Use Quality Gummy Manufacturing Equipment for More Consistent Products
When manufacturing gummy vitamins, there are a number of quality control concerns to look out for. As these products line store shelves, ensuring that they both taste great and are safe to consume are top priorities.
No matter the pharmaceutical product, whether gummy, softgel, tablet, or capsule, quality control provides a final line of defense against any defective product reaching consumer outlets. If you are interested in adding gummies to your product line or want to refine your processes, here are some quality control warning signs to look out for when completing your final inspections.
1: Water Activity
Water activity is used to measure the impact of moisture on a gummy’s final properties. From texture to shelf-life, improper levels can cause operational headaches at best and endanger consumer safety at worst. A bad batch of gummies can also result in a drastic loss of both time and money.
Generally, an ideal water activity level in a gummy product could range from 0.55 to 0.70, giving a range of 1.5. Quality control professionals can measure this in gummy vitamins and supplements within minutes by using a handheld water activity meter.
2: Improper Sealing
Sealing a gummy container properly is essential to keeping the product fresh before being purchased by the consumer. Depending on your preferred packaging method, there could be a number of sealing techniques you can use.
For example, if you are packaging gummies in a plastic bottle or jar, a combination of professional induction sealing and capping machines can ensure a better-protected product. The induction layer is typically a layer of thermoplastic sealed over the bottle’s opening before it is capped.
3: Unusual Textures
Gummies should have a smooth surface and a soft, chewable consistency. If you are missing one or both attributes from your final product, this could indicate a number of possible issues during the manufacturing process, such as:
Incorrect Temperature Settings
Temperature settings dictate much of the gummy’s final properties. Gelatin, the most common base ingredient for gummies, has a melting point ranging from 31.7–34.2 °C (89.06-93.56 °F). However, if you decide to swap gelatin for a plant-based alternative, this could require new temperature settings for your equipment.
Miscalculated Ingredient Ratios
Miscalculating ingredient ratios can be a common mistake in the early stages of gummy product research and development. These are precise measurements that might require some initial test batches before manufacturing gummy vitamins at scale. For example, too much or too little gelatin could produce an unusual texture that is either too chewy or tough to provide an enjoyable experience.
If you notice your gummies have an unusual texture, consider re-evaluating your ingredient ratios. You can adjust percentages and continue to refine through test batches until you have landed on a successful final product.
Sticking to Molds
Gummy molds determine the final shape of the product units. You may decide to use a traditional shape like a gumdrop or ring or a custom shape.
Not all molds are created equal, however. Using a high-quality mold and spraying it with the proper oil before depositing your gummy slurry can prevent the products from sticking the molds. If they stick to the molds, this could result in torn or incomplete products as a result.
Uneven Coatings
Gummy coatings are optional, but many manufacturers add them to enhance or modify flavor, prevent sticking, alter product texture, or control moisture levels. They are added during the final phase of the manufacturing process once the gummies have been cooled, solidified, and de-molded.
Do you find that your gummy coatings favor one side of the gummy over the other? Do they look unintentionally asymmetrical? This could indicate an error in the coating process. By using professional gummy coating equipment, however, you can prevent this in most cases.
4: Unpalatable Taste
Does your finished gummy vitamin taste odd or unlike its intended flavor? These signs could indicate that too little flavoring or sweeteners were added during the production process. In most cases, manufacturers can correct this by increasing the amount of sweetener or flavor.
If you are using a non-sugar sweetener, many of these alternatives are not a one-for-one match with sugar. They may require higher or lower levels to replicate a similar sweetness and taste.
5: Inconsistent Weights
When inspecting a complete, packaged product, do you find that multiple containers have vastly different weights? This could indicate an issue with the packaging process.
Consider adding or upgrading to a quality inline checkweigher as part of your packaging operations. These machines ensure that your packages are filled to a consistent weight or weight range.
Upgrade to Quality Gummy Manufacturing and Packaging Equipment Today
At CapPlus, we partner with both large and small pharmaceutical manufacturers to connect them with the highest quality gummy vitamin production equipment on the market. If you are considering extending your operations to include gummies or want to upgrade your existing machinery, contact us today to speak with one of our team members.