BATCH OR CONTINUOUS PRODUCTION?
A chocolate-coated nut centre could flow, via an enrober and continuous cooling tunnels, before being polished and wrapped. Continuous confectionery lines will
incorporate a variety of advanced subsystems, each designed for tightly controlled and uninterrupted mass flow. Continuous reactors, static mixers or continuous homogenisers, for example, will be employed to blend ingredients. The mixed mass is then conveyed through cooking zones where moisture is removed and heat exchangers can recover energy or pre-heat feeds. Accurate control of residence time, temperature and solids is essential on continuous production lines to maintain consistent properties. Confectionery masses can be
extruded, deposited, moulded or cast in a continuous fashion. Continuous depositors lay down layers in bar form; twin-screw extruders could form sheeting or depositors or nozzles could lay down gummies or drops. After formation, products will likely travel through cooling tunnels or conveyors
30 • KENNEDY’S CONFECTION • OCTOBER 2025
where heat is removed steadily to enable crystallisation, drying or setting to occur in a controlled manner. Throughout the continuous production
line, sensors will be employed to measure temperature, viscosity, moisture content, mass flow and product dimensions. A central controller is also a key feature, to ensure setpoints are maintained.
Flexibility and output According to Keith Graham, Senior Manager Business Development EMEA and Strategy at Coperion, the batch or continuous argument in confectionery manufacturing is usually resolved by considering flexibility and output. “For high output lines with few product changeovers continuous has always been, and remains, the clear favourite. For small flexible lines, batch is normally the obvious choice,” he says. “Most confectionery manufacturing processes involve cooking of a syrup, adding colours, flavours and other ingredients and then forming through depositing or extruding. Cooking may be either batch or continuous, but the forming processes
CONTINUOUS LINES ARE
CONSIDERED TO BE THE MOST ECONOMICAL SOLUTION FOR HIGH VOLUME PRODUCTS, WHERE CHANGEOVER
FREQUENCY IS LOW OR WHEN A SINGLE PRODUCT VARIANT IS RUN FOR EXTENDED PERIODS
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