At Frontline Food Consultants and Engineers, we offer end-to-end solutions for the development and production of high-quality gummies and jellies. From sourcing premium ingredients such as gelatin, pectin, sweeteners, and natural flavors, to formulating innovative recipes that cater to diverse consumer preferences, we ensure your product stands out. We optimize the cooking, molding, and cooling processes to achieve the perfect chewiness, clarity, and flavor.

Our services include Regulatory Compliance Guidance to ensure your gummies and jellies meet safety and labeling standards, and Sustainability Consulting to help you adopt eco-friendly production practices. We also provide Packaging Solutions that enhance product freshness and appeal, while our R&D team works with you to create new flavors, shapes, and functional benefits like vitamin-enriched or sugar-free options. Through thorough sensory testing and rigorous quality control, we ensure your gummies and jellies deliver consistent texture, taste, and visual appeal, ready for the market.

What are Gummies and Jellies?

Gummies and jellies processing begins with preparing a mixture of water, sugar, glucose syrup, and the chosen gelling agent. This mixture is heated to dissolve all ingredients and then cooked to a specific temperature that activates the gelling agent. Once the mixture reaches the right temperature, flavors, colors, and any added vitamins or acids (for a sour taste) are mixed in. The hot mixture is then poured into molds to shape the gummies or jellies. After being molded, the products are cooled and set, allowing them to firm up into their final, chewy form.

The final step involves coating the gummies or jellies with a thin layer of oil or sugar to prevent sticking and enhance their shelf life. The production of gummies and jellies involves several essential pieces of equipment. Mixing tanks blend gelatin or pectin with sweeteners, flavors, and colors while cooking kettles heat the mixture to achieve a smooth texture. The mixture is then poured into molds using depositing machines, forming the desired shapes. After molding, the products are cooled and set in cooling tunnels, with starch molding equipment used for specific shapes when necessary. Once cooled, the gummies or jellies are finished with coatings like sugar or oil in coating machines. Finally, wrapping and packaging machines seal the products for freshness, and storage and conditioning equipment ensures their quality is maintained before distribution.

The Production Process

1.Mixing and Cooking:

  • Objective: Homogenize and dissolve ingredients to form a uniform gel base.
  • Temperature Control: Gelatin solutions are typically heated to 85-90°C to fully dissolve and activate gelling properties.
  • Ingredients: Combination of high-fructose corn syrup, sucrose, water, gelatin or pectin, citric acid, flavoring agents, and colorants.
  • Equipment: High-shear mixers and cooking vessels equipped with precise temperature and agitation controls to ensure thorough mixing and dissolution.

2.Molding:

  • Objective: Shape the gel mixture into desired geometries and allow partial setting.
  • Mold Design: Utilization of silicone or starch-based molds, where the latter involves pouring the gel mixture into starch-filled trays to form the cavities.
  • Temperature: Molded gel is maintained at 40-50°C to ensure proper initial setting before cooling.

3.Cooling:

  • Objective: Complete gelation and achieve the desired textural properties.
  • Temperature Profile: Rapid cooling from 40-50°C to 10-15°C using cooling tunnels or refrigerated systems to prevent excess crystallization and achieve the desired firmness.
  • Cooling Systems: Air-blast coolers or refrigeration units are designed to ensure uniform cooling rates and avoid product deformation.

4.Demolding and Coating:

  • Objective: Remove gelled products from molds and apply surface coatings to enhance shelf life and texture.
  • Coating Processes: Application of sugar, acid, or oil coatings to prevent stickiness and enhance product stability.
  • Equipment: Automated demolding systems and coating machines to ensure efficiency and consistency.

5.Storage:

  • Temperature: Optimal storage at ambient conditions or slightly cooler to maintain texture and prevent microbial growth.
  • Packaging: Use of moisture-proof, barrier packaging materials to prevent dehydration and contamination.

Advantages of Gummies and Jellies

  • Customizable Formulations: Ability to adjust ingredient ratios and processing conditions to meet specific product requirements, such as functional fortification or dietary restrictions.
  • Extended Shelf Life: Formulation strategies and packaging solutions designed to prolong product freshness and quality.
  • Nutritional Enhancement: Integration of bioactive compounds, vitamins, and minerals into the gel matrix for added health benefits.
  • Textural and Flavor Consistency: Precision in process control to ensure uniform texture and flavor across production batches.

Engineering and Equipment Used in Production

Mixing Tanks:

  • Function: Efficiently blend and heat ingredients to create a homogeneous gel solution.
  • Design Specifications: Equipped with temperature control systems, agitation mechanisms, and in-line viscosity measurement tools to ensure consistent mixing.

Molding Systems:

  • Function: Shape the gel mixture into precise forms and sizes.
  • Design Specifications: Includes precision molds made of silicone or starch with automated filling and demolding mechanisms for high throughput.

Cooling Tunnels:

  • Function: Rapidly cool gelled products to set the texture and prevent post-processing deformation.
  • Design Specifications: Conveyor systems with controlled airflow and temperature settings to achieve uniform cooling.

Packaging Equipment:

  • Function: Protect and seal finished products to maintain quality and extend shelf life.
  • Design Specifications: Includes automated packaging lines with moisture-proof and tamper-evident features to ensure product integrity.