Aerated Jelly Masses Various methods of the production of ... · Aerated Jelly Masses Various methods of the production of aerated Candy Masses Markus Dittrich Feature by Klöckner

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Aerated Jelly Masses

Various methods of the production of

aerated Candy Masses

Markus Dittrich

Feature by Klöckner Hänsel Processing GmbH – 13.09.2005

KLÖCKNER HÄNSEL PROCESSING GmbH

Lister Damm 19

30163 Hannover

Tel: +49 511 62 67 351

Fax: +49 511 62 67 230

e-mail: [email protected]

http//: www.kloeckner-haensel.de

Aerated Jelly products and various methods

for the production of aerated candy masses

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Machinery for the production of aerated sugar masses

Contigrav

Metering and weighing system for all kinds of sugar masses

Siedomat/Turbomix

Batchwise cooking and pressure aerating system for candy bars, torrone and halwa

JellyStar

Continuous cooker for aerated jelly products and marshmallow

Turbomat

continuous aerating machine for bar foam, chewy candies and marshallow

CrossFlow

Continuous cooker for aerated hard candies and soft candies

Surcoliner + Strada

Continuous production of formed and filled soft candies

JellyBlend

Continuous dosing system for colour, flavour, acid and fruit juice



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Characteristics of the SPS controlled metering and weighing system CONTIGRAV

Recipe storage with up to 250 different recipes

automatic consumption measuring

coarse and fine dosing for a high accuracy

counting of the batches

tolerance control

Raw material weighing with the CONTIGRAV

Metering and weighing system for sugar, glucose, water, invert sugar etc.

Preparation of recipes for all kinds of aerated candy masses

Three installation sizes (250 liters, 500 liters, 750 liters)

Capacity: 9.000 kg/h max. of slurry

Optionally available with internal coil or steam heated double wall for dissolving

of the sugar crystals, also available with wall scraping agitator

Weighing system SIWAREX

Visualisation via touch panel

Simultaneous processing of up to 5 different recipes /product lines



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Cooking and pressure aerating system SIEDOMAT/TURBOMIX

Batchwise production of foam products on restricted place

Batchwise production of bar foam, torrone and halwa

Automatic processing via SPS-control

Capacity: up to 900 kg/h

Filling of the SIEDOMAT preferably with vacuum

Cooking with the SIEDOMAT with internal coil

After the cooking process, the mass is cooled with vacuum in the SIEDOMAT

Filling of the TURBOMIX with sugar mass and aerating agent gravimetrically or by vacuum suction

Beating in the TURBOMIX by a horizontal agitator, consisting of an inner and outer beating mechanism

Aerating under pressure with 3 bar max.

SIEDOMAT/

TURBOMIX

Aerating agent

CONTIGRAV



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Production of torrone with the SIEDOMAT/TURBOMIX

Torrone is a foam candy product, traditionally with a high portion of almonds. There is a difference between hard torrone (residual water content: approx. 1,5%) and soft toffone (residual water content: approx. 4%). The recipe consists of sugar, water, honey (which is partially replaceable by glucose) aerating agent (egg white) and almonds.

cooking Cooking under vacuum with the purpose of

with SIEDOMAT

prevention of yellowing, as a bright product is required

preservation of the flavouring agent in the honey

achievement of a high dry substance

(important for hard torrone)

gradual vacuum application

For hard torrone

Cooking at 120°C – 125°C

Residual water content approx. 1,5% Aerating

In the TURBOMIX

Cooked sugar mass is discharged simultaneously

with the aerating agent (slow speed of the agitator)

Suction of the vaporizing water by a vacuum pump

Additional vacuum application, in order to minimise the

residual water content (for hard torrone)

2 minutes beating under overpressure (2 – 3 bar)

(high speed of the agitator)



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Continuous aerating machine TURBOMAT

continous aeration of candy masses (marshmallow, bars and chewy candies)

SPS controlled product density

stepless adjusting of air quantity, rotor speed and system pressure

adding of colour, flavour and acid

capacity: 250 k/h to 2.500 kg/h

automatic metering of raw materials like cooked sugar mass, aerating agent, fat or fondant mass

Production of bar foam with the TURBOMAT aerating machine

Recipe basic mass (ZWG) bar foam: Continuous cooking in the CrossFlow cooker to 120°C, vacuuming

Water, glucose syrup, sugar to 106°C, (vacuum –0,45 bar), approx. 91,5% dry substance

Recipe aerating agent for bar foam: first mixing of Hyfoama with glucose syrup, after this adding of water

Hyfoama, glucose syrup, water if necessary rotative addition of water and Hyfoama in small batches

Simple calculation of the air quantity:

example: Initial density ZWG + aerating agent 1,45 kg/l

required density after aeration 0,60 kg/l

volumetric throughput ZWG + aerating agent 1.000 l/h

(before the TURBOMAT)

Air quantity: 1,45 kg/l - 0,60 kg/l . 1000 l/h 24 l/min

0,60 kg/l 60

Aerated Jelly products and different methods


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Production of bar foam with the TURBOMAT aerating machine

Recipe / Ingredients for bar foam: After the aeration, ingredients are continuously metered in the foam

Cocoa powder, vegetable fat, skimmed mixer, dry substance of the ready bar foam approx. 90%

Milk powder, salt, malt extract,

Powder sugar, vanillin

Recipe caramel lay : milk and fat components are separately weighed,

Glucose syrup, sugar, water, sorbitol, continuous cooking at 114°C, dry substance of the ready

Skimmed milk powder, vegetable fat, caramel lay approx. 85,5 %

Salt, lecithin

ZWG Milk and fat for

Caramel layer Continuous cooker for ZWG

TURBOMAT

Aerating agentl

Continuous cooker

For caramel

Continuous adding of

Raw materials

40

50

60

70

80

90

100

110

120

130

140

150

160

170

70 75 80 85 90 95 100

%TS

TK

[°C]

1,0 bar

0,1

0,2

0,4

0,6

0,8

1,5

2,0 bar

2,5 bar

3,0 bar

4,0 bar

3,5

0,05

0,3

0,5

I

II

III

IVI - not saturated

II - metastable

III - intermediate

IV - unstable



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Characteristics of the JellyStar

Turbulences caused by cross flows in the tube and by permanent changes of cross sections

Low steam pressures caused by high heat transition surface

no dead spots + FIRST IN – FIRST OUT = no scorching of the jelly mass

no areas with „no flow“ or areas with constantly slow flow

compact design, causing high heat transition surface with short residence times

Processing area easily accessible and easy to survey

low flow resistence = low pressure loss also for high heat surfaces

the JellyStar is appropriate for cooking under overpressure (supressed boiling) as well as for

„normal cooking“

Continuous Jelly cooker JellyStar

Cooking with

overpressure

Atmospheric

cooking



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Continuous jelly cooking plant

Appropriate for all jelly masses on basis of gelatine, starch, gum arabic,

pectin and agar agar

several construction sizes for throughputs of jelly masses of 500 kg/h to 6.000 kg/h,

as a pilot plant throughputs of 40 - 100 kg/h

Successfully applied by our customers for years , the traditional coil cooker has been

replaced by Klöckner Hänsel a long time ago

Continuous jelly production line consisting of dissolving station for jellying agents and raw material weighing unit CONTIGRAV and JellyStar with evaporation chamber



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Production of Jelly masses with aerated layer

Jelly product with an aerated layer are processed continously today. During this process, one part of the

Jelly mass is fed into the continuous aerating machine TURBOMAT.

CONTIGRAV

JellyStar witht

Evaporation chamber

TURBOMAT

Reservoir

FAS-station for foam

Volumetric, continuous

Feeding hopper

JellyBlend

Reservoir

Feeding hopper

Feeding hopper

Feeding hopper

JellyBlend, FAS-dosing unit

Gravimetric, batchwise

JellyStar with

Evaporation chamber

TURBOMAT


Reservoir



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Production of Jelly products with an aerated layer

Preparation of raw materials

E.g. weighing of a jelly containing recipe. Gelatine is dissolved separately and automatically

added to the slurry in the CONTIGRAV, weighing fully automatically, slurry is not pre-dissolved

before cooking, dry substance of the slurry e.g. 72%

Cooking

Atmospheric cooking to approx. 76% dry substance (108°C),

after this step vacuuming at – 0,5 bar to approx. 78% dry subst.,

during this process the mass cools down to approx. 90°C

Aerating

Aerating of one part of the cooked /vacuumed jelly mass,

before aerating the jelly mass is cooled down to approx. 60°C

via a plate heat exchanger

Metering of flavour/colour/acid

Colour, flavour and acid are added to the aerated jelly

mass via a continuous metering unit. If the jelly mass

is not aerated colour, flavour and acid are added

with the gravimetric dosing unit JellyBlend.

40

50

60

70

80

90

100

110

120

130

140

150

160

170

70 75 80 85 90 95 100%TS

TK

[°C]

1,0 bar

0,1 bar

0,2

0,4

0,6

0,8

1,5

2,0 bar

2,5 bar

3,0 bar

4,0 bar

3,5

0,05

0,3

0,5

I

II

III

IVI - not saturated

II - metastable

III - intermediate

IV - unstable



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Production of aerated and filled jelly products

Various types of aerated Jelly products can be processed:

non aerated jellies with filling and foam topping

two coloured aerated jellies without filling

two coloured aerated jellies with filling

two coloured aerated jellies with filling and foam topping

Appropriate as a filling for such products are basically

type of pectin: low value (such as for jam and yogurt)

pH – value 3,2 – 3,4

quote of pectine (net weight) 0,72%

Processing of a filling for aerated jellies:

1. step (solution A) boiling up of sugar, pectin, salt, water,

25 parts more of water than pectin

2. step (soultion B) boiling down to 106°C of sugar, glucose, fruit juice concentrate

(e.g. pear concentrate 65% dry substance)

3. step mixing of solution A and solution B

4. step Boiling down of the mixture to 109°C / 78% dry substance

5. step Adding of colour, flavour, acid (pH – value to be adjusted)

Batch cooker HRK

Contigrav for a jelly line



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Production of aerated jelly products

non aerated jellies with filling and foam topping

Basic recipe on basis of gelatine for non-aerated jelly (coating mass) and foam topping

6,5% gelatine (net weight), 250 Bloom, cooking to 80% dry substance, e.g. atmospherically

at 109°C, after this vacuuming at – 0,50 bar, cooling down by vacuum to approx. 90°C

The basic mass is cooked to a higher dry substance (approx. 1-2%) in order to make the basic

mass more solid for the absorption of the filling

Taking out the foam mass as a part or the basis mass, cooling it down to approx. 60 °C (plate heat exchanger) and aerating it in the TURBOMAT. Density after aeration approx. 0,60 kg/l

Adding of flavour and acid into the foam mass via the continuous

volumetric dosing unit JellyBlend

Adding of colour, flavour and acid into the non aerated jelly mass by the gravimetric dosing unit

JellyBlend, high dosing accuracy achieved by measuring the weights to be added

CONTIGRAV

JellyStar with

Evaporation chamber

Reservoir

TURBOMAT

Reservoir

JellyBlend

Feeding hopper

Feeding hopper


Volumetric, continous



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Production of aerated jelly products

two coloured aerated jellies with and without filling

recipe on basis of gelatine and pectin, 5,5% gelatine,

250 Bloom and pectin 0,5% high valued, cooking to 79%

dry substance, e.g. atmospherically 108°C, after this vacuuming

at – 0,75 bar, cooling down by vacuum to approx. 75°C

Dissolving of pectin separately with at least 10 parts more

recipe water, after this heating to min. 90°C in order to dissolve

the pectin

Temperature while pouring approx. 15°C lower than with non-aerated jellies, so that the foam will stay solid and the two colours would not

pour one into another

Aerating in the TURBOMAT

Adding of flavour and acid into the foam mass via the continuous volumetric dosing unit JellyBlend, control and adjustment of the acid amount by continuous pH – value measuring

11. Continuous cookers

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CrossFlow ROTAMAT JellyStar Universal cooker Rotor cooker jelly cooker

for all kinds of non-milky sugar for cooking of all for cooking of all jelly masses

masses, appropriate as milky and non-milky on basis of gelatine,

precooker and final cooker sugar masses starch, pectin, agar agar

The CandyLab

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Documents

Aerated Jelly Masses Various methods of the production of ... · Aerated Jelly Masses Various methods of the production of aerated Candy Masses Markus Dittrich Feature by Klöckner