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TUV-NORD

Project Report

Flat Lollypop Making Plant

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PROJECT REPORT FOR MANUFACTURING

 FLAT LOLLIPOPS

IN

ROTARY FLAT LOLLIPOPS MAKING AND

SANDWICH PACKING MACHINE

 

 

 

Content

Annexure

Process 

2.0

Plant & Machinery

2.1

Fuel/Power/Water

2.2

Man Power Required

2.3

          Raw Material Required

2.4

                            

 

 

Process : Annexure 2.0

 

COOKING OF SUGAR BATCH

COOKING PROCESS IN VACUUM COOKER:

In this process Stainless Steel Steam Jacketed Vacuum cooker with Motorized Stirring system is used to cook the sugar batch. The Batch is cooked with steam hence there is no pollution in the cooking area.

Steam is generated in Boiler far away from cooking area. And the steam is fed directly to cooker through a pipeline. First of all Water is put in the Vacuum Cooker and required quantity of sugar added. Steam is opened and stirring systems is also operated. When the sugar dissolved liquid glucose and other ingredients are added in the cooker. 

When the desired temperature is achieved, vacuum is applied and discharge valve is opened.  The vacuum itself sucks the batch into vacuum pan. The vacuum is applied to sugar boiled mass to remove the moisture left in it after cooking. This improves the life and clarity of cooked sweet as it is required to be Vacuum for 3 to 5 minutes in vacuum pan. There after the batch is discharged on the Water Circulated Cooling Plate by tilting the pan to cool down the boiled material. Where essence, flavor and colors etc. are mixed in the batch and temperature of mass is reduced to a specified level.

FORMING IN ROTARY FLAT LOLLIPOP MAKING

AND SANDWICH PACKING MACHINE

 

After the cooling of cooked material, the mass is put into the Batch Former. In Batch Former Four Stainless Steel rollers are present which gives the material a conical shape of Sugar rope. Heater is fitted under Stainless Steel Rollers to automatically keep the Sugar Batch warm. This rope is further fed to three-stage rope Sizer to give the required dia to rope.

The rope coming out from rope Sizer is fed to the Rope Sizer of Rotary Flat Lollipop Forming machine and Sandwich Packing Machine. Place Plastic Lollipops Sticks in Stick Hopper. When machine will be in motion, Stick feeding Roller picks sticks one by one and dropped in moving Forming Die.

Rope Coming from Rope Sizer of Lollipop forming is cut into required size by Knife and dropped on Feeding disk; feeding disk conveys pieces of sugar rope to the Forming Die. Here Upper Punches and lower Punches of Forming Die presses sugar pieces both side, at the same time Stick Pressure Came presses each stick in the Sugar Piece and Lollipop will be ready.

After Forming in Die, Stick Grippers grips each Lollipop from stick and Convey to Sealing Rollers. Here two Heat Sealable Film rollers are fitted in Lollipop packing section. Printed Photo eye marked Film roller will be fitted in up side and blank film roller will be fitted lower side. Both the films will come together. Gripped Lollipops goes through the center of both the films and sealing Rollers packed it in Sandwich style. After packing in sealing rollers, packed Lollipops goes through Cutting knife, here knife cuts sealed paper from the middle of each Lollipop.

Plant & Machinery : Annexure 2.1

 

S.NO.

Machines

Required

1.

STEAM BOILER

ONE

2.

STAINLESS STEEL STEAM JACKETED VACUUM COOKER

ONE

3.

COOLING PLATE WITH WATER CIRCULATION COOLING PLATE

ONE

4.

BATCH FORMER

ONE

5.

ROPE SIZER THREE STAGE

ONE

6.

PANEL BOARD FOR BATCH FORMER, ROPE SIZER AND ROTARY FLAT LOLLIPOP FORMING

ONE

7.

ROTARY FLAT LOLLIPOP FORMING AND SANDWICH PACKING MACHINE

ONE

 

Fuel / Power / Water Requirement : Annexure 2.2

 

Fuel / Power / Water Consumption

S.NO.

Name of Machine

Load

Nos.

Total Load

1.

Steam Boiler

2 h.p.

One

2 HP

2.

Vacuum Cooker

Stirrer

5 h.p.

1.5 h.p.

One

One

5 HP

1.5 HP

3.

Batch Roller

Heater

0.5 h.p

3 k.w 

One

One

0.5 HP

3 KW

4.

Rope Sizer

1 h.p.

One

1 HP

5.

Forming Machine

1 h.p.

One

1 HP

                                                                                       

          WATER

 

1.               About 10 liters water required per minute for cooling plate. (this water can be re-circulated after cooling)

 2.               About 40 liters water is required for circulation in the pump (this water can be re-circulated after vacuum)

 3.               About 300 kegs water per hour for the boiler even this can be collected in the form of steam and circulated again.

FUEL

            An Oil Fired Boiler Consumer Approx. 8 - 10 Liters of LDO (Light Diesel Oil) Per Hour. (This Boiler Can Operate Up To Two Cookers)

          

Man Power Required : Annexure 2.3

 

S.NO.

REQUIRED FOR  

NOS.

1.

STEAM BOILER AND COOLING PLATE

One

2.

VACUUM COOKER

One

3.

WEIGHING & DOSING

One

4.

ROTARY FLAT LOLLIPOP FORMING

One

5.

HANDLING

Three

6. 

PACKING & STORAGE

Four

 

 

Raw Material Required: Annexure 2.3

 

Sugar

Liquid Glucose

Citric Acid

Flavors and colors

Packaging material

Paraffin wax

Dusting powder

 

        Ingredients:- 

I)        Sugar

II)     Flavoring Material.

III)    Colors

 

            But the sweetening agents other than Sugar used in confectionery are corn syrup, Sugar cane

juice syrup, sugar, syrup, golden syrup molasses and honey, other Raw Materials used in

Confectionery

are:-

 

1.     Cereal Material

2.    Starch Powder

3.    Various nuts and fruits

4.    Flavoring Scents

5.    G.M.S. Emulsifier

6.    Milk Powder

7.    Liquid Glucose

 

SUGAR:-

            White Crystals Sugar with a polarization value of 99.9o is suitable for the manufacturing of quality confection.

 

CORN SYRUP:-

            The use of corn syrup permits of greater holding of dissolved Sugars. Fondants made with corn syrup contain more than 84% sugar in the liquids with Sucrose. Corn syrup should be crystal clear, should not change color when boiled.

 

FLAVORS:-

            The flavors of confectionery are of importance as it influences not only the sense of smell and taste but also the mouthful or the physical effort of the food in the mouth. The flavoring essence commonly peppermint are vanilla, lemon oil orange oil, other natural products, honey is also used as a flavoring agent synthetic flavors consisting of esters, ketons, alcohols, etc. Simulating the distinctive aromas of fruits like pineapple, strawberry and banana are also used.

            Acid taste is imported by the addition of tartaric citric molic acetic and lactic acid when citrus oils are used for flavoring it is usual to add acid to give the source taste Modified, Chocolate Imparts a bitter taste in high class confections, especially those flavored by citrus oils is added to give the bitter taste and to enhance the piquant flavor

 

         COLOURS:-

            A variety of natural and synthetic edible colors are employed for coloring confectionery. The colors are incorporated in the form of pastes. The confection is usually given the color of the fruit flavor as been reproduced synthetic of color are: - In digotine for Blue Shade, oil Red ox for red shade and orange and orange ss for orange shade. These should be absolutely pure and free from harmful impurities, particularly traces of arsenic and heavy metals. They should high

.