Co-extrusion system enhancements improve control and performance
- Product Development
As the market continues to grow and diversify, manufacturers are looking for a simpler and cleaner process with lower capital costs. Nowhere is this truer than of the market for nutraceutical and functional gummies, where the ability to avoid cross-contamination is vital.
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 starch-free process.
It’s easy to see why confectionery companies prefer starch-free depositing to the old processes. Quality appearance, smoothness and flavour release of hard candy and lollipops ensure a premium product. Equally important is the endless stream of product opportunities, some of them impossible with previous technologies.
Starch-free depositing gives jelly and gummy producers access to the nutraceutical and functional confectionery markets, and to 3D jelly manufacture. These are areas where starch moguls cannot operate, and where demand is rising.
Jellies and gummies can be used to deliver a variety of functional ingredients, including vitamins, minerals, protein, fibre, Omega-3, probiotics and energy supplements. They can also be made in 3D shapes such as fruits, animal characters, spheres and other geometric shapes.
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. White toffee can be coloured, flavoured, striped and swirled. Traditional brown toffee may be enhanced with chocolate, nuts, or jam centre-fills in a perfectly-shaped outer.
A wide range of fondant and fondant crème confectionery can be made in a variety of colours, flavours, fillings and shapes. They can be chocolate coated or include centre fillings like nuts, jelly, fruit pieces and liquids.
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. Plus there is the potential for profit from confectionery incorporating over-the-counter medications or dietary supplements; and, of course, the sugar-free option. 3-dimensional products are also achievable.
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.
Quality and versatility does not come at the expense of production costs. These systems require very little labour and are highly efficient, with negligible waste and low energy consumption.
Starch-free depositing development is ongoing and its appeal is broadening. The move away from every traditional process continues to accelerate.
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