Background Information:

Note: Arrows in the FRAME images indicate direction of flow and numbers indicate logical steps in the process.

"We have to find a way to automate the process AND keep the Gummi Bears from becoming one big ball of candy", proclaimed Brian Morse to his staff. "Reliable labor is expensive and difficult to find plus we are losing too much money on wasted product. We must find a low-cost solution to this manufacturing process problem. I know we can design the right system if we work together as a team. George and Pat, I want your team’s best solutions within the month."

After the meeting, George Morgan and Pat Patterson greet each other with enthusiasm. "Pat, this is the project we have been waiting for", grinned George. "With your electronics expertise, I know we can design a successful solution. I believe we need to explore the feasibility of a design similar to the one we saw last month." Pat nods and adds, "But, let’s make sure that we explore all of our options with our team members so that we can design the most cost-effective and efficient system."

Brach's Confections makes a variety of candies for shipment all over the world including "gummi" type candy products such as Gummi Bears. Brian Morse, George Morgan, and Pat Patterson are in the engineering department at the Chattanooga, TN plant. In FRAME A Brian and George discuss design ideas with Stuart Hilton and Tom Williams, faculty members at Chattanooga State Technical Community College.

The manufacturing process of making "gummi" candies is not a complex process; however, space limitations, a sticky product, and labor issues can complicate it. The process begins with a mixture of ingredients that constitutes the liquid version of the Gummi product and starch molds created from a pattern for the candy that is to be made. The hot liquid mix is poured into the starch molds as shown in FRAMES B and C. The liquid solidifies into a Gummi candy and is cured over a 24 hour time period. A machine that puts moisture and heat into the starch presses the starch molds from a pattern designed for the candy being made. (FRAME D.) Maintaining the right temperature and moisture is critical to maintaining the strength of the starch molds and the curing of the candy. A sensor detects if the correct temperature and moisture levels are in the starch molds. (FRAME E.) FRAME F is showing the hot liquid mix being fed into the starch molds.

After the Gummi candy has solidified, the candy is separated from the starch molds and then conveyed to a machine that tumbles the candy to knock off any last clinging particles of the starch molds (FRAME G and movie clip). The candy still has a white coating as shown in FRAME H. Next, the candy is conveyed to a machine that coats the candy with a light vegetable oil removing the white starch coating. (FRAME I.)

From the oiling process, the product is manually transported to the second level. The second level has weighing machines that prepare the candy for bagging. Notice the candy sticking on the side panels and also notice the construction of the conveyor belt in FRAMES J and K. Once the candy is on the second level, the product is distributed (FRAME L) to several machines that weigh the candy and when the correct weight is obtained it is then disbursed to the bagging machines. (A newer type of sorting machine is shown in FRAME M. Be sure to click on this movie clip to see one of these machines in action.) Once the candy is weighed, it is dropped through the ceiling (FRAME N) to the bagging machines on the first level (FRAMES O and P, be sure to click on the movie clip to see one of these machines in action.) FRAME Q shows the computer station where statistical reports about the bagging operation can be viewed.