C2 Jelly Gummy Mogul lecture

AGENDA
• MOULDING STARCH
• MOGULS
• TROUBLESHOOTING
• STOVING OR CURING
MOULDING STARCH
• One of four components of corn
–
–
–
–
Germ (oil)
Fiber (hull)
Protein (yellow Color)
Starch (carbohydrate)
Wheat starch is used extensively in Australia
MOULDING STARCH
• Components separated by the wet milling
process
– separation in water utilizing gravity
• Drying accomplished on belt or a flash
dryer
MOULDING STARCH
• Moulding starch is unmodified
– The starch can contain up to .3% oil
– The starch can contain up to 12% moisture
• Supplies dry atmosphere for the candy
– Moisture can pass into the starch or through the
starch
– Starch stored at 120F & 30% RH will have
about 6.5% moisture
MOULDING STARCH
• Oil can be added to the moulding starch
–
–
–
–
–
Moulds release better improving the print
Helps reduce starch dusting
White mineral oil in USA (.05-.3%)
Usually .05-.1% oil is added
Europe does not permit mineral oil, Europe
uses stabilized vegetable oil
Keeping the starch in shape
SIFTING
• Removes candy tailings
• Breaks up starch lumps
• Fluffs the starch
Keeping the starch in shape
DRYING & COOLING
• Starch picks up moisture from the candy
• Starch picks up moisture from the
environment. Corn starch has a 12%
moisture equilibrium in a 60% relative
humidity environment.
• Cooling should come after drying
Starch conditioning systems
• Convection dryers
– flash dryers (very short time)
– fluid bed dryers (long-NID,Makat,WD)
• Contact dryers
– spiral dryers (short time)
– steam tube rotary dryer (long time)
• Combination
– Vomm turbo dryer (very short time)
Moulding Starch Guidelines
PRODUCT MOISTURE TEMPERATURE
Pectin
6-8%
95-115F
Starch
6-9%
95-115F
Gelatin
6-7.5%
80-95F
Agar-Agar
6-8%
95-110F
Marshmallow 6-8%
95-105F
MOGUL
• A mogul is a starch moulding machine
• A mogul offers versatility
• Shapes are limitless
– Change shapes in 5 minutes
– Mould board patterns must be designed to
match the depositing pump & nozzle plate
configuration
MOGUL
Various candies can be deposited on a mogul
•
•
•
•
•
•
•
•
Starch
Pectin
Gelatin
Marshmallows
Toffee
Fudge
Caramel
Circus Peanuts
• Candy Corn
• Chocolate Covered
Cherries
• Various Gums
(Arabic, Agar-Agar,
Guar, Xanthan,
Carregeenan, Gellan)
• Others
MOGUL
• Multiple depositing options
–
–
–
–
–
Single flavor
Multiple flavor & colors
Side-By-Side flavors & colors
Double layer depositing
Center-In-Shell depositing
MOGUL
• There are three manufacturers of Moguls
– NID (most predominant in the USA)
– Makat
– Winkler & Dunnebier
Two Mogul Sizes
• Regular
– Tray size – 32” x 14.5”
– Speed – Up to 35
trays/minute
– Candy weight – Up to
6 Lbs./tray
– Starch weight – 12
Lbs./tray
(25,200Lbs/hour
through the mogul)
• Jumbo
– 60% more capacity than a
regular mogul
– Tray size – 47” x 16”
– Speed – Up to 35
trays/minute
– Candy weight – Up to 9.6
Lbs./tray (20,160Lbs of
candy/hour)
– Starch weight – 19 Lbs./tray
(39,900Lbs of starch/hour)
Parts of the mogul
• Feeder
• Starch buck
–
–
–
–
empties trays
separates candy from starch
refills trays with starch & levels starch
printing
• Depositor which includes weight controls
• Stacker
Accessories to the mogul
•
•
•
•
Surge bin for excess moulding starch
Pre-steamer & Sanding drum
Polishing drum
Starch conditioners
– removes moisture from the starch
– cools the starch to 100F
• Starch sifters
Troubleshooting at the Mogul
• Poor starch flow at the mogul
– Relative humidity is high in the department
(ideal RH < 50%)
– Moulding starch moisture is too high
– Moulding starch temp. < 80F
– Moulding starch oil content is too high
– Too much starch has dextrinized causing the
starch to be sticky
Troubleshooting at the Mogul
• Foreign candy in the starch
–
–
–
–
–
Hole in the mogul drum screen
Candy pieces are by-passing the starch sifter
The starch sifter screen has a hole
Candy from the previous run stuck to the tray
Candy by-passes the drum in the mogul
Troubleshooting at the Mogul
• Poor printing in the moulding starch
–
–
–
–
Relative humidity is too high
Starch could be too wet or dry
Starch could be too cold or hot
The vibrator on the printing section is not
working properly
– Mould board could be dirty
– Mould board screen could be blinded
Troubleshooting at the Mogul
• Poor depositing which causes tailing
– The candy sat in the depositing hopper too long
– Depositing temperature was too low
– The cut-off mechanism on the pump is not
working properly
– The nozzle plate nozzles have candy stuck on
them
– The hopper swing on the NID mogul could be
out of time with the tray movement
– The depositing pump could be worn
– The depositing pump could be under lubricated
Troubleshooting at the Mogul
• Crusty starch adhering to the candy
– When water drips into a starch impression, the
wet starch will stick to the hot candy & a white
starch crust blemish will be on the finished
piece of candy.
– Check the depositing hopper & steam line
connections
Troubleshooting at the Mogul
• Crusty starch adhering to the candy
– Make sure the water used to lubricate the tray
conveying system does not spray into the starch
– Water or oil which is used to lubricate the
depositing pump should be deflected outside
the tray
Troubleshooting at the Mogul
• Excessive starch skin on candy
– Moisture transfer within the product and the
moulding starch can not immediately replace
the loss at the surface and the product skins
– Moulding starch moisture too high (>9%)
– Deposit solids too low (<70%)
– Deposit temperature too high (>200F)
STOVING OR CURING
• Basic principles for curing candy
• Good air flow
– Eliminates hot & cold spots
– Accepted air flow rate is 30,000 cfm but this
can vary depending on the size & configuration
of the room
– Align stacks of candy in the direction of the air
flow
STOVING OR CURING
• Sufficient heating capacity
– Curing cycles can be determined which work
best for your products. Run 24 hour products
during the week & 48 hour products over the
weekend
– Graduated increases in heat seem to give the
best quality candy
STOVING OR CURING
• Sufficient cooling capacity
– Hot air should be exhausted outside & outside
air cooled & dehumidified before the air enters
the room especially, during the warmer months
of the year
STOVING OR CURING
• Ability to control relative humidity
– Keep the relative humidity <51%
– High relative humidity will cause the candy to
get sticky
– Moulding starch will absorb moisture from the
air
– It will take longer to cure candy in a high
humidity environment
STOVING OR CURING
• Curing cycles are critical to the texture
– Automatic pallet track system
– Stacks of candy move slowly through various
temperature zones
– Consistent product
– Very expensive ($2,000,000)
– Need a lot of space
STOVING OR CURING
• Stationary stacks of candy
– Rooms are loaded manually or a truck
– Generally, stationary stacks of candy will have
more textural variability as the temperature
increases in the room
– Good air flow will help reduce textural
variability by reducing hot & cold spots in the
room
STOVING OR CURING
• Curing rooms are the bottleneck
– Most candy plants have limited curing capacity
– Product formulation & maintaining good curing
room conditions is critical in achieving
established curing cycle times & consistent
textural product
STOVING OR CURING
• Curing temperatures and cycle times
–
–
–
–
–
Type of candy
Processing equipment
Design & curing room capacity
How many shifts per day
How many days per week
Curing Room Guidelines
Product
Temperature
Cycle Time
Pectin
120-160F
8-24 hours
Starch
120-160F
8-72 hours
Gelatin
75-95F
8-24 hours
Agar-Agar
90-110F
8-24 hours
Marshmallow 90-110F
24-48 hours