Business: production of caramel and all kinds of candies. Technology for making caramel

There are many business ideas, but not all of them are profitable.

There is one way to always get a decent profit - the production of caramel.

The rating of the caramel business in Russia is always on top. Caramel sales volumes are very high. You can even say that caramel occupies one of the leading places in sales. Caramel is always popular with buyers because it has a low price and has a pleasant taste. Therefore, this business idea will always be very beneficial for the entrepreneur.

Making caramel is very easy and profitable

First, let's figure out what it is. This is such a tasty product, which is made by boiling sugar with water and syrup. If you heat caramel to a temperature of more than 100 degrees, then it will be a viscous substance that can take any shape.

You can change the shape even from a temperature of 90 degrees. After the heating temperature drops and the mass cools down to 50 degrees, the substance will become solid and transparent, like glass. Only one technology is used for manufacturing, but two types of sweets can be made: with and without filling.

It may seem that caramel is monotonous. This statement is completely wrong. It may be the same in shape, but differ in richness of tastes. Entrepreneurs can purchase various molds that will allow them to make figured sweets.

Still sweets will differ in the type of filling, which can be very different. This business will develop thanks to the imagination of the entrepreneur himself. As you can see, this confectionery product can be completely different, despite the same manufacturing method.

The idea of ​​caramel production includes many nuances. For example, one of them would be a candy wrapper. About such important detail need to be taken care of in advance. You may even need to make it individual design so that your candies are visible to the buyer. The wrapper in this case acts as a brand.

If your caramel will appeal to customers, then it is by the wrapper that they will recognize it. Fantik can be very different. Can even be used to sell boxes.

But very often this product is sold in open form. Of course, in this case, you will spend less money, which will affect its value. But here you have to take into account the fact that sweets without a wrapper can stick together with each other. The box in which they will be located must be very well protected from moisture.

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Production of caramel with filling

So, you have decided to produce caramel, inside of which there will be a filling. First you need to stock up on raw materials. It will be: sugar, fats, acids, dyes, filler. The filler can be very different, its choice depends only on your imagination.

Making the product is very simple, even a beginner can do it. But if you decide to put production on stream, then it is better to invite specialists to work. The stages of making caramel can be divided into several main groups:

• making syrup;
• mass preparation;
• mass processing;
• filling production;
• candy formation;
• cooling;
• package.

But each of the steps may vary depending on what kind of caramel you need to make.

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General scheme for the production of caramel products

If we summarize the manufacturing process, then it will look like this. The first step is to sift the sugar and dose it. Then put the sugar into the mixer. We also put molasses and heated water there. All this is placed together in a digester, in which the components are mixed and dissolved.

As a result, we get a sweet syrup. This syrup must be placed under vacuum. For this, special equipment is used, which continues to cook caramel, while removing all particles of steam. When the mass is cooked, all other components are added to it (these are dyes and filling, then it is cooled). That's the whole process in general terms.

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Equipment for making caramel

In order to organize such production, it will be necessary to purchase the necessary equipment. We will need:

1. Several tanks.
2. Dosers.
3. Punching and rolling machines
4. Filling and packaging machines
5. Faucets.
6. Cooling container for caramel.

The equipment may vary depending on the manufacturer and on the type of caramel we need. But if you fully equip your production, then human labor in it will be minimized as much as possible. It should be borne in mind that a lot of money will be required for equipment, but in the future it will pay off with interest, since you do not have to spend money on salaries for a large number workers.

Machines will do everything for you. If you like this idea, then do not forget to find a room in which production will be established. It should be spacious enough, at least 400 sq. meters.

The room can be located anywhere, even in the middle of nowhere. It doesn't matter to you, because the products will be bought up at points of sale. But for it to get there, you still have to take care of the means of delivery. You may need a whole truck in the future. For the first time, you can get by with an ordinary passenger car.

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Making caramelized apples

There is another very profitable idea that helps organize good business. She is also associated with caramel. As mentioned earlier, anything can be made from caramel. But we talked only about the caramel itself in its purest form. But if you cover something with it, you get a completely new confectionery masterpiece.

Recently, caramel-covered apples have been very popular among buyers. This type of production also does not require particularly high costs and is considered very promising for a novice entrepreneur.

Such a business brings the owner a stable income. It will be even more profitable than the previous options. After all, apples covered with caramel can be made even on the go, trading in a street van.

The viscosity of this mass is so high that if it does not pick up moisture, then it is stable at normal temperatures(she is very hygro-pychna). The basic recipe is simple, but great care must be taken during production and handling, as well as when wrapping, otherwise crystallization and moisture absorption will occur.
When cooking sugar, sugar alone cannot be used to obtain hard caramel, as it quickly crystallizes when cooled (especially when stirred). To prevent crystallization in a traditional sugar cooker, the introduction of anti-crystallizers that inverted some of the sugar was used. For many years, acid potassium tartrate or cream of tartar (potassium acid tartrate) was used for this, which was added to the syrup at the beginning of cooking (from 31 g to 11.2 kg of syrup), which gave enough invert sugar when the cooking temperature reached 149 -154 °C.
The introduction of anti-crystallizers is not a particularly reliable method, and the amount of invert sugar formed varied significantly depending on the duration of cooking, the purity of the sugar, and the hardness of the water used to dissolve it. A more reliable technology is the introduction of a certain amount of invert sugar or glucose syrup, which allows you to get more stable results.

Technology and recipe of caramel

Initially, the sugar cooker used digesters powered by gas or coke. Over time, they were replaced first by high-pressure steam boilers, and then by continuous cookers and vacuum machines.
For learning, it is useful to cook caramel in a cauldron with the following recipe:

Sugar (fine sand)	14 kg 1
Glucose syrup (DE42)	Zkg	proportion may change.
Water	5 kg

Dissolve the sugar in the water and bring the solution to a boil, then add the glucose syrup and bring to a boil again. It is important that any traces of sugar crystals around the circumference of the cauldron above the level of the boiling syrup are washed away and completely dissolved. Previously, confectioners used a wet brush for this, but a jet of steam is also suitable. The remaining solid sugar leads to crystal growth, which significantly reduces the shelf life. finished product. Upon reaching a temperature of 143-146 ° C, a dye solution can be added, which must also be free of solid particles. Cooking continues until a temperature of 150 ° C, and then the syrup is poured onto a greased vegetable oil the table and allow to cool until it, while remaining soft and fluid, becomes plastic. The edges of the mass are folded inward, and a recess is made in the center of the mass. Finely ground citric acid (monohydrate, 0.5-1.0 wt%) and flavor are placed in it, and then they continue to add and knead until the ingredients are distributed over a viscous mass. After this mass has cooled down sufficiently, it is cut into pieces and fed to the forming rollers. With large production volumes, the caramel mass is fed to the rollers, which turn it into a “tow”, which is fed into a continuously forming device.

Industrial production Syrup dissolving and boiling

Sugar, glucose syrup and invert sugar (sometimes "waste" syrup) can be dosed into continuous dissolvers, from which the constant composition syrup enters the cookers (Fig. 19.19).
Cookers can be thin film periodical action or vacuum. The thin film cooker (see figure 19.26 below) has already been mentioned in the description of fudge production and operates with a steam pressure of 120-150 psi. inch. The operating principle of this device iswhat thin film syrup is mechanically distributed over inner surface steam heated cylinder high pressure. Rapid heat transfer to a thin film leads to rapid evaporation of water from the syrup, after which the boiled syrup enters a water-cooled rotating table with a hole in the center, through which the partially cooled syrup is removed. The cooled mass moves on steel belts through automatic mixers, where acid, flavors and dyes are continuously fed into the mass. The flavored viscous mass is then fed into the forming equipment.
The batch former is equipped with conical corrugated rollers that rotate and vibrate. A viscous caramel mass is served on upper part devices where the rollers are the widest - due to their movement, the mass turns into a bundle with a diameter of 2-3 cm (Fig. 19.20).
A rope from a forming device enters the calibrating machine for the manufacture of a tow. The sizing machine consists of four pairs of grooved rollers through which the rope must pass, thus forming a rope of a certain diameter. Obviously, both in the forming device and in the calibrating machine, the temperature and viscosity of the caramel mass must be certain and constant. Forming rollers can be different size in accordance with the size of the received products.
Cramel stamp. The tow, still in a plastic state, is fed into the stamping device, where it passes through a series of stamping plungers, turning the tow into separate products. The drawing on these products is determined by the shape of the surface of the stamp (Fig. 19.21).
Cooling conveyor/wrapper. Products after the stamp to prevent deformation are fed to cooling conveyors. These conveyors are made from metal mesh, which, together with air circulation, provide the necessary heat removal (see Fig. 19.20).
Filling introduction. The filling can be introduced into the center of the bundle with the help of a filling accumulator and a supply pipe. As a filling, fat pastes or concentrated fruit fillings can be used, which are introduced into the tourniquet during molding on rolls of periodic action (see the section "Soft caramel" below).
Package. There are many types of packaging machines, but it is recommended to wrap the caramel while it is still a little warm, and for the packaging workshop it is preferable to use an air-conditioned room with a relative humidity of 45% (this prevents the formation of sticky surfaces and subsequent crystal formation).

Technology: The tow coming from the batch forming device and the sizing machine is fed first to a pair of sizing rolls, and then to a rotating punching device equipped with plungers and control cams for punching and molding products. The molded articles are then fed onto a narrow top belt of a cooling conveyor driven by a Unip-ast device. Firm Natas-HoPeg, Viersen, Germany.

Vacuum cooking

Cooking caramel syrup under vacuum has several advantages:
the color of the syrup is light (when cooking on fire, the color becomes brownish);
cooking temperature is lower, which reduces the inversion of sucrose and allows you to save light color syrup;
there is a saving in the cost of evaporation and the duration of cooking is reduced.

Vacuum cookers are batch, semi-continuous and continuous. Them short descriptions and diagrams are shown in fig. 19.22 and 19.23.
Usually, when cooking under vacuum, the content of glucose syrup is higher, and in the batch cooker there is a boiler for boiling syrup, installed above the vacuum apparatus. After cooking to a predetermined temperature in the upper boiler, the syrup is fed into the lower boiler with the help of vacuum. An adjustable valve dispenses syrup at a constant rate. Acid, flavor and color are added to the syrup in the cauldron

Rice. 19.22. Vacuum digester
1 - filling (water, sugar, glucose syrup and, possibly, milk and fat); 2 - batch cooking apparatus; 2a - steam outlet; 3 - mixer; 4 - valve; 4a - valve stem; 4b - handwheel for valve control; 5 - heating with water vapor; 6 - vacuum chamber; 6a - connection to a vacuum device; 7 - device for turning the boiler; 8 - unloading boiler with finished boiled sugar mass. Firm Natas-NoNeg, Viersen, Germany
and are mixed. Then the mass is unloaded onto a cooling table, and when it reaches the desired plasticity, a bundle is formed from it, which is then molded into products of a given shape, as described above.

An example of a recipe and cooking conditions:

Glucose syrup (DE 42) 15 kg

Sugar (fine sand) 15 kg

Water 5 kg

Bring sugar and water to a temperature of 110 ° C, add glucose syrup and boil to 138 ° C. A vacuum of 620 mm Hg is created in the lower boiler. Art. The time for unloading the syrup into the lower boiler is 3 minutes.
For the manufacture of transparent fruit caramel (lollipops), another continuous technology is used. The boiled syrup is poured into recesses in metal molds, which are coated with mold lubricant from the inside. The molds are cooled and the products are then easily removed. This process requires the addition of flavoring agent, dye and acid to the boiled syrup, and special types of flavoring agents are required to reduce the loss of volatile components. Instead of citric acid this technology uses lactic or malic acid (Fig. 19.24).

Drawn caramel mass, caramel with soft filling, whipped caramel, furre (candies with filling, glazed with fondant)

Another example of the skill of a confectioner is the manufacture of drawn caramel from caramel mass. This is done as follows: the caramel mass is cooled until plasticity is reached, then stretched, folded and pulled out again until it becomes translucent and shiny. As you stretch, the transparency decreases. In the manufacturing process, air is included in the mass. If stored in warm, humid conditions at about 38°C, crystal formation may be accelerated.
This technology is often used in the production of soft candy caramel according to one of the few recipes that use cream of tartar (sour potassium tartrate) (see below for more on this).
Confectioners who performed this process by hand formerly used a large hook about 15 cm long with a section of about 1.5 cm, fixed at a height of about 1.8 m on the wall next to the cooling table. When the caramel mass became plastic enough, it was hung on a hook and pulled down, and then again lifted onto the hook; This process was repeated until the mass desired state. Gloves were needed to work with hot mass, and the final state of the product depended entirely on the skill of the confectioner.
Later, this process was mechanized by using crank-rocker mechanisms that fold and pull out a portion of plastic caramel mass weighing about 25 kg. This operation can be accurately calculated in terms of duration and gives a product of more stable quality (Fig. 19.25).
Rice. 19.25. Pulling machine for caramel mass
1 - control panel; 2 - pull levers; 3 - frame. Company Natas-NoNeg, Viersen, Germany
The drawn caramel mass can be used as a shell for soft caramel, jam, chocolate spread, truffles or sherbet.
Below are typical technologies and recipes for this class of confectionery products, but others are possible (everything is determined by the skill and ingenuity of the experimental confectioner).

"Edinburgh Rock"
Sugar	11.3 kg
Glucose syrup	3.6 kg
Water	3.85 kg

Dissolve sugar and glucose syrup in water and boil to 138-139°C. Pour the mass onto the cooling table, fold inward from the edges, and when it becomes plastic, add:

After these substances are well mixed into the mass, place the mass in a pull-zero machine, which should work until the mass acquires a spongy structure. Then pass the mass through the forming devices to obtain a diameter of 2-3 cm, and then cut. After cooling, the products crystallize and become quite crumbly.
In this class of products, the air is contained in the form of very small bubbles, in which it is in direct contact with the fragrance. This has already been noted in the section on marshmallows, and some flavors, especially essential oils, under such conditions are very susceptible to oxidative deterioration. In this regard, it is necessary to use flavors that are resistant to oxidation. Recommendations on the most acceptable type of flavoring can be given by their manufacturers, and for this type confectionery Synthetic citrus oils are usually better than natural ones. This is very important, as there are known cases of selling caramel with bad taste due to this reason alone.

Hard caramel type Mintoe (minto)

This is a very popular class of caramel where aeration is provided by the introduction of frappe.
Frappe
Egg white (or substitute) 142 g Water 284 g
Soak with occasional stirring until dissolved. Mix and then add
Glucose syrup 1.81kg
Beat until a thick foam is obtained.

Syrup
Sugar	9 kg
Glucose syrup	6.8 kg
Water	3.1 kg
Dissolve and cook to 138-139 ° C.

Add the frappe and beat it into the syrup; let cool to about 121°C, and then quickly mix with the following ingredients.

Note: Peppermint oil is a very volatile flavor, and some of it quickly evaporates from the surface of the caramel. This not only reduces the intensity of the flavoring, but leads to a change in its character, since some fractions of the oil evaporate faster. The flavor can be emulsified, but encapsulated flavors are also available.

Caramel with soft filling

Such caramel is made by feeding a soft filling from the filling accumulator through a flexible tube into a viscous caramel mass. This is done in a rolling machine, and the filling becomes the center in the caramel body, which is fed to rollers that form a plastic rope into individual products with a soft filling (see descriptions and diagrams above).
This technology requires certain skills, since the body must be processed as hot as possible, and the filling must be about the same temperature. To obtain a "satin" sheen, the caramel body is drawn out for a short time and usually only slightly colored and flavored. The taste should be created mainly by soft filling.

Hull recipe
Sugar	11.3 kg
glucose syrup	3.6 kg
Water	3.85 kg

Dissolve sugar and glucose syrup in water and boil to 146 °C. Caramel is poured onto the table, flavored and colored (see above), and, if necessary, processed on a pulling machine to obtain the required appearance.

Heat jam, glucose syrup and water, then boil to 117°C.
Cool slightly, add citric acid solution and flavor and dye (if necessary). It is best to prepare this mixture before use and keep warm.

Truffle filling
fondant mass	11.3 kg
cocoa mass	1.36 kg
Sweetened condensed milk (whole)	2.72 kg
Vanillin, dye	if necessary

Melt the fondant at 60-63 ° C and add cocoa mass to it. Heat the condensed milk to 93°C, stirring gently for 15 minutes, then add the fondant and mix well.
As a filling, nougat, soft toffee and various pastes can be used. It is advisable to avoid fillings obtained according to " cold technology”, in which the mixtures are made without heating to a temperature that destroys microorganisms and their lipolytic activity. Another option is also possible - the ingredients can be heat sterilized before use. The inclusion of dairy products, some canned fruits and ground nuts can cause problems, and it is always necessary to maintain a minimum content of the liquid phase in the fillings (75%).

Mint candy caramel
Sugar 15 kg
Wine stone 45 g
Water 6 kg
Boil up to 135 °C. Pour onto a counter to cool, then fold towards the center.
Powdered sugar	750 g
Peppermint Oil	7 ml

Draw the product to a porous consistency and then run the product through formers and store the products in warm, humid conditions until they acquire a crumbly texture.

This mint candy can be made without powdered sugar (crystallization occurs during pulling and subsequent storage; crystallization is slower and the texture is finished products turns out to be different).

Candies with filling, furre

Initially, these products consisted of a filling (nut paste, marzipan, canned fruit or truffles) that was dipped into fudge. The fudge is melted at 60-63°C and transferred to small jacketed cauldrons heated with hot water. These boilers are usually built into the tables so that the edge of the boilers is on the same level with their surface, and the temperature of the water in the jacket is regulated using a thermostat. The filling is glazed by dipping on a fork, as in manual chocolate glazing (a wire fork with two or three prongs is used for glazing). The filling on a fork is dipped into liquid fondant and removed with fondant icing, then inverted onto waxed paper in a tray. This manual technology requires high qualifications to achieve uniformity and is quite expensive.
With this technology, fudge recipes with a low content of glucose syrup are often used (so that the fudge quickly hardens). If long shelf life is required, these fondants should not be used. Some confectioners advise including 0.05% acetic acid as a preservative, but if enough time is allowed to dry after glazing, traditional fondant can be used. Such sweets can be covered with granulated sugar or white chocolate icing.
Mechanical methods have been developed for glazing fondant, but one of the problems here is the constant evaporation of moisture from the fondant itself, giving a gradual increase in the thickness of its layer. To reduce the viscosity of fudge, you can add a reasonable amount of syrup with a concentration of 75% and the same sugar / glucose syrup ratio as fudge, but water is not recommended.

Special properties of caramel

Although the recipe for caramel is relatively simple, it is subject to physical changes that significantly affect its shelf life. A pronounced effect on the properties of caramel is provided by chemical changes, inversion and "caramelization".
Some insight into the problems associated with caramel can be provided by the data below.

microstructure

Caramel has long been likened to glass, as it is in a non-tastable state between fully amorphous and crystalline states. Maintaining a state close to amorphous is the result of a very high viscosity of caramel at room temperature. The transition to the crystalline state is carried out by reducing the viscosity - by raising the temperature or increasing the moisture content. That is why storage in warm or humid conditions promotes crystallization (granulation) of caramel and milk candies.
The paper describes many interesting properties of hard caramel:
Voltage. The stress streaks seen in freshly deposited caramel disappear very quickly, demonstrating that the sugar is still in a mobile state, although it has a very high viscosity. Analogous strips in glass practically do not change.
Air inclusions. Vacuum cooking, kneading and stretching produce air bubbles of various shapes and sizes, which affect product uniformity.
Flavoring substances are often very poorly distributed, appearing in the form of large inclusions, non-uniformly distributed over the mass of products. This is especially true of citric acid, and its unmelted crystals are found in caramel. Since citric acid crystals melt at 126°C and anhydrous acid at 153°C, good distribution can only be expected in the case of crystalline acid if it is introduced into a very hot or liquid melt. Acid particles give unpleasant taste sensations.

water activity

There is a huge difference between the water activity of caramel "glass" and caramel of the same composition, but after crystallization (0.25 compared to 0.75). Non-crystalline sugar is very hygroscopic and readily absorbs surface moisture. If this is allowed to happen, a relatively dilute solution forms on the surface, which crystallizes and leads to a kind of chain reaction, so that the entire product eventually crystallizes. That is why it is important to wrap the caramel immediately after shaping.

Compound

Currently, caramel is mainly made from sugar and glucose syrup. Invert sugar is rarely used (except in countries where sugar is produced and glucose is difficult to obtain).

The ratio of sugar and glucose syrup varies depending on the cooking method - in an open vat, thin-film or vacuum apparatus. This ratio is also related to the type of molasses used (see section "Glucose Syrup" in Chapter 8) - for example, low sugar molasses is viscous, less hygroscopic and sweet.
With any composition, sugar decomposes into two monosaccharides - dextrose and fructose. Fructose makes caramel more hygroscopic and prone to stickiness when exposed to air. Vacuum cooking reduces inversion as more low temperatures and less cooking time. The inclusion of "acid-containing waste" leads to a significant inversion. Such waste should be dissolved, neutralized and decolorized before use.

Colour

The longer the boil and the higher the temperature, the more the color changes to yellow or light brown. Fruit candy, clear caramel and similar products must be free from this defect.

Defects

The main defects and their causes are briefly listed below.The caramel has become sticky. She gained moisture from the air for the following reasons:
1. Too much "inverted" content (see above).
2. The relative humidity in the forming and packaging room is too high (should be 45% or less). Caramel should be wrapped warm, at about 32 ° C.
3. Incorrect packaging material selected - the water vapor permeability of the caramel wrapper and packaging is too high.
4.High humidity at the point of sale (also related to point 3).

The caramel has crystallized.
1. Too high sugar/glucose syrup ratio.
2,The moisture content is too high.
3. Added solid "waste".
4.Storage in humid conditions.
5. Keep warm.
With regard to point 5, it should be understood that heat softens hard amorphous caramel and makes a very concentrated syrup more mobile and prone to crystallization.

Caramel- a product made from caramel mass (with and without filling).

As the main raw material for the production of caramel, granulated sugar, molasses, food acids, dyes, essences are used. For the preparation of fillings, fruit and berry semi-finished products, nuts, honey, cocoa products, fats, dairy products, coffee, wines and spirits are used.

Non-traditional types of raw materials include secondary dairy products (natural whey), fruit and berry and vegetable powders, bases from dried fruits and berries, concentrated fruit and berry juices, grape must, products of extruded and exploded cereals, powder sugary semi-finished products.

Extracts are used in the production of caramel. These are complex various substances: essential oils of organic acids, polyphenols, polysaccharides, minerals and alkaloids. Also use natural essential oils of sage, anise, mint.

The technological process of making caramel consists of a number of stages: preparation of caramel syrups, obtaining caramel mass, preparation of fillings, molding, cooling, caramel surface protection, wrapping, packing, packaging.

Caramel syrups are sugar syrup or sugar invert solutions with stable technological parameters: humidity not higher than 16%, content of reducing substances not higher than 14%.

The manufacture of caramel syrups is carried out by continuous or batch processes. With continuous methods, the syrup is made by dissolving sugar and molasses or sugar and invert syrup at a syrup station or in sectional solvents, and with a periodic method, by acid hydrolysis with the addition of a 40% lactic acid solution, in dissulators. Caramel syrups with a temperature of + 90 ... 95 ° C are sent through filters for boiling.

Caramel syrup is boiled down to obtain a caramel mass in a continuous vacuum apparatus with an external evaporation chamber. Cooking caramel mass is carried out at a steam pressure of 5-6 kgf / cm and a vacuum in a vacuum chamber of 650-700 mm Hg. Art. The syrup is boiled down to a residual moisture content of the caramel mass of 1–3%. With these humidity parameters, the caramel mass retains an amorphous state. This eliminates the need for intra-shift washing of vacuum apparatuses.

Caramel mass can be obtained by non-vacuum boiling of caramel syrup in a serpentine cooking column connected to a steam separator.

For obtaining caramel mass film devices are also used, in which moisture evaporates from caramel syrup from a large surface in a thin layer. Vertical film machines of rotary type operate at atmospheric or reduced pressure.

The duration of boiling is about 20 s, the temperature of the outgoing caramel mass is about +152 ° C. Such a short-term exposure practically does not lead to the decomposition of sugars and an increase in the content of reducing sugars.

But milk syrups must be boiled in vacuum apparatus at a lower temperature to avoid coagulation and burning of milk proteins. The caramel mass should leave the vacuum apparatus with a temperature of + 110 ... 116 ° С.

The finished caramel mass is unloaded from the vacuum apparatus every 1.5–2 minutes using an unloading machine directly onto the cooling table. Cooling continues for 20–25 s to a temperature of +88…95 °С. During cooling, dyes, essence and acid are added to the liquid mass using dispensers.

Before forming a transparent caramel, an opaque appearance can be given, for which the caramel mass is processed on a pulling machine. The transparent caramel mass is transferred to the molding by the transfer conveyor, bypassing the pulling machine.

The preparation of caramel fillings is mainly carried out according to the same technology as most candy masses. They differ only in the recipe and final moisture content.
Caramel is produced with liquid (fruit and berry, liqueur, jelly, honey, milk), semi-liquid (fondant) and thick (marzipan, butter-sugar, whipped, nut, chocolate) fillings.

The molding of caramel products is carried out on units consisting of a number of machines operating synchronously. The units include caramel rolling machines with filling (or without it), calibrating, shaping machines and a cooling apparatus. The stuffing filler injects the stuffing through a pipe inside a rotating one having the shape of a cone. From the top of the cone, several pairs of rollers pull a round bundle with a filling inside.

The molding of products from caramel tow is carried out on cutting, stamping and rolling, rotary, roller, roller captive, wrapping machines.

Candy caramel is formed by rolling, leaving for cooling in the form of a ribbon. Individual caramels are sent for cooling (up to +20 ° С). After cooling, the caramel enters a vibratory conveyor or a perforated drum to split the bridges between the caramels.

The surface of the finished caramel mass is protected from the influence of ambient air by wrapping the caramel in a moisture-proof label. In addition, products are coated with a thin layer of a wax-fat mixture (wax, paraffin and refined vegetable oil) or sprinkled with non-hygroscopic materials.

Coating with a wax-fat mixture (glossy) is carried out in coating pans or continuously operating devices.

Sprinkling caramel is made with sugar or a mixture of powdered sugar and cocoa powder, most often in pans. Then the caramel is dried, the excess sugar is sifted out, and the caramel is transferred to the packaging.

Packaging consists of wrapping each caramel, packing them, weighing, labeling and other packaging operations.

Open caramel (montpensier, candy caramel, satin pillow, etc.) is packaged in a sealed container that protects products from air access.

Caramel is a confectionery product obtained by boiling sugar syrup with starch syrup or invert syrup to a caramel mass with a moisture content of 1.5-4.0%. Caramel is obtained only from caramel mass (candy) or with fillings. Various confectionery masses are used as fillings: fruit, liqueur, honey, fondant, milk, nut, chocolate and others.

Depending on the method of processing the caramel mass before molding, the caramel shell can be transparent or opaque (pulled).

The main raw materials for the production of caramel are: granulated sugar, starch syrup, fruit and berry preparations, dairy products, fats, cocoa products, nut kernels, food acids, essences, dyes, etc.

The technological process of preparation consists of the following stages: preparation of syrup and caramel mass, cooling and processing of caramel mass, preparation of caramel fillings, caramel molding, caramel wrapping or surface finishing, packaging.

Let us consider in more detail the individual technological stages.

Syrup preparation

Caramel syrups are sugary or sugar-invert solutions with a moisture content of not more than 16% and reducing sugars not more than 14%. Molasses or invert syrup is introduced into sugar syrup as anti-crystallizers, because. when boiled, sugar crystals are released from the resulting solution. In addition, dextrins contained in molasses significantly increase the viscosity of the solution, which slows down the crystallization process. The preparation of caramel syrups is carried out in a batch or molasses-mechanized way. The most widely used flow-mechanized method of preparing caramel syrup under pressure. The syrup preparation cycle lasts 5 minutes. Sugar, molasses and water are fed into the mixer with a steam jacket; the mixture is stirred, heated to 65-70 0 С and in the form of a mushy mass consisting of sugar crystals and a water-treatment solution, it is pumped into a coiled cooking column, where a pressure of 450-550 kPa is applied, which corresponds to a temperature of the syrup at the outlet of 125-140 0 С.

Preparation of caramel mass

Caramel mass is an amorphous mass obtained by boiling caramel syrup to a solids content of 96 - 99%.

To obtain caramel mass, coil vacuum apparatuses are used. Such an apparatus consists of two parts: a heating (cooking column) and an evaporator (vacuum chamber). Caramel syrup is pumped from the bottom up into the serpentine of the cooking column, washed with heating steam at a pressure of 500-600 kPa. Further, the boiling syrup, together with the secondary steam, enters the upper part of the vacuum chamber, where the syrup boils intensively. The boiled mass then flows into the lower chamber, from where it is unloaded as it accumulates. The temperature of the caramel mass at the exit from the vacuum apparatus is 106-125 0 С for sugar-treacle syrup and 115-135 0 С for sugar-invert syrup.

Preparation of fillings

The fillings used in caramel production must meet the following requirements: they must not deteriorate during storage, so the sugar content in them must be at least 70%; to prevent the crystallization of sucrose, anti-crystallizers (molasses or invert syrup) should be introduced into the filling. The fillings should not include perishable fats capable of quickly rancidity, interact with the caramel mass and dissolve it. The consistency of the filling should be quite viscous.

Fruit and berry fillings are obtained by boiling the fruit pulp with sugar and molasses. The filling process includes the preparation of raw materials, dosing, mixing of the main components and their boiling. The preparation of fruit and berry raw materials consists in desulphurization (scalding) of the blanks with steam in order to remove sulfur dioxide (preservative) followed by rubbing the mass on rubbing machines to separate the fruit pulp. The pureed raw materials are mixed with syrup, and then boiled down.

Liquor fillings are obtained by boiling sugar syrup to 84-87% solids with the introduction of a mixture chilled to 70 0 C, containing alcohol or alcoholic beverages, acid, essence, paint, etc.

Fondant filling is a fine-crystalline mass in a rich sugar syrup. It is obtained by churning with simultaneous cooling of a sugar syrup containing no more than 30% molasses to the mass of sugar in the syrup. The content of solids in the filling is not less than 90%.

Butter-sugar (cooling) fillings are obtained by mixing powdered sugar with coconut oil and crystalline glucose. Replacing part of the sugar with glucose increases the "cooling" taste. The content of solids is not less than 97.5%.

Chocolate-nut filling is a mass obtained by mixing crushed nut kernels, cocoa liquor, coconut or cocoa butter with powdered sugar. The content of solids is 97.5%.

Caramel mass processing and caramel molding

Before molding, the caramel mass is subjected to cooling with simultaneous coloring, aromatization and acidification, followed by rinsing or stretching of the mass.

The caramel mass leaving the serpentine column is fed to a cooling machine, where it is cooled to a temperature of 80-90 0 C. During the cooling process, food acid, essence and dye solution are introduced into the caramel mass. To obtain a transparent caramel, the caramel mass, after cooling, is sent for a warm-up. The purpose of the warm-up is to evenly distribute the introduced components in the mass, as well as to remove large air bubbles. The warming process consists in repeatedly turning and kneading the caramel layer.

In the manufacture of caramel with an opaque shell, the caramel mass after cooling is subjected to stretching with repeated folding on special pulling machines. The mass is saturated with air, loses its transparency, acquires a silky sheen.

The mass prepared in this way enters the caramel rolling machine. In this machine, the caramel mass is given the shape of a truncated cone (loaf). To obtain caramel with filling, a filling filler is installed on the machine.

To separate the caramel tourniquet into individual caramels and give them a certain shape, various molding methods are used.

After molding, the caramel is cooled in order to transfer it from a plastic state to a solid one.

To protect the caramel surface from moisture, the caramel is wrapped or packaged in a sealed container. Caramel should be stored in clean, dry, well-ventilated warehouses at a temperature not exceeding 18 0 C and relative humidity not more than 75%.

The technological scheme for the production of caramel with filling can be divided into the following main stages:

preparation of caramel mass;

cooling and processing of caramel mass;

preparation of fillings;

molding and cooling caramel;

processing, wrapping, packaging and packaging of caramel.

Figure 1 shows the machine-hardware scheme for the production of caramel with fruit and berry fillings. The main raw materials for its preparation are granulated sugar, starch syrup and fruit and berry blanks.

Figure 1 - Machine and hardware diagram for the production of caramel with fruit and berry filling

Sugar from the warehouse is transferred to the preparatory department of the caramel shop or in bags (for container storage), by an auger (redler) or a pneumatic transport system (for bulk storage).

Sugar is loaded into the sieving funnel 17, where it is cleaned of foreign and ferrous impurities, then the elevator 18 is fed into the intermediate hopper 19. From the hopper, the tape dispenser 20 and the screw 21 sugar is dosed into the continuous solvent 22.

Using volumetric dispensers 23,24 and 25, molasses, invert syrup and water heated to a temperature of 65-70°C are fed into the mixer-solvent in predetermined quantities.

In mixer 8, equipped with a steam jacket, the recipe components are mixed at a temperature of about 70°C, which ensures the dissolution of the bulk of the sugar.

The resulting sugar-treacle mixture with a moisture content of 17-18%, with incompletely dissolved sugar crystals, is continuously supplied by a plunger pump 10 to the coils of the cooking column 11, heated with steam at a pressure of 450-550 kPa. The syrup boiled down to a concentration of 84-86% of solids through a glass filter 26 enters the collector-cooler 27, from which it is pumped by a gear pump 2 to the intermediate collector 28.

Plunger pump 10 caramel syrup is continuously fed into the coil of the vacuum apparatus 30. The apparatus is heated by steam at a pressure of 500-600 kPa. Here the syrup is boiled into the caramel mass to a solids content of 97.5%.

The vacuum chamber 31 of the apparatus is connected by a pipeline through a condenser to a wet-air pump 29, with the help of which a vacuum is created in the vacuum chamber. From the receiver of the vacuum chamber, the caramel mass is periodically (after 1.5-2 minutes) poured (manually or automatically) into the funnel of the cooling machine 33.

The cooled caramel mass in the form of a wide thin tape passes under the dispensers 34 and 35, from which flavoring and aromatic substances (acid, dye and essence) are supplied to the surface of the caramel tape. Upon exiting the cooling machine, the mass at a temperature of 90°C is pressed to evenly distribute the additions, and is transferred to the pulling machine 36 by a belt conveyor. Here it is repeatedly pulled and folded, saturated with air. When processed for 1.0-1.5 minutes, the structure and color of the mass change, and a uniform distribution of the introduced additives in it is achieved. The temperature of the mass is reduced to 85-80°C.

The drawn caramel mass is transferred by a belt conveyor to the 38 rolling machine, where it takes the form of an elongated cone. The filling is fed inside the cone with the help of filling filler 37.

The main raw materials for the preparation of fruit and berry fillings are sugar, molasses and fruit and berry preparations in the form of pulp or applesauce. Puree from barrels 1 (or a collector for bulk storage) is pumped by pump 2 into tank 3 with a mixer for blending.

The blended mixture of applesauce is pumped by pump 2 to scalder 4, flows into intermediate container 5, from where it is pumped to collector 6.

Applesauce is fed into the 7 masher and then pumped to the 9 mixer to prepare the fruit-sugar mixture. Sugar syrup and molasses are dosed into the mixer by volume measuring cups. The prepared mixture is supplied by pump 10 to the coiled cooking column 11 with a steam separator 12. The column is heated with steam at a pressure of 500-600 kPa. The filling is boiled down to a moisture content of 14-19%.

From the steam separator, the filling flows into the intermediate container 13 and is pumped into the tempering machine 16. The filling is cooled to a temperature of 80-85°C, flavoring and aromatic substances are introduced from volumetric dispensers 14 and 15. With a gear pump 2, the filling is fed through an annular pipeline into the funnels of filling fillers 37. A glass filter is installed in the pipeline. The temperature of the filling must be 10°C lower than the temperature of the caramel mass in the 38 machine.

The cord-drawing machine 39 forms a cord of a certain diameter (14-16 mm) from a caramel loaf and transfers it to caramel molding.

The stamping machine 40 cuts the caramel tow into individual slices and gives them one shape or another. Stamped chains from individual slices of caramel are transferred to a narrow belt conveyor 41, blown with cold air. The caramel mass in the bridges between the individual products quickly hardens, and therefore, passing to the vibrating distributor 42, the chains of the molded caramel fall apart.

In the AOK unit, caramel is cooled to a temperature of 25-35 ° C, it becomes hard enough, which allows it to be wrapped, processed and packaged.

Chilled caramel is fed by the 44 vibrating tray to the distribution conveyor 45, and then to the wrapping machines 46.

From the wrapping machines, the caramel enters the assembly conveyor located at the bottom of the distribution conveyor 45, then it is fed by an inclined conveyor to the weighing hopper. After weighing, the caramel is poured into a box installed on the conveyor of the pasting machine. Packed caramel enters the finished product warehouse.

Obtaining caramel mass consists of two technological processes:

preparation of caramel syrup;

boiling caramel mass.

In caramel production, combined syrups are usually used, which include not one type of sugar, but two or more. At the same time, I use sugar, invert, sugar-treacle, sugar-invert, sugar-invert-treacle syrups. Sugar syrups are made by dissolving sugar in water, usually by heating. Molasses is added to sugar-treacle syrups when heated. A syrup with a solids content of about 70% is boiled down to a final boiling point of 110-114°, while it still contains 14-17% water.

If the molasses in the syrup is completely or partially replaced by invert sugar, it must be prepared by inverting beet sugar.

To make caramel without molasses, invert syrup should be added to the sugar solution in such an amount that the finished syrup contains 17-19% invert sugar, counting on the dry matter of the syrup. Then in the finished caramel mass there will be 20-22% invert sugar, since in the manufacture of caramel from syrup, the amount of sugar increases by 2-3%.

Caramel syrup enters a vacuum apparatus, where most of the water is removed from it during boiling and a caramel mass is obtained. The caramel mass leaves the vacuum apparatus with a temperature of 110-120 ° (on molasses) or 125-135 ° (on invert). At the same time, it has a relatively low viscosity, however, as the temperature decreases, its viscosity increases, and at 70-80 ° the mass becomes plastic, it can be molded. With a further decrease in temperature, the mass hardens, loses plasticity and becomes brittle at 50-40 °.

The caramel mass unloaded from the vacuum apparatus needs to be “processed” - cooled, tinted, acidified, flavored. The mass must first be somewhat cooled, so that with the subsequent introduction of food acid into it, the hydrolysis of sucrose decreases, and with the introduction of an alcoholic solution of flavoring, the loss of alcohol and aromatic substances that evaporate to a greater extent at a higher temperature of the mass would decrease.

With the in-line method of caramel production, processing processes are carried out with continuous movement of the caramel mass along an inclined path. At the same time, acid in the form of a powder, and paints and essences in drops are continuously added to the moving caramel mass and mixed with it when passing through rollers or for drawn caramel mass - when processed on a continuous pulling machine. This machine has several horizontal parallel rods rotating relative to each other so that they draw out the caramel mass, put one layer on top of another, and pull it out again.

The elongated mass becomes opaque and acquires a satin appearance due to the repeated refraction of light rays passing through the layers of air in the caramel mass. Her specific gravity less (1.3-1.2 g) than undrawn (1.5 g), due to the fact that it includes layers and air bubbles. After pulling, the caramel mass acquires the ability to sugar more easily, so it is less moistened and sticky (after some exposure).

To give the caramel an appearance, and sometimes to give the shell a resemblance to the color of fruits and berries, various food colorings, previously dissolved in water, are introduced into the caramel mass. The concentration of aqueous solutions is 5-10%.

Aromatization of the caramel mass is carried out at a temperature below 90°C with an alcoholic solution of aromatic substances. At the processing temperature of the caramel mass, the alcohol evaporates, and the aromatic substances remain in the mass.

To give certain varieties of caramel a pleasant sour taste, the caramel mass is acidified during cooling, using crystalline organic food acids (citric, less often tartaric and malic) for this.

Caramel is made with the following fillings:

fruit and berry;

liquor;

dairy;

fondant; marzipan;

oil and sugar (cooling);

creamy whipped; walnut; chocolate-nut; jelly; from cereals, legumes and oilseeds.

At the same time, fillings, despite their diversity, must have some general quality characteristics, including being stable during storage and not changing their properties. palatability and consistency. Therefore, the mass fraction of sugars in the filling should not exceed 70%. The filling should also not: contain perishable fats and other components; interact with the caramel mass; dissolve it. The consistency of the filling should be homogeneous and have sufficient viscosity.

Fruit and berry fillings are prepared by boiling a mixture of sugar, molasses and fruit and berry puree. They are based on applesauce, you can add cherry, apricot, plum, etc. puree to it, as well as supplies and other flavorings. To avoid sugaring the filling during storage, it must contain at least 30% reducing substances, and an increase in this indicator by more than 60% can lead to the dissolution of the caramel shell.

Liquor fillings include, in addition to sugar and molasses, wine, liquor and other alcoholic beverages; fruit and berry puree can be added to these fillings. In this case, the mass fraction of reducing substances in the liqueur filling should not be lower than 30%.

Honey fillings, in addition to sugar and molasses, also contain bee honey; fruit and berry puree can be added to them. The mass fraction of solids should be 84-88%.

Dairy fillings, in addition to sugar and molasses, contain milk, butter, coffee, cocoa can be added. The mass fraction of solids is also 84-88%.

These four fillings are obtained by boiling all constituent parts usually in a vacuum apparatus under vacuum in order to better preserve the quality of the feedstock.

Fondant fillings consist of small sugar crystals surrounded by intercrystalline syrup with the inclusion of air bubbles. They are prepared by churning sugar syrup while it is cooling. Fruit and berry supplies, dairy products, etc. can be added to the fondant mass. The mass fraction of solids in this filling is about 90%.

Whipped fillings are obtained by whipping egg whites with the addition of sugar-treacle syrup boiled down with fruit and berry puree or milk, etc. The mass fraction of solids in these fillings should be in the range of 85-87%.

Refreshing or butter-sugar fillings are made from a mixture of powdered sugar and coconut oil, with the addition of acid and mint oil or mint flavoring. Some varieties of caramel include the introduction of glucose instead of sugar, which increases the "cooling" effect. For the preparation of fillings, mechanical mixing of the components is used. These fillings are characterized by a high content of solids - not less than 96.5%, and when powdered milk is added - not less than 99.5%.

Marzipan fillings are made from a mixture of powdered sugar with grated almonds or apricot kernels or other unroasted nuts. This mixture is brewed with hot sugar syrup and stirred while cooling; flavorings such as coffee, cocoa, honey, milk, fruit and berry supplies, etc. are often introduced.

Nut fillings consist of a powdered mixture of powdered sugar with roasted nuts, with solid fat (cocoa or coconut butter); various flavors may be added. The mass fraction of solids in these fillings should be at least 97.5%.

Chocolate nut fillings contain grated roasted nuts, powdered sugar, coconut oil and cocoa products. Cocoa butter and coconut oil are introduced in molten form at a temperature of 30-40°C.

Jelly fillings are obtained by boiling sugar-treacle-agar syrup with the addition of fruit and berry puree.

Fillings from cereals, legumes and oilseeds are prepared using flour and semolina from the above crops with the addition of sugar, fat, cocoa products, etc. In this case, legume flour must be deodorized, i.e. odorless by heat treatment.

After rinsing or stretching the caramel mass, it is molded in the form of a bundle of a certain section. Optimum temperature to perform this process are 70-80°C. Caramel loaf, depending on the type of caramel and filling, is obtained by pulling caramel tows different ways: without filling, with liquid filling and with thick filling.

Caramel tourniquet for candy caramel is obtained by rolling a caramel loaf to a certain thickness.

A tourniquet with a thick filling is formed from a pre-cooked cake, consisting of an upper shell and a filling, rolled in the same way as for candy caramel.

A caramel tourniquet with a liquid filling is obtained by introducing the filling into the caramel mass through a tube located inside the caramel cone.

In our country, for the formation of caramel with and without filling, chain (cutting and stamping machines) are most widely used.

Forming cutting (linear) machines have two ring chains, in which knives are placed at regular intervals (steps). Moving along with the caramel tourniquet, the knives of the upper and lower chains, gradually approaching, first compress and then cut the warm plastic shell of the loaf. At the same time, the edges of the shell interlock, preventing the filling from flowing out. The loaf is cut into separate pieces, which are in the form of pillows, cylindrical or flattened.

Stamping machines have sharp protrusions instead of knives that cut the loaf, and on the sides there are stamps that are pressed against the loaf when the chain moves and form separate cut pieces. The result is caramel. various shapes(bricks, nuts, etc.) with a pattern on the surface. Other molding machines are also used.

The molded caramel has a temperature of about 60°C. So that it does not change its shape and does not stick together, it is quickly cooled by blowing air on the cooling conveyor; after some cooling, the caramel chain is broken into separate pieces. After cooling, they become hard and brittle.

Chilled caramel is wrapped in paper or released open (without wrapping). The wrapping is done “in the lock” (“in the tail”, “in the corner”), when the ends of the paper on both sides are bent, or “twisted”, when the ends of the paper are twisted on both sides; you can use one or two papers, as well as foil between them. It is also used to wrap caramel in packs (tubes) in the form of round tablets.

For open caramel, usually used protective treatment surfaces - glossing, sprinkling. When glossing, a fat-and-wax layer is applied to the surface of the caramel in dragee boilers or in continuous polishing machines; products acquire a polished shiny surface. Sprinkling caramel with sugar, cocoa powder, etc. produced in dragee boilers. First, during their rotation, the caramel is wetted with sugar syrup, and then the sprinkling material is added, which adheres evenly to the moistened surface of the caramel. Some varieties of caramel with filling are glazed with chocolate. Open caramel, not subjected to special treatment to avoid moisture and sticking, is packed in a tin or other hermetically sealed container.