Confectionery

Save on Scrap
with Rotary Sweet Rolls
Engraved, cylindrical rolls offer confectioners
a new tool for creating novel shapes and profiles
without the waste of scraps.

R
OTARY moulding tech- enrobing. sheet and cut process for lozenges
nology has been widely used Topping is another secondary and other sugar-based shapes. The
in the biscuit and cookie process to add value to the basic scrapless nature of the process
industries for many years. APV product. additionally ensures accurate
Baker has now translated this Easy roll changeover enables a control of product weight and
concept to confectionery forming to wide range of eye-catching confec- shape, as well as texture and
offer manufacturers the ability to tionery to be made cost-effectively, moisture content.
deliver a wide range of innovative making it particularly suitable for The AirForm process is also
and attractive products. In the the dynamic character merchan- starchless, eliminating the cost of
AirForm moulder, APV Baker has dising market. starch, and minimising environ-
engineered a new format for the The process is scrapless, mental impact at a point when
scrapless forming of sugar based eliminating the quality problems ‘green’ issues are clouding the
pastes or doughs, marzipan, associated with the need to re- future of starch-based production
fondant, praline, mints, gums, chew incorporate scrap in the time- methods.
mixes and pharmaceutical pastes. consuming and labour-intensive The machine (pictured below) is
Rotary moulding offers
significant advantages over the
conventional sheet and cut process,
particularly in the ability to create
an unlimited variety of shape and
profile combinations. Possibilities
include embossed shapes and 3D
profiles, perhaps based on film or
television themes. As the process is
not limited to a single shape or
character on the mould, a whole
sporting team or set of characters
can be produced simultaneously.

Scrapless and starchless

moulding
Cylindrical moulding rolls are
engraved with the product shape,
paste is pressed into the engraved
chamber, and then positively
ejected to ensure high yield. The
nature of the process ensures total
consistency in the end product, and
regimented discharge simplifies
secondary processing, such as

FOOD & BEVERAGE ASIA AUGUST/SEPTEMBER 2005

 Confectionery

Examples of shaped candies made by pressing

paste into cylindrical moulding rolls.
of modular design ensuring rapid washdown for
cost-effective product changeover. Removal of
the head for cleaning and product changeover,
and of the roll and the hopper, are all tool-free.
Excellent hygiene levels offer significant
benefits for manufacturers of pharmaceutical and
functional confectionery, as the system can be
validated to meet cGMP and FDA hygiene
requirements.
Full PLC control is standard, with a touch-
sensitive HMI screen – also validatable to FDA
requirements, including 21 CFR part II (electric
records and signatures)

Engineering moulded solutions

APV Baker has successfully executed a major
contract using this technology. Significant
process problems associated with the previous
production method were overcome, and six
production lines replaced by two. There were
significant savings in labour, waste and
downtime, energy, floor space and drying time.
Rotary moulded products contain less
moisture than those produced by the rotary
cutting process, reducing drying time and cost.
A complete production package can be
engineered, from raw materials to the finished
product. The service includes product trial and
demonstration facilities in APV Baker ’s
Innovation Centre at Peterborough, where
customers are encouraged to develop their ideas,
with the backing of experienced food
technologists, in conditions of total
confidentiality.
A full aftermarket service includes the ability
to continue design of new products and
manufacture of moulds to turn them into
profitable production. Enquiry No: 017

FOOD & BEVERAGE ASIA AUGUST/SEPTEMBER 2005