Starch Moulding Systems


and functional fields, exactly the right proportion of active ingredients is added to ensure that the therapeutic dose is correct. Every deposited piece is precisely the same weight, and the process is reproducible. The consistency achieved by starch-free depositing ensures products have a high-quality appearance, taste and mouthfeel. The absence of starch means that plant hygiene and the working environment are significantly improved.” Starchless (or starch-free) moulding refers to continuous depositing of final solids into reusable moulds, and cutting starch from the process removes the need for trays, allocating drying times and factory floor equipment. Without starch, there is no dust in the air and a lot less cleaning and machinery is needed.


Many of the companies entering the market have a background in healthcare products and are new to confectionery manufacturing.


Quality, cost, hygiene and


cross-contamination problems drive them away from starch moguls which they regard as old-fashioned. “Existing producers have transferred to starchless technology to remain competitive through reduced costs and improved quality,” Keith notes.


• Functional products must contain the claimed quantity of active ingredients. Accurate dosing and precise control are essential. On a starch mogul expensive additives can transfer into the starch itself as moisture is extracted from the product. This reduces the concentration of the additives and also creates a cross-contamination risk. On a starch-free plant, there is no moisture or active ingredient loss – everything that goes into the mould stays in the mould


• Outputs can be controlled economically on a starchless moulding plant compared with a 4 tonne/hour mogul. High outputs are not required – people tend to consume one piece a day compared with numerous items with conventional confectionery.


• The production environment and hygiene is much improved.


Mogul operations involve starch in the atmosphere which is a health hazard and incurs cleaning costs. Starchless moulding takes place in a clean, hygienic environment.


• Mogul costs are higher: high levels of energy are required to reduce moisture content and clean and dry the starch.


“Fairgrieves’ 2021 lightweight thermoset starch mogul trays were significantly improved and re-engineered from their predecessors, with a smooth surface to hold any type of sweets, gum or confectionery”


KennedysConfection.com Kennedy’s Confection July 2022 31


“The traditional starch mogul process for jellies and gummies is not suitable for healthcare products: not only does the use of the starch bring with it the risk of cross- contamination and hygiene problems, but the long multi- stage process does not lend itself to economic low and medium volume production,” says Keith. The flexibility needed to make the expanding range of products, particularly to meet specific, targeted needs has been a challenge. But Keith says starchless moulding provides the ability to change products quickly and without cross-contamination. “Cleaning time and waste are minimal, so recipes can be changed rapidly making short runs economic,” he says.


Modernising existing processes


North East manufacturer Fairgrieve Compression Moulding says the production of confectionery starch trays has long been a staple of the specialist moulding businesses’ product line. Widely used for producing gummy candy or jelly sweets, Fairgrieves has supplied some of Europe’s biggest confectionery producers - including Storck, the German makers of Bendicks chocolates, Werther’s Original and Toffifee.


It remains a specialist manufacturing area in which the business continues to lead the way internationally today, and only last year that Fairgrieves gave this much in-demand product a modernisation.


A focus was placed on more effective production methods, a lighter overall product, improving levels of performance and reducing delivery costs – bringing benefits to both the business itself, and its clients across the world.


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