Continuous Cooking and Starchless Depositing

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Lynn Small
5 years ago
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1 Confectionery

Continuous Cooking and Starchess Depositing Baker Perkins continuous cooking and starchess depositing technoogies bring exceptiona eves of reiabiity, efficiency and ow production costs to the

Our focus on creating innovative end-products aied to ow-cost production can be seen in our commitment to both process deveopment and equipment design.

2 Continuous Cooking and Starchess Depositing Baker Perkins continuous cooking and starchess depositing technoogies bring exceptiona eves of reiabiity, efficiency and ow production costs to the manufacture of unique, high-quaity confectionery. Our focus on creating innovative end-products aied to ow-cost production can be seen in our commitment to both process deveopment and equipment design. Our atest cooking and ServoForm depositing systems continue to deiver the best in fexibe and efficient high-output production, whie setting new standards for ease of use, hygienic design and energy efficiency. Backed by our comprehensive Lifetime Support programme to ensure ong-term performance and reiabiity, a cooking and depositing system from Baker Perkins wi provide a high return on investment for many years. Unique, high-quaity confectionery High efficiency Low production costs Versatie process Fexibe systems Exceptiona reiabiity Compete contro Maximum hygiene Low maintenance 2

Products Every Baker Perkins cooking and depositing system is capabe of a wide range of variations on the standard product type.

four-component heads, oipop depositing and muti-head configurations aso avaiabe there is virtuay no imit to product variety.

or soft centre-fis, and with every possibe coour and favour.

centre-fied, ayered and striped options. Jeies & Gums A types of jeies, gums and fruit paste confectionery.

suppements. Baker Perkins hygienic, starch-free process is suitabe for production to vaidation standards.

3 Products Every Baker Perkins cooking and depositing system is capabe of a wide range of variations on the standard product type. Even the simpest two-component, singe-head depositor can produce an array of soid, striped, ayered or fied candies, and with four-component heads, oipop depositing and muti-head configurations aso avaiabe there is virtuay no imit to product variety. Hard Candy Muti-coour, muti-component hard candies in one, two, three and four coours; in stripes or ayers, with one or two hard or soft centre-fis, and with every possibe coour and favour. Loipops Ba, doube-ba and fat oipops in one, two, three or four coours, with a muti-component capabiity providing soid, centre-fied, ayered and striped options. Jeies & Gums A types of jeies, gums and fruit paste confectionery. Creation of striped, ayered and centre-fied products is possibe; incusions can be incorporated whie intricate product shapes present branding opportunities. Functiona & Medicated Jeies, gums, hard candy or fruit snacks fortified with vitamins, mineras, fibre, rea fruit juice or other suppements. Baker Perkins hygienic, starch-free process is suitabe for production to vaidation standards. Toffee & Carame High-quaity toffee and carame products can be made in an assortment of coours, and can incude added-vaue centre fiings such as nuts, jam and chocoate. Fondant & Fudge Fondant and fudge confectionery in a variety of coours, favours, fiings and shapes. They can be chocoate coated and incude centre fiings ike nuts, jey or fruit pieces. 3

Process Hard Candy Cooking and depositing systems that faciitate production of attractive, high-quaity and coourfu hard candies using either sugar or sugar-free recipes.

The one-shot depositing action can combine up to four coours and components in a singe piece to produce a wide range of attractive candies that have exciting taste and texture combinations.

maximum hygiene and ow maintenance. Muti-coour, muti-component candies can be produced in stripes or ayers and hard or soft centre-fis can be incorporated.

4 Process Hard Candy Cooking and depositing systems that faciitate production of attractive, high-quaity and coourfu hard candies using either sugar or sugar-free recipes. The ServoForm continuousy deposits syrup into soid mouds using a starchess process. The one-shot depositing action can combine up to four coours and components in a singe piece to produce a wide range of attractive candies that have exciting taste and texture combinations. The nature of the depositing process creates compete contro throughout the system, eading to extremey high dimensiona, shape and weight accuracy, negigibe scrap rates and efficient wrapping, pus maximum hygiene and ow maintenance. Muti-coour, muti-component candies can be produced in stripes or ayers and hard or soft centre-fis can be incorporated. Superior appearance, high carity and rapid favour reease with a smooth mouth fee are quaity advantages created by depositing when compared to other production methods. Hard candy ines incorporate automatic weighing, feeding, dissoving, and coour / favour / acid addition, as we as the market eading Microfim cooker, which matches the ServoForm depositor in its abiity to deiver superior quaity with high operationa efficiency. Hard Candy New Feed System ServoForm TM Hard Candy Depositor AUTOFEED MICROFILM TM COOKER COLOUR / FLAVOUR ADDITIONS SERVOFORM TM HARD CANDY DEPOSITOR 4

Jeies & Gums Starchess mouding is the most cost effective method avaiabe for the production of jeies and gums.

abiity to innovate and add vaue to their product range.

The ServoForm depositor can produce jeies and gums in soid, striped, ayered or centre-fied varieties. Incusions such as rea fruit pieces can be incorporated and iquid centre-fis are aso possibe.

5 Jeies & Gums Starchess mouding is the most cost effective method avaiabe for the production of jeies and gums. The eimination of starch from the process significanty reduces production costs and improves hygiene whie the capabiity to produce a wider range of higher-quaity products gives confectioners the abiity to innovate and add vaue to their product range. The depositing process creates compete contro throughout the system, eading to extremey high dimensiona, shape and weight accuracy, negigibe scrap rates and maximum hygiene. The ServoForm depositor can produce jeies and gums in soid, striped, ayered or centre-fied varieties. Incusions such as rea fruit pieces can be incorporated and iquid centre-fis are aso possibe. Depending on the product, soid meta, poymer or rubber mouds are used with either a mechanica or air ejection system. These give enhanced definition and can pace the products on the take-off conveyor in a regimented format ready for chocoate enrobing or other downstream processing. The ServoForm process deposits syrups at fina moisture into soid mouds instead of starch trays. The resut is a range of high quaity jeies, gums and fruit snacks produced with significanty ower capita and running costs, pus a much reduced environmenta impact. Jeies Turbofim Cooker for Pectin Jeies Mouds AUTOFEED MICROFILM TM COOKER COLOUR / FLAVOUR ADDITIONS SERVOFORM TM JELLY DEPOSITOR 5

Process Loipops Baker Perkins competey automated, high-capacity oipop depositing technoogy produces high-quaity oipops with the potentia for an amost unimited product variety, and

Lines can produce a wide range of oipops in up to four coours, with a muti-component capabiity providing soid, ayered and striped options for a variety of ba, doube ba, 3D, shaped and

Fat and shaped oipops aow surfaces to be embossed for character merchandising, whie a range of profies such as fowers, hearts or anima shapes can aso be produced.

6 Process Loipops Baker Perkins competey automated, high-capacity oipop depositing technoogy produces high-quaity oipops with the potentia for an amost unimited product variety, and offers greater production fexibiity than other processes. Lines can produce a wide range of oipops in up to four coours, with a muti-component capabiity providing soid, ayered and striped options for a variety of ba, doube ba, 3D, shaped and fat oipops. Centre-fied oipops can be deposited to add a new range of textures to a product portfoio. Fat and shaped oipops aow surfaces to be embossed for character merchandising, whie a range of profies such as fowers, hearts or anima shapes can aso be produced. As we as the ServoForm oipop depositor, Baker Perkins oipop systems incude automatic weighing, feeding, dissoving, and coour / favour / acid addition, pus the Microfim Cooker - the industry standard for sugar and sugar-free high-boied oipops and candies. Ba Loipops Automatic Stick Insertion (Ba) Mouds Ba Loipops AUTOFEED MICROFILM TM COOKER COLOUR / FLAVOUR ADDITIONS SERVOFORM TM LOLLIPOP DEPOSITOR STICK PLACEMENT 6

Ba Loipops The ServoForm ba oipop system deposits cooked syrup into soid mouds using a starchess process.

and favour. Fat Loipops Sticks are first fed into the mouds by an automatic insertion system.

7 Ba Loipops The ServoForm ba oipop system deposits cooked syrup into soid mouds using a starchess process. One-shot depositing of up to four coours and components enabes a vast array of visuay appeaing oipops to be produced with exciting taste and texture combinations. Muti-coour, muti-component ba and doube ba oipops can be produced in stripes, ayers and random patterns with hard or soft centre-fis, in every possibe coour and favour. Fat Loipops Sticks are first fed into the mouds by an automatic insertion system. Pacement mechanisms then ensure the sticks are accuratey positioned and firmy hed within the mouds before the cooked syrup at fina moisture is deposited by the ServoForm depositing head. The ServoForm fat oipop depositor can produce a wide range of oipops in up to four coours, with a muti-component capabiity providing soid, ayered and striped options for fat oipops in a variety of shapes. After depositing, the mouds pass beneath a fuy automatic system that paces sticks accuratey and consistenty. The system hods the sticks perpendicuar during the cooing process unti the product has set. Fat Loipops Automatic Stick Insertion (Fat) Mouds Fat Loipops AUTOFEED MICROFILM TM COOKER COLOUR / FLAVOUR ADDITIONS STICK PLACEMENT SERVOFORM TM LOLLIPOP DEPOSITOR 7

Process Soft Confectionery For high-quaity toffee, carame and fudge, Baker Perkins ServoForm depositing patform offers greater quaity and fexibiity than other production methods.

Baker Perkins systems can be specified to hande a recipes, with a fu range of cooking temperatures and eves of carameisation.

Products can be made in an assortment of coours, and can incorporate added-vaue centre fiings such as jam or chocoate. A ine with rubber mouds can produce the fu range of toffees, carames and fudges.

8 Process Soft Confectionery For high-quaity toffee, carame and fudge, Baker Perkins ServoForm depositing patform offers greater quaity and fexibiity than other production methods. Toffee recipes and ingredients can vary widey, from budget to premium quaity with high proportions of fat and mik. Baker Perkins systems can be specified to hande a recipes, with a fu range of cooking temperatures and eves of carameisation. As we as producing traditiona soid toffee, ingredients such as butter, nuts, dried fruit and a variety of favours can easiy be added to the production process. Products can be made in an assortment of coours, and can incorporate added-vaue centre fiings such as jam or chocoate. A ine with rubber mouds can produce the fu range of toffees, carames and fudges. A meta moud/ air ejection system may be specified if regimented discharge for enrobing is required. Cooking systems are moduar and can incude a fuy automatic Autofeed system to weigh and mix ingredients, whie the speciaised Carabend cooking and carameising unit offers a comprehensive seection of process capabiity and outputs. Soft Confectionery Scraped Preheater Carabend Toffee Cooker AUTOFEED SCRAPED PREHEATER & MICROFILM TM COOKER CARABLEND TM TOFFEE COOKER FONDANT ADDITION SERVOFORM TM SOFT CONFECTIONERY DEPOSITOR 8

Fondant & Fondant Crème Cooking Baker Perkins provides compete cooking and depositing systems for the continuous production of fondant and fondant crème, which can be used in a variety of soft

For base fondant, fuy automatic ingredient weighing and mixing is foowed by cooking and drum cooing. Agitation in a fondant beater then crystaizes the sugar to produce a fine fondant.

Adding bob syrup to the beaten fondant produces a fine-crysta confectionery crème, idea for depositing.

9 Fondant & Fondant Crème Cooking Baker Perkins provides compete cooking and depositing systems for the continuous production of fondant and fondant crème, which can be used in a variety of soft confectionery products. Base fondant can aso be produced in buk as an ingredient for bakers and confectioners. For base fondant, fuy automatic ingredient weighing and mixing is foowed by cooking and drum cooing. Agitation in a fondant beater then crystaizes the sugar to produce a fine fondant. To produce a fondant crème, the fondant is passed to a crème mixer where it is combined with hot bob syrup. This is cooked with the fondant syrup but bypasses the cooing and beating stages. Adding bob syrup to the beaten fondant produces a fine-crysta confectionery crème, idea for depositing. Use of the fondant preparation system aongside Baker Perkins ServoForm depositor provides great fexibiity and process contro. Product quaity is improved through a more consistent shape, and depositing brings the fexibiity of making a variety of shapes, coours and favours simutaneousy. Compared with traditiona forming processes, space, abour and cost are reduced, whie hygiene and safety are improved. Production cyces are cut consideraby. Individua fondants can be produced in a range of coours, favours and shapes, and can incorporate centre fiings such as nuts, jey, fruit pieces and iquids. The regimented discharge from the depositor enabes a direct ink to the enrober for output that is chocoate coated. Fondant Base Fondant Fondant Drum AUTOFEED FONDANT COOKING SYSTEM COLOUR / FLAVOUR ADDITIONS COOLING DRUM, BEATER & MIXER 9

Process Functiona & Medicated Baker Perkins ServoForm depositors enabe hard candy, jeies and fruit snacks containing suppements for the heathcare, functiona and medicated markets to be manufactured

Products may be manufactured in ow-sugar or sugar-free formats, with no more than 1% fat whie fruit snacks may contain up to 100% rea fruit paste.

10 Process Functiona & Medicated Baker Perkins ServoForm depositors enabe hard candy, jeies and fruit snacks containing suppements for the heathcare, functiona and medicated markets to be manufactured in a hygienic, starch-free environment. This aso makes the process idea for products where vaidation is required. Products may be manufactured in ow-sugar or sugar-free formats, with no more than 1% fat whie fruit snacks may contain up to 100% rea fruit paste. The technoogy enabes vitamins, mineras, fibre, energy and other suppements to be incorporated, as we as natura ingredients such as rea fruit paste, juice or pieces. The ServoForm system ends itsef we to process vaidation for reguated products. The process is consistent and repeatabe, there is no recycing of starch and the equipment is hygienic and easiy ceaned. The depositing process creates compete contro throughout the system, eading to extremey high dimensiona, shape and weight accuracy with negigibe scrap rates and maximum hygiene. Compared with a starch mogu, energy costs, footprint and capita costs are a significanty ower. Functiona & Medicated Hard Candy Functiona & Medicated Jeies & Gums ServoForm TM Jey Depositor AUTOFEED MICROFILM TM COOKER COLOUR / FLAVOUR ADDITIONS SERVOFORM TM DEPOSITOR HARD CANDY OR JELLY 10

Sma Batch Depositing Baker Perkins ServoForm Mini depositor sits at the heart of a 50+ kg/hr manuay operated production ine capabe of producing deposited candies, jeies, toffees and oipops incuding

The ServoForm Mini is a servo-driven, short run confectionery depositing system designed for entry-eve operations or experimenta and deveopment work in arger organisations.

Mouds are manuay oaded onto a continuous indexing moud conveyor; the mouds then pass through the depositor and are manuay unoaded for cooing and demouding.

11 Sma Batch Depositing Baker Perkins ServoForm Mini depositor sits at the heart of a 50+ kg/hr manuay operated production ine capabe of producing deposited candies, jeies, toffees and oipops incuding high-vaue medicated or functiona products at piece weights ranging from 2g to 16g. The ServoForm Mini is a servo-driven, short run confectionery depositing system designed for entry-eve operations or experimenta and deveopment work in arger organisations. Based on Baker Perkins proven ServoForm depositing technoogy, the ServoForm Mini deposits a high-quaity, smooth product with a consistent size and shape, and high piece-weight accuracy. Mouds are manuay oaded onto a continuous indexing moud conveyor; the mouds then pass through the depositor and are manuay unoaded for cooing and demouding. The ServoForm Mini features an eectricay heated hopper suitabe for singe-coour products; a second hopper can be incorporated for two-coour or centre-fied products. PLC contros incorporating fu process visuaisation, recipe management and aarm handing provide compete contro of the depositing process. The hygienic nature of the ServoForm Mini makes it idea for production to vaidation standards for heathcare products. As we as being capabe of vaidation, Baker Perkins starchess depositing technoogy brings high standards of quaity, convenience and hygiene to heathcare confectionery production, eiminating the time and cost penaty of the traditiona starch process. Low scrap rates, quick product changeovers and continuous processing mean a rapid payback is assured. Hard Candy Loipops Jeies 11

Equipment A compete Baker Perkins confectionery process ine comprises a cooking system for weighing, mixing and cooking, foowed by a ServoForm depositor.

Cooking Systems The range bends proven cooking technoogies within a moduar design to create a series of high-efficiency cooking systems for many types of sugar, ow-sugar or sugar-free confectionery.

Autofeed Weighs and mixes up to 8 dry and iquid ingredients Fu batch reporting for tight cost contro Optiona poyo dissoving unit for sugar-free syrups Microfim Cooker Cooks most types of sugar and

12 Equipment A compete Baker Perkins confectionery process ine comprises a cooking system for weighing, mixing and cooking, foowed by a ServoForm depositor. Systems are designed to offer exceptiona eves of performance, whether suppied as stand-aone units or combined into a fu production ine. Cooking Systems The range bends proven cooking technoogies within a moduar design to create a series of high-efficiency cooking systems for many types of sugar, ow-sugar or sugar-free confectionery. Dedicated and muti-purpose systems can be created in this way, offering outstanding cooking performance and ow production costs. Autofeed Weighs and mixes up to 8 dry and iquid ingredients Fu batch reporting for tight cost contro Optiona poyo dissoving unit for sugar-free syrups Microfim Cooker Cooks most types of sugar and sugar-free hard candy, mik or cream candies, carames, toffees, fudges, jeies, gums and fruit snacks Appies vacuum directy onto a swept thin-fim for rapid cooking of high-boied candies with negigibe process inversion Atmospheric version used for ow-boiings Vacuum modue avaiabe for cooking of sugar-free syrups Turbofim Cooker Compact and efficient jey cooker Combines continuous dissoving and cooking of syrups into a singe modue Pate pack cooker that may aso be used for hard candy Carabend Cooker Continuousy cooks and carameises toffee and carame Independent contro of cooking and carameisation Suitabe for addition of further ingredients such as fondant, butter or coours Additiona output capabiity with Microfim cooking modue Fondant & Fondant Crème Pant Speciaised system for the preparation of fondant and fondant crème Cooing and beating process for the production of base fondant Cooing, beating and mixing process for the production of fondant crème 12

ServoForm Depositor Range ServoForm depositing patforms are moduar systems comprising a depositor head, starchess moud set, cooing tunne and automatic oipop stick pacer.

As we as fexibe ines for hard candy, oipops and soft confectionery, combination ines for hard candy and either oipops or soft confectionery are possibe, enabing an even greater product range to be

Operating costs are kept ow by fuy automatic operation, incuding an automatic washout system and servo-controed drives that reduce the number of components.

13 ServoForm Depositor Range ServoForm depositing patforms are moduar systems comprising a depositor head, starchess moud set, cooing tunne and automatic oipop stick pacer. Products can contain up to four simutaneousy deposited components for maximum versatiity; ate addition of coours and favours achieves this with minimum compexity. As we as fexibe ines for hard candy, oipops and soft confectionery, combination ines for hard candy and either oipops or soft confectionery are possibe, enabing an even greater product range to be made on a singe machine. Muti-head systems can be suppied either to maximise output from a singe ine, or for the production of the atest generation of muti-ayered/ cup products. Operating costs are kept ow by fuy automatic operation, incuding an automatic washout system and servo-controed drives that reduce the number of components. ServoForm Hard Candy Continuous production with a starch-free process to deiver one-shot depositing of up to four coours/components. Creates crysta-cear candies with no air bubbes and no fashing. ServoForm Loipop One-shot depositing for ba and doube ba or fat oipops; consistent size, shape and weight accuracy; automatic stick insertion ensures repeatabe quaity and wrapping efficiency. ServoForm Jey Starch-free production of jeies. The hygienic starchess process is idea for functiona and medicated products, especiay where vaidation is required. ServoForm Soft Confectionery Depositing of cooked syrups into siicone or meta mouds for added-vaue, superior-quaity soft confectionery products. Air ejection technoogy creates confectionery pieces that are perfecty shaped, with a smooth surface finish, and regimented discharge for downstream chocoate enrobing. ServoForm Mini Baker Perkins ServoForm Mini depositor sits at the heart of a sma batch production ine capabe of producing deposited candies, jeies, toffees and oipops, incuding high-vaue functiona and medicated products. 13

Innovation Centre Baker Perkins offers a its customers faciities to deveop new products and processes, produce sampes for test marketing, and conduct feasibiity trias.

The Innovation Centre at Peterborough contains a wide range of production and aboratory-scae equipment dedicated to the confectionery industry.

avaiabe, and speciaised units can be brought in - from other suppiers if necessary - to compete a process.

14 Innovation Centre Baker Perkins offers a its customers faciities to deveop new products and processes, produce sampes for test marketing, and conduct feasibiity trias. Products that can be tested using our unique starchess process incude hard candy in soid, striped, ayered and fied varieties; soft confectionery such as toffee, carame and fondant; and gums and jeies. The Innovation Centre at Peterborough contains a wide range of production and aboratory-scae equipment dedicated to the confectionery industry. Customers are guaranteed tota confidentiaity, working with or without the hep of Baker Perkins experienced food technoogists. avaiabe, and speciaised units can be brought in - from other suppiers if necessary - to compete a process. Aternativey, customers are wecome to bring aong their own technoogies to integrate with our existing equipment. The variety of process technoogies avaiabe under one roof enabes us to cross conventiona process boundaries, and to offer a variety of process soutions for a singe product. This range of equipment is permanenty Deveop new products and processes Produce sampes for test marketing Conduct feasibiity trias Eectronic Lab Depositor Mechanica Lab Depositor 14

Lifetime Support When choosing equipment from Baker Perkins, customers expect and get the best in terms of equipment specification, reiabiity, end-product quaity and ow production costs.

We offer a broad range of services to hep maintain and improve ine performance and extend usefu ife.

15 Lifetime Support When choosing equipment from Baker Perkins, customers expect and get the best in terms of equipment specification, reiabiity, end-product quaity and ow production costs. Lifetime Support ensures that these expectations are met for as ong as the equipment is in production. We offer a broad range of services to hep maintain and improve ine performance and extend usefu ife. This covers everything from repacement parts to major repairs and rebuids and incudes on-site engineering services such as panned maintenance contracts, faut-finding and pant optimisation. There are aso upgrades avaiabe to key features to improve performance and reiabiity. A Compete Moud Service Mouds are at the heart of a successfu depositing ines. The correct choice of moud has a huge impact on the quaity and character of the confectionery and the efficiency of the depositing system. A compete moud service is avaiabe to support the fu range of Baker Perkins depositing pants in production throughout the word. Moud Design Baker Perkins bespoke moud design service aows manufacturers to bring new confectionery products to market faster and more economicay than ever before. The atest CAD software is used to create fu coour 3D confectionery designs that can be sent eectronicay wordwide for customer appraisa. The atest 3D printing techniques are then used to create a mode of the design to the exact size and shape proposed. Moud Refurbishment Baker Perkins provides a refurbishment service to extend the ife of meta mouds for hard candy. Mouds can be re-coated and worn pin and spring ejector mechanisms repaced. To minimise disruption for customers, we offer a roing program to refurbish a compete moud set over an agreed extended period. FDA approved coatings are used to recoat the mouds and our experts are avaiabe to advise on the best seection for your appication. A repacement service for rubber mouds used in toffee and gummy production is aso avaiabe. Hard Candy Mouds Loipop Mouds Toffee Mouds 3D Jey Mouds 15

16 Baker Perkins Ltd Manor Drive Paston Parkway Peterborough PE4 7AP United Kingdom T: F: E: Baker Perkins Inc 3223 Kraft Ave SE Grand Rapids MI USA T: F: E: I: Baker Perkins 01/17

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