APPLICATION
Popcorn – caramel
The very light texture of expanded corn seeds (popcorn) makes them sensitive to moisture. Only high solid-content sugar syrup can be applied. The alternatives are 100 % fat-based ingredients, such as a savoury slurry or chocolate.
BASE
Core products
The core is the result of the sudden expansion of corn seed. The minute water content evaporates, leaving a hollow texture. The starchy material and fine texture tend to draw moisture and spoil the surface. There are different sorts of maize: butterfly or mushroom varieties.
RECIPE
Ingredients
The ingredient is sugar diluted in water, heated to a boiling point, and cooked until it reaches the appropriate concentration. The addition of an oil or emulsifier prevents agglomeration and eases dispersion.
RECIPE
Ingredients
The ingredient is sugar diluted in water, heated to a boiling point, and cooked until it reaches the appropriate concentration. The addition of an oil or emulsifier prevents agglomeration and eases dispersion.
PROCESS
How does it work?
Upstream. The maize cores popped with the intense heat. The water inside reaches a boiling point, and the cores expand brutally under pressure build-up.
Coating. The coating involves applying a dense and hot sugar syrup that disperses partially. It leaves parts of popped corn apparent, white flesh and yellow skin, in a mesh of yellow sugar—syrup preparation by dissolution, cooking, and vacuum EV.
Downstream. The highly concentrated syrup sets by cooling, with nil moisture. Conversely, the coated product must be packed and protected from water to soften the inner and melt the syrup.
Step 1.
Product Dosage.
Step 2.
Syrup dosage 10-20%
Step 3.
Cooling and setting.
PROCESS
Coating system
The operation occurs in a rotary tumbler whose length and diameter are calculated to accommodate the product flow. Baffles inside enhance the tumbling action.
The coating relies on the dispersion of the liquid ingredients first, then on the mechanical friction caused by tumbling.
Liquid and powder ingredients can be added separately.
One option is to mix the finely ground powder into the syrup (cocoa, cinnamon) and carry out just one application. However, this ‘slurry’ must be constantly agitated until it is applied.
Dedicated spraying systems best disperse the liquid ingredients. The powder can be distributed with a vibratory tray. It is a continuous operation.
Rotation speed and tumbler tilt angle are adjusted to achieve the required friction and residence time. After coating, the product must be thoroughly dried in 2 or 3-tier driers for packaging.
PROCESS
Coating system
Syrup application drum.
PRODUCT EVALUATION
How do you measure your success?
Key quality features
Coated popcorn is the unique combination of a crunchy and soft bite.
Aspect
The balanced colour contrast of the popped product and its coating texture.
Texture
The crispy texture of the hard syrup and the soft bite of the popcorn flesh. No stickiness.
Product integrity
No broken product nor fine dust.
Key quality parameters
A controlled combination of material (water evaporation, syrup application), mechanical (application and dispersion) and thermal (boiling, cooling) transfers.
Temperature
Critical syrup preparation, handling, dosing, dispersion, and setting are essential parameters.
Motion
Thorough mixing to disperse the syrup while gentle enough to preserve the fragile popped structure.
Dosage
Balance the dosing of the low-density popped cores and the syrup.
APPLICATION
Discover more applications