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Confectionery & Chocolate

Easy-clean conveying systems, versatile precise feeding and specialty extrusion for even the most challenging confectionery products

Growth in the global confectionery industry currently includes three major segments:

companies making chocolate directly from cocoa beans,

companies using purchased chocolate to make candy products,

and companies producing non-chocolate candy.

The non-chocolate candy segment includes a wide variety of products including jellybeans, chewing/bubble gum, licorice and hard candies.

Coperion’s food components fulfill the highest demands in hygiene, ease of cleaning, and gentle product handling. The processes for any one of the above manufacturing segments may involve both batch and continuous operations. The completely integrated material handling and feeding systems supplied by Coperion K-Tron ensure the optimum in accurate, cost efficient and safe process design, for both types of process operations in all three segments. Coperion K-Tron high accuracy feeders and pneumatic conveying systems are used for transfer, weighing and feeding to the batch cookers, or mixers. In addition, Coperion K-Tron loss-in-weight (LIW) powder and liquid feeders and Coperion high efficiency extruders are used for the production of a variety of products including caramel and chocolate, chewing gum, licorice and various filled candies. Innovations in both material handling and extrusion for confectionery manufacture are an integral part of the overall Coperion systems solution.

Typical products and ingredients include sugar and sugar based blends, corn syrup solids, licorice, chewing gum and chewing gum base, chocolate crumb, raw and roasted cocoa beans, caramel products, hard and soft candy gels, candy wafers, cocoa powder, maltodextrins and milk powders for chocolate manufacture, pectin, gelatins, chocolate bar inclusions: nuts, raisins, etc.



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Description

Features and Benefits

  • The Coperion ZSK Mega Volume Twin Screw Extruder produces highest quality products owing to its outstanding dispersion, which is especially beneficial for triggering the excellent dispersing properties of, for example, flavors within chewing gums, producing a more intensive and longer lasting flavor.
  • Coperion K-Tron feeders dispense high value flavors and ingredients with the highest accuracy, resulting in ingredients savings.
  • Coperion and Coperion K-Tron provide complete material handling and conveying lines for all types of confectionery products and ingredients, inclusive of difficult-to-handle and potentially hazardous materials like sugar.
  • Coperion and Coperion K-Tron’s line of ingredient batching systems ensures efficient transfer and precise ingredient delivery.
  • Our innovative product lines include components for conditioning sugar in order to prevent issues due to moisture absorption or caking during storage. Examples are the Coperion Bulk-X-Change dry product heat exchanger and our high efficiency rotary valves.
  • In all Coperion and Coperion K-Tron product lines a complete range of options is available in design and execution, ensuring product safety, quick product changeover and minimized costs. The options include, for example, hygienic designs supporting different cleaning techniques.

Application Example

Batch Weigh Vacuum Receivers in Food Production

Coperion and Coperion K-Tron’s product range is utilized throughout the entire confectionery process. The application sheet linked below outlines a variety of confectionery and candy manufacturing processes and defines the specific equipment options available for increased efficiency as well as ingredient and process savings. In addition, it evaluates material transfer techniques for a variety of difficult-to-handle products, such as sugar or corn syrup solids, which may be challenging concerning safety and flowability.

Comprehensive Product Range

Twin Screw Extruder ZSK 43 Mv PLUS

Extruders

Custom engineered extrusion designs and systems for a variety of confectionery product shapes and sizes

The internal components of Coperion’s ZSK extruders are custom engineered in a modular system which offers the possibility of setting up a custom configuration tailored to confectionery requirements. Typical melting and shearing applications such as chewing gum base extrusion or sugar melting are easily mastered by the high torque capabilities of this series of Coperion twin screw extruders. Additional confectionery applications include extrusion of chocolate crumb and caramel masses.

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Feeding Equipment

Supreme accuracy for cohesive and high value ingredient feeding

The Coperion K-Tron line of gravimetric and volumetric feeders ensures maximum accuracy and reliability - be it integrating twin screw, single screw or liquid loss-in-weight feeders directly in the extrusion process, or batching ingredients into the mixer via GIW or LIW techniques, or simply metering inclusions to a confectionery process via belt or vibratory feeders. A wide variety of feeder configuration options ensures the optimal choice for feeding even the most difficult-to-handle materials like cocoa powders, chocolate crumb and sugar blends.

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Material Handling

Optimal component options for raw ingredients and finished products

The innovative and custom engineered line of Coperion and Coperion K-Tron rotary valves and diverter valves ensures reliable, long term and safe operation. Coperion’s PSR and ATEX rotary valves are ideal for integration into systems handling explosive materials, such as integration into sugar milling and conveying systems. The easy-clean and hygienic design of Coperion and Coperion K-Tron components ensures quick cleaning and confectionery product changeover.

Plants & Systems

Global systems design and product know-how for a variety of confectionery processes

Our Global Systems Engineering Group has extensive application experience in the entire confectionery process line, whether simply transferring raw ingredients to a batching station or designing process lines for the complete chewing gum or extruded candy product. In addition, integrated control systems which emphasize process safety and product quality are provided for a variety of programming options including ingredient control and recipe management.

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Service

Superior Global Service

Our global service personnel possess extensive material handling and process design knowledge for these special hygienic applications and are available 24/7 to assist you with your confectionery and chocolate process needs.

Typical process flow diagrams

Coperion’s ZSK twin screw extruders are in use for several different applications in chocolate manufacturing
Coperion’s ZSK twin screw extruders are in use for several different applications in chocolate manufacturing
Candy manufacture conveying system. The vacuum sequencing system conveys sugar beads from fiber drums to a sprinkle feeder above a conveyor belt. The second inlet of the receiver was used to recycle the remaining sugar beads at the end of the conveyor belt back into the process.
Candy manufacture conveying system. The vacuum sequencing system conveys sugar beads from fiber drums to a sprinkle feeder above a conveyor belt. The second inlet of the receiver was used to recycle the remaining sugar beads at the end of the conveyor belt back into the process.
Pressure Differential (PD) trucks and railcars use positive pressure to unload material, whereas other types of delivery can often be done by either positive pressure or vacuum pneumatic conveying, or a combination of vacuum and pressure conveying
Pressure Differential (PD) trucks and railcars use positive pressure to unload material, whereas other types of delivery can often be done by either positive pressure or vacuum pneumatic conveying, or a combination of vacuum and pressure conveying
Conveying and batch weighing line including sanitary filter receivers for conveying raw ingredients (including sticky materials) to various LIW feeders for the extrusion line.
Conveying and batch weighing line including sanitary filter receivers for conveying raw ingredients (including sticky materials) to various LIW feeders for the extrusion line.
Coperion’s PSR and ATEX rated rotary valves are ideal for integration into high pressure explosion protection milling systems
Coperion’s PSR and ATEX rated rotary valves are ideal for integration into high pressure explosion protection milling systems
Coperion’s reliable rotary valves are the right choice for the discharge of powder and granules out of silos and hoppers into dilute phase or dense phase pneumatic conveying systems
Coperion’s reliable rotary valves are the right choice for the discharge of powder and granules out of silos and hoppers into dilute phase or dense phase pneumatic conveying systems

Frequently Asked Questions

What are some tips for choosing a feeder to handle my cohesive material?

There are several options when feeding cohesive materials, dependent upon process requirements, material characteristics and the required feed rates for delivering material to the process. In the case of screw feeders, for example, often when using a single screw feeder for a cohesive material, the material is flung off the screw flights in the screw outlet tube and then sticks to the wall of the tube. This material will then accumulate and cause buildup and eventual fluctuations in the otherwise consistent output of the screw feeder. In these cases, a co-rotating twin screw design will be the better choice. Twin screws are often used for more cohesive powders because of the "self-wiping" effect of one screw against the other, which not only helps to transport the material, but also minimizes or even eliminates the buildup of cohesive materials in the outlet tube.

In addition, different screw type configuration options allow to optimize the feeder for the cohesive material. For example, if the cohesiveness of a powder is due to a higher moisture content, or high fat content as in food materials, a twin screw with a finer pitch might create a type of extrusion or squeezing effect thus releasing the moisture and causing additional material buildup issues. In this case, a screw configuration with a larger tolerance on screw flights, such as an auger type, might be better suited.

Finally, the use of specific non-stick coatings on the feeder components in contact with the material can also be investigated. For food and pharmaceutical applications there are FDA-approved coatings available, which are often extremely efficient when dealing with non-free flowing and sticky materials.

Where high flow rates must be achieved or low headroom is an issue, weigh belt feeders are the answer. Typically, cohesive materials will pose additional challenges for weigh belt feeders by depositing on the belt and influencing the weighing results, which in turn impedes the perpetuation of accurate feed rates. Coperion K-Tron masters this challenge by adding a second weigh bridge and correlating controls to compensate for these weighing inaccuracies thus continually tare the belt. This option in design provides for the highest accuracy while reducing downtimes for maintenance and calibration. In addition, the use of scraper bars in the weigh belt feeder design also helps to minimize the negative effect.

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