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intensive operation. Bosch was the first company to seek to reduce the energy used during this process with the development of the pressure dissolver (dissolving without vaporization) in 1980. Recently, Bosch has taken this
innovation one step further by introducing a new dosing and mixing unit BDK 2000, which provides significant savings in energy consumption through improvements to dosing and crystallization.
The continuous dosing and mixing unit BDK 2000 makes it possible to produce a sugar-glucose syrup solution with a dry substance of up to 90 percent without the addition of water. The unit’s integrated TurboMixx mixing system produces a homogeneous mix by dissolving the sugar into the glucose syrup. For the utmost in dosing precision it features a gravimetric system with load cells and a flow meter. The subsequent dissolving process in the Rapidsolver heat exchanger guarantees a crystal-free solution, which also allows production to be stopped and started without product loss. The mass is heated by flowing around a pipe bundle containing steam. In the case of machine stoppages, the mass is not damaged due to the small steam volume and quick steam release. As the required moisture level is already reached after dissolving, cooking is not necessary anymore to reduce water content, saving significant amounts of energy and reducing production costs. Gelatine or other gelling agents can be gently added after the dissolving process.
Manufacturers can fully benefit from reduced processing time and minimal floor space by combining the BDK 2000 with the crystallizer BZK 1000 B. The BZK 1000 B allows for rapid inline crystallization eliminating the need for interim storage, avoiding lengthy storage times that disrupt production, and reducing manual labor requirements. The mass can be directly fed into a subsequent filling and forming line.
A successful partnership
Rudi Jahnke Süßwaren e.K., a successful family-owned confectionery business in Germany, has recently adopted Bosch’s energy-efficient confectionery production line. The company produces famous German licorice sweets such as candies and cross squares, traditional sweets, such as May leaves with woodruff flavor and lemon and raspberry drops. For those with a taste for upscale confectionery treats, Jahnke offers “two-tastes-in-one” fruit candies, such as eucalyptus lime and cranberry. Founded in Hamburg in 1980, Jahnke started using Bosch machines in 1989 and since then, the partnership has continued to strengthen. Bosch played such a vital role in meeting Jahnke’s production and packaging goals that the company has moved exclusively to Bosch machines, benefitting from its expertise at every step of the production process, from manufacturing to packaging. When Jahnke began to handle thousands of kilograms of candy per shift, its owner started to search for ways to conserve energy to reduce production costs, while also
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maintaining the high quality of the products. The new production line from Bosch was the perfect replacement for Jahnke’s old electronic dosing and mixing unit that whisked sugar, glucose and water together, before adding them to the pressure dissolver. The new technology also enabled the implementation of a second production line without the need to replace the original boiler with a bigger one. Until the changeover to BDK 2000, Jahnke used an electronic dosing and mixing unit to whisk sugar, glucose and water together, a mixture that was then added to the pressure dissolver. Though satisfied with the machines that delivered consistent, high-quality product, Jahnke faced ever-increasing energy costs and needed technology that demanded less energy. The BDK 2000 was the ideal solution for Jahnke, which came complete with the TurboMixx mixing system and Rapidsolver heat exchanger. Jahnke has seen clear results after the switch to this complete manufacturing line by Bosch, with energy savings of 60 percent. Torsten Ress, Production Manager at Jahnke, emphasized: “The new Bosch technology could enable the establishment of a second production line without the need to replace the original boiler with a bigger one.” Heinz Jahnke, Company Director, added: ”Due to the new System we can save two-thirds of the energy as well as increase the quality of our products which, with regard to our customers’ growing demands, becomes a very important criteria.” Due to the energy and water savings, the conversion to Bosch machines turned out to be worthwhile. Ress confirmed: “The development of these machines is trend-setting within the confectionery industry, because it gives us manufacturers the possibility to produce more efficiently and sustainably.”
The future
Bosch’s goal for the future is to further enhance its customers’ efficient production lines through machines that use less energy, incorporate strong design features that reduce the need for maintenance, and consume less packaging material. As a partner to many of the leading candy producers in Europe, the company aims to anticipate customer needs as new trends and demands emerge, ensuring that the candy consumers buy is sustainably and efficiently produced, as well as deliciously irresistible.
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