Forming and Extrusion
“By leveraging extrusion techniques, manufacturers have been able to provide consumers with options that cater to their dietary preferences, whether it be reduced-sugar, sugar-free, fibre- enriched, or nutrient-fortified confections”
stages, from equipment selection and maintenance to process control and product consistency. One of these challenges is process control. Maintaining precise control over various parameters, including temperature, pressure, and speed, is critical for achieving consistent product quality. Variations in these parameters can affect the texture, shape, and taste of the final product. Ensuring tight process control requires skilled operators and comprehensive monitoring systems to detect and rectify any deviations promptly. These systems utilise sensors, automation, and data analytics to monitor and adjust temperature, pressure, speed, and other critical variables in real-time. Continuous feedback and automated adjustments improve process efficiency and ensure consistent product quality. Like any machinery, extrusion equipment
requires regular maintenance to ensure optimal performance.
H o w e v er ,
s c h e d u l in g maintenance activities while minimi sing production
downtime can be a challenge. Manufacturers develop preventive maintenance programs to ensure regular and timely equipment maintenance. Scheduled maintenance activities, such as cleaning, lubrication, and parts replacement, are performed to prevent breakdowns and minimise production downtime. Manufacturers may also leverage predictive maintenance techniques, such as condition monitoring and equipment diagnostics, to identify potential issues before they cause major disruptions. Different confectionery formulations may have unique
ingredient properties that can impact the extrusion process. Some ingredients, such as fat, moisture, or additives, can affect the flow properties and consistency of the confectionery mass during extrusion. Manufacturers conduct thorough ingredient analysis to understand their properties and compatibility with the extrusion process. By optimising formulations and adjusting ingredient ratios, manufacturers can enhance flow properties, consistency, and overall extrusion performance. This helps improve process efficiency and minimises challenges related to ingredient compatibility. Confectionery manufacturers often produce multiple
product varieties, requiring frequent cleaning and changeovers between different formulations. Proper cleaning protocols are essential to prevent cross-contamination and maintain product integrity. Confectionery manufacturers develop efficient cleaning and changeover procedures to minimise downtime between product batches. This may involve implementing standardised cleaning protocols, investing in automated cleaning systems, and utilising quick-release mechanisms for easy equipment disassembly and reassembly. Streamlining cleaning and changeover processes reduces cross-contamination risks and maximise production efficiency. Achieving consistent product quality, shape, and texture across batches is a constant challenge in extrusion-based confectionery manufacturing. Any variations in the extrusion process, such as fluctuations in temperature, pressure, or ingredient
34 Kennedy’s Confection July 2023
KennedysConfection.com
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