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Hard caramels
At first sugar and water are boiled to 110 °C until clear, then the pre-heated starch syrup is
added and the mass heated to 157 °C under normal pressure and to 147 °C under vacuum until
the desired water content of 1–2% is reached.
Formerly the sugar mass has
been cooked on an open fire.
This required a lot of
experience as eventually the
correct final cooking temperature
had to be reached.
Hard caramels are produced from:
sugar, starch syrup and water,
aroma, colour and acid are added.
Basic recipe:
60 kg sugar
37 kg starch syrup
3 kg water
Nowadays this is done by a semicontinuous
boiling unit, e. g. by
Robert Bosch/Hamac-Höller,
Otto Hänsel or Carle & Montanari
Hard caramels
With the discontinuous
method the finished sugar
preparation is poured with
great care onto a water chilled
cooling plate that has been
covered with a separating
agent. It is then die-casted and
kept at the same temperature
until further processing.
The mass is worked through by an automatic kneading cylinder and aroma, acid and colour are
added and heated to 70–90 °C. Continuous units would refrigerate the confect mass in separate
tempering and kneading sections with up to 10 m length.
Those are equipped with kneading cylinders and rotary tablets and coated with a separating
agent.Aroma, colour and acid are continuously incorporated.
Manufacturer of machines: Bosch, Otto-Hänsel,Theegarten, Ruffinatti, Backer Perkins,…
With all production methods the aroma is worked into the hot candy mass (110–140 °C).
A big part of the volatile aroma compounds evaporates and the loss amounts to up to 60 %.This
is why stabilizing dissolvers such as e. g. propylenglycole or triacetin are used for thermo-stable
aromas. Recommended dosage: 100–200 g/100 kg boiled candy mass.
After adding aroma, acid and colour the hot candy mass is pressed into moulds or die-casted.
The pressing is done by a chain moulding system.
➃Cooling tunnel: In the cooling tunnel the boiled sweets are being chilled down to the packing
temperature of 70–80 °C.
➀
➁
➂
➃
Immediately after the boiled sweets have been cooled
down they are individually
wrapped, since any exposure to humidity and odours
must be avoided.
Producers of wrapping machines are:
e. g. Nagema or Rose-Theegarten,…
Various types of wrapping:
➀Double twist wrap
➁Stickpack wrap
➂Fold wrap
Wrapping capacity approx. 240–1,500 pieces/minute
The finished product must be stored cool and dry.
Sugar
Sugar is the general term for sweet-tasting, white crystals.
Sugar (chem. description = sucrose) is a carbohydrate,
subgroup – disaccharide, consisting of 2 monosaccharids.
D-glucose (dextrose or glucose)
D-fructose
The chemical formula of sucrose is: C12H22O11
Extraction from sugar cane and sugar beet through photosynthesis, this is a metabolism process.
By means of solar energy and chlorophyll the high-energy substance sugar
C6H12O6 is produced from water (H2O) and carbon dioxide (CO2).
History of sugar
Sugar cane origins from New Guinea where it is said to have grown as early
as 15,000 B.C. It then has been spread all over the globe.Around 750 A.C/A.D.
the Arabs have cultivated sugar cane and planted it in Sicily and Spain.The
sugar produced there has been a highly desired merchandise.Apparently it
was during the time of the crusades when sugar has reached Central Europe
through Venice for the first time.
Starch syrup
The name for starch syrup within the sweets industry is glucose syrup.
It is a purified and concentrated watery solution of D-glucose. Glucose is made with acid or
enzymes from maize or potato starch, through hydrolysis.
Various types of starch are differentiated by their degree of saccharification, which is measured in
DE (Dextrose Equivalent). DE-Value = dry substance content of reduced sugar (D-glucose)
The most commonly used starch syrup is 38–42 DE, with 80 % dry substance.
Starch syrup inhibits sugar crystallization and acts as a softening agent.

devamı...

Sugar
Sugar is the general term for sweet-tasting, white crystals.
Sugar (chem. description = sucrose) is a carbohydrate,
subgroup – disaccharide, consisting of 2 monosaccharids.
D-glucose (dextrose or glucose)
D-fructose
The chemical formula of sucrose is: C12H22O11
Extraction from sugar cane and sugar beet through photosynthesis, this is a metabolism process.
By means of solar energy and chlorophyll the high-energy substance sugar
C6H12O6 is produced from water (H2O) and carbon dioxide (CO2).
History of sugar
Sugar cane origins from New Guinea where it is said to have grown as early
as 15,000 B.C. It then has been spread all over the globe.Around 750 A.C/A.D.
the Arabs have cultivated sugar cane and planted it in Sicily and Spain.The
sugar produced there has been a highly desired merchandise.Apparently it
was during the time of the crusades when sugar has reached Central Europe
through Venice for the first time.
Starch syrup
The name for starch syrup within the sweets industry is glucose syrup.
It is a purified and concentrated watery solution of D-glucose. Glucose is made with acid or
enzymes from maize or potato starch, through hydrolysis.
Various types of starch are differentiated by their degree of saccharification, which is measured in
DE (Dextrose Equivalent). DE-Value = dry substance content of reduced sugar (D-glucose)
The most commonly used starch syrup is 38–42 DE, with 80 % dry substance.
Starch syrup inhibits sugar crystallization and acts as a softening agent.
Jelly
➀
➁
➂
➀Powdering
➁Stamping
A mogul plant by Winkler & Dünnebier ➂Die-casting
Output: 6–36 trays per minute
Then the trays are moved and placed underneath the die-cast jets.The die-cast solution is being
applied simultaneously through 42 jets in 12 rows and filled into the moulds.The filled starch
trays must be left for approx. 12–24 hours for the solution filled in to become solid. During this
phase the dry starch powder (powder temperature approx. 20 °C, with 5–7% remaining humidity)
extracts a certain amount of humidity from the die-casted item.
The next step is the powdering process.Turning the full starch tray by 180° delivers the finished
item.The starch must be properly removed from the powdered jelly items, which will then be
singled out on a grid conveyor and finally exposed to vapour.Thereafter the humid items run
through an angularly placed, perforated drum which is coated with dry sugar. In this drum the
sugar will stick to the item without itself dissolving.
Alternatively the sugar coating of the jelly items may be replaced by chocolate coating. In this
case the powdered items will run through a coating machine where a thin layer of chocolate is
applied.Thereafter the products will be refrigerated in the cooling tunnel.
Wrapping the finished product represents the final processing step.There is a great range of
different wrappings, most frequently however, the items would be wrapped into a bag.The
wrapped items are additionally packed into cartons to protect them during transportation and
storage.

Agar-Agar
is a gelling agent extracted from seaweed.
As a gelling agent it binds the 30-fold quantity of water. It is not soluble in cold water.
Agar-agar solution gels when cooled down to 35–45 °C and becomes liquid at
95–98 °C.This is an important characteristic of agar jellies as they can
be re-liquidized by warming thus easy processing is facilitated.
Agar-agar is generally available as a white-grey to light yellow powder and is
highly water-soluble.The thread-type needs to be soaked in lukewarm water
for 12 hours.
Pectin
is a gelling substance occurring in many plants. Pectin is a so called
hydrocolloid (substance that swells in water). Pectin is highly
water-soluble at 80 °C!
The following fruits have an especially high pectin content: apple, quince, currant, citrus fruits.
The source material for the production of pectin is pressing residue of fruits.
For example:
Apple residue contains 10–15% pectin (apple pectin)
Citrus peel contains 20–35% pectin (citrus pectin)
There are low and highly esterified types of pectin. Highly esterified types of pectin are used for
the gelling of confitures, marmalades, jellies and jams.
The latter can gel with a content of at least 58 % dry substance and with an
acidity around pH ~3.5.
Low-dose esterified types of pectin are used for the gelling, thickening and stabilizing of products
with a low dry substance content – such as ketchup, diet jam, yoghurt ingredients.