Gummy manufacturing is a popular segment in the pharmaceutical industry as the product range in vitamins and supplements is expanding. However, the production process is more complex than pills and capsules. Although quality control is crucial in all divisions, it also gets more challenging when it comes to manufacturing gummy vitamins. Manufacturers often struggle with concerns such as maintaining the taste and integrity of gummies as they line store shelves. If you plan to add gummies to your product line, here are some quality control essentials you can rely on.
Ensure proper water activity level
Since gummies contain moisture, water activity levels are a crucial aspect of manufacturing quality. Improper water levels can affect the product’s texture, reduce shelf life, and cause operational headaches. Besides the manufacturing concerns, consumer health may also be at risk. Manufacturers must ensure ideal water activity levels, which typically range from 0.55 to 0.70. Quality control professionals can track and measure the amount during the batch testing stages.
Regulate taste
Gummies are not to be popped like pills, so taste regulation is a significant part of the manufacturing process. Ideally, the taste of the finished product must be according to the intended flavor. Anomalies indicate errors in the measurements of flavoring or sweeteners during the production process. As a manufacturer, you can address the issue by making minor adjustments in the amount of flavor or sweetener. It is better to test small batches to master the ingredient quantities and ensure proper taste.
Prioritize textures
The texture of gummies should be smooth, and they must have soft, chewable consistency. It is a vital quality parameter you cannot overlook. If anything is missing, your process may have a gap of one or more points. Typically, a gummy manufacturer should check factors like the manufacturing machinery, temperature settings, ingredient ratios, and mold shapes to find the issues. You may need to rework one or more factors to get a perfect texture for your products.
Ensure even coatings
Another quality control factor that deserves attention is gummy coatings. They enhance the product’s flavor, alter its texture, prevent sticking, or control moisture levels. Coatings are the finishing job after cooling, solidifying, and de-molding gummies during the final phase of production. You must ensure that they are even with coverage across the entire surface. An asymmetry indicates an error in the coating process.
Get the sealing right
Although sealing the gummy containers may not have anything to do with the production process, it can affect the quality and shelf life of the product. Proper sealing keeps the product fresh until it reaches the consumer. You may check different sealing techniques and choose one according to your packaging method. For example, induction sealing with a layer of thermoplastic is apt for plastic bottle packaging.
Quality control is a vital aspect of manufacturing, even more in the pharma industry. Since gummy manufacturing is relatively new and tricky, you may have to go the extra mile with quality checks. Assessing these factors can help you find the gaps and resolve them effectively.