (and the copper pans used to cook them) resembled the musical instrument.

While legends date back to feudal Japan, the modern “sandwich” iteration was actually invented in 1914 at a bakery called Usagiya in the Ueno district of Tokyo.

Before this, it was often served as a single folded layer.

Today, it is ubiquitous across Japan and parts of East Asia, famously cemented in pop culture as the favorite snack of the anime character Doraemon.

The Product Profile

The Shell:
Unlike a Western pancake which relies on milk and melted butter, the Dorayaki batter traditionally leans on eggs, sugar, flour, and a crucial addition: Honey (or Mirin). This humectant is what gives the crust its signature moist, sticky surface and distinct dark golden color.
The Filling:
The standard is Azuki (sweet red bean paste), available in Tsubuan (chunky) or Koshian (smooth).
Modern Varieties:
Contemporary productions have expanded to Custard (very popular), Matcha cream, Chocolate Ganache, and even Chestnut paste (Kuri).

The Production Process: Automated Full Line

An example of supplier of industrial production lines for this product is FOTEC Machinery with their Automatic Dorayaki Full Line designed to replicate the delicate texture of traditional Japanese confectionery while delivering the high throughput required by modern food manufacturers.

Below, we detail the technical specifications of each station in this continuous production system, built with our signature AISI 304 Stainless Steel for hygiene and durability.

The video footage (referencing the Mesin Produksi Dorayaki Otomatis Full Line) demonstrates how this traditional artisanal product is adapted for high-volume manufacturing without losing its delicate texture.

Here is the technical breakdown of the industrial process:

1. Mixing and Batter Aeration

The quality of a Dorayaki is judged by its “honeycomb” internal structure.

Ingredient Control: The process begins with mixing the sugar, eggs, and honey. Low-protein flour (cake flour) is added last to minimize gluten development, ensuring the product remains tender rather than chewy.
Specific Gravity: In automated lines, controlling the specific gravity of the batter is vital. If the specific gravity is too high (dense), the pancake won’t expand; too low (airy), and the surface will pit.

2. The Batter Deposition Station (Volumetric Piston Depositor)

The process begins at the Batter Depositor. Unlike standard gravity-fed hoppers, this unit utilizes a multi-piston volumetric dosing system.

Technical Function: The depositor is synchronized with the belt speed (VFD controlled). It uses pneumatic pistons to draw batter from the hopper and deposit it onto the heated plates.
Key Feature: The “suck-back” mechanism ensures a drip-free deposit, guaranteeing a perfect circular spread—critical for the Dorayaki’s aesthetic. The deposit volume is adjustable via the PLC interface to control the diameter and thickness of the pancake base.

3. The Thermal Processing Zone (Gas-Fired Tunnel Griddle)

The batter travels through our Gas Heated Griddle, effectively a conductive tunnel oven.

Heat Transfer: We utilize heavy-gauge copper or alloy conductive plates that retain heat efficiently. The tunnel design minimizes thermal loss, creating a controlled micro-climate that encourages the “oven spring” (rise) of the batter.
Combustion System: A linear array of gas burners provides consistent BTUs across the entire width of the belt, ensuring every row cooks identically. This eliminates the “cold spots” common in manual griddles.

4. The Turnover Mechanism (Mechanical Flipper)

Midway through the baking cycle, the product reaches the Automatic Flipper Station.

Operation: A synchronized mechanical arm equipped with thin-profile spatulas slides beneath the semi-cooked pancakes.
Precision: The flipper executes a rapid 180-degree rotation. This stage is timed precisely when the batter has set but before the top dries out, ensuring the “raw” side hits the griddle to seal the crumb and create the signature golden-brown color on both sides.

5. Cooling and Orientation (Transfer Conveyor & Row Turner)

Post-baking, the pancakes are ejected via an air-assist or mechanical arm onto the Cooling Transfer Conveyor.

Alignment: The products enter a Row Turner/Aligner. This component uses guide rails or active rollers to re-orient any skewed pancakes, aligning them perfectly into the lanes required for the sandwiching station.
Cooling: The open-mesh or sanitary belt design allows for ambient heat dissipation, firming the structure slightly to prepare it for the weight of the filling.

6. The Filling Station (Wire-Cut Depositor)

The bottom pancakes pass under the Filling Depositor.

Dosage: Similar to the batter depositor, this unit uses a high-viscosity pump suitable for dense fillings like Azuki bean paste (Anko), custard, or chocolate.
Cut-Off Mechanism: To handle sticky fillings, this station is equipped with a Wire-Cutter or guillotine cutoff. This mechanism slices through the stream of filling the moment the piston cycle ends, preventing “tailing” or trailing drips that could ruin the seal.

7. The Sandwiching Assembly (Pick-and-Place Capper)

The final assembly occurs at the Sandwiching Station.

Automation: A vacuum-actuated or mechanical Pick-and-Place arm lifts the “top” pancake from a parallel lane (or alternating row) and deposits it precisely onto the filled “bottom” pancake.
Sealing: The unit applies a calibrated compression force. For “Closed Sealing” variants, a crimping mold presses the outer edges of the Dorayaki together, sealing the filling inside.
Branding (Optional): As seen in our configuration, a Heat Stamping module can be integrated here to brand your logo directly onto the crust surface using a heated die.

😊 Thanks for reading!

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