Gummy Manufacturing Process

Gummy Manufacturing Process

Today, I will show you how to make gummy.

It doesn’t matter the shapes you need for your gummy, flavour, colour options or quantity – this guide explores everything you’re looking for about the gummy manufacturing process.

Let’s dive right in:

What is Gummy?

Gummy candy is a peculiar candy made up of sweeteners, colourings, gelatin and flavourings.

Due to its viscous nature, you can mould gummy candy into unlimited shapes.

This makes it one of the most ingenious confection commodities ever.

What is Gummy Candy Manufacturing History?

In 1920, a factory worker in Bonn, Germany started his own line of candies after being in employment for a few years.

This worker, named Hans Riegel, manufactured soft candies in the shape of bears using gum Arabic.

A new formula was developed with gelatin and remained a reserve for the rich.

Because of its chewy texture, Riegel’s candy rapidly became popular not only in Germany but also around Europe.

Several years later, they were first exported to the USA for children who learned about this new fad from their German classes.

Today, SaintyCo has managed to revolutionize the industry with modern and efficient gummy making machine.

What are the Benefits of Gummies?

Due of its versatility, gummy candy is one of the most popular forms of candy in the market.

This is because of its flexibility in shape, size and color.

It is also very sweet and contains the following dietary supplements:

i. Contains Protein

The protein content present in gummy bears is lower than that in other foods like yoghurt.

However, it’s still significant, accounting for 5% of daily protein intake of an average person albeit in 15 pieces of candy.

Protein gives a feeling of fullness while holding food in the stomach and prevents over eating

ii. Minerals and Vitamins

A 1.5 Oz serving of chocolate gummy bears contains 2% and 4% of daily need of vitamin A and Calcium respectively.

Note that some gummy candies do not contain any minerals.

iii. Fat-free

You can comfortably include gummy bears in the diet for everyone, even those with a cholesterol problem.

The fat free nature makes them safe for all groups.

iv. Contains Simple Carbohydrates

Simple carbohydrates in the form of fiber and starches are present in this sweet candy to give you that energy boost.

Which is the Equipment Used in Manufacturing of Gummy?

The common machinery used in the production of gummy candies include:

a) Batch-wise Jelly Cooking System

This machine offers an input, cooking and fusing of raw materials for continuous jelly candy production.

It consists of sugar and gelatin dissolving cooker, buffer tank, mixing tank, pump, valves, jacket pipes and controlling cabinet.

b) PLC Controller

This equipment comes with total PLC control with a touchscreen to facilitate the operation of the full process.

It is accurate in recipe management and controls the products’ size and weight.

c) Candy Molds

This one designs and shapes gummy as required.

d) Acid, flavor, Color Dosing and Mixing System

This refers to an automated, compact machine that mixes the additives through an accurate metering system.

This produces quality and consistent end product.

e) Depositing and Cooling Section

Consists of a cooling tunnel, oil sprayer after moulding, de-moulding apparatus, air conditioner and controlled depositor to discharge the molds through a conveyor.

f) Holding Tank

This is a 150- liter tank with temperature control and electric heating for holding fruit jam or chocolate to be infused into the gummy.

G600 gummy production line-0

 Gummy Candy Manufacturing machine

What Chemicals are in Gummy Candy?

The chemicals used in gummy candy comprise of:

· Gum Base

This is one of the primary ingredients in gummy that provides its characteristic chewy texture.

Its production involves blending and heating several vegetable or synthetic substances, such as rubber with softener such as paraffin and antioxidants

· Gum Arabic

It is a gum used to stabilize emulsions in candy coatings.

You get gum Arabic by extracting it from the Anogeissus latifolia tree.

· Gelatin

A protein that functions as a gelling agent in gummy candy.

Manufacturers of gummies obtain it from collagen derived from beef bones and calf or pork skin.

· Dextrose

A corn sweetener made from dehydrated corn- starch.

Also known as corn sugar, it is the dry form of glucose.

How do you Mass Produce Gummy Candy?

Factories produce thousands of Gummy candies at a time.

The first step is to mix the ingredients together in a large vat and cook until it thickens into slurry.

You then pour the slurry into molds with custom shapes.

To prevent the candies from sticking, you line the molds using corn starch.

Allow the slurry to sit in the molds for a day after cooling it to 65 degrees Fahrenheit.

Next, remove them from the molds and tumble in oil to keep them fresh and soft.

Eventually, the gummy is then ready for packaging.

What are the Distinct Characteristics of Gummy Candy?

The success of gummy bears spawned the production of several other gummy candies in various shapes and sizes.

Besides, the most popular shapes for gummy candy are those of animals and fruits, measuring about 2cm.

Also, the most common gummy candy flavors include orange, pineapple, raspberry, strawberry and lemon.

They come in orange, colorless, red, green and yellow colors respectively.

In all these variations, manufacturers strive to preserve the chewy, rubber-like texture of the original gummy candy.

Why is Gummy Candy Oily?

After molding of gummy candies, the manufacturing system tumbles them in mineral oil before packaging.

This oil prevents the gummy candies from sticking together and also preserves the candy to keep it fresh and soft.

What are the Direct Materials Used to Manufacture Gummy Candy?

The direct materials mixed together to make gummy are glucose syrup, flavouring, citric acid, sugar, starch, food coloring and gelatin.

You refer to them as direct materials since they are what gummy contains.

Gelatin is responsible for gummy’s peculiar characteristic.

It is a protein obtained from animal tissues that thicken to gel when placed in water.

The quantity of gelatin used in manufacturing dictates the texture of gummy.

 Can you Melt Gummies?

Yes. Gelatin, which is a direct material in the production of gummy, is thermo reversible.

This means that it gets thinner when heated, giving gummy its distinct “melt in the mouth” characteristic.

The amount of gelatin used in the recipe determines the amount of time taken by gummy to melt.

How do you Keep Gummy Candy Firm and not Melting?

The gummy melting characteristic comes from gelatin.

To prevent the gummy from melting, use appropriate amount of gelatin when mixing up the ingredients.

The alternative would be to use pectin instead of gelatin, which you derive from fruits.

Plant cell walls use pectin to attach cells together.

When using gelatin, consider refrigerating the gummy in molds to allow them to bind and prevent melting.

 How do you Prevent Sticking together of Gummies?

Sticking together of gummy candies is as a result of adhesive force between the ingredients and sugar used in production.

To prevent sticking, sprinkle powdered sugar or corn starch over the gummy candy and shake well.

Alternatively, you could dry the gummies for 3 days.

Start off with plenty of gelatin then back down from that.

Allow them to harden overnight in a refrigerator.

Spray coconut oil on hands and the back of gummies in the mold before rubbing them with your hands while removing each.

Ensure they have thin but proper oil coating, then dry them off at about 85F to prevent drooling of mold.

Moreover, you may even blow them with a fan to speed up the drying process.

Note that this process works on a small scale production.

When using this method on larger gummies, they tend to droop out of shape, so dry them in a refrigerator.

This process is much longer.

Moreover, gummies can lose about 3% moisture per day when fully exposed to cool temperatures.

When you use fan, they can lose as higher as 10 percent of moisture.

After about 72 hours of drying, the gummies will be stiffer and not as sticky.

G80 Small Scale Gummy Production Line-0

 Gummy Making Machine

What Direct Labor Costs are you likely to Incur in the Production of Gummy Candy?

Like any other industry, the number of personnel needed to run a factory solely depends on size of the plant.

A gummy production factory could have up to four depositing lines of different capacity.

Since they are semi or fully automated, two to three workers can handle the entire candy production line.

Another additional worker handles the trays, collecting and packaging the gummy candy.

Any additional personnel like drivers, security etc., are expendable.

What are some Examples of Manufacturing Overhead Costs that you will Incur during the production of Gummy?

Manufacturing overhead costs are any costs incurred by a factory other than the direct labor and direct materials needed to manufacture gummy.

You can equally refer to them as indirect costs.

For each unit of gummy produced, a certain percentage accounts for these overhead costs like:

  • Salaries of maintenance personnel, manufacturing managers, quality control and materials management staff.
  • Depreciating equipment used in the factory
  • Production facility property taxes
  • Janitorial staff wages
  • Factory utilities

Manufacturing overhead costs are important since they determine the cost of production for each unit, and help to save on expenses.

For gummy production of any scale, overhead would also include energy costs, water, telephone, gas cleaning, insurance, accounting and legal fees.

What are the two Types of Flavors Used in the Making of Gummies?

Flavor is an important characteristic of all foods we eat today.

Gummies, in all their complexity, contain flavors to enhance their taste and texture.

Both natural and artificial flavourings are used in the production of gummy.

Natural flavor refers to the extracts of any other product of heating, roasting or enzymolysis that has the flavourings components.

You can extract them from fruits, spices, dairy products or any other natural sources.

Their main value in gummy is flavoring, rather than nutritional.

Artificial flavors, on the other hand, come from sources other than natural.

A majority of gummy confections contain up to 90% sugar water and a little fruit juice.

They use dyes and synthetic flavors that are mainly chemicals developed in the lab.

Which Factors Influence the Textural Characteristics of Gummy Candy?

Gels based on pectin, starch and gelatin confer gummy candy’s characteristic firm structure, its chewiness, and softness.

An ungrained soft colloidal system containing gelling agents, sugars, water and other components support this structure.

Water acts as a plasticizer to aid gel formation, whereas starch increases the hardness of gelatin-based gummy confections.

 Shapes of Gummy

 Shapes of Gummy

The eight popular gummy candy shapes in the world are:

  • Gummy bears,
  • Jelly beans,
  • Jelly bottles Fruit jelly,
  • Worm gummies,
  • Lego gummy,
  • Jelly rings, and
  • Gummy sharks.

What are the Main Factors to Consider during Selection of Gummy Making Machine?

There are several factors to consider when choosing the ideal gummy making machines.

Some of these factors include:

Production Capacity

If you intend to have big capacity production, you should consider a similarly bigger machine with a higher level of automation.

Dimensions of Machine

The size of your production facility should determine the dimensions of the machine that you use.

The dimensions refer to the length, width, height and weight of the gummy making machine.

Pneumatic Requirements

This refers to the pressure requirements of the machine.

The discharge pump should be able to bear enough pressure for water.

Consider at least a 6m high pump for a 4 meter high cooker.

Materials used to make the Machine

Make sure that the material used to make the machine(s) are of brand components for industrial jelly.

The best gummy making machine should have its body and frame made of stainless steel.

SUS304 is the best material for all parts coming in contact with food.

As per your budget and workshop, there are also options of getting customized gummy making machines.

What is the Best Storage Condition for Gummies?

You should store gummy under conditions that preserve their freshness for the longest time possible.

Citric acid is an important ingredient that you can add into the gummy to prevent microbial bacteria growth.

As for the storage, consider a well-sealed airtight package with minimum air leakage.

Also ensure to use completely dry packages since moisture could jeopardize the integrity of the product.

Store gummy in a cool and dry environment, preferably dark.

This helps in increasing its shelf life to up to a year if the packaging remains intact.

Should you Dry Gummy Candy before Packaging?

Yes, there is need to dry gelatin-based gummy candy before packaging.

Modify the gummy manufacturing machine to add a drying room.

The gummy candy from the cooling tunnel stays in the drying room for at least eight hours before you package it.

However, there is no need to dry gummy candy made from pectin or carrageenan.

How do you Package Gummy Candy?

The packaging of gummy candy should be attractive and eye-catching enough for easy stocking in retail outlets.

Furthermore, the packaging should not only encourage sales, but also clean and safe with a guarantee of preserving the gummy freshness.

There are three ways in which you can pack most gummy:

  • In a pouch
  • A single pillow bag
  • Plastic bottle.

Double and single twist packaging are not ideal for gummies.

Ensure to package the jelly in time after the drying process is complete.

Inventive packaging solutions that work well with gummy merchandise currently comprise of metal containers and alternative reclaimable alternatives.

In addition, you should be able to use compostable pouches and baggage, and CBD cans created from rescued plastic.

You may utilize a laminated material to supply ultraviolet illumination and odor protection, and gas and humidness barrier.

Furthermore, it’s advisable that you conduct intensive analysis on laws distinctive to your country or region to ascertain compliance.

What are some Upgrades that you may Face During Gummy Manufacturing Process?

With the growth of gummy candy’s popularity, many people want to try new flavors and recipes.

When manufacturing gummy, update yourself with the latest trends in the industry through magazines, amazon, google or YouTube.

Some of the upgrades you may have to conduct could include:

  • Changing the shapes of the jelly from the traditional monotonous to shapes to newer, more thoughtful designs
  • Switching up the gummy candy formula into the latest trends, for example, CBD gummies and THC candies.
  • Upgrading the designs of the candies for example through mixing up the colors to come up with new ones.

What are Challenges of Gummy Manufacturing?

Some of the challenges you may face during gummy bear manufacturing process are:

Sticking Gummy Candy

The adhesion between the ingredients in the gummy and sugar leads to stickiness between the gummy and the molds.

If your gummy is excessively sticky, the remedy is to sprinkle corn starch and shake.

Gelatin Fails to Set In

Certain ingredients contain enzymes that will bar the gelling of gelatin and cause it to not set in properly.

Such ingredients are particular flavours from fresh fruits like pineapple, papaya and mangoes etc.

Failure of Gummy to Bloom

If you don’t add enough water when mixing up the ingredients, the gummy does not hydrate hence fails to cook appropriately.

Ensure perfect blooming by regulating the amount of water added into the mixing tank

Weight and Size Variation

Failure to check on the parts of the gummy making machine could let some red flags go unnoticed.

Worn out parts of the molds for example is a red flag that leads to lack of uniformity in the gummy candies.

Variation in the depositing and molding process also leads to this problem.

Improper Mixing of Ingredients

If you do not mix and regulate the gummy raw materials properly, the jelly may fail to get to the required thickness.

A regular checkup of the machines is important to keep them running smoothly.

The heavy ingredients risk blocking the outlet pipes and thus there is need to optimize the speed of operation.

What are the Regulatory Requirements for Gummy Manufacturing?

Generally, gummy manufacturers are subject to the existing Good Manufacturing Practice, popularly known as CGMP & PC rule.

The provisions of cGMP require manufacturers of gummy candies to handle with utmost care:

  • Staff
  • Sanitary operations
  • Controls and facilities
  • Plants and grounds
  • Machinery and equipment
  • Distribution and warehousing including handling of human food by-products used as animal food and level of defect action.

Existing Good Manufacturing Practices reduce the occurrence of microbial, physical and chemical contaminants and allergens.

The practices also safeguard against contamination of finished gummy products, equipment, and raw materials.

There is need to train staff on how to handle food, food hygiene and safety.

So depending on your unique production requirements, SaintyCo offers a range of gummy bear machines.

Contact us today for all you gummy manufacturing machine needs.

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