Blog: Avoiding the low-cost moulder trap
Baker Perkins focused on the potential for new, high-quality deposited candies, lollipops and soft confectionery at ProSweets in Cologne, January 27 to 30, 2013 (Hall 10.1, Stand C-048).
One shot ServoForm™ depositing systems can combine up to four components into a single piece in a range of different patterns, shapes and formats. They offer greater product quality and variety, with lower energy and production costs, compared with traditional methods such as die forming, starch mogul or cut and wrap.
The possibilities for innovation range from hard candy, through ball and flat lollipops to toffee, soft candies and jellies.
The latest ServoForm™ lollipop technology has the potential to generate an array of innovative high-quality flat lollipops. For the first time, an unusual shape, as well as the colour and pattern combinations in the candy, can enhance the visual appeal of flat lollipops. Embossing the surface is another new way of increasing the interest and variety of round or shaped lollipops.
The new capability brings character merchandising to the lollipop sector. Connections to movie, music and sports themes are possible in the product rather than just the packaging. Seasonal ideas, typically for Christmas, Halloween and Valentine’s Day, can also be pursued.
Multi-headed ServoForm™ depositing systems are used for ‘long term’ three-layered hard candy products with a genuine ‘sandwich’ appearance. ‘Long term’ layering involves a dwell time between each deposit, allowing the first layer to form before the next one is deposited. This clear separation gives a true ‘layered’ effect, with different colours, textures and flavours: a popular application is a sandwich of crystallized Xylitol between two layers of sugar-free hard candy.
Centre-filled toffees, fondants and fudges are just some of the high value products that can be made on the new ServoForm™ Soft Confectionery depositor. Soft centres such as jam, cream, jelly, chocolate, praline and fruit paste can all be one-shot deposited to add value and variety to a product range.
Two-component depositing can also be utilized to produce layered or striped soft confectionery, while solid inclusions such as nuts and fruit pieces can be added to broaden end product diversity. Where chocolate coating is required, the ServoForm™ depositor can be configured to discharge in a regimented format, ideal for direct-linking to in-line chocolate enrobing.
Another innovation is a high added-value toffee cup, complete with filling and topping or inclusion. These indulgence products require a multi-headed depositor and flexible rubber mould technology - more economic, precise and hygienic than conventional processes. The first head deposits a toffee cup, the second a filling – fondant, praline, chocolate, jam and jelly are among the possibilities. A third head can add a topping such as chocolate, or inclusions including nut or fruit pieces
As well as product variety, consistent high-quality and low cost of production are reasons why depositing is chosen ahead of conventional methods. The nature of the depositing process creates great flexibility and process control. Dimensional, shape and weight accuracy are extremely high; fillings are accurately positioned in the centre; and scrap rates are minimal.
Operational costs are also lower when compared with traditional processes. Set-up is quick and easy using a simple touch-screen interface with recipe-driven change management. Once running, the process requires very little operator intervention. An automatic wash cycle and hygienic design features minimize cleaning and changeover times for greater line efficiency.
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