Producing the perfect gummies and jellies

When we say we are gummy experts, we mean it. Backed by over 95 years of jelly expertise, we deliver seamless confectionery processing and packaging solutions that bring your sweet visions to life. When it comes to gummies and jellies every production step has a direct impact on the final product’s quality. From precise mixing and dosing to dissolving, depositing, starch conditioning, and product finishing, each technology must meet highest standards to deliver a perfect product at the end. That’s why our Makat turnkey line integrates all process steps of starch-based jelly production into one efficient system. All to ensure high-quality jellies and gummies with perfect consistency, as well as a delicious taste and appearance that will catch the consumers’ eye and delight their taste buds at the same time.

Curious to learn more about some examples of the technology integrated in the Makat line? Click on the hot spots of the image and find out how the solutions from Syntegon ensure efficiency and quality during each production step.

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The Makat BLK Rapidsolver is at the heart of Syntegon’s innovative kitchen technology and a key element when it comes to the quality of the final product.

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Once the gummy bears have been destarched from their starch molds, the Makat TF system takes care of starch conditioning, returning the starch to its baseline.

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Once the jellies have made it to the product finishing line, the Makat BC96 oiling drum ensures they receive a perfect glossy coating.

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Every gummy bear starts as a liquid deposited into starch molds and requires gentle handling during its transport.

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Once the jellies leave the Makat line, we also offer flexible packaging solutions to ensure that your sweet treats get the eye-catching packaging they deserve.

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Getting the slurry right

The Makat BLK Rapidsolver is at the heart of Syntegon’s innovative kitchen technology and a key element when it comes to the quality of the final product. The patented system produces high-quality homogeneous, clear and transparent jelly mass and ensures its gentle handling. Its flexibility allows manufacturers to use any common gelling agent to produce a variety of jellies and gummies. Launched 20 years ago, the Rapidsolver has been a mainstay in the industry ever since thanks to its hygienic design as well as innovative features that have been added and improved on over time to meet the evolving demands of our customers and the market – such as added energy-saving features.

Treating liquid jellies right

Every gummy bear starts as a liquid deposited into starch molds and requires gentle handling during its transport. That’s why the Makat RS (Roto-step) system moves the trays with utmost care and makes sure the soon-to-be sweet treats are being well protected during transport, as they deserve it. Since its launch in 2001, the system’s servo-driven chainless tray transport optimizes mold tray movements and keeps acceleration low even during high-speed production – this preserves both the printing and depositing results. Thanks to continuous optimizations, the Makat RS is designed for durability and causes minimal wear on the equipment, thus lowering the overall maintenance cost and contributing to a high OEE.

Shaping your sweets’ success

When it comes to shapes and sizes of jellies and gummies there is no limit to the imagination – and for more than 95 years manufacturers have used our depositing technology to turn their sweetest ideas into reality. From a classic mono-gummy to complex center-in-shell creations, our proven systems offer maximum flexibility to produce a variety of candy in many shapes and colors. Thanks to high depositing accuracy and tailless depositing technology, even highly viscous jelly masses can be handled with precision. Manufacturers can choose from different depositing systems tailored to their specific candy types, which ensures consistent results with every batch.

Keeping starch in optimal condition

Once the gummy bears have been destarched from their starch molds, the Makat TF system takes care of starch conditioning, returning the starch to its baseline. The system is available in different sizes to accommodate various starch throughputs and features a whirl layer with excellent heat transfer properties and advanced air-cooling. This the system efficiently dries and cools the starch, delivering consistent starch conditioning results, regardless of external factors such as humidity for optimal product quality all year round. In addition, the Makat solution allows manufacturers to adjust the residual time and energy input for optimal process control and requires significantly less energy than conventional stream dryer systems. Thanks to its small footprint and compact design it is ideal for efficient jelly production.

Adding the finishing touch

Once the jellies have made it to the product finishing line, the Makat BC96 oiling drum ensures they receive a perfect glossy coating. This will not only make them shine but also protect them against environmental factors. With its high degree of automation and digital condition monitoring, the BC96 offers reliable, time-saving processes and consistently high product quality. Operators can easily specify individual target values for each product recipe via the Human Machine Interface (HMI) –so the Makat BC96 can automatically apply the polishing agents. Its centerlining functionality minimizes process variability and ensures consistent quality with minimal product waste. The system quickly adapts to different recipes and product chanceovers, while the quality is constantly high and the downtimes are kept to a minimum. Recipe management, centerlining, automation and process monitoring as well as operator guiding features of the Makat BC96 all align to reach multiple goals: enhanced process reliability, higher quality of gummies, less waste and a high machine uptime.

“Many confectionery producers are facing the challenge of varying product quality and line performance in different production shifts as well as a lack of skilled personnel. Centerlining features and automation can help to overcome this issue, not only for the kitchen or depositing line, but also for the finishing equipment. That was our motivation to develop our new Makat BC96”.

Dr. Sandra Link, Product Manager at Makat.

Sweets perfectly packed

Once the jellies leave the Makat line, we also offer flexible packaging solutions to ensure that your sweet treats get the eye-catching packaging they deserve. From various vertical packaging styles to shelf-ready cartoning and case packing solutions – we have you covered.

Ready to optimize your starchbased jelly production and your sweets’ packaging process? Contact our experts!

With nearly a century of jelly expertise, Syntegon is committed to support manufacturers in optimizing their confectionery processing. Whether at our own Application Technology Center in Dierdorf, Germany, or at your production site, we work together to develop customized products and processes for an efficient jelly production with improved cost-benefit and increased machine output.

What you can expect from us:

Recipe development: Adapting existing products or developing new recipes in various shapes, flavors and all types of gelling agents in our laboratory kitchen
Process analysis and optimization: Analyzing and improving your individual production process and line
Process testing: Reproducing and testing existing processes as well as developing new production parameters for implementation on your industrial system and testing suitable nozzles
Cooking process: Deciding on the best cooking process
Format design: Designing format parts to improve cost-benefit and increase machine output
Operator training: Training your operators on the machines

Producing the perfect gummies and jellies

Getting the slurry right

Treating liquid jellies right

Shaping your sweets’ success

Keeping starch in optimal condition

Adding the finishing touch

Sweets perfectly packed

Ready to optimize your starchbased jelly production and your sweets’ packaging process? Contact our experts!

Your benefits

Improved efficiency

Fast and flexible support

Quick integration of new products

Reduced time-to-market

Optimized processes and new synergies

Interested in food processing & packaging solutions?