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factor that seems to deter the thorough evaluation of the scientific aspects of soft panning is the complexity of the variables that influence this process. Ingredient choices have a large influence on the finished product, including the center, syrup ingredients, drying powder material and minor or optional ingredients.The majority of soft-panned products are sucrose based, so that will be the focus of this paper. However, sugafree and dextrosebased products are also popular. The Center The center is commonly the largest portion of any soft-panned product. The center can be from 50 to 70 percent of the finished piece by weight. Gel centers are the most common. However, they are not all the same.The formulation and production of gel centers could make a paper in and of itself but there are a few comments that need to be made since the characteristics of any center influence the soft-panned product greatly. Centers may contain starch, gelatin, pectin or even a combination. Some of the newer modified starches or gums may also make an acceptable center for soft-panned products if the resulting gel is robust enough to hold up to the tumbling action and the weight from a fully loaded pan. Some of the most important attributes for centers are related to uniformity. Size, shape and moisture uniformity are all important for any center. For gel centers, uniform size and shape are directly related to the quality of depositing. Size and shape uniformity allow an equal coating to be achieved on the majority of pieces in the pan since surface area is important to the amount of syrup and dry ingredients that are required. Mogul maintenance, frequent board weights and even sifting to remove depositing defects can help keep centers uniform. Starch-deposited centers with flat tops can even have sunken backs if improperly dried, creating a great surface for the engrossing syrup to glue two pieces together. For sugar-sanded centers, using a uniform size of sugar like bakers special sugar can be a good starting surface on which to base a soft-panned shell.Also, for a gel center, be aware that issues in cooking or depositing can cause centers that are softer and more easily deformed, even though they are at the proper moisture level. For instance, gelatin base that is held for an extended period at a high temperature, especially in the presence of acid, will degrade, resulting in softer, less rigid centers.Also, high methoxyl pectin can pregel if held too long after acid addition and then can easily tear during further processing. Even starch, if not properly hydrated or cooked, can create a weaker center. Any of these changes in center quality can greatly impact the ability to soft pan the centers as well as the stability of any finished product. Other centers can present challenges of their own. Having a nut center presents a challenge due to adherence of the shell to the center as well as possible water absorption. Most choose to subcoat these centers. Subcoating ingredients will be discussed later along with optional ingredients. Uniform-sized nut centers can be selected for soft-panned products.Any other center for soft panning may have similar challenges but may also have other unique attributes that need to be controlled to produce a stable, uniform end product. Engrossing Syrup The composition of the engrossing syrup varies depending on the texture desired. For normal sugar-based products, the syrup is normally a noncrystallizing syrup made up of sugar, corn syrup and water. For syrup, bulk granulated sugar is normally used. Different corn syrups can be used, for example, ➤ Soft Panning One factor that seems to deter the thorough evaluation of the scientific aspects of soft panning is the complexity of the variables that influence this process. 58 th PMCA Production Conference, 2004 41
Soft Panning The larger the grain of the sugar, the more the candy pieces are reliant on the tumbling action of the pan to produce a durable smooth coating. 42 or 62 de. Most manufacturers seem to formulate with the type of corn syrup that they typically have on hand. Syrup preparation usually involves bringing the water and sugar to a boil to dissolve the sugar and then adding the corn syrup. The composition of the syrup has a direct influence on the finished texture of the bean. The ratio of sucrose to corn syrup (on a solids basis) strongly affects the textural attributes of the finished product.A ratio of 1 part sucrose to 0.5 parts of corn syrup (on a solids basis) produces a harder texture as opposed to a 1 to 1 ratio, which produces a soft texture. Sometimes thinned corn syrup can be used to make an even softer product. Some traditional materials suggest that solids of most syrups used should be 70 to 72 percent. However, more practically, higher solids closer to the 74 to 78 percent range are used. As with any cooked syrup, sugar inversion can play a role in possible defects. Since most syrups used in soft panning are noncrystallizing, the creation of invert sugar is less likely to slow production as in hard panning but it may cause other faults like instability of products in storage. Factors that influence the rate of sugar inversion are the ash level of the sugar, the cooking and holding time at high temperatures and the presence of acid. Dry Powder The next major ingredient is the dry powder that is added to the shell. Normally, two to three sizes of sugar are used for dry charging.The order that the sugar is added is from the largest to the smallest size. Particle size and particle size distribution are two of the most important factors for the dry charge material. Extra fine granular, bakers special sugar, 6X confectioners sugar and 10X confectioners sugar can be used.The larger the grain of the sugar, the more the candy pieces are reliant on the tumbling action of the pan to produce a durable smooth coating. Optional Raw Materials Minor and optional raw materials used in soft panning are those ingredients that are used in smaller amounts but can be critical to making the variety of products that are seen in the market today. Colors, flavors, waxes, center subcoat ingredients, confectioners glaze, acids and other flavoring/ decorating ingredients are those ingredients that warrant being mentioned. Colors can be either dye or pigment based. Traditionally, FD&C dye-based colors were used in jelly beans but now many products are made with FD&C aluminum lakes as well as colors from natural sources. The use of pigments like FD&C aluminum lakes, titanium dioxide or carmine can hide some crystallization faults in soft-panned coatings. FD&C dyes and most other colors from natural sources usually produce a more transparent appearance. Colors are typically added to the engrossing syrup. Flavors, on the other hand, can be added to a subcoat, in the engrossing syrup or even directly onto the pieces during the engrossing process. Mostly liquid flavors are used. Water-soluble powders can also be used but they may not be as cost effective.The carrier of liquid flavors may influence the panning process. Oils may interfere with tumbling and cause pieces to slide in the pan. Large amounts of propylene glycol or glycerin (common carriers for liquid flavors) may interfere with stability by holding moisture in the shell until stressed, causing sticky surfaces in packaged products.Alcohol-based flavors evaporate quickly, sometimes flashing off top notes as well. Depending on the desired flavor, various acids can be used in soft-panned items. Buffered lactic acid solution, malic, fumaric, tartaric or citric acid can be added ➤ 42 58 th PMCA Production Conference, 2004
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