Forming and Extrusion
“Forming and extrusion processes are being enhanced by the integration of advanced sensors and quality control systems. These technologies allow for real-time monitoring and analysis, ensuring consistent product quality and reducing waste”
proportions, can lead to inconsistencies in the fi nal product. Manufacturers implement rigorous quality assurance protocols to monitor product consistency and detect any deviations in real-time. This involves conducting regular quality checks, sampling, and testing procedures to ensure that product specifi cations are met. Advanced quality control systems and statistical process control methodologies help manufacturers maintain consistent product quality and minimise variations. Operating extrusion machinery requires skilled personnel
with expertise in process control, troubleshooting, and equipment maintenance. Training employees to handle the complexities of extrusion technology and ensuring a competent workforce can be a challenge for confectionery manufacturers. Manufacturers invest in comprehensive training programs to enhance the skills and knowledge of their workforce. This includes training operators in extrusion technology, process control, troubleshooting, and maintenance procedures. Ongoing training and knowledge sharing ensure that operators are equipped to handle challenges and operate extrusion machinery effectively. Manufacturers collaborate closely with extrusion machinery
suppliers to ensure they select the most suitable equipment for their specifi c needs. Equipment suppliers often provide guidance and expertise to help manufacturers choose the right machinery, taking into account production volume, product specifi cations, and fl exibility requirements. By adopting these strategies and approaches, confectionery manufacturers can effectively address the challenges associated with extrusion machinery. Collaborating with equipment suppliers, implementing advanced process control systems, prioritising preventive maintenance, optimising formulations, streamlining cleaning procedures, investing in training, and implementing robust quality assurance measures collectively contribute to maximising the potential of extrusion technology and ensuring smooth confectionery production processes.
Healthier confectionery options
Extrusion technology has not only revolutionised the confectionery market in terms of effi ciency and versatility
36 Kennedy’s Confection July 2023
but has also contributed to the development of healthier confectionery options. Manufacturers have embraced extrusion techniques to incorporate a variety of healthier ingredients into their products, offering consumers choices that align with their dietary preferences and health-conscious lifestyles. Reduced-Sugar and Sugar-Free Confections: Extrusion
technology has been instrumental in the creation of reduced- sugar and sugar-free confections, addressing the growing demand for healthier alternatives. By utilising specialised extrusion processes, manufacturers can incorporate alternative sweeteners, such as stevia or erythritol, in precise ratios to achieve desired sweetness levels while reducing overall sugar content. This allows for the production of confections with lower glycemic impact, catering to individuals who are mindful of their sugar intake. Real product examples include: Hershey’s Sugar-Free Chocolate: Hershey’s has utilised
extrusion technology to develop their sugar-free chocolate range. By adjusting the extrusion process and incorporating alternative sweeteners, they offer consumers a guilt-free chocolate experience without compromising on taste. SmartSweets Gummy Bears: SmartSweets has leveraged extrusion techniques to create gummy bears that are low in sugar and high in fi bre. Their extrusion technology allows for precise control over ingredient ratios, resulting in gummies that provide a satisfying chew and enjoyable taste while containing minimal sugar.
Extrusion technology has facilitated the integration of dietary fi bres into confectionery products, enhancing their nutritional profi le. Fibre is known for its numerous health benefi ts, including improved digestion, increased satiety, and blood sugar management. With extrusion techniques, manufacturers can incorporate fi bre-rich ingredients, such as inulin, psyllium husk, or oat fi bre, into confections. These ingredients not only boost the nutritional content of the product but also contribute to its texture and mouthfeel. Fibre One, a popular brand, has used extrusion technology to develop fi bre-enriched brownies. By incorporating oat fi bre and other dietary fi bres during extrusion, they have created a delicious confectionery option that offers a good source of fi bre. Numerous protein bar manufacturers have adopted extrusion technology to produce fi bre-rich bars. By incorporating fi bre sources like chicory root fi bre or soluble corn fi bre during extrusion, they enhance the nutritional value of the bars, making them a convenient and healthy on-the-go snack
Nutrient-Fortifi ed Confections:
Extrusion technology has enabled the integration of essential vitamins, minerals, and other functional ingredients into confectionery products. By incorporating these ingredients during the extrusion process, manufacturers can create confections that offer added health benefi ts beyond traditional sweets. Some confectionery companies have utilised extrusion technology to create fortifi ed chocolate bars. By incorporating vitamins, such as vitamin D or B vitamins, during the extrusion process, they enhance the nutritional value of the bars, making them a more wholesome treat.
Extrusion technology has also been used to develop
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