Bourbon is a delightful sandwich treat featuring two crisp, rectangular chocolate biscuits layered with rich, velvety chocolate cream. A touch of sugar crystals on top adds the perfect sparkle and crunch to this timeless indulgence.
MANUFACTURING PROCESS
1. Ingredient Handling & Weighing
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All raw materials like flour, sugar, fat, cocoa, and flavorings are measured precisely.
2. Dough Mixing
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Creaming of fat and sugar, followed by blending with flour, cocoa, and liquids to make a uniform chocolate dough.
3. Sheeting & Cutting
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Dough is rolled into thin sheets.
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Biscuit shapes are cut using rotary cutters with holes and "Bourbon" embossing.
4. Baking
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Baked in a continuous oven at 180–220°C for 6–8 minutes until crispy.
5. Cooling
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Biscuits are cooled to room temperature to stabilize texture and avoid moisture retention.
6. Cream Filling Preparation
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Chocolate cream is made from fat, sugar, cocoa, and flavorings.
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Whipped to a spreadable consistency.
7. Sandwiching
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One biscuit is topped with cream and another is placed on top.
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Sugar crystals may be sprinkled.
8. Packaging
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Packed using automated flow wrap machines in pouches, trays, or wrappers.
9. Quality Check
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Biscuits are checked for crunch, thickness, filling consistency, and taste.
Bourbon Biscuit Flavour Variants
1. Classic Chocolate
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Biscuit: Cocoa-flavoured
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Cream: Smooth chocolate buttercream
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Timeless and universally loved
2. Dark Chocolate
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Biscuit: Rich, intense dark cocoa
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Cream: Bittersweet chocolate
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Appeals to mature palates and dark chocolate lovers
3. Milk Chocolate
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Biscuit: Light cocoa flavor
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Cream: Creamy milk chocolate
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Kid-friendly and mild in taste
4. Mint Chocolate
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Biscuit: Cocoa base
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Cream: Cool mint-flavoured chocolate
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Refreshing twist for chocolate-mint fans
5. Orange Zest
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Biscuit: Cocoa with orange oil
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Cream: Tangy orange-chocolate cream
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Zesty and aromatic
6. Coffee Mocha
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Biscuit: Cocoa with a hint of coffee
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Cream: Mocha-flavoured cream
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Perfect for coffee & chocolate fans
7. Hazelnut Chocolate
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Biscuit: Chocolate base
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Cream: Nutty hazelnut-chocolate blend
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Inspired by Nutella-style flavours
8. Salted Caramel
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Biscuit: Cocoa with a pinch of salt
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Cream: Sweet-salty caramel chocolate
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Sweet meets salty in this gourmet twist
9. Strawberry Chocolate
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Biscuit: Cocoa
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Cream: Strawberry-infused chocolate
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Fruity and playful — loved by kids
10. Vanilla Choco
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Biscuit: Chocolate base
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Cream: Classic vanilla buttercream
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Subtle and creamy
11. Peanut Butter Chocolate
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Biscuit: Cocoa
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Cream: Peanut butter and chocolate blend
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Protein-rich indulgence
12. Almond Fudge
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Biscuit: Cocoa with almond bits
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Cream: Chocolate fudge with almond essence
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Premium nutty experience
13. Chili Chocolate (Gourmet/experimental)
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Biscuit: Rich cocoa
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Cream: Chocolate with a spicy chili kick
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For adventurous taste buds
Bourbon Biscuit Ingredients
1. Biscuit Base (Chocolate Biscuits)
| Ingredient | Purpose |
|---|---|
| Refined Wheat Flour (Maida) | Provides the structure and bulk of the biscuit |
| Sugar (Powdered or Granulated) | Adds sweetness |
| Cocoa Powder | Gives chocolate flavor and dark color |
| Hydrogenated Vegetable Fat / Butter | Adds richness and crisp texture |
| Invert Sugar / Glucose Syrup | Enhances sweetness, helps retain moisture |
| Baking Soda (Sodium Bicarbonate) | Leavening agent for slight puffiness |
| Ammonium Bicarbonate | Additional leavening for lightness |
| Salt | Balances sweetness and enhances overall flavor |
| Emulsifiers (e.g., Lecithin) | Improves dough consistency and shelf life |
| Vanilla / Chocolate Essence | Adds aroma and flavor depth |
| Water or Milk | Helps form the dough and improves texture |
2. Cream Filling (Chocolate Buttercream)
| Ingredient | Purpose |
|---|---|
| Icing Sugar / Confectioner's Sugar | Smooth sweetness for cream |
| Hydrogenated Fat / Butter | Creamy base |
| Cocoa Powder | Chocolate flavor |
| Milk Solids / Milk Powder | Adds creaminess |
| Emulsifiers (Mono- and Diglycerides) | Ensures smooth consistency |
| Chocolate or Vanilla Essence | Enhances taste and aroma |
| Salt (pinch) | Balances the sweetness |
3. Flavour Additions (For Variants)
| Flavour Variant | Additional Ingredients |
|---|---|
| Mint Chocolate | Mint essence, green color (optional) |
| Orange Zest | Natural orange oil or essence, orange peel |
| Coffee Mocha | Instant coffee powder or coffee extract |
| Hazelnut | Hazelnut paste or essence |
| Salted Caramel | Caramel essence, pinch of sea salt |
| Strawberry | Strawberry essence, natural pink color |
| Peanut Butter | Roasted peanut paste or powder |
| Vanilla Choco | Vanilla extract or natural vanilla |
| Almond Fudge | Almond essence, almond pieces |
| Chili Chocolate | Mild extrachili (capsicum oleoresin |
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