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Brief Project Report 

Flat Lollypop Making Plant

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Process : Annexure 2.0

COOKING

First Method :- There are two Methods for Cooking of Candy Mass. One is open fire Cooking in the open type over any type of Coal or diesel Bhatti with Manual Stirring, Manual Handling or Cooked Mass to the Vacuum Pan than to the Cooling Plate. This process is caused to pollution also

Second Method :-  Other  method of cooking is with steam jacketed stainless steel cooking with motorized chamber stirring. The quality of the product made with this system is excellent moderate and there is no manual handling of cooked batch. There is no pollution in the cooking area Thus this system is suggested in this report.

                                 Steam is generated in the boiler with help of fuel and this boiler is kept away from the cooking or processing area to maintain the cleanliness. Steam is supplied to the cooker through the pipeline. While operating the cooker, put sufficient water in cooking chamber, add sugar, liquid glucose, switch on the stirrer (Alternately sugar, liquid glucose syrup can be pumped from the pre-dissolved tank) when sugar is dissolved put other ingredients in cooking chamber step by step. When the desired temperature is achieved, vacuum is applied and valve is opened. It sucks cooking mass into lower pan, cooking chamber’s valve closed. Here vacuum is applied further for 4-5 minutes to remove the moisture of mass. This improves the quality and clarity of sweets. Next step is to release the vacuum and thick syrup of lower pan is poured on cooling plate by tilting the pan. Here color, flavors and other things are added to the batch

Batch Roller :-  Put the Sugar batch in Batch roller after cooling on Cooling Plate. Batch roller  produce a thick Conical shaped rope of Sugar. This rope is further fed to three-stage rope Sizer

Three Stage Rope Sizer :- Rope Sizer give the required dia to Sugar rope according to Forming Die and then the rope coming out from rope Sizer is fed to Forming Machine.

Flat Lollypop Forming :-  In forming machine put the Lollypop Sticks in Hopper at a time (Hopper Capacity one Kg Stick at a time). Coming rope from Three-stage rope Sizer further fed to sizing wheel of Lollypop forming Machine. These Sizing wheel are according to final size and weight of Lollypop. Sugar rope go through two roller, at the same time pressure gutka push the stick into the Sugar automatically. After forming of Lollypop, a stick puller knife lift the Lollypops one by one  and ready pieces are discharged on the Three Way cooling conveyor after cooling, lollipops are ready for packing.

PACKING PROCEDURE      

First Method

Sandwich Type packing of Lollipops

                                 We have available sandwich type wrapping machine for packing flat lollipops in sandwich packing style. In this machine lollipops are manually placed on the moving conveyor and the sealers of the machine pack the lollipop in two sheets of heat seal able film. Packed lollipops can be retained individually or continuous strip of packed lollipop can also be formed in this machine.

Second Method   

Pouch Style Packing

                                Form fill and seal machine is used to pack lollipops in pouches with stick. . In this machine lollipops are manually placed on the moving disk of Machine. Paper coming from real breket fed through Paper shoot, where to round sealers are installed for center sealing. At the same time Disk drops Lollypops one by one in to the one side opened pouch. After that pouch fed through  lower sealers, where the sealers sealed other side of pouch.  

WATER

1.    About 10 Liters Water required per Minute for Cooling Plate 

        ( This Water can be recirculated after cooling)

2.    About 40 Liters Water is required for circulation in Vacuum Pump (Vacuum Cooker)

        (This Water can be recirculated after Vacuum)

3.    About 300 Liters Water per hour for the Boiler even this can be collected in the foam of steam condensates and circulated again

FUEL

An Oil fired Boiler Consume Apex 8 - 10 Liters of  LDO ( Light Diesel Oil)  per Hour

(This Boiler can operate up to three Vacuum cookers. There is less consumption of fuel for each batch if more then one Vacuum cooker is installed 

Other material for special products and raw materials application.