March 24, 2023

Syntegon expands starchless gummy and jelly portfolio with next-gen turnkey solution

Closed production process with innovative kitchen, depositing, and oiling
• Designed for special requirements in the production of functional gummy and
jelly products
• Smooth processes thanks to high automation levels and digital monitoring

With the new turnkey line NutraFlash, the Syntegon subsidiary Makat Candy Technology sets new standards in the starchless production of gummy and jelly products. Manufacturers can increase the quality of sensitive products with upgraded kitchen, depositing, and finishing technologies.
Besides producing gummies and jellies with high dry substance content and dosing
ingredients precisely, the new line enables accurate starchless depositing in reusable
plastic molds. The holistic turnkey approach ensures a highly reliable, closed
production for consistent product quality along the entire process. To this effect, the
system includes end-to-end recipe management and a coordinated control concept
for harmonized operations.

“Our line covers all steps of jelly production from dosing and mixing the ingredients to
product finishing,” explains Dr. Sandra Link, product manager at Makat Candy
Technology. The starchless technology plays an increasingly important role in the
production of so-called nutraceuticals. These highly sought-after functional sweets
contain valuable ingredients such as vitamins or minerals. As a consequence,
nutraceuticals require special handling along the entire production line, for example
precise dosing to ensure the right additive content per individual piece. Makat relies
on proven technologies for all process steps. The new turnkey line allows for even
smoother production thanks to comprehensive adaptations. “Our high degree of
automation combined with digital condition monitoring helps manufacturers to achieve
reliable and time-saving processes with low reject rates,” Sandra Link explains.

Two-step dissolving process with Rapidsolver Solids +
The Makat Rapidsolver Solids + is at the heart of the starchless kitchen. As a special
execution of the proven Rapidsolver, the system achieves high dry substance content
of up to 86 percent when dissolving the base jelly mass – a special characteristic of
starchless production. It eliminates the need for subsequent moisture removal by
means of starch, as is the case with starch-based depositing in a mogul line. “This
significantly reduces process times and enable manufacturers to produce gummies
and jellies in a time- and cost-efficient manner,” Sandra Link emphasizes. Adding
supplements is another special feature in the production of nutraceuticals. The often
sensitive ingredients are optimally protected from excessive thermal stress since functional additives are only added shortly before depositing and the dwell times in the depositor are kept short.
Tailless depositing with the CMP Special tail-cutting nozzles of the CMP depositor ensure a high-quality processing, even of highly viscous and difficult jelly masses. Once the products have been
deposited into reusable plastic molds, they cool down in the line’s integrated cooling
tunnel. This spares manufacturers additional handling processes, such as removing
the molds and cooling the products in external cooling chambers.

When dissolving the base jelly mass, the new line
achieves high dry substance contents. This results
in shorter process times and time-efficient gummy
and jelly production.

Flexible product finishing with the BC 96
The application of polishing agents in the fully automated BC 96 oiling drum has also
been adapted significantly: in addition to a centerlining functionality for lower process
variability, the drum features a Human Machine Interface (HMI). This allows operators
to enter individual target values for each product recipe and call up the data as
required. This way, the BC 96 ensures consistently high quality during the oiling
process in addition to fast product changeovers and product-specific oiling.

Continuous condition monitoring

Sensors facilitate preventive error detection at the oiling drum and at several other
process steps of the turnkey line. Integrated software immediately detects deviations
and reports them to the operator via status lights at the line’s respective production
stations, as well as via HMIs. “Thanks to these status updates, operators can
promptly initiate troubleshooting and safeguard the availability of the entire line,” Sandra Link explains.
Monitoring, line control, and cleaning are based on a uniform concept: the recipe-
controlled approach covers all production steps and ensures both consistent results
and fast and easy product changeovers. CIP (cleaning in place) cycles for the kitchen
and the depositor offer different cleaning modes, while the line’s hygienic stainless
steel design enables fast and thorough cleaning – for the safe production of gummy
and jelly products. In addition, the entire line is designed for contamination-free
product handling, thus the line’s closed loop eliminates for example the need for
manual mold handling.

Support from the Application Technology Center
Starchless nutraceutical production not only provides many advantages; it also poses
numerous challenges. Manufacturers need to precisely coordinate the complex
interplay of ingredients, formulations, and processes. Makat Candy Technology
therefore offers comprehensive support for the demanding production of various
gummies and jellies. At its own Application Technology Center in Dierdorf, Germany,
the company also works with its customers to develop individual products and
processes that support successful and efficient starchless production.

The new turnkey solution NutraFlash includes
kitchen, depositing line, and product finishing for
precise starchless production.

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