The dynamics of the confectionery industry are nowhere more apparent than in the jelly sector. For manufacturers, who are constantly developing new, colourful creations, this fast-moving market environment triggers the need for efficient and flexible process technology.

Process requirements for the production of jellies are high: a high level of precision is required for the continuous dosing and mixing of ingredients. Especially when it comes to very small quantities, volumetric dosing and mixing stations are best suited. The kitchens also have membrane pumps with flow control and a high dosing accuracy of up to 1 %.

“Sustainability is also an important issue in jelly production,” emphasizes Dr Sandra Link, Product Manager at Makat Candy Technology, a Syntegon Technology company. “By using our patented Rapidsolver, we enable significant energy savings in this process – up to fifty percent by expanding the Rapidsolver with the Energy Recovery System ERS”. The Rapidsolver’s optimized design enables a reduction in steam pressure of up to 0.5 bar. This not only reduces energy consumption within the dissolving process, it also reduces the heat load on the mass and thus protects the quality of the product.

The geometry of the Rapidsolver’s mixing elements ensures a first in/first out principle and reduces dead corners, which in turn decreases cleaning times. The hygienic design and the CIP system with rotating spray balls also facilitate cleaning.

After mixing, dissolving, and preconditioning for further processing, the jellies are deposited. Here, starch depositing process is the established standard for manufacturers who want to respond quickly and flexibly to market trends. “The Makat HLM (high-performance mogul) works particularly precise and ensures consistently high product quality,” notes Dr Sandra Link.

The stamps used to form the negative moulds in the starch can be easily exchanged to create a wide range of variations in size and shape. The Makat HLM also features a PLC-controlled process monitoring and is ideally suited for the use of Industry 4.0 solutions. For enhanced sustainability, the brushless RNC 6000 tray edge cleaning system reduces not only starch losses, but also production waste, cleaning effort, as well as costs.

New products require innovative manufacturing processes, such as starchless depositing. Dr Sandra Link explains. “Starchless depositing eliminates the need for starch. Instead, the jelly mass is poured into reusable moulds”. After depositing, the jelly mass passes through an integrated cooling tunnel and is brought to the demoulding temperature. Depending on the recipe, the jellies are form-stable already after 20 min.

“In the starch-based depositing process, the starch trays have to remain in a curing room for up to 72 hours,” Dr Sandra Link explains. “The starchless depositing process has several advantages: it reduces production time, and the products no longer have to leave the machine for cooling. In addition, producers save the space and energy costs for the curing rooms, as well as all expenses for starch handling and conditioning”.