Should You Supersize Your Mogul?

Discussion Period (Q&A)
Should You Supersize
Your Mogul?
Tim Murphy
Ferrara Pan Candy Co.
T
he decision to purchase a “jumbo
mogul,” as opposed to a standard size,
is one that should be given serious consideration.This paper will compare the upscaling in size of three mogul systems: Makat,
Winkler + Dünnebier, and NID. Information on the Makat was taken from the
upscaling experiences of Charles Fox, director of engineering, Brach and Brock Confections. I will relate the experiences that
Ferrara Pan Candy Company had with the
upscaling of a NID mogul system. Finally,
the manufacturer has provided information about the Winkler + Dünnebier mogul.
The specific areas of comparison will be
production, depositing systems, starch drying systems, staffing and the mogul itself.
PRODUCTION
There are few differences between the two
sizes of moguls. The major change is simply
the difference in the size of the depositing
board. Specifically, the printable area of
the depositing board has increased from
458 square inches to 763 square inches.
This 66 percent increase in the area of the
starch board does not necessarily represent an equal increase in production volume.The production increase will be based
on three factors: the configuration of the
mold pattern of the board, the quantity of
cooked candy the cooking system can
deliver and the board-per-minute speed of
53rd PMCA Production Conference, 1999
the starch mogul. For example, the increase
in production for an individual board of
starch jelly beans at Ferrara Pan Candy
Company worked out to about 60 percent,
based on the mold pattern. This represented a production increase from 4,200
pounds per hour to 7,500 pounds per hour.
Space has to be the first consideration.
Ferrara Pan found the change to a jumbo
mogul a lesson in space consumption. The
standard mogul, its oiler, sander, dry rooms
and service area took up an area of 5,760
square feet.The jumbo mogul was designed
with the same list of equipment to fit into
an area of 6,336 square feet. Its predeposit
mixing and cooking systems are significantly different in their square-footage
requirements. The floor area requirement
for the standard system is 1,778 square
feet, but 2,880 square feet are required for
the jumbo system.
The predeposit equipment lists for both
systems are the same. They include the
following:
• Powder starch feed hopper.
• Dry sugar hopper.
• Regular conversions corn syrup tank and
feed system.
• High DE corn syrup tank and feed system.
• Batch mixing tank.
• Colloid mixing tank and feed system.
• A heated mixing tank prior to cooking.
• Two buffer tanks.
Murphy has held
the position of vice
president of quality
control at Ferrara
Pan since 1992. He
began work there in
1981. Prior to this
appointment he was
employed at A.E.
Staley Manufacturing Company.
Murphy is an
active member of the
American Association of Candy Technologists and the
National Confectioners Association.
Tim Murphy
153
Should You Supersize Your Mogul?
It has been • A coil cooking system.
observed that • A vacuum tank after the cooker.
• An acid mix tank.
the jumbo
• A system for adding fruit after the batch
moguls tend to
is cooked.
operate more • A system for adding color, flavor and
acid.
quietly than the
Included in this list is the starch drying
standard-sized
equipment.
moguls.
THE STARCH BOARD
Brach and Brock Confections was the first
user of the jumbo-sized mogul in the
United States and faced the problem of
developing the starch board jointly with
the starch-board manufacturing company.
Charles Fox stated that he had reservations concerning the tray deflection. There
were two issues. First was the exaggeration of the upward curve of the starch
board due to the expanded width of the
board, which would cause a poor print.
This turned out not to be the case, as there
was no noted print distortion. The second
issue was that the starch board would sag
if unsupported, causing instability of the
stack. A center support was added to the
Brach and Brock starch board and a support was added to the mogul. Ferrara Pan,
in turn, went further by adding two more
supports across the length and four bead
supports across the width of the starch
board. In comparison, the starch board of
the standard-sized mogul has no supports
but does have the slight upward bow. Ferrara Pan has experienced no significant
difference in the life expectancy of the two
sizes of boards.
Although not in violation of OSHA regulations, a noted drawback to the expanded
board width is that occasionally boards
have to be removed from the mogul. The
weight of the starch board, filled with starch
and candy (approximately 27–30 pounds),
coupled with the exaggerated width
requires greater dexterity from the mogul
operator than is experienced with the standard-sized board.
154
The costs for the two sizes of boards are
in the $9–$10 range for the standard and
the $14 range for the jumbo.
THE COOKING SYSTEM
For Ferrara Pan, the cooking system of the
jumbo mogul presented some new innovations. Our standard system uses one cooker
that contains two 108-foot copper coils. The
maximum volume output for our standard
mogul’s cooker is 7,500 pounds per hour.The
jumbo system uses two cookers, each containing a single 128-foot stainless steel coil.
The output for the larger system is 13,000
pounds per hour.The advantages with stainless steel are that it is easier to clean and it is
resistant to attack from the acids that are in
many of the formulas.The disadvantage of the
stainless steel coil is that it requires more
steam pressure to achieve the same cook.
For starch jellies, we have found the stainless steel coil requires 110 psi, while the copper coil only requires 95 psi to achieve the
same cook. The volume of steam directly
relates to the quantity of candy that the steam
is cooking.Another area of energy increase is
that there are two 5-horsepower motors driving the pumps on the larger stainless steel
coils of the jumbo system, in contrast to the
two 3-horsepower motors operating the
smaller standard system.
THE JUMBO MOGUL
It has been observed that the jumbo moguls
tend to operate more quietly than the standard-sized moguls, which was not expected.
Charles Fox attributed this decrease in
noise to the heavier board weight and less
angular displacement caused by slight differences from misaligned board pushers.At
Ferrara Pan, we noticed that the larger
mogul operates smoothly at 30 boards per
minute. The standard-sized mogul can
achieve this speed; however, it appears to
run more smoothly at 28 boards per
minute. Fox stated that the Makat operates
quietly and efficiently at 30 boards per
minute. Peter Lindner of W+D has stated
53rd PMCA Production Conference, 1999
Should You Supersize Your Mogul?
that their jumbo mogul operates comfortably at 32 boards per minute.
The jumbo mogul’s production is maximized when depositing one product at a
time with minimum changeovers, since
making changeovers has become a more
difficult task. One of the problem areas is
the difficulty in handling the increase in
physical size of the nozzle plates and moldboards. The larger coils, tanks and color-flavor-acid systems have doubled the time
required to clean and sanitize the candy
mixing and cooking system. With the
increased output it is necessary to use
larger systems to handle the outflow of the
candy. Ferrara Pan chose to go with a 10foot oiling drum and two standard sanders.
The jumbo oiling drum is twice the size of
the drum used on the standard mogul. The
increase in size is necessary to achieve the
required retention time for candy to be
oiled properly. It is necessary to use two
sanders as opposed to a single unit, like
the oiler, because it is beneficial to reduce
the amount of time the candy pieces tumble against one another, thereby rubbing off
the sugar or sugar-acid coatings. In comparison, Brach and Brock custom-built
their own oiling drum instead of using a
commercial drum.
Ferrara Pan uses a manual transfer of
the stack of starch trays from the end of
the mogul to the drying room. There are
two stacks, 60 boards high, on the jumbo
system. The standard system utilizes two
stacks of 50 trays.The advantage of increasing the number of trays per stack is that
less square footage of storage space is
required in the drying rooms. The starch
boards have been reduced by one-fourth
of an inch in height for the jumbo system.
This reduction has made the jumbo stack of
starch boards only nine inches taller than the
standard. The headspace in the dry rooms
had to be adjusted to accommodate the
nine-inch increase.
53rd PMCA Production Conference, 1999
THE DEPOSITING HEADS
The most significant change Ferrara Pan
encountered with the purchase of the
jumbo mogul is the lateral deposit head.
The standard-sized moguls that Ferrara
Pan operates all have swinging-pendulum
depositing heads in which the jacket of the
depositing hopper is heated with hot water
but the depositing head is not. The head on
the depositor of the jumbo mogul can be
heated, allowing for higher solids to be
deposited. A second advantage of this
depositing head is the synchronization with
the starch mold to deposit directly into the
center of the mold cavity. The older standard-system depositing head was also on a
pendulum that followed the mold; however, it swung up and out, away from the
starch mold. This system did not allow as
precise targeting of the deposit. The lateral deposit head is available on all sizes of
moguls from NID.
W+D offers a similar type of depositing system with their moguls. Makat’s
depositing system is stationary; the moldboard stops under the depositing head and
is filled, all in one shot. The Makat also
has a stainless steel rotary valve and is
capable of a large array of color combinations with its programmable slides.
The most
signifiant
change
encountered
with the
purchase of the
jumbo mogul is
the lateral
deposit head.
STARCH DRYING
It is recommended that 100 percent of the
starch be conditioned and dried. With the
increased board size and speed of the jumbo
mogul, the starch drying systems have to
handle 50 to 60 percent more starch than the
standard-sized mogul. Ferrara Pan is using
a system which allows the starch to be
passed three times across an airflow for
heating and also three times for cooling
within two starch drying boxes. The difference between the jumbo-sized starch dryer
and the standard-sized is the area of the
starch bed.The standard-sized bed is 11 feet
wide by 30 inches deep. The jumbo-sized
box is 141⁄2 feet wide by 36 inches deep. The
jumbo-sized mogul has a square footage
155
Should You Supersize Your Mogul?
There are
advantages and
disadvantages
to upscaling to
the jumbo
mogul.
Production has
increased with
the jumbo
system 60
percent.
increase of 66 percent in board area; however, it is only a 60 percent increase in air
volume due to the reduction in the board
height. Therefore the jumbo mogul has a
60 percent increase in drying air volume to
match the increase in the starch volume.
The Makat system, utilized by Brach and
Brock, uses a similar type of drying. However, instead of three passes in one box,
they use six independent starch drying
boxes: three independent boxes used for
drying and three independent boxes used
for cooling. Each of these boxes uses only
a single pass of air.
The Winkler + Dünnebier starch drying
system is quite different from NID’s and
Makat’s. Warm preconditioned air is mixed
with the starch within a drying tube. From
there, a multipocketed filter separates the
starch from the moist air. The starch then
goes to a cooler, which is different from
NID’s and Makat’s cooling systems. The
cooler is a water-jacketed trough housing
two cooling conveyer screws. A water/glycol solution is used to cool the metal plate
of the trough as well as the conveyers. An
advantage of using the screw conveyers as
the cooler is in eliminating the introduction
of outside air, preventing the remoistening
of the starch after it is dried.
Following are two other features that
differentiate the moguls:
Starch Tray Tipper. The Makat and the
W+D utilize a 180° board tipper. In comparison, the NID utilizes two sets of arms.
One set turns over the starch board. The
second set rights the board.
The Destarching Systems in the Starch Buck.
The NID and the Makat both use rotating
drums to remove the candy.The NID uses a
single drum.The Makat uses multiple drums
to destarch the candy.The W+D uses a twotiered sieve to destarch the candy.The sieves
are removable for cleaning.
STAFFING
To staff the jumbo mogul Ferrara Pan uses
seven people, as opposed to five in the
156
standard mogul. The increase comes from
the use of two individuals in the cooking
area, as opposed to one in the standard, and
two individuals filling the candy boards,
with only one in the standard mogul. The
mogul operation position and the palletmoving positions remain the same.
CONCLUSION
There are advantages and disadvantages to
upscaling to the jumbo mogul. Production has
increased with the jumbo system 60 percent.
The design of the depositing systems has
improved. However, these design improvements are available on all new moguls
regardless of size.
Starch drying systems, while innovative,
remain energy neutral, showing no advantage with an increase in size.
Staffing required a 40 percent increase in
personnel to handle the 60 percent increase
in production.
And finally, the jumbo mogul, producing 60 percent more product, operates
faster, and more smoothly than its standard counterpart. The jumbo requires
almost twice as much time for cleaning
and daily maintenance.
WOULD WE DO IT AGAIN?
When Charles Fox was asked, “Would his
next purchase of a mogul be a jumbo?” he
replied, “Given the increased productivity
in terms of pounds per man-hour and the
relatively small differential capital cost, I
believe that any future mogul purchases
would be jumbo-size machines.” He further explained that it was an economical
way of acquiring future capacity because it
is not necessary to operate the starch mogul
at maximum speed.
When Bernie Woziwodzki, chief of the
engineering department at Ferrara Pan
Candy Company, was asked the same question, he replied, “Yes, I would buy a jumbo.
I am thinking about replacing a standard
with a jumbo!”
■
53rd PMCA Production Conference, 1999
The
Pick SC7-3
Candy Cooker
The
Pick Pilot
SC 3
Gerber
Mexico
Gerber
Mexico
REMOTE
ELECTRONIC
CONTROLLER
TO DCS
PREMIX
KETTLE
SCV
PI
I
SEPARATOR
FILTER
P
STEAM
INLET
TI
180°F
T
OPTIONAL
STATIC
MIXER
PD PUMP
PICK
SANITARY
HEATER
RTD
BPCV (TIED TO
HI TEMP ALARM)
DIVERT VALVE
FLASH
CHAMBER
PUMP
COLOR &
FLAVOR
POT
MOGUL
HOPPER
MOGUL
HOPPER
MOGUL
MOGUL
HOPPER
CONFECTIONERS G THIN-BOILING STARCH
PRESSURE COOKED SUGARED JELLIES
Ingredients:
Sweetose® 4300 corn syrup (Staley)..........234.0 lb
Granulated sugar.................................160 .0
STALEY® confectioners G starch................54.5
Water................................................ 58.0
Total............... 506.5
Procedure:
1. Slurry all ingredients and preheat to 180°F.
2. Pressure cook at 280-300°F depending on cooker
type.
3. Add color and flavor. Deposit at 78-79% solids.
4. Dry in moderate hot room (120-130°F) for about
30-35 hours, and shake out after the second day
in starch.
5. Steam and sugar sand, and then dry (overnight
on stock trays) prior to packaging.
Note: The preceding should be considered as a
good all-purpose starting formula. The piece
size, packaging and configurations, and other
conditions of use may require adjustments of
the slurry moisture and starch-use level.
JET COOKER - GELATIN "GUMMY" JELLY
Ingredients
Gelatin 250 Bloom - 20 mesh
Water
Sugar
Corn Syrup (43 DE)
Crystalline Fructose
AS IS
3.8
4.6
16.6
21.5
3.5
50.0
Process:
1. Mix gelatin with boiling water.
2. Hold 20 minutes to hydrate gelatin.
3. Add sugar, corn syrup, and fructose to gelatin
solution.
4. Heat slurry to 180°F.
5. Jet cook at 255°F.
6. Collect product in heated pan.
7. Add citric acid, flavor, and color.
8. Deposit in starch moulds.
9. Dry 24 hours at 100°F.
ING ds
0.905
0.0
1.0
0.805
1.0
ds WT
3.4
0.0
16.6
17.3
3.5
40.8
WATER
0.4
4.6
0.0
4.1
0.0
9.2
DIRECT STEAM INJECTION (DSI)
EQUIPMENT CONSIDERATIONS
Minimum
· Jet cooker sanitary #4 finish.
· Backpressure control valve, spring loaded, air
loaded, plug style. Maintains product pressure
at 100 PSIG or less depending on slurry temperature requirement.
Example:
Product
Temperature
Approx. Line Pressure
Gelatin Process
248°F
20 PSIG
Jelly Hi Amylose
330°F
95 PSIG
· Atmospheric or vacuum flash chamber to
contain and direct excess flash steam.
· Culinary steam line consisting of steam
separator, steam filter, stainless steel steam
control valve.
· PD (positive displacement) product pump.
· Temperature control loop consisting of a
temperature sensor, controller, and I/P
transducer.