APPLICATION
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 ingredientssuch as a savoury slurry, chocoalte
BASE
Core products
RECIPE
Ingredients
The addition of an oil or emulsifier prevents agglomeration and eases the dispersion.
PROCESS
How does it work?
Upstream
The maize cores are popped by applying a intense heat. The water inside reaches a boiling point and the cores expand brutally under the build-up pressure
Coating
The coating consists in the application of a dense and hot sugar syrup which disperses partially. It leaves parts of popped corn apprent, white flesh and yellow skin, in a mesh of yellow sugar.
Syrup preparation by dissolution, cooking, vacuuum ev
Downstream
The highly concentrated syrup sets by cooling, next to nil moisture being left in it. Conversely, the coated product must be packed and protected from moisture which would soften the inner and melt the syrup
1.
Product dosage
2.
Syrup dosage 10-20 %
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 finely ground powder into the syrup (cocoa, cinnamon) and carry out just one application. This ‘slurry’ needs to be constantly agitated until it is applied.
The liquid ingredients are best dispersed by dedicated spraying systems. The powder can be dispersed 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 needs to be thoroughly dried in 2 or 3-tier driers to be ready for packaging.
PROCESS
Coating system
Syrup application drum
PRODUCT EVALUATION
How do you measure your success?
Key quality features
Coated popcron is the unique combination of a crunchy and soft bite
Aspect
Balanced colour contrast of the popped product and its coating
Texture
Crispy texture of the hard syrup and soft bite of the popcorn flesh. No stickiness
Product integrity
No broken product nor fine and dust
Key quality parameters
A controlled combination of material (water evaporation, syrup application), mechanical (application and dispersion) and thermal (boiling, cooling) transfers
Temperature
Key parameter in syrup preparation, handling, dosing, dispersion and setting
Motion
Thorough mixing to disperse the syrup while gentle enough to preserve the fragile popped structure
Dosage
Balance dosing of the low-density popped cores and the syrup
