In a typical gummy production line, the total energy intensity generally ranges from 0.5 to 2.0 kWh per kg of finished gummies, depending on the specific equipment, batch size, and product formulation. This figure accounts for the energy consumed across all primary processing steps-mixing, cooking, depositing, drying, cooling, and packaging. However, it’s important to note that exact values vary among manufacturers due to differences in line design and operational efficiency.
The step that dominates the energy use in gummy production is drying. While cooking (heating the slurry) and cooling (setting the gummies) do contribute, the drying step-often performed in tunnel dryers or drying rooms-consumes the most energy per kilogram of output. This is because drying relies on sustained, controlled heat to remove moisture from the gummy surface and interior, a process that can require extensive energy input over several hours. In contrast, cooking typically uses steam or direct heat for a relatively short period, and cooling often relies on ambient or chilled air with lower total energy demand.
Breakdown of Energy Use by Step
- Cooking: Energy is required to heat the slurry (typically to around 80-105°C) for gelatin hydration and ingredient blending. This step accounts for roughly 15-25% of total energy, with steam being the most common heating medium.
- Drying: The most intensive step, consuming 50-70% of total energy. Drying tunnels use heated air (often via gas or electric heaters) to reduce moisture content from around 20-25% down to 12-14% over 12-24 hours.
- Cooling: This step uses chilled air or cooling tunnels to rapidly reduce product temperature after drying. Energy consumption is 10-20% of the total, as it primarily powers compressors and fans.
Why Drying Is the Dominant Energy Consumer
The drying stage requires heat to maintain consistent air temperature and humidity within the drying chamber, often at 40-50°C for many gummy types. Since moisture removal is an endothermic process, the energy input must overcome the latent heat of vaporization. Additionally, drying times are long, meaning the equipment runs for extended periods, amplifying total kWh. In contrast, cooking is a batch process with shorter duration, and cooling relies on less energy-intensive heat transfer methods.
It’s worth emphasizing that each gummy production line is unique. Factors such as line speed, gummy size, humidity control, and the type of energy source (electric versus gas) can shift these percentages. At KorNutra, our focus is on optimizing these steps to reduce overall energy intensity while maintaining product quality. We design our processes to minimize drying times and improve thermal efficiency wherever possible.