Developing new technology for commercial production of meat substitutes
- Product Development
Starch-free depositing is replacing the starch mogul as the process of choice for gummy and jelly production, particularly in the vitamin supplement and nutraceutical markets.
Jellies and gummies are increasingly being used to deliver a variety of functional ingredients including vitamins, minerals, fibre, CBD, protein, Omega-3, probiotics and energy supplements. They appeal to customers looking to boost their intake of essential nutrients, but who prefer to do so in a non-pharmaceutical format.
Jellies and gummies are particularly effective in the children’s supplement market because of their palatability.
A big problem for producers of healthcare jellies and gummies is that the starch mogul process brings with it the risk of cross-contamination of the active ingredients. Starch-free depositing overcomes this, while Baker Perkins’ and Rousselot’s development work to reduce setting times also reduces capital and operating costs significantly.
This has been achieved through a combination of Rousselot’s innovative new SiMoGel™ gelatin, especially formulated for starch-free depositing, and Baker Perkins’ ServoForm™ depositors and cooking systems.
The development has focussed on being able to remove the products from the moulds in the shortest possible time. A number of factors contribute to this, not least that the syrup is deposited at final solids. This not only promotes rapid setting of Rousselot’s special SiMoGel™ formulation but also reduces the need for energy-intensive stoving or drying, further strengthening the economic case for starch-free processing.
Setting times for gelatin gummies with additives have been reduced to as low as 15 minutes, although this can vary with the specific recipe, additives and final product characteristics required. To allow the product to achieve final texture and moisture some additional resting and/or drying time may be necessary, but still significantly less than a mogul line.
It is important to stress that this is not an ‘off-the-shelf’ process. Every product is unique, especially in the healthcare industry, and trials are essential. A full range of test equipment along with expert process support is available in the Baker Perkins Innovation Centres in the UK and USA.
Baker Perkins works closely with suppliers of other high-performance gelling agents, including pectin and carrageenan, on quick-set processes. These enable manufacturers to benefit from starch-free depositing across the full range of jelly and gummy textures.
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