JELLY CUP PRODUCTION
This was the key product that drove
the business as it is very easy to manufacture and has an extremely
high customers acceptance level.
It is still being manufactured in a limited way as the demand for this product
by the public warrants the limited production until a new owner takes over.
This was the company's main line during their peak production
period and there was no way they could keep up to orders even though it
is a very easy product to produce.
Method of production:
Hot water is gravity fed from the steam heated holding tank into the electrically
heated mixing tank where it is then stirred and kept heated for approximately
40-45 minutes to dissolve sugar, agar-agar, acid and tri-potassium which
was previously added.
When completed it is then gravity fed into a third tank where colours and
flavours are added and stirred for approximately 5 minutes. This is then
pumped into the feed hopper on tub filler ready for filling and sealing
the cups.
The tub filling and sealing process of each batch ( approx 120 litres ) takes around 40 minutes producing approximately 720 x 150ml cups or during a seven hour shift ( approximately 6480 cups ).
At present the finished cups are placed into trays to cool overnight then
packed the next day ready for despatch.
To Note:
A more economical way would be to install a cooling tunnel to take the products directly from the conveyor of tub filling and sealing machine, making it possible to pack as it is produced. Unfortunately due to financial restrictions the present director was unable to instigate this procedure.
The tub filling and sealing machine is currently set up to produce 75ml diameter cups, but is capable of producing most sizes by changing the cup inserts to the required size. The speed of production can also be increased or decreased with the variable speed drive.
Production on this machine has been limited to jelly cups 75ml x 150ml and sauces 75ml x 100g tubs. Present fittings limited to 75mm cups or tubs.
However this machine is quite capable of packing almost anything owing to its variable speed and has the ability to change cup sizes to suit any trend in the market place.
Possibilities of production with this machine are almost endless and limited only by ones imagination.
In addition to the products currently being produced
the long term goals was to produce a full range of products in cups ~ example:
Ø Jelly and custard in a variety of flavours.
Ø Jelly, fruit and custard in a variety of flavours.
Ø Puree fruit.
Ø Trifle ( the cup filling machine would have to be converted
to place the cake between the jelly and custard ).
The cup filling and sealing machine is the key machine that was used
at all times, mainly with the jelly cups.
It is designed
to place the product into a desired size cup then places a foil
seal lid to hold that product from spilling, e.g. fruit juices,
liquid sauces and soups, or almost any liquid or semi liquid product.
This machine alone will pack many other products to enhance this operation.
This procedure is automatically performed
with finished product leaving the machine on a conveyor system .
Above shows some of the jelly packs that were used to display the product when released to the chain stores. This was the company's main production which still has a major public following.
