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is too hot, another is too cold and the last is just right. In this way, dilemmas arise in soft panning unless certain attributes are just right. For example, if the dose of engrossing syrup is too high, it can lead to doubles and clumping. If the dose is too low, the distribution will be uneven across the pieces and lead to uneven coating. If pan loading is too low the centers will not tumble correctly, which will interfere with proper coating. If it is too high the centers may crush (if soft) or pieces will become flying projectiles after the shell starts to build. Product can stick together and form doubles if the engrossing syrup solids are too high, if the centers are improperly subcoated, if too much syrup is added at once, if the centers are too soft, if the pan speed is too slow or if the dry charge sugar is added too late. Malformed shapes or uneven surface coating can be from too much sugar at the beginning of the process, if the application of syrup is too small to evenly distribute, if the sugar granulation is too small (or too many fines) or if the centers are nonuniform. Finished soft-panned products normally have 10 to 17 percent moisture in the shell but this does depend on the panning technique as well as any migration of moisture between center and shell. An Experiment with Variations Since jelly beans are still used as the main example of soft panning, an experiment to produce various jelly beans with variations in engrossing syrup composition as well as the type of sugar used for dry charging was conducted.With the exception of the largeproduction-pan run done for video purposes, all samples were made in a small 15inch lab pan (which for soft panning is not optimal since the tumbling action is instrumental to forming the coating). For comparison purposes, a typical formula was done in the small pan as well as the production size. These formulations were made with four layers that had similar amounts of engrossing syrup and the amount of dry sugar required to dry each layer (Figure 4).This means that the resulting products may have different weight gains resulting in differing center to shell ratios. In Run 6, the one made with only sucrose in the engrossing syrup, the amount of that syrup had to be increased slightly just to wet the pieces properly. In Run 4, made with the larger seasonal jelly bean center, the amount of syrup seemed to make the pieces overly wet so there were a larger number of doubles formed. All jelly beans were placed in trays overnight and then polished. A 65° Brix finishing syrup was applied to wet the powdered sugar on the surface.When dry, this was followed by an application of wax (beeswax and carnauba) in alcohol and glazed with a shellacbased confectioners glaze. Various evaluations were done on the six jelly bean runs.The results can be seen in Figure 5. Center and shell percentages were calculated in two ways. First, all the ingredients used were put into a formula by weight and then the percentage of center was calculated (denoted as calculated). This method does not take into account any loss of ingredients to the pan or surrounding air.The second method is based on the weighing of a number of finished beans and subtracting the original weight of the same number of centers. This method is denoted as measured in the data table. Finished jelly beans from each run were taken apart and water activities and moistures were taken on both the shell and center for each. During the production batch, samples were also taken periodically for similar evaluation (Figure 4).The trends of changes in moisture do not seem as apparent as expected; piece-to-piece variation may be to blame. Moistures were ➤ Soft Panning If the dose of engrossing syrup is too high, it can lead to doubles and clumping; if the dose is too low, the distribution will be uneven and lead to uneven coating. 58 th PMCA Production Conference, 2004 45
Soft Panning Finished soft-panned products normally have 10 to 17 percent moisture in the shell. done by an outside laboratory with a losson-drying technique that is done slowly so as not to experience case hardening on the gel centers.The products made in the small pan had much higher moistures than the production run. The moistures found in the production run were much more typical with 10 to 17 percent finished-product moisture levels and were essentially the same between center and shell. Water activities were done with a benchtop water activity measurement device. Only the production sample, Run 1, had a higher water activity in the center than the shell. In examining the resulting jelly beans from the above experiment, there are a few observations that need to be pointed out. Run 1, the production run, looked the Production Run/Run # 4th Wetting 4th Wetting Glazed and Before Powdered After Powdered Stored in Trays 2nd Wetting 3rd Production Run Sampling Moisture and Water Activity Results Wetting Sugar Addition Sugar Addition Wax Only Glazed Overnight % Moisture shell 15.9 15.5 14.6 14.2 11.7 13.7 15.4 % Moisture center 15.2 15.4 18.5 14.7 13.3 12.5 15.8 Water activity (shell) 0.623 0.686 0.672 0.683 0.581 0.590 0.477 Water activity (center) Figure 4 0.595 0.696 0.598 0.629 0.580 0.553 0.508 Production Run Evaluations Run 1 Run 2 Run 3 Run 4 Run 5 Run 6 Pan Size Production size Lab size Lab size Lab size Lab size Lab size Syrup Type Combined corn Combined corn Combined corn Combined corn Thinned corn Sugar syrup syrup and sugar syrup and sugar syrup and sugar syrup and sugar syrup Gel Center Type Small gourmet Small gourmet Small gourmet Large seasonal Small gourmet Small gourmet Dry Charge Sugar Bakers special Bakers special Extra fine granular, Bakers special Bakers special Bakers special Center and Shell Relationship and powdered and powdered bakers special and powdered and powdered and powdered and powdered Center % (measured) 52.1% 66.4% 69.5% 67.6% 63.3% 63.3% Shell % (measured) 47.9% 33.6% 30.5% 32.4% 36.7% 36.7% Center % (calculated) 52.0% 65.4% 64.7% 65.3% 61.2% 62.1% Shell % (calculated) Syrup Formulation 48.0% 34.6% 35.3% 34.7% 38.8% 37.9% Sugar to corn syrup solids ratio 0.9:1 0.9:1 0.9:1 0.9:1 0:1 0:1 Water % 19% 19% 19% 19% 13.4% 27% Sucrose % 33% 33% 33% 33% 0% 73% 42 de corn syrup % 48% 48% 48% 48% 86.6% 0% Solids—°Brix Formulation 74.9° 74.2° 73.0° 72.5° 70.7° 73° Center % 52.0% 65.4% 64.7% 65.3% 61.2% 62.1% Syrup % 7.4% 8.5% 8.4% 8.5% 7.9% 10.2% Red color dispersion % 0.5% 0.6% 0.6% 0.6% 0.6% 0.7% Berry flavor % 0.3% 0.3% 0.3% 0.3% 0.3% 0.3% Citric acid % 0.3% 0.1% 0.1% 0.1% 0.1% 0.1% Extra fine granular sugar 0% 0% 18.0% 0% 0% 0% Bakers special sugar 34.1% 19.4% 5.7% 22.6% 28.3% 19.3% Powdered sugar 5.5% 5.7% 2.1% 2.5% 1.6% 7.2% Total sugar dry charge 39.6% 25.1% 25.8% 25.1% 29.9% 26.5% Moisture and Water Activity Results % Moisture shell 15.4% 22.0% 20.6% 25.1% 26.4% 21.4% % Moisture center 15.8% 24.6% 22.7% 24.5% 24.5% 24.9% Water activity (shell) 0.477 0.498 0.460 0.511 0.489 0.512 Water activity (center) Figure 5 0.508 0.482 0.441 0.494 0.454 0.494 46 58 th PMCA Production Conference, 2004 ➤
Page 1 and 2: Back to Basics — Panning Soft Pan
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