Here’s a look at our gummy manufacturing process
Okay, let’s make some gummies!!
First thing’s first: our getup. Since we have strict sanitation control, we must perform a thorough check of our clothes at the entrance to ensure that we don’t bring any dirt or dust into the factory.
Checking ingredients → measurements
The most important part of anything is how you start! We first need to make detailed checks of our raw ingredients.
We look at closely at the number of shipments received, check packaging for tears or stains, make sure everything has been stored correctly and follows quality guidelines, and so on. If everything is in tip-top shape, then we’re off to measuring!
Mixture dissolving refers to the process of mixing and dissolving ingredients.
After adding a syrup called "mizuame" and other ingredients, we stir the mixture and add heat. Once the solution comes to a boil, we add sugar.
We continue boiling down the solution, checking its weight as we go.
When it has reached our specifications, we check its sugar levels (Bx). If it hasn’t quite reached our specifications yet, we continue boiling and concentrating the solution. We also can’t forget to write down changes in weight on our check sheet.
Afterward, we add heat and everyone checks to make sure that the gummy mixture is coming along smoothly.
Expansion and Dissolution
We finally add gelatin, the congealing agent, after we’ve added anti-foaming agents as needed.
Of course, just like all other ingredients, we first confirm the gelatin’s lot number, check its freshness date, and make sure there are no tears or stains on its packaging. At the same time, we always make sure our measuring devices are functioning properly.
Once everything’s been cleared, we spread and dissolve the gelatin evenly in the water.
We stir well to make sure it’s completely mixed in…
Measuring additives → mixing
We color the mixture to match the gummy’s flavor. Just like other ingredients, additives are thoroughly inspected in advance. After inspection, they are measured, and we sign off the checklist.
Colorants don’t dissolve well, and can easily lump up or result in uneven coloring if added directly. So, we dissolve colorants ahead of time and then add them to the mixture. The order ingredients are added in is quite important. This is why we’re sure to follow our “order of operations management chart” when making gummies.
Brix (Bx, sugar levels) preparation → pumping
We check the degrees Bx. When everything is checked off, we pump the solution into a storage tank. To keep the solution from cooling as it’s transferred, we heat up the piping ahead of time. If we haven’t reached our specified degrees Bx, we adjust by adding water before pumping the liquid.
The amount of water added is, of course, also noted on our checklist, and we transfer the gummy liquid in perfect confidence.
We check temperatures inside the storage tank to ensure that our gummies are kept nice and warm as they await the next stage of the gummy-making process.
That's the end of initial preparations. Next we’re on to the filling process.
Bringing in trays → starch injection → molding
The white powder blanketing the tray is corn starch.
Corn starch can be used to make a variety of shapes, and since it’s a food product itself, it’s entirely safe to use. We check to see if the mold is fully pressed to the end.
Gummy filling time!
Time to set the tray on the filling machine! The gummies are ready to take form at last!
Here we need to monitor the gummy liquid’s temperature, and also make sure that there are no leaks or air bubbles.
Once everything’s cleared our requirements for filling, it’s into the tray!
Filling complete! → drying
The gummies fit the mold perfectly!
Newly filled gummies are still liquid, so they will need to be dried for three to four days in a special drying room. Before bringing in the gummies, however, we first check the room's temperature and turn on the fan!
Time to say goodbye for awhile until the gummies harden. Sleep tight, little gummies! We'll see you again when you've hardened up!
Reuniting with our gummies (demolding)
After a set number of days has passed and the gummies are fully dry, we bring the gummy tray out from the drying room.
First, we removed the corn starch that’s blanketing the tray, and then remove the gummies from the tray.
We coat the gummies in oil, a thin edible layer of starch called "oblaat," etc. A key point is to make certain everything is sprayed on evenly.
Here we toss out any gummies that don’t meet our product standards, like deformed gummies, duplicate gummies, gummies with dents, or torn gummies.
Next, we use a metal detector to make sure that the gummies don’t contain any metal fragments.
Before beginning the inspection, we first use test pieces of iron (Fe) and stainless steel (SUS) so make sure the machine is operating properly.
If any products fail this inspection, they are retested and then everything is thrown out, regardless of whether subsequent screenings show no abnormalities. Further, we take the product in question to our quality management room to use as data to prevent similar problems in the future.
The gummies came out great!
The gummies are finished!
The next steps in the process are as follows: weighing → packaging → boxing → shipping.
We don’t want to spoil what kind of product we’re making, so please forgive us for not posting any pictures.