Confectionery: Processing Technology
Confectionery Production Principles
All confectionery products have a number of common requirements. They must have an extended shelf life under ambient storage conditions and although this may be assisted by protective packaging their inherent properties must provide stability against microbial deterioration and stability of shape. In sugar confectionery, shelf life is achieved by reducing water activity through control of the composition and RH during storage. Stability of the shape is aided by the inclusion of ingredients such as gelling agents or fats which create structure and prevent flow during storage.
By formation of a gloss as in hard boiled sweets, toffee and nougat or by allowing crystal growth as in fondant creams. Also, soft or liquid centres may be held firm by being enclosed within a rigid shell.
Confectionery Production Processes
The processes commonly employed for the production of confectionery products are briefly described below:
1. Cooking
Cooking of sugar is usually carried out in either gas fired cooking pans or in steam-jacketed kettles. Sometimes vacuum is applied for cooking at low temperatures. Cooking is carried out to achieve high temperatures for dissolving sugar. It also frequently involves caramelization of sugars.
2. Drop rolling
The drop roller was one of the earliest sweet forming machines. It consists of two synchronized brass rolls engraved with matching impressions. The processed confectionery mix in the form of a plastic mass is fed into the rolls and forced into the impressions.
3. Moulding
Depending on the type, confectionery products are moulded in different ways. Boiled sweets are deposited into teflon-coated aluminium moulds fitted with ejector pins. After cooling, the pins are depressed from the underside of the moulds to eject the solid boilings. Toffees are deposited in silicone rubber moulds. After setting, the mould is deformed by plungers which push the toffee out.
4. Extrusion
Extruders of various types are used for forming bars and sheets from pastes and plastic confectionery bases. Lozenges are formed by passing the paste through a screw extruder and die to form a sheet which is then reduced in thickness by subsequent sizing rollers. In case of bars, the sheets are slit by rotary knives and sized to desired length.
5. Plastic forming
The plastic forming operation is widely used in the confectionery industry for converting plastic masses such as boiled sugar or toffee into individual sweets. In this process, the product will be tempered to correct consistency and flavour ingredients incorporated during the kneading process in the case of boiled sugar or on a slab, cooling drum or cooling conveyor in the case of toffees. The mass is then fed into a batch roller for obtaining the product in the form of a rope. The rope is the fed to a presizer followed by sweet former (to give desired shape to final product) and later packaged.
6. Wet crystallizing
Wet crystallizing is the process of building up a thin coherent coating of sugar crystal on the surface of a sweet. This seals the surface, and when used on products such as fondant creams or marzipan, retards drying out, extending the shelf life from a few days to 6 months or more.
7. Panning
Panning is an operation which has been used by the confectionaries for centuries. In principle it is the application of coating to centres tumbling in a revolving pan mounted at about 30 to the horizontal. The operation consists of adding enough coating medium to cover the centres completely with no surplus and drying this off either with hot air (hard panning), extra sugar (soft panning) or cold air (for chocolate). Coatings may be sugar syrup (hard panning), glucose syrup dried off by the application of fine sugar (soft panning) or chocolate, solutions containing food grade colours, edible gums, etc.
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