Hard Sugar PanningWalter Vink 2007 Panned Confections Workshop HARD PANNING • Hard Sugar Coated – Jaw breakers, Lentils, Chewing gum,Jordan almonds, Fruit chews. • Hot Panned – Boston baked beans, French burned peanuts, Sweet-n-crunchy nuts, Honey roasted nuts. 2007 Panned Confections Workshop HARD PANNING • Applying the correct amount • Of the correct material • At the correct time 2007 Panned Confections Workshop HARD PANNING Hard panning involves all five senses Visual appearance Sound of the product tumbling The smell of the center coating Feel of the product as it dries Taste (smoothness) on the tongue 2007 Panned Confections Workshop SUGAR PANNING FUNCTION OF INGREDIENTS • SUCROSE – Forms the shell – Crystallizes easily – Forms very fine crystals – Forms a very strong coat – Protects the center 2007 Panned Confections Workshop SUGAR PANNING FUNCTION OF INGREDIENTS • CORN SYRUP – Provides flexibility and strength during the early stages of coating 2007 Panned Confections Workshop . SUGAR PANNING FUNCTION OF INGREDIENTS • FILM FORMERS – Provide a barrier between the center and the coat – Prevents transfer of oils and moisture between center and coat. – Provides a base to which the coat can adhere 2007 Panned Confections Workshop . – Gum Arabic – Dextrins – Starch – Gelatin 2007 Panned Confections Workshop .SUGAR PANNING FUNCTION OF INGREDIENTS • FILM FORMERS contd. SUGAR PANNING Properties of Syrups • • • • • Coating Ability Syrup composition Syrup temperature Adhesive properties Ability to crystallize and dry 2007 Panned Confections Workshop . SUGAR PANNING Properties of Syrups • COATING ABILITY – Must be able to flow and coat the centers uniformly 2007 Panned Confections Workshop . SUGAR PANNING Properties of Syrups • SYRUP COMPOSITION – Sealing or Gumming syrups contain a film former such as Gum Arabic or dextrin (10%-30%) to form the base for coating and the barrier to prevent moisture or oil migration 2007 Panned Confections Workshop . to promote faster crystallization and weight build-up.SUGAR PANNING Properties of Syrups • ENGROSSING SYRUPS – 68-75% solids. – Produce a moderately smooth coat. 2007 Panned Confections Workshop . – May contain 1-5% corn syrup or film former to build coating strength and flexibility. SUGAR PANNING Properties of Syrups • SMOOTHING SYRUP – 67% OR LESS SOLIDS TO PROMOTE FINE CRYSTALS – Solids are reduced at the end of the process to obtain a super smooth finish 2007 Panned Confections Workshop . 2007 Panned Confections Workshop . – Sealing syrups are added at room temperature – Engrossing syrups can be slightly above room temperature – Smoothing syrups are room temp.SUGAR PANNING Properties of Syrups • SYRUP TEMPERATURE – Must be low enough to prevent softening or melting of the centers. SUGAR PANNING Properties of Syrups • ADHESIVE PROPERTIES – The adhesive nature of the syrup is low after charging but increases dramatically as drying and crystallization begin. – The product becomes extremely sticky. 2007 Panned Confections Workshop . SUGAR PANNING Properties of Syrups DON’T PANIC !!! 2007 Panned Confections Workshop . 2007 Panned Confections Workshop .SUGAR PANNING Properties of Syrups • ADHESIVE PROPERTIES Contd. – At maximum adhesiveness. – If powder is needed. – A small amount of powder may also be added if the product sticks to the pan. air is applied to promote drying and end the stickyness. subsequent charges should be reduced in volume. THE SCIENCE OF HARD SUGAR PANNING In order to achieve proper drying. each governed by their own scientific principles must be considered: A. Crystallization 2007 Panned Confections Workshop . Air flow B. two key factors. THE SCIENCE OF HARD SUGAR PANNING • AIR FLOW – Volume of air – Direction of the air – Temperature of the air – Relative humidity of the air 2007 Panned Confections Workshop . THE SCIENCE OF HARD SUGAR PANNING • Volume of air – Must be sufficient to maintain product bed temperature – Sufficient to remove the moisture from the pan – Maintain the desired humidity gradient between the product and the air in the pan 2007 Panned Confections Workshop . 2007 Panned Confections Workshop .THE SCIENCE OF HARD SUGAR PANNING • DIRECTION OF THE AIR: – Must contact the product bed – Process is slower when air contacts only the product bed surface. – Process is faster and more efficient when the air flow is through the product bed. THE SCIENCE OF HARD SUGAR PANNING Figure 1 AIR FLOW THROUGH THE BED 2007 Panned Confections Workshop . 2007 Panned Confections Workshop .THE SCIENCE OF HARD SUGAR PANNING Figure 2. for maximum smoothness. – The type of coating syrup • Dextrose and polyhydric alcohols have significant latent heat to be removed. • Prevent melting or softening. 2007 Panned Confections Workshop . – The degree of smoothness desired • High Temp for fast build-up. lower Temp.THE SCIENCE OF HARD SUGAR PANNING • AIR TEMPERATURE Key factors: – The type of center to be coated. THE SCIENCE OF HARD SUGAR PANNING RELATIVE HUMIDITY OF THE AIR What is it? How is it determined? How does it affect the process? 2007 Panned Confections Workshop . 2007 Panned Confections Workshop .THE SCIENCE OF HARD SUGAR PANNING Relative Humidity Air is a mixture of gasses including water vapor. The total pressure of air is the sum of all of the partial pressures of these gasses. This amount is called the saturated vapor pressure of water in air at the given temperature.THE SCIENCE OF HARD SUGAR PANNING Relative Humidity Contd. Air will hold a maximum of amount of water at any given temperature. This amount is expressed in mm Hg at Temp in C 2007 Panned Confections Workshop . Relative humidity is defined as the ratio of the actual vapor pressure to the saturated vapor pressure at temperature T. Air usually holds less than the saturated amount of water.THE SCIENCE OF HARD SUGAR PANNING Relative Humidity Contd. 2007 Panned Confections Workshop . Equation I.: RH = Actual vapor pressure of water at T Saturated vapor pressure of water at T 2007 Panned Confections Workshop .THE SCIENCE OF HARD SUGAR PANNING Relative Humidity Contd. : % RH = Relative humidity X 100 2007 Panned Confections Workshop .THE SCIENCE OF HARD SUGAR PANNING % Relative humidity Equation II. 2007 Panned Confections Workshop . Equilibrium relative humidity (ERH).THE SCIENCE OF HARD SUGAR PANNING How does this relate to drying? All materials which involve water have a water vapor partial pressure. This is expressed as Water Activity (AW) or if a percent. of water of solute 2007 Panned Confections Workshop . These can be calculated using RAOULT’S LAW (Eq.III. + the mole fract.): AW of a solution = mole fraction of water______ the mole fract.THE SCIENCE OF HARD SUGAR PANNING Determining AW or ERH. * Syrup solids content * Speed of drying. 2007 Panned Confections Workshop .THE SCIENCE OF HARD SUGAR PANNING CRYSTALLIZATION: The main factors which control the size and shape of sugar crystals are: * Syrup viscosity. * Condition of the bed. 2007 Panned Confections Workshop .THE SCIENCE OF HARD SUGAR PANNING CRYSTALLIZATION Contd. Factors: Syrup solids content and viscosity will be covered under processing. The two main causes of rough surfaces are: Drying too fast ! Drying too slow ! 2007 Panned Confections Workshop .THE SCIENCE OF HARD SUGAR PANNING CRYSTALLIZATION Contd. THE SCIENCE OF HARD SUGAR PANNING Crystallization Contd. Drying too fast: Promotes the growth of large irregular twin crystals. Results in a rough surface 2007 Panned Confections Workshop . THE SCIENCE OF HARD SUGAR PANNING Figure 3 TYPE 1. TWIN SUGAR CRYSTAL 2007 Panned Confections Workshop . THE SCIENCE OF HARD SUGAR PANNING Figure 4 TYPE 2 TWIN SUGAR CRYSTAL 2007 Panned Confections Workshop . THE SCIENCE OF HARD SUGAR PANNING Figure 5 TYPE 3 TWIN SUGAR CRYSTAL 2007 Panned Confections Workshop . THE SCIENCE OF HARD SUGAR PANNING Figure 6. CONGLOMERATE SUGAR CRYSTAL 2007 Panned Confections Workshop . 2007 Panned Confections Workshop . Drying too slow: Charge can dissolve the previous coat causing supersaturation and the growth of large irregular twin crystals.THE SCIENCE OF HARD SUGAR PANNING Crystallization Contd. Wet product can pick material from the pan surface which dries in a rough surface. The increased latent heat must be removed.THE SCIENCE OF HARD SUGAR PANNING Considerations for Sugar Free Panning The same principles of proper air flow and crystallization apply. 2007 Panned Confections Workshop . 1. Engrossing 4. Gumming 3. Smoothed 2. Color Coat 2007 Panned Confections Workshop . prevents formation of spotted surface or pealing.Gumming Sealant layer between center and shell • Holds fats inside. • Fills in a rough surfaced center • Improved Adhesion • Improved Flexibility (reduced chipping) 2007 Panned Confections Workshop . Gumming Ingredients • • • • • Gum Arabic Gelatin Dextrin (from corn or tapioca) Low DE Maltodextrin Film Forming Starches • Dry with starch or powdered sugar • Opportunity for addition of flavor. or salt • Drying step prior to further coating? 2007 Panned Confections Workshop . acid. Dry 3. Application of 40-60 layers is common. Products such as large jawbreakers can receive over 300 layers. Coat 2. The water is then evaporated from the liquid allowing the sugar to form crystallized layers. Repeat 2007 Panned Confections Workshop . 1.Engrossing A liquid sugar solution is applied to the surface of a center. no crystals • Sucrose Syrup Solids – 67% to 72% solids typical for engrossing – 75%-77% for larger centers • Syrup Temperature – Hotter syrup has lower viscosity and dries quicker – Not too hot… do not want evaporation or inversion – Typical temperatures 85°F to 150°F • Viscosity less than 200 centipoise 2007 Panned Confections Workshop .Engrossing Syrup Preparation • Sugar Syrup Preparation . dextrin. but impacts quality • Addition of 0. or gelatin for added flexibility – Gum arabic can be added for hardness 2007 Panned Confections Workshop .5% to 1% Gum Ingredient – Corn syrup.Optional Engrossing Steps • Titanium Dioxide to Provide White Color – Added to all layers or just last few coats • Dry Dosing with Powdered Sugar – Speeds process. maltodextrin. • A smooth surface is critical before applying colored layers. 2007 Panned Confections Workshop . the low points get filled in. As the syrup dries. • The extra moisture insures uniform syrup coverage. Any bumps or dips will result in varied color intensity. but with lower syrup solids.Smoothing • Similar to engrossing. • Insoluble lake colors do not produce the same brilliance as dyes. 2007 Panned Confections Workshop . but with the addition of color dyes and lakes. but they do not bleed.COLOR COAT • Color syrups solutions similar to smoothing syrup. • Dyes produce brighter colors. “melting in your hand”. but the water soluble dyes tend to bleed.