Candy Manufacturing Technology

Candy manufacturing technology and candy manufacturing techniques are truly fascinating. The industry has evolved from hand operations (which still do exist in smaller facilities) to fully automated manufacturing lines.

Candy is a delicate, delicious, treat that we all love. It comes in many wonderful flavors including milk chocolate, caramel, peppermint, dark chocolate, butter scotch and various other fruit and mint flavors. It also comes in many consistencies such as chewing gum, hard candy, soft candy and all sorts of great delicious configurations and shapes. So while so many of us love candy we rarely think how is it made, why each bar tastes the same, how it is kept at a reasonable cost, and how such massive volumes can be manufactured with such consistency. Candy manufacturing is truly amazing.

Candy manufacturing is not just something the large manufacturers like M&M Mars and Hershey have to think about but also the specialty gourmet candy manufactures and smaller private label gourmet candy companies.

There are many interesting technologies involved in candy manufacturing as well as very many types of candy manufacturing equipment. There are machines made for specific processes as well as complete integrated candy manufacturing processing lines.

Candy Manufacturing equipment should be FDA authorized and approved. The technology found in many modern candy manufacturing machines is truly sophisticated. The machines are often highly automated; computer controlled and have user friendly touch screen interfaces. Manufacturing equipment integrated with sophisticated electronics, sensors and programmable controllers as the current state of the art.

A Candy Manufacturing Example

A good example demonstrating the use of candy manufacturing equipment is in the manufacturer of hard candy. Hard candy manufacturing involves many of the machines above including candy vats, ovens, mixers, candy rollers and candy twisters. Further demonstrating this is the manufacturer of butterscotch.

A batch of butterscotch candy mix is prepared in a large cooking vat which is called a vacuum cooker. The butterscotch starts from raw materials such as sugar, and flavorings. These raw materials are mixed in the vacuum cooker until a pliable mass of butterscotch candy is available for further processing. The next step in the process is to put the mass of candy through a series of water cooled plows and formers in what are called a kneading machine. The butterscotch is twisted and pulled as it is passed down a long trough. The plows and formers move the candy along, elongating it, forming a huge giant continuous string of candy. The mixture is still very large in diameter and blobby at this time. In order to get the candy to the desired diameter and consistency for consumption further processing is required. The mixture is next extruded and elongated further to size using a long series of rollers and dies. This is the final diameter forming process and brings the candy closer to the final configuration for the end consumer. After this extruding the long rope like shaped candy is cut into individual butterscotch buttons and transported on a conveyor belt through a sorter and eventually a candy wrapping machine. The candy is then packaged to appropriate containers and ready to ship to the customer.

Manufacturing Techniques

Candy Aerating

Marshmallows, snowballs and aerated chocolate are examples where aeration technology would be used. Each application can use a specifically designed mixing head. These devices also facilitate perfect temperature control during the aeration process.

Candy Molding

Three popular molding techniques include polycarbonate injection molds, thermoformed spinning molds and silicone rubber molds. These types of molds are often used in the manufacture of chocolate candy.

Candy Stamping

Stamping is done with dies that cut the candy to shape from a slab. An example is in the manufacture of chocolate or taffy.

Candy Drawing

The drawing of candy is similar to the drawing of metal or plastic. A candy bullion is pulled through a series of dies reducing it in size or forming its perimeter to a shape. The dies can be temperature controlled to help in the process.

Candy Cooling

Cold water is often used to cool the equipment that actually is in contact with the candy. Through this the candy is kept cool as it is manufactured. An example is in the cooling of forming and drawing dies. Other solutions include the use of a refrigerant.

Candy Coating

Enrober machines are used for coating candy. For example the delicious thin coating found on chocolate coated cookies or a candy bar is often applied by an enrober. Some of these machines are extremely sophisticated and can be quite large. They are of manufactured from stainless steel and designed to run 24/7. They contain pump units and high end ones are packed with advance electronics to optimize chocolate consumption minimizing waste. This can be a big money savor.

Automatic Decorators

These machines as the name indicates are used in decorating candies and cakes. The decorators apply icing or chocolate designs on cookies, cakes, other baked items and chocolates. Designs range from thick to thin, zig zags to curves, straight lines to single and double loops, cross-hatching and random designs. Designs can often be changed rapidly to afford a variety of decorated product. Decorators can be often custom designed to fit most speeds and sizes of conveyors or enrobers.

Packing

Candy Wrapping and Packaging

Wrapping machines are another category of candy manufacturing equipment. Some wrapping machine manufactures also offer art work consulting as a service. This allows the customer to custom design a wrapping for their candy as well as wrap it. An example might be a foil holiday wrapper for a chocolate candy product. Also fitting into this class of manufacturing equipment is high speed packing equipment and sealers. These solutions include completely automated packaging systems capable of denesting, filling, tray sealing, sleeving and cartooning. Some leading edge automated systems can seal at a top speed of 400 ppm and load 800 bars per minute.

Integrated Candy Manufacturing Solutions

These solutions are typically full assembly lines of candy manufacturing equipment. They are often computer controlled to form a automated candy manufacturing process. They frequently have conveyor belts and may be completely enclosed. These machines are also used by cookie manufacturers as well. These systems are advertised as complete candy manufacturing solutions and are customized based on the particular product being manufactured.

Bar making is a great example of a product that lends itself to a integrated candy manufacturing solution. For example a custom designed processing system is available to produce binder, cream, caramel, jelly, icing to produce breakfast snacks, health and energy bar products. These systems are integrated with a bar line system including a slab former, cooling, slitter, spreader and guillotine cutter.

Candy Quality Control Equipment

Not only is technology key in the manufacture of candy but also in the quality control of candy. Systems such as high speed check weighers, metal detectors and x-ray systems are good examples of technology being used to assure good candy quality.