If you want to make sugar free gummy bears, then all information you’re looking for is right here.
You will learn how to choose the right ingredients, mix ingredients, mold gummy bear, store and select the right manufacturing equipment.
Keep reading if you want to be an expert on starchless gummy bear.
What is Sugar Free Gummy Bears
Sugar free gummy bears are confectionaries that lack the sugar as a sweetening ingredient.
Alternatively, you will use other sweetening ingredients such as maltitol to make the sugar free gummy bears.
Sugar free gummy bear
Sugar Free Gummy Bear Ingredients
You will have to mix particular ingredients in specific quantities to make the sugar free gummy bear ingredients.
Here are the main ingredients that you need to make the sugar free gummy bears.
It is the most important ingredient that you will use in making the sugar free gummy bears.
It is a type of hydrolyzed collagen that you can derive from bovine bones, skins and cartilages.
You can choose among the numerous sweeteners in the market as long as they are free of sugar.
In this case, the aim is to eliminate sugar completely so you need to use other sweeteners such as maltitol.
Water is a universal solvent that will also come in handy in the manufacturing of sugar free gummy bear candy.
It is the ingredients that will mix with gelatin to form a thick solution or gel thus making it chewy and gummy.
Gelatin is odorless and tasteless in its natural form thus the importance of using flavors to give it the unique taste.
You can use different flavors like fruit flavors to create a wide variety of different types of sugar free gummy bears.
· Food Grade Colors and Dyes
You will also add different colors and dyes to the ingredients to give the sugar free gummy bears a unique color.
In this case, you will use federally regulated dyes that are healthy and will not cause irritations on the body.
· Corn Syrup
Corn syrup is also a very important ingredient in the manufacture of sugar free gummy bears as it retains the moisture.
Apart from that, corn syrup also helps in making the sugar free gummy candy softer while increasing the volume.
· Citric Acid
Citric acid acts as an artificial flavor for gummy candy while preserving and increasing the shelf life.
It has a very low pH thus creating a very difficult environment for bacteria to grow and thrive in.
Mixing the Sugar Free Gummy Bear Ingredients
As soon as you have the ingredients in place, you will begin the manufacturing process by mixing all the ingredients.
At this point, you will have to adhere to the quantity requirements of the ingredients to make perfect gummy bears.
Measure the ingredients and mix them properly in the ingredients mixing and melting tank.
The mixing and melting tank will heat, nix and cool the ingredients in a bid to make a homogenous mixture.
The process will take between two and three hours depending on the quantity and type of ingredients you use.
As soon as you complete the compounding process, you will obtain samples of the homogenous mixture for quality tests.
You will take the sample to the laboratory for quality tests in accordance to the production specifications.
Molding Sugar Free Gummy Bear Ingredients
Molding gummy bear
After confirming the quality of the sugar-free gummy bear ingredient mixture, the manufacturing process proceeds to mold.
Molding of the ingredients involves shaping the ingredient mixture in different forms such as the shape of a bear.
The ingredient mixture will flow from the mixing and melting tank into the machine hopper then on to molding station.
You can also opt to use a supplementary machine such as the Mogul to help in the molding process.
Ensure that you use starch as an additional ingredient at thus stage to perform the following:
- Prevent the molten ingredient mixture from sticking to the walls of the machine
- Hold the mixture in the right position during the cooling, drying and setting process
- Absorb enough moisture in a bid to have the perfect texture for the gummy bears.
The molding machines have trays of different shapes that will mold the sugar free gummy ingredients.
Cooling Sugar Free Gummy Bear Ingredients
As soon as the molten ingredients take form on the trays, you will have to cool them down.
Cooling of the gummy candy ingredients will allow them to maintain the shape of the bear.
You will allow the machine to cool off the gummy bears for a period of 24 to 26 hours.
You must also note that the cooling period will depend on the cooling temperatures of the machine.
Demolding of Sugar Free Gummy Bear
After cooling the sugar free gummy bear candy, you will remove them from the trays.
The process of removing sugar free gummy bear candy from the trays is known as demolding of gummy bear candy.
You will transport the sugar free gummy bears into a large drum tumbler with coating oil.
Oil Coating of Sugar Free Gummy Bear
At this point, the machine will mix the sugar free gummy bears with enough food grade oil.
The food grade oil will absorb excess corn starch from the sugar free candy.
Apart from that, it will also assist in keeping the sugar free gummy bears fresh and soft for a long period.
Drying of Sugar Free Gummy Bear
You will set the drying requirements of the sugar free gummy candy such as drying temperatures and time.
Usually, sugar free gummy candy will take about 72 hours to get rid of all the excess moisture.
Ensure that you get rid of all the excess moisture leaving the sugar free gummy candy as chewy as possible.
Apart from that, you must also change the position of the sugar free gummy candy during the drying process.
Usually, you will dry the sugar free gummy candy for 48 hours on the back before turning them to the front side.
Sorting of Sugar Free Gummy Bear
The sugar free gummy bear candy is now ready for packaging but you have to sort them out first.
Here, you will sort them out according to shape, size, color and flavor.
You can also mix the different types of sugar free gummy bears as long as they are of the same size.
Packaging of Sugar Free Gummy Bear
Finally, you will package the sugar free gummy bears into different packages according to the different sizes.
Make sure that you purge the packages of moisture and air that might affect the shelf-life of the candy.
Seal the packages completely to eliminate the chances of moisture or air entry into the package.
The type of package will also matter as it will be the main selling point of the sugar free gummy bears.
Make sure that the package is as eye catching as possible with proper labels that indicate the ingredients.
There are three main ways of packaging sugar free gummy bears which include:
- Single Pillow Bags
- Pouch Packages
- Plastic Bottles especially for the healthy types of sugar free gummy bears
After that, you will proceed to storage of the sugar free gummy candy.
Storage of Sugar Free Gummy Bear
Store gummy bear
You should store the sugar free gummy bears in a cool and dry place to maintains its freshness for long.
Apart from that, you must also store the sugar free gummy bears in a particular order for easy access.
Depending on the storage conditions, sugar free gummy bears should be good for about 6 to 12 months.
Challenges in Manufacturing Sugar Free Gummy Bear
At the moment, there is a great need to improve the efficiency, speed and safety of the gummy bear manufacturing process.
There has been great concern on the safety of the gummy making process especially on the molding stage.
Apart from that, the other challenge is in the drying process of the sugar free gummy bears.
Starch dryers in the sugar free gummy bear manufacturing machines often pose an explosive hazard.
To address this challenge, you should consider using the spark proof switches and blast walls to maintain high safety levels.
In addition to safety issues, manufacturers are facing a huge challenge especially in consumer satisfaction.
Consumers are increasingly looking for better flavors apart from the normal flavors they get in the market.
Manufacturers have a great challenge of exploring new flavors for the sugar free gummy bears.
Quality Control of Sugar Free Gummy Bear Manufacturing Process
Quality assurance is paramount in the manufacturing process of gummy bear candy.
You have to ensure that every process in the production of gummy bear candy is in the right order.
Quality control will begin straight from the selection of sugar free gummy bear candy ingredients.
If possible, you can test the quality of the raw materials in the quality assurance laboratories.
Alternatively, you can outsource the raw materials from trusted suppliers who provide high quality raw materials.
Apart from the raw materials, you must also look at the quality of the manufacturing processes, packaging and storage conditions.
You can refer to the international standards of quality assurance such as:
- Current Good Manufacturing Practices (cGMP)
- Food and Drug Administration (FDA) Quality Standards
- International Standards Organization (ISO) Quality Standards
Parts of Sugar Free Gummy Bear Manufacturing Machines
Parts of gummy bear making machine
Sugar free gummy bear manufacturing machines are often semi-automatic or fully automatic.
Implying that these machines have different parts that enable them to work in solidarity to make sugar free gummy bears.
Here are the main parts of the sugar free gummy bear manufacturing machine.
· Machine Hopper
This is the part of the machine that will receive all the ingredients from the mixing and melting tank.
It is available in various capacities depending on the type of machine that you intend to use.
Apart from that, it has sensors that can automatically detect the ingredient levels and refill whenever its appropriate.
· Control Panel
The control panel is the part of the machine that allows you to program and monitor the operations of the machine.
It comes complete with a touch screen that allows you to configure the settings of the manufacturing machine accordingly.
· Dosing Pump
The dosing pump will automatically deposit or dose the molding plates with the appropriate amounts of ingredients.
It will work according to the production specifications set on the control panel of the sugar free gummy bear manufacturing machine.
The frame is the main support system of the sugar free gummy bear manufacturing machine.
It supports all the other parts of the machine and covers them completely from the effects of the weather.
· Servo Motors
The servo motors are responsible for controlling the movements of the transport systems of the sugar free gummy bear manufacturing machines.
It works together with the gears to control the speed of the conveyor belts and other rotating systems.
· Molding Station
You will depend on the molding station to shape the sugar free gummy bears.
The molding station has a tooling system that is capable of changing the molds of the sugar free gummy bears.
· Cooling System
The cooling system consists of refrigerators that you can program to cool the sugar free gummy bears accordingly.
Equipment for Manufacturing Sugar Free Gummy Bear
Apart from the sugar free gummy bear manufacturing machine, there are other equipment that you will need.
Here are the main types of equipment that you will need alongside the sugar free gummy bear manufacturing machine.
· Coil Cooker Sugar Free Gummy Making Machine
This is the machine that will heat all the ingredients and melt them to a liquid state.
Apart from that, it is capable of mixing all the ingredients to form a homogenous mixture.
· Weighing Machine
You will use the weighing machine to quantify the amount of ingredients you need to make sugar free gummy bears.
Apart from that, it can also mix the ingredients and transport them to the main machine via a vacuum pump.
· Blending System
You will use the additive blending system to add more ingredients to the sugar free gummy bear manufacturing machine.
· Jacket Cooker
This is another type of heating and blending machine that will blend and heat all the ingredients to form homogenous mixtures.
· Gel Molding Machine
The machine will assist in molding gum and jelly masses into various forms and shapes.
· Gummy Bear Cleaner
The gummy bear cleaner will help in getting rid of excess starch from the surface of the sugar free gummy bears.
It will also assist in removing any type of debris that might adhere on the surface of the sugar free gummy bears.
· Oiling Drum or Oiler
The oiling drum is responsible for oiling and mixing the sugar free gummy bears with enough oil to absorb excess starch.
In addition to that, it will help in maintain the texture of gummy candy while making them extra soft.
· Gel Conditioning Room
The gel conditioning room will assist you in the conditioning process of the gummy candy.
Custom Options for Sugar Free Gummy Bear Molding Machines
You can make the sugar free gummy candy into different shapes and sizes depending on the type of mold.
Here are other custom options for the sugar free gummy bear molding machines:
- 2D Gummy Bears Mold
- 2D Multi-fruit Jelly Candy Mold
- Silicon Sugar Free Gummy Bear Mold
- 3D Strawberry Sugar Free Gummy Bear Mold
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Contact us today for customizes solution in sugar free gummy bear making process.