Gummies have become one of the most popular confectionery items enjoyed by people of all ages thanks to the supplement industry. Gummies are a classic confection, come in various shapes, sizes, and flavors and are also great delivery agents for functional ingredients which is one of the biggest macro trends in food right now. Now, they are also the number one edible product in the majority of legalized states. Large and small companies are entering the gummy landscape, and regardless of if you plan to make your own gummies or use a contract manufacturer, it is important to understand what challenges your brand may face.
The number one problem that manufacturers face when developing their gummies is that they do not set properly. Causes of an improper setup are typically a result of:
Incorrect ratios of ingredients
Lack of temperature controls
Improper pH
Humidity & Curing Issues
The result is a gummy that has an undesirable texture, may clog your equipment or could result
in a food safety issue and a failed product in the market. I have spent the past few years formulating and setting up gummy manufacturing processes for a number of brands in the very competitive California edibles market and have resolved a number of the major issues first-hand. In this second installment of our Gummy Series, I will explore the reasons why gummies may not gel properly, the implications for your finished product(s) and what aspects you can adjust to hopefully prevent or quickly resolve these issues for your own operation.
Incorrect Ratio of Ingredients in your gummy recipe
The correct ratio of ingredients is crucial in making gummies. The most important ingredients are water, sugar, gelatin or pectin, buffer, and corn syrup. If the ratio of these ingredients is not correct, it can affect the gummy's texture and set.
For example, if your gummy recipe uses too much water, corn syrup or buffering agent, the gummies will be too soft and will not set. On the other hand, if you use too much gelatin or pectin, the gummies will be too hard and rubbery, set too quickly and clog your depositor, or have a bite that is too “brittle” (for pectin gummies). It's important to test, retest and dial in your formula carefully with production scale-up trials to get the perfect gummy consistency. Once the formula is finalized, proper training of your manufacturing personnel and processing controls should be implemented to ensure the formula is adhered to.
Lack of Temperature Controls
Temperature plays a crucial role in gummy making. When the ingredients are heated, they dissolve and combine to form a syrup. The syrup needs to be heated to a specific temperature and for a specific amount of time to activate the gelatin or pectin and drive off enough moisture. If the gummy syrup is not heated to the correct temperature, the gummies will not set properly.
Alternatively, if the temperature of the gummy solution is too low, you may never dissolve and activate the pectin or gelatin, resulting in a gummy that never sets.
If the temperature is not maintained during depositing, you may experience pre-gelling in your depositor and a complete loss of your batch (for pectin formulas).
If the temperature is too high for too long, the gelatin can break down, resulting in a gummy that is too soft or your brix will go too high and the gummy texture will be undesirable. It's important to use a calibrated thermometer and monitor and maintain the temperature carefully to get the perfect gummy texture.
Improper pH
The pH level of the syrup also affects the gummy's texture and set. Gelatin and pectin gummies require a specific pH level to set properly. If the pH level is too high or too low, it can affect the gummy’s ability to set.
The ideal pH level for gummies is between 3.0 and 4.0. If the pH level is too high, you can add citric acid to lower it. If the pH level is too low, you might be able to salvage it with the use of a buffer or you may ultimately have to start over and reduce the level of acid in your product. Once the pH is between the 3.0 and 4.0 mark though, the clock has begun for the gummy to start setting up, so its important to act quickly at that point.
Humidity and Curing Issues
Humidity can also affect the gummy's texture and set. If the humidity is too high during curing, the gummies will absorb moisture from the air and become sticky. Ultimately, your target Brix and water activity will never be met and that is both a problem for consumer acceptability but also food safety reasons. If you are located in a humid environment, it's best to have tight humidity controls in your manufacturing facility to avoid this detrimental issue.
Alternatively, if during the curing process the humidity is too low, the outside of the gummy will harden too fast and create a “crust” where the moisture within the gummy is not evenly distributed.
Issues with humidity become especially apparent during the shelf life of the gummies. If the gummies are not stored in an airtight container after curing is finished, oftentimes you will see either sticky or hard gummies inside which can be a negative experience for your consumers.
As a backup plan for packaging the finished gummies you could choose to include silica gel packets to absorb moisture in the final packaging if you are unable to tightly control the environmental factors for your manufacturing facility.
To summarize, if you ever attempted to make gummies you have probably run into one of these issues and have come to realize that gummy manufacturing is a delicate process that requires attention to detail and careful processing controls. If the gummies do not gel properly, you should start with analyzing your formula’s ingredient use levels, cooking and depositing temperatures, pH level, and/or humidity during curing (best practice is to start with the first and work your way through each variable one by one if you are unsure).
By using a tested formula and having control in place to monitor these factors, you should be able to make perfect gummies every time. Reach out to The New Flavor for help in developing your next gummy product!
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