How to process confectionery products effectively
The confectionery market in the UK is worth an estimated £3.8 billion as of 2022. Although consumer behaviour is subject to change and popular products may evolve, it is a relatively stable sector.
Manufacturers, therefore, may access promising opportunities and favourable profit by processing confectionery products. However, you will only secure the rewards if you consistently create optimal output that meets customer expectations.
Confectionery, including sweets and chocolates, bring unique requirements to your plant. You must be ready to address them to guarantee performance and quality.
We explore the challenges associated with confectionery products and how to overcome them in your processing practices.
The challenges of confectionery
You need to be aware of every product’s distinctive characteristics when processing. Confectionery is no different. Understanding the challenges posed (which we’ve listed below) is crucial to overcoming them.
Sticking
Many confectionery products, such as soft sweets and marshmallows, are sticky in integrity. It leaves them prone to sticking during the production process, leading to disruption and build-up in your machines. If they get stuck, they may also get damaged, affecting presentation and quality.
You must minimise sticking with coated surfaces that allow for better product flow. Doing so will allow you to maintain speed and productivity while protecting your output quality.
Portion control
Most confectionery products come in packs of set sizes, whether chocolate boxes or sweet bags. You must adhere to every package’s weight limits for consistency and compliance.
You must ensure accuracy across your production line and adhere to parameters at every stage, so you only use the materials you need. This improves cost control, supply management and customer experience.
Mixing configurations
Many confectionery products mix materials, such as sweets of different flavours, shapes and sizes. You need to be prepared to process these materials together and mix them in the appropriate amounts.
It requires intelligent machinery that will mix configurations and enable agile handling.
Delicate handling
Confectionery products are often fragile, leaving them prone to damage if not handled correctly. Damage will create presentation issues and lessen output quality, potentially leading to customer dissatisfaction and recalls.
You must ensure your line handles your products carefully, minimising the risk of damage whilst maintaining productivity.
Productivity
Productivity is crucial in any plant. The better your productivity, the better the output and cost management throughout your plant.
There are many factors which will influence this, including fast and accurate machinery, efficient processes and appropriate resources.
By facilitating productivity, you will generate better results and value for money.
What you need to process confectionery products effectively
Once you know the challenges confectionery processing entails, your production lines must be designed to overcome them. We have listed our top tips for preparing your plant.
Seek delicate handling
As we have already mentioned, many confectionery products are easily damaged. If a product is damaged, customers are less likely to buy them or may complain. It is imperative to have machinery that handles them delicately to minimise the impact.
Look for features such as minimal drops that reduce the danger posed to your products. In some cases, you may include manual handling into your processes to prevent the impact of machinery or hard surfaces.
Another consideration is the speed of your equipment, as faster machinery may result in more damage. However, you need to balance this against productivity.
By seeking systems which offer delicate handling, you will achieve higher quality output and avoid presentation issues.
Purchase compatible machinery
You understand the characteristics of your products. With these determined, identify characteristics of machinery that meets your needs.
A common challenge associated with confectionery is product sticking. Seek systems with specific features, like anti-static coating or rounded bucket heads, that maintain product flow and minimise the risk of sticking.
It is also crucial to have hygienic systems with an appropriate IP rating. As sweets and chocolates leave residue in your production line, you will need to clean these regularly to prevent build-up and meet industry standards. Ease of cleaning is crucial to speeding up the process and reducing downtime.
There may be other features you need to consider, especially if you’re working with products of specific sizes or formats. Whatever your needs are, ensure your production line is fully compatible, as this will boost performance.
Maximise productivity
Productivity is integral to managing costs and adhering to timelines. Many manufacturers in the confectionery sector will need to process high volumes at a time to fill packs and meet demand. This can be quite the task, so you enhancing productivity is key.
Options for boosting productivity include utilising machinery with a high load capacity or faster speeds. However, you must remember not to compromise quality in favour of time, so ensure the equipment is compatible with your product.
Effective processes allow you to meet output requirements within your timeframe. This will enable you to remain productive and create a high-quality product that meets expectations. Train your staff on these processes and equipment for an even smoother experience.
Ensuring your systems are well-maintained also helps to minimise unexpected downtime or other issues.
Having accurate systems
Most confectionery products are sorted into a pre-determined pack size. You must adhere to weigh limits to meet requirements and deliver consistency. Accuracy is crucial.
Every system you utilise needs to offer precision with minimal room for giveaway. Weighers have to sort the exact amount of product required for each production stage, which will culminate in the right quantity or weight in your packaging as agreed under the project specification.
Accuracy will also be critical across your non-weighing equipment, including inspection systems. This ensures you continue confident that your output meets the necessary criteria and there are no underlying issues i.e. contaminants.
It also supports your cost control, stock management and waste reduction management by ensuring correct amounts of materials are utilised in every pack.
Include product inspection
Like any other food, confectionery is susceptible to contamination. If left unaddressed, it could lead to customer complaints and potential health issues – not to mention product recalls and legal action. This has a financial and reputational cost that any manufacturer wants to avoid.
The contamination your products are prone to will depend on many factors, including your plant environment, where you source materials from and the processes involved. Common contamination sources include metal, dirt, and hair, as well as biological contaminants and allergens.
In confectionery, especially smaller products, it is hard to uncover contamination. X-ray is often recommended as the industry leader for inspection technology, allowing you to detect various contamination types.
By investing in an inspection system, such as x-ray, it will allow you to detect contaminants and eliminate them. It also helpa you to pinpoint other issues, including product clumps or presentation problems.
Determining the issues will enable you to rectify them before they go to your customers, protecting your reputation and improving quality.
Be agile
The term ‘confectionery’ may apply to a broad spectrum of products, encompassing various shapes, sizes and integrities. In many cases, you work with multiple types at one time. It’s therefore crucial that your production line can cope with each.
Versatile machines will allow you to process a wider range of materials. Features to look out for include:
- Programming to set parameters (including mixed products)
- Compatibility with a wide range of product types
- Accuracy
- Automated functionality that reacts to performance data
Most crucially, you need equipment that will consistently offer high-quality output. It means that you will meet customer requirements and generate positive results no matter what you need to process.
Yamato's solutions
Yamato has years of experience supporting confectionery manufacturers to optimise their production lines. Our solutions comprise accurate weighers, innovative inspection systems and beyond.
Our most popular machines for confectionery processors include:
- Alpha Series multihead weigher – a highly accurate weigher with maximum return on investment
- Epsilon multihead weigher – providing excellent performance at an affordable price
- J-Series checkweigher – allowing you to check the weight of your batches for enhanced accuracy
- X-ray systems – offering premium inspection across a broad range of products
We offer many other products, including customised systems, allowing you to find the perfect fit for your plant and its objectives.
We will support you with after-sales support, including project management, staff training, service contracts and the commissioning of your line.
Get in touch with a team member today to find out how we can help you.