Transforming Gummy Bear Production: A Case Study with TCI Culinary

The Challenge of Outdated Production Methods

A well-established confectionery company faced significant challenges with their gummy bear production line. Their reliance on a traditional starch mogul system resulted in high operational costs and quality control issues. This outdated method not only created substantial waste but also consumed excessive labor hours. Moreover, it hindered the launch of a new premium product line, stifling innovation.

The manufacturer’s gummy production relied heavily on this starch mogul system. While it has historical significance, it presented modern-day challenges for a company looking to expand.

Key Issues Identified

1. High Defect Rate: The process of pressing shapes into trays of starch, depositing the gummy liquid, and later removing the set candy was imprecise. This resulted in a 12% defect rate due to misshapen products and starch contamination, leading to a financial loss of £30,000 per month.

   
   

2. Labor-Intensive & Slow: The system required extensive labor for de-moulding, sifting, and conditioning the starch, totaling 800 hours of labor monthly. This created a slow, cumbersome production cycle that limited output.

   
   

3. Barrier to Innovation: The company aimed to launch a new line of intricate, multi-flavored gummy shapes. However, the starch mogul system could not produce the sharp detail required, putting a halt to product development.

   
   

Our Solution: A Modern Approach

To tackle these challenges, TCI Culinary introduced a complete starchless depositing solution. By replacing the entire starch mogul line with custom-designed silicone moulds, the manufacturer could deposit the gummy mixture directly into the final mould.

Benefits of the New System

• Precision and Detail: The silicone moulds were engineered to produce flawless, highly detailed shapes every time. This innovation finally made the new premium gummy line a reality.

  
  

• Radical Efficiency: The starchless process eliminated the need for starch preparation, pressing, and extensive cleaning. The gummies could be de-moulded cleanly and quickly, significantly reducing the production cycle time.

  
  

• Seamless Integration: The system was designed to work with their existing kitchen and depositing equipment. This minimized capital expenditure and downtime during the transition.

  
  

The Bottom Line: Increased Profitability

Profit Increase: ~£63,750

By partnering with TCI Culinary to abandon their legacy starch system, the confectionery manufacturer not only solved their core issues of waste and inefficiency but also unlocked the potential for innovation crucial for their growth.

The adoption of a clean, efficient, and precise starchless silicone moulding system built a more profitable and agile production line. This case study proves that moving beyond traditional methods is essential for securing a competitive edge in the modern market.

Conclusion: Embracing Innovation

In today's fast-paced food production environment, it is vital to embrace innovation. By modernizing operations, bakeries, chocolatiers, and food manufacturers can achieve greater efficiency and creativity. TCI Culinary stands ready to support these transformations, helping businesses thrive in a competitive landscape.

For more information on how TCI Culinary can assist in modernizing your production processes, feel free to reach out. Together, we can explore innovative solutions tailored to your specific needs.