Low-output confectionery production system

Baker Perkins has launched an innovative, low volume starch-free confectionery production system. It is ideal for flexible small batch production in the fast-growing nutraceutical and supplement markets, as well as standard confectionery.

The system comprises continuous cooking and starch-free depositing processes with a typical output of 60 kg/hr and piece weights ranging from 2g to 16g. It uses the same process and control technology as Baker Perkins’ well-established high-output ServoForm starch-free depositors.

The new system can produce a full range of sugar or sugar-free jellies and gummies, hard candy, lollipops, toffees, caramels and three dimensional products in one or two colours and with centre-fillings.

The ServoForm Mini depositor was launched as a stand-alone machine to bring the benefits of starch-free production to artisan confectioners making a wide variety of products in small batches.

ServoForm Mini depositor 

Combining it with the Turbofilm continuous cooker has created a seamless system that brings these benefits to low-volume production of dietary supplements and functional products.  Full PLC control incorporating process visualisation, recipe management and alarm handling provides complete process control.

The Baker Perkins Turbofilm is a versatile, compact and hygienic continuous cooker for gelatin, carrageenan and pectin-based gummies as well as hard candy. The self-contained skid-mounted system cooks and evaporates a sugar-based slurry to create base confectionery syrups.   Colouurus, flavours and active ingredients are incorporated after cooking using a new, accurate in-line dosing and mixing system.

Solid moulds that can easily be cleaned, along with easy access to every part of the machine for cleaning, make the ServoForm Mini ideal for healthcare production environments. Low scrap rates, quick product changeovers, accurate deposit weights and continuous processing mean a rapid payback is assured.

Baker Perkins Turbofilm 

Consumer preference for gummies rather than pills or capsules as the delivery mechanism for dietary supplements is increasing, particularly amongst millennials who see these products as functional foods rather than remedies. 

However, the production process for anything that claims a health benefit is a level higher than many traditional food manufacturing processes. Often this includes adherence to the principles of GMP and being readily validated to FDA/EMEA standards. The accuracy, consistency, control and hygiene of the Turbofilm cooker and ServoForm Mini depositor are ideal for the demands of this market.

Each deposit is individually metered with accurate weight and dosage control. The syrup is deposited at final solids into solid starch-free moulds, guaranteeing dimensional accuracy and a smooth surface finish. This eliminates the costly, time consuming and labour-intensive drying operation associated with starch moguls, and makes the process much more manageable. Cross contamination is also reduced with the elimination of starch.

Moulds are fed through the ServoForm Mini as required and an advanced mould sensing system prevents syrup being deposited when a mould is not present. Changing between different products is as simple as picking up a different mould set and selecting the product profile from the stored list on the control system.

Uniquely, moulds are available in either metal or silicone with the selection dependent on end product type and recipe. This choice would normally be made after testing of the various options in the confectionery laboratories within Baker Perkins’ Innovation Centers in the UK and USA.   

Solid metal or silicone moulds offer substantially better end product quality when compared with starch moulds. Metal moulds also offer superior cooling, impart a better surface finish and can hold more intricate shapes. A unique book mould has been developed that enables the production of fully three-dimensional gummies or hard candy.