Gummi Candy: Moldando o sucesso com os magnatas

Gummi candy—comprised of gelatin or pectin, sweeteners, flavorings, and colors—is a relatively new candy invention, first created in the early 1900s in Germany by Hans Riegel, founder of the Haribo company. Haribo began in the Riegel family kitchen, Hans Riegel and his wife Gertrud its first two employees. In 1922, inspired by the dancing bear shows popular across Europe, Hans Riegel introduced his gummi prototype, named the Dancing Bear, or Tanzbären in German—the precursor to the modern-day gummi bear. Gummi candies were popular in Europe, but it wasn’t until the 1980s that they gained traction in the United States. During this time, several companies, including Haribo, Trolli (makers of the popular gummi worms) and Jelly Belly, entered the market.

Advances in automation have improved the precision, quality, and production speeds of gummi production, although the process largely remains unchanged. The first step is compounding—blending the raw ingredients together, usually in a batch mixing tank equipped with heating and cooling capabilities, commonly referred to as a kitchen. The mixed ingredients are pumped directly into a starch molded mogul. The use of starch helps prevent the candy from sticking to the molds, holds the candy in place during drying, cooling and setting, and absorbs any additional moisture which might cause a deviation in texture. From the mogul, trays of candy enter the curing/stoving room before being moved to a starch buck where they are inverted to dump the candies. They then move along a vibrating sieve with oscillating brushes to remove excess starch. Starch is cleaned and dried, then recirculated and reused. Finally, the candies can either receive further decoration or proceed directly to the packaging machines.

In addition to gummi candies, gummi vitamins and nutraceuticals have become very popular, fueling several recent Dennis Group projects with Sweet’s, Mondelez, and Zachary Confections.

Sweet’s is a pioneer for mogul manufacturer, Tanis

One of Dennis Group’s first big mogul projects was with long-term client Salt Lake City-based Sweet Candy Company. Due to a new client co-manufacturing their organic gummi line of products with Sweet’s, the company embarked on a 50,000 SF expansion to accommodate a new kitchen, mogul, drying area, and high-speed baggers. Well into this expansion the mogul company, which had already purchased the steel and begun welding the frame, had to inform Sweet’s that they were filing for bankruptcy and would be unable to complete the equipment.

Sweet’s was scrambling to find a solution when Tanis, the supplier of their starch gummi kitchen, stepped in and offered to build and install both the mogul and the kitchen. Moguls were a new product line for Tanis. They were in the process of making model 1-A for a company in Indiana, and Sweet’s received model 1-B a few months later. Dennis Group’s team worked closely with Sweet’s during the development of this line, and in the coming years helped them automate their processes, including four baggers capable of 180 bags per minute.

Mondelez Canada adds automation and capacity for popular gummies

Mondelez International required a new production line to support their starch-molded gummies, including popular brands like Swedish Fish and Sour Patch Kids. They enlisted Dennis Group to design and install a comprehensive new mogul line, which included ovens, stoving rooms, and a kitchen. This 12,000 SF expansion was particularly challenging because it required integrating new lines with existing packaging lines, necessitating the construction of a second-story mezzanine above the active production space. There were limited staging areas
during construction, due to the facility’s proximity to residential areas, making just-in-time delivery of materials and equipment crucial.

One of the standouts features of Mondelez’s new production line is the automated guided vehicle (AGV) system, which efficiently transports trays from the mogul to the curing rooms. This automation, coupled with high-speed baggers capable of handling 180 bags per minute, has significantly boosted production capacity. Additionally, the implementation of desiccant drying systems (desiccants are materials such as starch or silica gel that speed the drying
process) has allowed for faster candy curing without compromising quality.

Zachary Confections AGVs show their school spirit

Family-owned Zachary Confections enlisted Dennis Group (on a referral from OEM Tanis) for assistance with a 25,000 SF warehouse conversion to accommodate two new gummi lines, including a kitchen, mogul, stoving room, and packaging. This highly automated facility only requires a few operators for both the kitchen and the mogul. AGVs—decorated for the family’s alma mater of University of Michigan—stack the trays and place them in the oven.
Starch molding requires careful dust hazard analysis, and the rooms that handle starch are Class 2, Div 2 certified. Zachary holds the distinction of being the only US facility to manufacture candy corn, so you can imagine how busy they get as October approaches.
The gummi candy market continues to evolve with plant-based or vegan options, the use of natural flavors, reduced sugar options, new innovative shapes, and the growth of functional
or nutritional supplements. According to market research conducted by Grand View Research, the U.S. gummi market size was estimated at USD 3.12 billion in 2023 and is expected to grow at a compound annual growth rate (CAGR) of 11.6% from 2024 to 2030,
making it a high growth sector. Most of this growth is driven by the rising popularity of vitamin-based gummies, as adults make up 78% of the end-users. There will continue to be ample
opportunity for starch molded gummi capital projects in the future, which is a very sweet prospect.