Feature article: Delectable Apple and Fruit Gums

The optimization of production processes is a constant source of inspiration in the food industry. How can product quality, yield or efficiency of existing processes be improved? Claudia Neuhold, Business Development Manager at ZETA, explains: “At the beginning, we analyze the entire production process - from acquiring the raw materials to storing the end product. Then we work out solutions together with the customer, for example, to minimize product losses or to mix the products with greater care. There are many parameters that can be adjusted. More efficient heating and cooling processes, for example, are becoming increasingly important in terms of sustainability.”

The development of effective concepts for food safety begins with a detailed analysis of the production process. Together with the customer, ZETA works out options for improving the hygienic design of the process systems.

ZETA's structured product development turns ideas into reality

Successful product development begins with the creation of a test and examination matrix as well as the screening and selection of the right raw materials. Process solutions are then evaluated and pilot tests are organized. These take place in the in-house innovation laboratory, the ZETA TechCenter, or, if desired, in the pilot systems of partner companies. The results from the various test series lead to the final draft of a defined production process.

Success story - apple and fruit gums: product and process development

A Russian company that produces fruit concentrates, a supplier for producers of juices, jams and confectionery, wanted to integrate forward in the field of fruit gum production. The aim of the investment in a new production line was to avoid using expensive imported products, to successfully expand the line of business and to improve the company's added value.

The customer from St. Petersburg commissioned ZETA with the development of the product recipe and manufacturing process for the product "apple-fruit gum". At the beginning, the ingredients produced by the customer itself, such as apple juice concentrate, apple sauce, water, pectin, citric acid, were selected in order to create a stable, reproducible recipe. ZETA carried out pilot tests in close cooperation with the customer to determine the best fruit gum recipe. The fruit gum product is manufactured in four steps in the developed process.

First: Preparation of the premix in a stirred tank. Second: Concentration under vacuum. This critical step involves bringing the premix to a high level of suspended solids. Two vacuum cooking systems and different recipe processes were tested. The third, also critical step is the shaping. Hot and cold extrusion were tested for this purpose and a number of parameters were varied during the extrusion process. The last step is cooling in a tunnel.

Successful project implementation and maximum customer satisfaction

The Russian customer was extremely satisfied with the result of the extensive pilot tests: ZETA supplied a finished, production-ready fruit gum recipe. This successful collaboration was by no means over after product development; on the contrary, ZETA was commissioned to create a corresponding concept design for the manufacturing process. The ZETA experts developed a concept design for the process equipment. This included the entire process, from the preparation of the raw material, to the production of the premix, shaping and cooling and finally to the packaging of the product. ZETA was able to successfully complete this concept design project and hand over the relevant documents to the customer.