10 confectio introduction copy copy .pptx

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1. The term confectionery is ambiguous and describes a spectrum of sweet goods and takes on different meaning depending on the country in which it is used, for example in the United Kingdom the term applies to any sweet product including cakes. In the United States confectionery is candy and includes sugar confectionery and chocolate confectionery. Globally, confectionery foods represent 50% by volume of foods produced and 60% by value. The Indian confectionery market is estimated INR 338.2 Billion in 2022  and is segmented into sugar-boiled confectionery, chocolates, mints and chewing gums. Sugar-boiled confectionery consisting of hard-boiled candy, toffees and other sugar-based candies, is the largest of the segments and it is valued at around Rs. 20,000 million. Some of the largest companies active in the confectionery sector are Cadbury, Nestle and  Perfetti . In India

2. Classification of Confectionery Sugar confectionery Chocolate confectionery Flour confectionery Milk-based confectionery

3. Sugar Confectionery Groups Amorphous sugar confectionery These products are characterized by hard, chewy, homogenous and non-crystalline nature. It includes hard boiled candy, caramels, toffee, taffy, brittles, gums, jellies, etc Crystalline sugar confectionery Crystalline candy  usually has fine sugar crystals and a lower sugar concentration than non-crystalline candy . To make crystalline candy, the sugary syrup is stirred continuously as it cools to ensure the sugar crystals remain small. Fudge is an example of a crystalline candy.

4. Sugar glass

5. Raw Materials and Ingredients Used in Sugar Confectionery Sucrose Sucrose derivatives Glucose syrups Honey Intense sweeteners Bulk sweeteners Fats Emulsifiers Milk products Gelling agents, thickeners and stabilizers Colours Flavours

6. Key ingredients used in sugar confectionery: The major ingredients of the sugar confectionery are sugar, glucose syrup or invert sugar and water. The purpose of using reducing sugars is to control or prevent crystallization ; whether crystallization occurs or not, it is required that the level of dissolved solids in the water should never less than 76% in order to prevent microbial deterioration. Sugar solubility: Sugar dissolves in water to give a saturated solution of 67.1% solids at 20C. However, up to 74% solids, undisturbed sugar syrup will not crystallize unless seed crystal is present or mechanical or thermal shock is encountered. This metastable state is utilized in the wet crystallization process. The presence of invert sugar or glucose syrup increases solubility of sugar and TSS in solution at saturation

7. Confectionery Production Processes Cooking : Cooking of sugar is usually carried out in either gas fired cooking pans or in steam-jacketed kettles. Drop rolling : The drop roller was one of the earliest sweet forming machines. It consists of two synchronized brass rolls engraved with matching impressions. Moulding : Depending on the type, confectionery products are moulded in different shapes. Boiled sweets are deposited into teflon -coated aluminium moulds fitted with ejector pins. After cooling, the pins are depressed from the underside of the moulds to eject the solid boilings . Extrusion : Extruders of various types are used for forming bars and sheets from pastes and plastic confectionery bases. Lozenges are formed by passing the paste through a screw extruder and die to form a sheet which is then reduced in thickness by subsequent sizing rollers. In case of bars, the sheets are slit by rotary knives and sized to desired length .

8. Confectionery Production Processes Plastic forming : The plastic forming operation is widely used in the confectionery industry for converting plastic masses such as boiled sugar or toffee into individual sweets. In this process, the product will be tempered to correct consistency and flavour ingredients incorporated during the kneading process in the case of boiled sugar, cooling drum or cooling conveyor in the case of toffees. The mass is then fed into a batch roller for obtaining the product in the form of a rope . The rope is the fed to a pressurizer followed by sweet former (to give desired shape to final product) and later packaged. Wet crystallizing : Wet crystallizing is the process of building up a thin coherent coating of sugar crystal on the surface of a sweet. process consisting in growing a continuous layer of crystalline sugar on the surface of products by immersing them in a slightly supersaturated sugar solution (the products are located in the same layer). This not only provides protection of the centers, but also significantly improves the appearance, making the surface " sparkling". This seals the surface, and when used on products such as fondant creams or marzipan, retards drying out, extending the shelf life from a few days to 6 months or more.

9. Confectionery Production Processes Panning: Panning is an operation which has been used by the confectionaries for centuries. In principle it is the application of coating to centres tumbling in a revolving pan mounted at about 30 ℃ to the horizontal. The operation consists of adding enough coating medium to cover the centres completely with no surplus and drying this off either with hot air (hard panning), extra sugar (soft panning) or cold air (for chocolate). Coatings may be sugar syrup (hard panning), glucose syrup dried off by the application of fine sugar (soft panning) or chocolate, solutions containing food grade colours , edible gums, etc. Steps included Engrossing:  Engrossing describes the process of coating the prepared inclusions with chocolate or another coating. Polishing:  After engrossing,  most panned confections have a dull appearance  that needs polishing for a more attractive appearance. This step and glazing are parts of the finishing process. Glazing:  Glazing often consists of different layers,  such as a sugar syrup coating followed by shellac coverin

10. CANDIES Candies represent a subgroup of amorphous sugar confectionery which are characterized by hard, chewy, homogenous and non-crystalline nature. These are also called as glass. The glassy state of matter is not a thermodynamic phase but a supercooled liquid and exhibit a sharp transition temperature between glassy and rubber states. Most sugars will form a glass but pure sucrose does not form a glass. Therefore, commercial sugar glasses are always made from sucrose and some other sugars such as invert sugar, glucose syrup, etc. Any additive required to stabilize a sucrose glass is traditionally referred to as a “doctor” by confectioners. Sometimes, acids are added to sucrose for in situ generation of invert sugar. In practice, boiled sweets (or high boilings ) become unstable by absorbing water. Initially the product becomes sticky, then soft, followed ultimately by crystallization.

11. Classification

12. Products include   fruit drops, acid drops, barley sugars, toffee, butterscotch, caramel . lozenges lollipops

13. Butterscotch  is a type of confectionery whose primary ingredients are brown sugar and butter. Some recipes include corn syrup, cream, vanilla, and salt.

14. Hard Boiled Candy

15. Hard candy is produced by boiling a sugar syrup to the hard crack temperature which, on a candy thermometer, is about 149°C (300°F). At hard crack, water content is low and the sugar mass is extremely viscous

16. Formulations

17. Hard candy is nearly 100% sugar by weight; Recipes for hard candy may use syrups of  sucrose ,  glucose ,  fructose  or other sugars. Sugar-free versions have also been created. Once the syrup blend reaches the target temperature, the candy maker removes it from the heat source and may add  citric acid ,  food dye , and some flavouring , such as a plant  extract ,  essential oil , or  flavorant . The syrup concoction, which is now very thick, can be poured into a  mold  or tray to cool. When the syrup is cool enough to handle, it can be folded, rolled, or molded into the shapes desired. After the boiled syrup cools, it is called  hard candy , since it becomes stiff and brittle as it approaches  room temperature . Chemistry Chemically, sugar candies are broadly divided into two groups:  crystalline  candies and  amorphous  candies. [1]   Crystalline candies  are not as hard as  crystals  of the mineral variety, but derive their name and their texture from their microscopically organized sugar structure, formed through a process of  crystallization , which makes them easy to bite or cut into.  Amorphous candies  have a disorganized crystalline structure. Hard candies are non-crystalline, amorphous candies containing about 98% (or more) solid sugar.

18. Sugar glass  (also called  candy glass ) is a brittle transparent form of  sugar  that looks like  glass . It can be formed into a sheet that looks like  flat glass  or an object, such as a bottle or drinking glass. Sugar glass is made by dissolving sugar in water and heating it to at least the " hard crack " stage (approx. 150 °C) in the  candy  making process.  Glucose  or  corn syrup  is used to prevent the sugar from recrystallizing, by getting in the way of the sugar molecules forming crystals. 

19. The glass–liquid transition, or glass transition, is the gradual and reversible transition in amorphous materials (or in amorphous regions within semicrystalline materials) from  a hard and relatively brittle "glassy" state into a viscous or rubbery state  as the temperature is increased

20. Large scale production process Hard candy production consists of preparing the syrup mixture, cooking the mixture, and bringing the sugar mass to the right consistency and shape before packaging. Mixing First, the dry and liquid confectionery ingredients are weighed and mixed into a homogeneous slurry using an auto-feed system  or  batch dissolver . Individual ingredients are fed sequentially from a  bulk handling  system into a weighing and  mixing tank  mounted on load cells at each support

21. Cooking After mixing, a microfilm cooker, shown below, is used to cook the slurry rapidly and create the final product. The process is continuous and cooks the mixture in two stages. First, the sugar slurries are mixed, and then cooked and converted to a product with the proper moisture content. The continuous process produces very little waste and is efficient in its use of energy and water. A pressure-dissolving system reduces recipe water, which permits higher temperatures and increases saturation levels of sugar. The increase in saturation means there is less water to evaporate, so less energy is needed to evaporate water from the mixture. After cooking the candy, the mixture is mixed with other ingredients such as flavorings, acids, and colorings. The mixture is then cooled and tempered to a temperature suitable to feed into a batch former.

22. Cooling/Forming of Candy The mixing and cooling operation can be done in a  batch kneader  and continuous cooling/tempering band respectively. The continuous cooling band is made of stainless steel and has a framework made of steel tubing and a water-cooling system. The sugar mass is cooled in the belt by the cold-water system and the temperature is controlled by a thermostat. For the batch kneader unit, the sugar mass is kneaded and plowed above a steel belt, which accelerates heat transfer and changes the sugar to the right consistency. After the sugar mass reaches the right consistency, it is fed to a batch former, that shapes the cooled and tempered sugar mass into a cone to feed to a rope sizer. The former is equipped with a heating system to keep the sugar mass at an appropriate temperature to prevent cracking or very viscous behavior. The rope sizer then sizes and delivers the sugar mass at a specific diameter to the candy maker machine. Additionally, an electric heater is used within the rope sizer to keep the sugar rope in the perfect plastic condition. The rope sizer acts as the connection between the batch former and the candy maker

23. The candy maker or candy shaping machine is followed by the cooling and wrapping equipment. Hard candies, specifically, are made by a hard candy maker that contains rotary dies suitable for any shape or size of candy. The candy maker is a highly efficient automatic machine that consists of a cast frame, sizing unit, rotary die, candy discharge belt, and control system. The cast frame provides a strong foundation used to absorb all vibrations from candy embossing and shaping. The sizing unit is composed of two sizing rollers that are used to obtain the desired sugar rope diameter. The candy shaping unit is a continuous, automatic, multi-position process, in which the unfilled sugar rope obtained from the rope sizer is squeezed and separated into multiple sections. In this unit, a piece of sugar mass is cut off and shaped using a roller and toothed ring and is subsequently put on a die plate. A scraper is used to prevent fine sugar pieces from sticking to the die plate and causing the next shaping process to malfunction. The sugar mass can also be shaped using a candy depositor. The depositing process allows the cooked sugar to be fed directly to the candy depositor, which places it into individual candy mold. The molds are then fed into a cooling tunnel that hardens the cooked candy, which are then fed to the candy ejector.

24. Packaging and Quality Control Candy formed by either the depositor or candy shaping machine is then packaged in a high-speed wrapper or enrobing machine. Quality control throughout the process is achieved by controlling the temperature and water content of the sugar during production to ensure it keeps its plastic characteristics. Quality and purity of water are also maintained to ensure proper sanitation and ingredient preparation https://youtu.be/Lh-28EILxp8

25. LOZENGES   Lozenges a hard boiled sweet are made from icing sugar which is mixed with a binder solution, sheeted, cut to shape and allowed to dry common types of lozenge are extra strong mints and medicated lozenges. Compressed tablets have a smooth, shiny surface; lozenges tend to have a rather rough finish.   The main ingredients of lozenges is icing sugar. The grade of sugar chosen will have a radical effect upon the final product. A fine particle size sugar must be used. The next ingredients consider is the binde r. This is usually gum Arabic, gelatin , gum tragacanth , or more often a blend. To overcome texture problems and to reduce the raw material cost a blend is more usually used as the binder. Gum Arabic, is made up as 50 % solution with water, gelatin is soaked in twice its weight of water . .    

26. Lozenge manufacture The icing sugar and binding sugar solution are mixe d together. After mixing the lozenge mix should have a firm , doughy texture. Hard candy lozenges are manufactured by cooking process by dissolving desired quantity of sugar to prepare the candy base to get an amorphous, non-crystalline glassy state in one third amount of water at the temperature at about 110oC. Sucrose, dextrose, maltose and lactose are added as sweeteners. citric, tartaric, fumaric and malic acid etc are added as acidulents to strengthening the candy base . Colours approved are added with shades like orange, red, green or yellow. Flavours used include menthol, eucalyptus oil, and cherry flavor etc. The flavours used for lozenges are frequently volatile and can be lost during the mixing process, the flavours are best added at the last possible minute The moisture content should be between 0.5 to 1.5%. This mass is then transferred to a water-jacketed stainless steel cooling table for mixing of the flavor. The mixed mass is either poured into mould to get desired and uniform size lozenge which are packed as single units using wrappers.