Developing new technology for commercial production of meat substitutes
- Product Development
Starch-free depositing is replacing the starch mogul as the process of choice for gummy and jelly production remarkably quickly, particularly in the burgeoning functional and nutraceutical market. There’s no comparison to the advantages of cost, quality, speed and hygiene that the process provides.
Ingredients including vitamins, minerals, protein, fibre, Omega-3, probiotics and energy supplements, plus fruit pulp and pieces can be included. Over-the-counter pharmaceuticals such as aspirin and paracetamol in capsule form seem certain to join the list soon.
In an environment where hygiene - particularly the elimination of cross-contamination - and strict recipe accuracy are critical, the starch mogul simply cannot be considered. With a depositor, consistent high-class starch-free products support premium pricing, and the process adheres to the principles of GMP; validation to FDA/EMEA standards is straightforward.
Depositing into solid moulds at final or very high solids ensures consistent, accurate weight and dosage control; the smooth surface and dependable shape with no shrinkage convey the high-quality image necessary for this sector. Striped, layered and filled products are all possible.
For companies prepared to innovate, the opportunities are boundless. Gelatin, pectin and carrageenan formats can be utilised – the latter with vegetarian and vegan recipes for plant-based diets. The full range of gummy and jelly textures is achievable.
Baker Perkins’ starch-free jelly and gummy depositing systems offer a unique capability to produce full-form three-dimensional jellies and gummies in intricate shapes - a starch mogul can make two-dimensional products only.
Jellies from a starch-free depositor are more attractive due to the better surface finish, while the absence of lengthy stoving and complex starch handling systems means that production cost is lower.
Product possibilities include completely spherical balls; full fruit shapes such as raspberries, strawberries and pears; as well as animals and cartoon characters. There is also obvious potential for character merchandising linked to television and movies.
The origin of this new technology was the development of our patented design of ‘book’ mould for lollipops. This has been adapted for jellies and gummies in a high-efficiency depositor ensuring 100% ejection of the products.
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