Blog: Avoiding the low-cost moulder trap
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Making 3-Dimensional jelly confectionery using a depositor with a hinged mould is a significant innovation, providing an efficient method of making complex 3-D shapes at high output and high efficiency to ensure that production costs are kept low.
Conventional technologies can produce a contoured surface on the product but the bottom will always be flat. Baker Perkins’ new 3-D mould technology produces a true three-dimensional shape.
Product possibilities include balls or spheres; fruit shapes such as raspberries, strawberries and pears; and there are also merchandising opportunities linked to animals and cartoon characters. Baker Perkins can explore any ideas for new 3-D shapes in our dedicated confectionery Innovation Centre in Peterborough.
These jellies can be made in one or two colours, with stripes and layers, and with centre-fills – including liquid centres. Outputs from 600 to 1,200 kg/hour can be achieved, dependent on piece size.
This innovation is based on well-established technology used for Baker Perkins’ market leading lollipop depositing systems. 3-D jellies can also be produced in lollipop format, with the addition of a stick placing unit into the line.
Deposited confectionery is growing rapidly in the functional and medicated product sectors.
As well as being more palatable than the alternatives of tablets or capsules, confectionery overcomes a psychological barrier caused by the association of these delivery systems with illness and medical intervention.
The functional sector ranges from boosting the intake of essential nutrients such as vitamins, minerals, fibre and protein to adding beneficial supplements such as folic acid and Omega-3 to the diet. This sector also extends to sports nutrition, where confectionery is ideally suited to portable and convenient energy and recovery products.
Medicated products include ingredients such as antiseptics, menthol and eucalyptus oil to alleviate the symptoms of minor ailments such as coughs, colds, sore throats and nasal congestion.
High accuracy dosing and maximum effectiveness of the active ingredients make depositing uniquely suitable for medicated and functional products. Additionally, glossy finish, consistent size and smooth mouth feel are in keeping with the high quality consumers expect of healthcare products.
Of the technologies available to the medicated and functional confectionery sectors, depositing is the most appropriate because of the efficiency, hygiene, accuracy and product quality it offers. The process adheres to the principles of GMP and is readily capable of validation to FDA/EMEA standards.
Baker Perkins' cooking and starchless depositing systems for confectionery are used to make a wide selection of products, including hard candy, lollipops, toffees, caramels, fudge, jellies and fondant.
Depositing offers higher quality and more production flexibility, with reduced production costs compared with older technologies such as die forming, starch mogul or cut-and-wrap. Depositing is preferred by companies seeking to grow innovative, high-quality confectionery brands
Baker Perkins’ one-shot ServoForm™ depositing systems can unite up to four components into a single sweet in a variety of different patterns including multi-colour centre-fills, stripes, layers and inclusions. Adding value, interest and variety in this way makes a significant contribution to commercial success.
Our unique swept thin-film Microfilm™ cooking process provides precise and consistent cooking of a wide variety of confectionery syrups. The process is continuous; cooking in two stages dissolves sugar slurries and converts them to final-moisture. The Mirofilm™ process is suitable for many types of sugar confectionery syrup. As well as hard candies and lollipops, the capability includes soft confectionery such as toffee, caramel, gums, jellies and fruit pastes.
In the jelly sector, the Turbofilm™ is a skid mounted plate heat exchanger unit containing everything necessary to cook jellies. By combining continuous dissolving and cooking of syrups into a single compact module, it brings benefits of very low energy for jelly cooking.
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