Baker Perkins is introducing a new batch cooker to its range of small, flexible production systems for the functional gummy and confectionery markets.
It will be launched on the Baker Perkins stand at ProSweets (Hall 10.1, Booth F-080).
Full detail of the exhibition can be found at www.prosweets.com.
NEW JellyCook™ batch cooker
The new JellyCook™ batch cooker feeds a ServoForm™ Mini depositor; the system brings the benefits of starch-free production of gummies and jellies to companies operating in healthcare and supplement markets. Products using gelatin, pectin, carrageenan or blends as the gelling agent can all be produced.
The semi-automatic JellyCook™ cooker produces 30kg batches; a high output model with two cookers will produce 60kg/hour. A reservoir tank accepts syrup from the cooker and feeds the depositor. Simplicity is a decisive benefit, with all operator actions prompted by messages on the HMI screen. The JellyCook™ is oil heated and electricity is the only service needed.
An intelligent control system with an adaptive weighing system guides the operators through the process of making each batch. To ensure consistency between batches ingredient additions are recalculated in real time to match quantities added rather than set points. It also enables precisely the right amount of active ingredients, colours and flavours to be added at the end of the cook cycle.
Accurate dosing of high-value active ingredients is critical in a process which must be readily capable of validation to FDA/EMEA standards. Addition at the end of the cooking process after evaporation ensures stringent control.
Gummies and jellies and can be used to deliver a variety of functional ingredients including vitamins, minerals, protein, fibre, Omega-3, probiotics and energy supplements for sectors including nutraceutical, sports nutrition and pharmaceuticals.
The hygienic and precise nature of Baker Perkins’ ServoForm™ Mini starch-free depositing process makes it ideal for the functional confectionery market, where lower consumption levels compared with standard confectionery creates the demand for low-output production. The system is also ideal for pilot plants in larger companies.
Full three-dimensional jellies
In the premium confectionery sector, three-dimensional jellies are high-value and rapidly growing in popularity.
Starch-free depositing is the only method capable of manufacturing these complex shapes at high outputs and with low production costs.
Product ideas include balls or spheres, animals and cartoon characters, and fruit shapes such as raspberries, strawberries and pears. Baker Perkins' unique 3D mould technology and ServoForm™ depositors ensure that the products have a smooth, high quality appearance and accurate piece weight. Products can be made in one or two colours; with stripes and layers; with solid or soft centre-fills; and with inclusions such as real fruit pieces.
Benefits of starch-free depositing
Starch-free depositing is more cost-effective than a mogul in every respect, including capital and operating costs, floor space and process inventory. The starch process involves handling and filling starch trays, drying out the products, recycling the starch and keeping the line clean so labour, energy, and consumable costs are high. Starch-free depositing is a simpler process that requires less equipment and floor space, while the absence of starch means that plant hygiene and the working environment are significantly improved. Cross contamination is also reduced.
The process is scalable with systems available from 30 kg/hr up to 1,000 kg/hr. They are economically viable for companies of any size, from start-up operations to established high-output manufacturers in both the confectionery and nutraceutical sectors.
All types of sugar and sugar-free gummies, jellies, hard candies, lollipop and caramels in stripes, layers and centre-filled varieties can be produced. Baker Perkins’ expertise in starch-free depositing stretches back over many years, initially with an emphasis on hard candies and lollipops. Starch-free depositing is long-established in these sectors - now jelly, gummy, toffee and fondant producers are increasingly turning to the process.
Multi -colour, multi-component hard candies come in a limitless variety of one, two, three and four colours; in stripes, swirls or layers, with one or two hard or soft centre-fills, all with vibrant colours and every flavour imaginable.
Lollipops cannot be produced by the starch process; die forming is slow, inconsistent, and quality is low – so this is yet another area where starch-free offers many benefits. Three main styles of lollipop are the classic ball pop and the double ball lollipop, plus flat lollipops in an assortment of shapes. All are available in the same variety as hard candies.
For toffee and caramel, starch-free offers wider product variety plus higher quality, efficiency, consistency and output. Systems produce the full range of traditional toffees and caramels, and extend process capability to a range of products that cannot be made by any other method.
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