The Crucial Role of Shaker Decks in Jelly Bean and Small Candy Production

The Fascinating World of Shaker Decks in Confectionery Production

The mesmerizing sight and sound of jelly beans cascading down a shaker deck is a quintessential part of candy production. As one of the most important machines in the jelly bean packing process, shaker decks gracefully shuffle and mix candy to perfection. Let's explore the wonders of shaker decks and their integral role in crafting delicious confections.

What Are Shaker Decks?

Shaker decks, sometimes called trays or tables, are sloped platforms fitted with vibrators. As their name implies, they shake and shuffle products as they move down the line. Shaker decks are a key component in processing jelly beans as well as other small candies like M&Ms, Skittles, Tic Tacs, and more.

These contraptions feature a perforated surface that allows air to flow through, preventing items from sticking as they tumble along. Shaker decks are set at an angle and vibrate at high speeds, relying on gravity to keep products rolling. This constant agitation ensures thorough mixing and coverage as candies make their way from one end to the other.

Why Are Shaker Decks Important in Candy Making?

Shaker decks serve several critical purposes in candy production:

• Mixing - Shaker decks blend batches of jelly beans or other candies to distribute flavors, colors, and coatings evenly.
• Coating - As candies shake, they pick up fine layers of dusting powders like confectioner's glaze that help prevent sticking.
• Polishing - The constant rubbing and tumbling polishes candy shells to a perfect shine.
• Separating - Shaking candies loosens them from clusters, resulting in individual pieces.
• Cooling - Airflow through the perforated decks cools freshly coated candies.
• Sizing - Shaker decks often feature screens to grade candies by size.

Without this technology, jelly beans and other small confections would clump, stick together, and have uneven flavors, colors, and textures.

Shaker Deck Designs

While shaker deck principles remain the same, their exact designs vary. Different candy types and production volumes require tailored solutions. Some key variations include:

• Single deck - One sloped tray for small-scale operations.
• Multi-deck - Stacking several trays together increases throughput.
• Linear motion - Shaker decks mounted on bearings that glide back and forth.
• Oscillating motion - Shaker decks that vibrate in an arc-like pattern.
• Screening - Built-in screens classify candies by size.
• Zoned vibration - Separate vibratory motors control shaking in zones.

Shaker deck capacity ranges from just a few kilograms up to 10,000 kg per hour for large plants. Their width can extend over two meters to accommodate mass volumes.

Key Components of Shaker Decks

Let's look at the main parts that make up shaker deck systems:

• Trays - Stainless steel perforated trays mounted at an angle. Different holes sizes suit various candy sizes.
• Vibratory motors - Electric motors with offset weights create the shaking motion.
• Springs or rubber mounts - Absorb vibration to isolate motion to the trays.
• Screen frames - Interchangeable screens classify candies into size ranges.
• Control panel - Controls tray angle, vibration intensity, and other settings.
• Food-grade finish - All parts polished to a sanitary finish.

Together, these components gently shake candies along in an even, controlled manner.

The Shaker Deck Process

Let's go through a typical jelly bean shaker deck process from start to finish:

1. Jelly beans enter the shaker deck feed end through an opening or chute.
2. Cascading down the perforated tray, beans mix and spread out into a single layer.
3. Air blows through the deck, preventing sticking as beans tumble.
4. Beans rub together, polishing off rough edges for a smooth surface.
5. Any clustered beans separate into individual pieces through the shaking.
6. Beans pick up a fine coating of dusting powders like confectioner's glaze.
7. Vibration intensity and direction can vary along the deck's length.
8. Interchangeable screens grade jelly beans by size near the discharge end.
9. Cooled and polished beans exit the shaker deck for further processing or packaging.

Modular shaker decks allow operators to customize the process by adding components like sifters and sugar applicators.

The Mesmerizing Sights and Sounds

One of the most memorable parts of shaker decks is the delightful sensory experience they create. Seeing rivers of colorful jelly beans cascade down the trays is a visual treat. The characteristic rattle and hum of beans bouncing provides sweet music to the ears.

Being up close to watch jelly beans dance and shimmy down the line is satisfyingly hypnotic. The aroma of fresh candies and sugary dust in the air completes the sensory delight. It's pure confectionery joy!

Shaker Decks: The Unsung Heroes of Candy Craft

Shaker decks may not get the glory of candy wrapping machines or lollipop makers, but they play an indispensable role. Their non-stop shaking and shuffling transforms raw candies into perfect finished products ready for packaging. Thanks to their concentrating mixing power, jelly beans, M&Ms, and other small delights have delicious coatings and flawless finishes.

So the next time you savor the crunchy candy coating or admire the smooth polish of a jelly bean, remember the shaker deck that made it all possible! Their steadfast service keeps the flavors shaking and the good times rolling in candy plants worldwide.

FAQs

How do shaker decks work?

Shaker decks are sloped vibrating trays that use gravity and motion to shuffle small candies. The shaking action polishes, coats, and separates the candies as they move down the line. Perforations in the deck allow air to flow through to prevent sticking.

What candies use shaker decks?

Shaker decks are commonly used for small or round candies like jelly beans, M&Ms, Skittles, Tic Tacs, and nonpareils. Their constant agitation provides an even finish.

How does a shaker deck polish candies?

As candies rub together on the shaker deck, their edges become smooth and rounded. The abrasion between candies combined with any dusting powders gives them a polished look.

Why are shaker decks perforated?

The holes or perforations in the shaker deck allow air to pass through. This prevents candies from sticking together or to the metal tray surface during shaking.

Can shaker decks size candies?

Yes, shaker decks will often have interchangeable screening frames so candies can be graded by size. Larger candies stay on top while smaller ones fall through.