Equipment
machine is designed to produce with format cylinders ranging in length from 705 to 1050mm. Subsequently, format cylinders from the BF 1000, as well as other manufacturers, can be used. Production capacity is said to be up to 50 strokes/minute.
Kavanagh believes that Zed Candy has already reaped the benefits from investing in state of the equipment. “Zed Candy is now positioned as a European brand using European equipment and all products are sold in Europe – with a total of 70 countries across the world.”
In the mix
Around 1million tonnes of chewing gum were produced worldwide in 2010. And while a stick may appear to be a simple product, the process of making the finished article requires special equipment and technical expertise. Globally, the production of chewing gum is a competitive industry, with each manufacturer’s formula and approach being a closely guarded secret, backed by research in the choice and design of mixing equipment, and recipe development to obtain desired textures and flavours. UK mixer specialist, Winkworth’s involvement in the manufacture of chewing gum stretches back over the decades, with the company having provided machinery to leading gum manufacturers around the world. The company believes that the type and choice of mixers is crucial to success in the manufacturing processes. The raw materials - often solid blocks of rubber, powders or liquids - do not lend themselves to be easily mixed
together. Gum mixing will expose any weaknesses in design, material strength, construction techniques or manufacturing and will result in early machine failure or fatigue.
Mixing gum, however, typically follows two distinct ‘mixing’ stages and, according to Winkworth, both of these can be carried achieved with its Z Blades mixers. 1st Gum base is the
main ingredient in chewing gum and is what makes it chewable. It provides a longer lasting flavour, improved texture and reduced tackiness and also brings the other ingredients together. Chewing gum products in the 19th Century used natural gum bases, such as the milky white sap, known as chicle, of the sapodilla tree, native to Central and South America. This has now been replaced with modern synthetic rubber such as Polyisobutylene.
The preparation of gum base requires a robust, heavy duty Winkworth Double Z Blade (Sigma Blade) mixer. This is necessary because the synthetic rubber is supplied in solid bales or blocks that are tough and need to be processed into a smooth textured mass before it can be used. The Winkworth Z Mixer motor/gearbox drives and solid, cast stainless steel blades must be robust enough to cope with the heavy demands. They must break down these larger rubber blocks into smaller pieces and squeeze, knead and grind them through the narrow gap between the rotating blades and the pan.
Turning the heat up
According to Winkworth, the grinding and kneading action is assisted by the addition of tackifiers/resins and fillers. Temperature control is critical and with all the ingredients being added cold, it is essential to raise these to the desired temperature. This is said to be achieved by heating the walls of the mixing pan, typically using steam, to approximately 100°C. This helps to melt the resins, creating initially a very tough, sticky mixture and then a smooth, lump free pumpable liquid.
Manufacturers differ in the way they then onward process the prepared gum base – often depending on
40 Kennedy’s Confection September 2012
whether it will be used immediately or transported for use elsewhere. Certain manufacturers will discharge from the Winkworth Z Mixer either by tilting or bottom discharge into shallow trays, which are then left to cool down and stored. For continuous processes, the hot liquid gum base is discharged into a heated and agitated storage hopper, such as a Winkworth steam heated ‘U’ Trough mixer, with a screw discharge device to feed a heated positive displacement pump.
This may then either feed directly onto the line (via heated pipework) or through to a pellitising system, for bagging and storage. If left to cool, the gum base will harden to a tough and solid mass. The first stage in the production of chewing gum is now complete.
The second mixing stage involves combining other ingredients with the gum base to make the chewing gum mass. The gum base has to be conditioned to the right temperature. If starting from cold then heat will need to be applied through the integral double walls of the mixer during the first stages of remixing to soften and melt the gum base. With the mixture heated to around 50-70°C, some of the other powder ingredients are added to help with the melting, kneading and mixture preparation.
Additional ingredients that can be added to the mix include: natural or artificial sweeteners such as powdered sugar; softeners such as glycerine (to keep the gum soft and flexible); bulking agents (to produce the right density of gum); flavourings such as spearmint, peppermint or cinnamon; colourings; preservatives; and other additives. “The mixer is a vital component in the final chewing gum outcome,” believes Winkworth’s managing director, Grant Jamieson. “Winkworth’s experience in
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