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Maker - Product Challenge

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Gummies mixing Equipment

Industrial mixing equipment is used to combine two or more solid, liquid or gaseous segregated ingredients into a homogenous single product. The choice of mixing technology depends largely on the physical state of the ingredients and the desired final product. But the sensitivity of the ingredients, the process temperature, and pressure requirements are also critical factors. All these parameters result in a wide range of industrial mixers.

Mixing

Gummy candy are a very popular confectionery, because they are versatile and appeal to a wide variety of tastes. Another reason for the popularity of this delicious candy is the fact that it’s easy to produce, particularly in small quantities. For medium to large scale production of gummies, there is a multitude of gummy manufacturing equipment to help ensure that you end up with a good product.

Gummies

Prepare your ingredients for soft candy production. This is a highly flexible continuous cooking system that is capable of processing a wide variety of mixed ingredients under a completely controlled range of conditions. It produces a consistent soft confectionery product with an infinite range of color, flavor, and texture.


<h2>Consistent, soft candy cooking with extremely flexible process controls</h2>
The Candyflex system from Ter Braak is a highly flexible Pressure cooker for caramel and soft candy with working capacities from 300 to 1000 kg/h. The system consists of a three-stage process including pre-dissolving and caramelizing under pressure, film cooking/evaporating with or without vacuum conditions, and vacuuming which, either subject the substrate to vacuum, or simply uses the vacuum chamber as a buffer vessel. The system allows complete control of critical process variables through the three stages allowing the user to develop a flavor and texture profile that is perfectly suited to their product.

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Pressure cooker for caramel and soft candy

Prepare your ingredients for any whipped or aerated product component. This is a pressurized whipping machine and batch cooker for producing soft fruit candy, nougat mixtures, chocolate bar core mixtures, and other whipped and aerated products.


<h2>Consistent, whipping and aeration from an automatic batch cooker</h2>
The Preswhip system from Buhler Group is an automatic batch cooker using either thermosiphon or TBT batch cooking technology. The system also includes an integrated pressure whisk mechanism for substrate aeration. The whipping and cooking processes are independently controlled to adapt to a wide range of process needs.

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Whipping machine for soft candy

When making jams and marmalades, gelling agents, such as pectin, are used to thicken the fruit juices. Pectin occurs in fruits naturally, but there are some fruit types that are not rich in its content. In this case, pectin is added during the mixing process. Dispersing and hydrating pectin could be difficult because when mixed with water, the powder tends to form agglomerates that don't break down easily. This can lead to poor quality results and reduced yield, so it is crucial to choose a proper mixing technology.


<h2>Mixing emulsifiers, thickeners, and other food stabilizers</h2>
The Thickeners Preparer from Ghizzoni is a mixing unit used for preparing emulsifiers and thickeners, such as pectin or starch. This process provides a more controlled environment for the gelling agent solution, resulting in more consistent quality and better yield of the final product. This unit is usually integrated with the vacuum cooker, and its capacity is proportionally adjusted to it (usually emulsifier’s capacity is 10% of the vacuum cooker batch size). It is available in capacities ranging from 20 liters to 500 liters.

Emulsifier and mixer for gelling agent

Mainstream technology for the preparation of gummies and jellies relies on a coating of starch on mold trays to avoid the stickiness of the sugary mix. But starch creates risks of microbial contamination. In addition, the entire operation of layering and removing starch from depositing stations slows down the gummy manufacturing process. The use of starch presents many hygiene and cross-contamination risks, as well as efficiency, quality and financial compromises.


<h2>Remove starch from the depositing stage to make higher quality confectionery</h2>
The ServoForm system for gummies and jellies from Baker Perkins is designed for high output starch-free production. The depositor technology produces high quality, high-definition gummies and jellies and eliminates the formation of crusts typically caused by starch.

Instead of traditional starch trays, cooked syrups and fruit pastes are deposited into solid molds made from metal, polymer, or rubber for maximum hygiene. These molds, combined with continuous, accurate depositing at final moisture, create high quality confectionery pieces that are perfectly shaped, with a beautifully smooth surface finish.

Devised for rapid production and quick product changeovers, the depositor technology can produce an almost unlimited variety of solid, striped and layered confectionery with multiple flavours and components. Fillings and inclusions can be incorporated easily.

Consistent product size, shape and weight contribute to improved wrapping efficiency, and enhanced hygiene features reduce cleaning and maintenance costs throughout the line.

High Output Industrial Production Line for Gummies and Jellies

The traditional method for gummy and jelly production uses starch to keep the ingredients from sticking to the mold trays. But, as an organic byproduct, starch raises concerns about microbial contamination. Moreover, starch leads to coarser edges of individual sweets, lowering the quality of the end products. The use of starch presents many hygiene and cross-contamination risks, as well as efficiency, quality and financial compromises.

<h2>Make high-definition gummies that are free from starch</h2>
The ServoForm Flexi system for gummies and jellies from Baker Perkins is designed for starch-free production. Starch-free depositing is both more hygienic and economic than traditional starch mogul production for the lower throughputs that are typically required for functional, nutraceutical and healthcare markets.

The ServoForm Flexi system offers the capability to produce gummies and jellies with longer setting times. 3D, solid, striped, centre-filled and layered products with gelatin, pectin or specialized gelling agents are deposited at final solids so no drying is required, only setting/conditioning.

A unique single-piece plastic mould allows for rapid product changeovers. The strong, rigid construction provides resistance to twisting to maintain depositing accuracy and stack stability, and is designed to survive both manual and automatic handling for multiple cycles. They are temperature resistant to allow hot product and automatic washing.

Flexible Output Line For Gummies and Jellies

The original technique for making gums and jellies exploited the non-stick properties of starch to form candies. However, the use of starch presents many hygiene and cross-contamination risks, as well as efficiency, quality and financial compromises.


<h2>Make quality products free from starch</h2>
The low output ServoForm Mini system for gummies and jellies from Baker Perkins is designed for 100% starch-free production for a variety of products. Based on Baker Perkins’ high-output ServoForm confectionery depositing technology, the ServoForm Mini deposits high quality products with a consistent size and shape, and high piece weight accuracy.

The small footprint, low energy costs and elimination of starch significantly reduce production costs compared with traditional starch moulding processes. Low scrap rate, quick product changeovers and continuous processing mean a rapid payback is assured.

Full servo control and detailed recipe management allows for complex mixes with up to 4 components and unlimited shape designs. The ServoForm is optimized for full 3D gummies as well as striped, layered, and center-fill options.

Low Output Production Line for Gummies and Jellies

In the food industry, mixing processes often involve solid and liquid combinations such as flour and vegetable oil or milk powder and water. Conventional technologies perform these processes in batches. However, a continuous system able to mix multiple dry and wet ingredients simplifies the production process and ensures product consistency.


<h3>Compounding and mixing of powders and grains with liquid ingredients</h3>
The Various Mix, from Hansa Mixer, is a versatile mixing system that compounds and mixes up to 3 dry substances (including powder and granules) with up to 10 liquid substances. The capacities of the mixing vessels range from 60 to 100 liters, and the speeds of the mixing head and the eccentric screw pump are regulated by a frequency converter.

The mixing head and frame are  made entirely of stainless steel and the removable sheet-metal plates make the mechanical components easily accessible.Recipes can be adjusted through its touchscreen controls. System options include automatic filling devices for the dry substance hopper, automatic dosing of additives, volumetric or gravimetric flow metering, and remote control operation. The mixer’s frame has 4 or more caster wheels for improved mobility.

Continuous mixer for pumpable media

By gradually investing in the individual parts, a production line grows along with the company, allowing startups to enter the world of automated confectionery &amp; nutraceutical manufacturing.


<h2>Develop nutraceutical gummy formulations safely with a modular system</h2>
The complete production line from Tanis involves several pieces of equipment designed to function together to maximize laboratory-scale production output for nutraceutical gummies. Gummy production begins with the OTC 400S NS Kitchen, which features a pre-blending vessel for the homogeneous mixing of ingredients and a continuous cooking system with temperature control for precise cooking without burning the blended ingredients. The system also has an integrated vacuumizer to remove air bubbles and excess moisture during cooking.

The Additive Blending System (ABS) accurately weighs the gummy mass before incorporating pre-weighed additives. The mixing system ensures a thorough and even blend for the perfect gummy formula. After cooking, the mixture goes to the OTC 400S NS depositor, which features heated contact surfaces to prevent pre-gelling of the product and is equipped with a closed jacketed pump housing for accurate dosing of the moulds provided. Each mould is made of hygienic and rigid polycarbonate or silicon material.

The loaded moulds are then stored in the OTC 400S NS Conditioner, which features integrated air handling units with a desiccant dryer capable of uniformly distributing airflow between trays within an environmentally controlled closed system to dry the gummies quickly. As soon as the gummies are dried and ready, they are loaded into the OTC 400S NS Demoulder, which features an automated system for removing CBD gummies from the trays without any physical contact from the operator using sanitary compressed air.

All pieces of equipment have hygienic designs suitable for handling high-value products like CBD gummies and are also designed to match the capacity of the next equipment, which allows easy adjustments to the settings of the operation.

Lab scale production line for nutraceutical gummy production

High-value products like CBD gummies demand precision equipment such as starchless machinery. This facilitates cleaner ingredient profiles, aligning with this industry's trend toward more natural and transparent product labeling. It also guarantees no cross-contamination, ensuring product purity and enhancing gum and jelly production efficiency.


<h2>Produce CBD gummy formulations safely with a modular system</h2>
The complete line from Tanis comprises a range of specialized equipment designed to work seamlessly together, maximizing production output for the start-up production of CBD gummies. CBD gummy production begins with the OTC 400S NS Kitchen, which features a pre-blending vessel for the homogeneous mixing of ingredients and a continuous cooking system with temperature control for precise cooking without burning the blended ingredients. The system also has an integrated vacuumizer to remove air bubbles and excess moisture during cooking.

The Additive Blending System (ABS) accurately weighs the gummy mass before incorporating pre-weighed additives. The mixing system ensures a thorough and even blend for the perfect gummy formula. After cooking, the mixture goes to the OTC 400S NS depositor, which features heated contact surfaces to prevent pre-gelling of the product and is equipped with a closed jacketed pump housing for accurate dosing of the moulds provided. Each mould is made of hygienic and rigid polycarbonate or silicon material.

The loaded moulds are then stored in the OTC 400S NS Conditioner, which features integrated air handling units with a desiccant dryer capable of uniformly distributing airflow between trays within an environmentally controlled closed system to dry the gummies quickly. As soon as the gummies are dried and ready, they are loaded into the OTC 400S NS Demoulder, which features an automated system for removing CBD gummies from the trays without any physical contact from the operator using sanitary compressed air.

All pieces of equipment have hygienic designs suitable for handling high-value products like CBD gummies and are also designed to match the capacity of the next equipment, which allows easy adjustments to the settings of the operation.

Start-up production line for CBD gummy production

Giving aerated jelly some bite

Hansa Mixer modular precision technology mixes and/or foams doseable media in absolute conformity to the recipe: gases, fluids and solids.

Jellies may seem like simple treats, but formulating their fluffy-yet-chewy mouthfeel is an intricate process. The foamy texture is created by finely dispersing air bubbles, but the signature bite depends on the crystallization effect of sugars.

Sugar molecules provide structure and friability, but they are especially tricky to handle. If the confectionery mass sets, sugars start melting and losing their crystalline properties.

Keeping compounds fresh is a primary headache if you’re making aerated mass for jellies, and production becomes a race against time to stop the effects of aging.


<h3>Anti-aging advice for aerated jelly production</h3>
The short shelf life of the mass not only causes sugar de-crystallization but leads to dosage errors. In the rush to keep the mix fresh, operators have less time to double-check recipe standards.

In fact, the process steps between mixing ingredients and depositing them are where most production imperfections occur. As the adage goes, haste is waste.

Aging, therefore, presents a double problem for aerated products. But Oliver Klein from Hansa Mixer has some pertinent advice: “Don’t change the production pace; change the production method.”
<h3>Keep calm and compound in real-time</h3>
The conventional way of compounding a formula is by mixing the ingredients in batch. The engineers at Hansa Mixer looked at the problem and developed an alternative: a real-time compounder.

“The solution is practically compounded mix on demand, producing a fresh blend at the moment it is needed,” explains Oliver. Suddenly his advice becomes more clear.

If the batch mixer creates multiple challenges, real-time compounding addresses a few. By eliminating overproduction, it minimizes idle time and keeps the mix from aging. Meanwhile, any discrepancies in the formulation can be corrected immediately without wastage.

Real-time mixing keeps powder in place, giving aerated jelly mass its distinctive texture. The best way to sustain the crystal bite is by keeping the compounds fresh.

Food

To make candy, all you need to do is create a syrup by dissolving sugar and boiling it to your desired consistency. For medium to large scale candy production, candy making equipment fully automates the whole process and takes care of other production regulations and standards (such as hygiene and proper homogenization). Planning on getting one? There’s a wide range of choices to pick from.

Candy

Our food chain starts in the soil, growing crops and livestock. But between the fields and the stores, there is a line of industrial food processing equipment. Processes may be as minimalistic as cleaning fruit and as complex as homogenizing milk alternatives made from pressed legumes. In each case, processing technology is an important link in the food production chain.

Tech is [was] keeping vitamin gummy manufacturers from cutting starch

Chewy, sweet, and nutritious. Vitamin gummies were a couple’s attempt to get their child to take their essential micronutrients. The idea quickly caught on, and manufacturing vitamin gummies soon grew into a whole new industry.

Vitamin gummies

Vitamin C is an essential nutrient, but the human species lost the ability to produce it biologically during the course of evolution. Instead, we source the substance either from whole foods or vitamin C manufacturing. The chemical characteristics of the natural nutrient and processed compound are the same, but supplements offer higher concentrations, especially to persons with nutrient deficiencies.

Vitamin C

Baker Perkins supplies technology for the bakery, biscuit, confectionery, supplements, snack and breakfast cereal sectors, The company's production machines are based on over 100 years of experience in the field.

When the starch mogul was first introduced in the early 1900s, it revolutionized the way jellies and gummies were produced.

The machine punched a mold into a bed of starch, much like an industrial cookie cutter. The gelatinous mixture was left to set until the starch absorbed enough moisture to produce a solid.

Although gums took hours to form, the technique relatively quick method for mass-producing candies in a more-or-less consistent shape. But it didn’t come without its costs. Manufacturers now needed extra space for starch rooms and a whole new process of filling starch trays, then separating the starch from the formed candies and drying it again for re-use.

Nevertheless, the clouds of starch particles that filled the shopfloors were a step forward from the laborious hand-forming of the day.


<h3>New gummy products, old manufacturing methods</h3>
The mogul technique is still widely used today, but gummies have changed considerably over the decades. Gummy products have expanded to include medicated formulations like vitamin gummies. Meanwhile, greater awareness of the contamination risks associated with starch is prompting regulators to introduce stricter validation standards for manufacturers.

Bulk starch sitting in storage is fertile ground for microorganisms, including pathogenic ones. This raises a new set of challenges, particularly for producers of vitamin gummies. They must constantly monitor the starch for microbial contamination and treat it with radiation before using it.
<h3>The time of starch-free production technology</h3>
Baker Perkins developed a system to manufacture high-quality gummies without any starch. The syrup formula is accurately deposited into 3D molds made from food-grade material.

But besides eliminating contamination issues, removing starch from the process simplifies the operation. No tray-filling, no handling issues, and no starch drying. In addition, the system allows manufacturers to form high-definition vitamin gummies with multiple coloring possibilities.

Unlike traditional methods, starch-free production simplifies demolding while fully preserving the shape of the gums. Keith Graham, marketing manager at Baker Perkins, explained to us how the combination of the mold material, the surface finish, and a special spray solution impacts the end product. “Getting these parameters right is the key to achieving 100% demolding.”

The reasons to move past the starch mogul have been mounting for years. But, just like the time the mogul was invented, the industry needs an efficient alternative to take the leap.

Baker Perkins has roots in the same era when the starch mogul became the obvious way to produce jelly products. The next step forward is taking vitamin gummies starch-free.

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Pharmaceutical

Eating is more than just nutrition, but we have found ways to increase the nourishing power of our foods. Nutraceuticals manufacturing, from vitamin C powder and probiotics to omega 3 oil, is a concentration of natural ingredients and health supplements that complement our diets. While dietary supplements are not quite haute cuisine, the process of extraction and purification is no less a blend of science and art.

Nutraceuticals

Find production technology for Gummies mixing, and connect directly with leading machine manufacturers worldwide