Nutraceutical gummy and jelly production: Starchless on the fast lane

By Holger Brack, Food Engineer MSc

Winkler und Dünnebier Süßwarenmaschinen GmbH

Head of Product Technology Lab and Applications

Rengsdorf, Germany

In the production of gums and jellies with additives like nutraceuticals, supplements, or even over-the-counter (OTC) sweets, the traditional manufacturing process using starch powder, known as Mogul technology, is becoming less significant.

Gums and jellies have reached a very high level of consumer acceptance. Growth rates, often in the double digits, reflect the success story that stems from a combination of sweet, fruity flavors and an enticing chewing texture.

Moreover, fruit gums are now aligning with the latest food trend by exclusively using natural and authentic raw materials sourced from organic agriculture. Declarations of being vegan or organic assist in shedding the unhealthy image often associated with these small treats.

The once "boring" fizzy tablet or gel capsule, which initially garnered only modest approval from consumers, has now been transformed into the form of fruity gum or jelly.  This represents an emotional enhancement and a far more appealing method of consumption. Healthy snacking can contribute to  well-being.

Nutraceutical gummy with sugar

Today, functional additives such as melatonin (to cure sleeping problems), hyaluronic acid (joint pains) and cannabis oils (CBD) are added to fruit gums. In countries where THC has been legalized (such as Canada and some US states) fruit gum applications as well with effects of THC play an increasing role. Experiments regarding the application of ''painkillers'', such as paracetamol or ibuprofen are already taking place on laboratory levels. It is only a matter of time before such products are approved by FDA or EMA.

Traditional fruit gum production does not correspond with the strict hygienic rules and the GMP principles of the new production environment: the main reason why more and more companies turn towards the starchless production technology.

Production has to be done with stable moulds, which have to be cleaned after using and before every product change, so that a cross contamination can be excluded. As an alternative silicone or polycarbonate moulds can be used, as well as a production directly into blister (made in pack).

The use of Teflon coated aluminum moulds is from the hygienic point of view, a disaster! Apart from the metal residues and the bad cleaning possibilities also an easy handling of the moulds (e.g. mould changing) is not possible since they are mainly mounted firmly to the transport chain. In such manufacturing plants products are often blown out of the moulds by an unfiltered air stream without any order.

Thanks to the rapidly growing market for nutraceuticals, supplements and OTC jellies, WDS has developed a new direction regarding the moulding processes. A change towards polycarbonate moulds allowed the development of a completely new, modern, clean and highly efficient plant technology for jelly manufacturing, which has its roots in the moulding of chocolates. WDS is extremely successful in building moulding plants for jellies and chocolates. This versatility together with a deep knowledge concerning complex moulding processes have now created a modern generation of starchless moulding plants for gums and jellies.

Deposited mass in polycarbonate moulds

At first glance, the plant layout is similar to a chocolate moulding plant. At a second glance it is clear that a few important and new processes are integrated for hygienic jelly production: Coating of the moulds with a waxing oil, quick depositing of the masses with a maximum protection of the ingredients and orderedly demoulding results without damaging the product. Proven processes as efficient mould cooling, automatic mould weighing and changing, mould deduction by shift register or the ejection of polluted or damaged moulds have been taken as well-known standards from the chocolate manufacturing plants.

The advantage of polycarbonate moulds lies in the very narrow product layout and increased production capacity together with low investment costs. Polycarbonate moulds in the right composition are more resistant to alcoholic and aromatic hydrocarbon compounds and most of all to all the surfactants weakening the durability of the moulds with every washing process.

The handling inside the plant is more compatible thanks to their lighter weight; complex product shapes are easier to implement and porosity as well as absorption and release of product substances can be eliminated up to 100%.

Starchless product variety                                                                      

Such a manufacturing process leads to a production capacity of up to 1 million fruit gums per hour. Apart from the ConfecPRO, WDS´ high-performance plant resulting in up to 3 tons fruit gums and jellies per hour, WDS delivers with its ConfecECO complete solutions even for smaller production needs in the area of 200 to 800 kg per hour.

Furthermore, for product development WDS offers pilot plants for all important process steps which enable a direct upscale to production scale.

Nutraceuticals, supplements and OTC sweets build the bridge to a completely new plant technology for gums and jellies that helps to close the conjunction between confectionery, food and medicine.