How Are Jelly Beans Made: Production Process Analysis

Желейные бобы, a very popular gummy candy in the confectionery landscape, is a star product for all candy brands, because of their colors, flavours, and overall chewy satisfaction. Jelly beans are small but the complexity of how they are produced is much more involved than one might ever think or expect, making each of the production methods impact the jelly bean’s flavor, appearance, and shelf life.

As confectionery brands continue to introduce unique flavours and branded designs on the shelves globally, knowing how jelly beans are made not only aids in improving product efficiencies, but assists brands in making informed decisions regarding quality control or factory selections.

Next, Конфеты LeChao will break down the entire production process of jelly beans from a manufacturer’s operational perspective, while offering industry insight, along with operational process milestones needed to be able to master the main processes.

I. Syrup Formula: The First Step in Determining Jelly Bean Texture

The core of jelly beans lies in their syrup formula, which determines almost 70% of the product quality. A typical formula includes granulated sugar, starch syrup, pectin or gum arabic, food acids, and natural flavorings.

Key Points Analysis

1. Solids Controlled at 75%–80%

This is crucial for maintaining the soft, non-collapsed core of jelly beans. Too low a solids content results in a sticky core, making them prone to deformation during transport.

2. Different Regional Taste Preferences

• The North American market prefers fruity sweet and sour flavors, such as berry, lemon, and orange.
• The Middle Eastern market prefers sweeter, coconut-based flavors.
• The Asian market favors refreshing flavors, such as grape, lychee, and peach.

2. Customized Flavor Techniques

Reputable manufacturers offer “visualized flavor adjustments,” allowing brands to quickly determine flavor intensity.

4. Data Example

Industry statistics show that over 65% of best-selling jelly beans come from mixed fruit flavor combinations, indicating that complex flavors are more competitive in the market.

II. Starch Molding: The Secret to Jelly Beans’ Unique Shape

The classic oval shape of jelly beans is not achieved through plastic molding, but rather through a dry starch mold bed (Starch Mogul).

Key Points of the Process

1. Starch Tray Imprinting

Bean-shaped grooves are pre-pressed into the mold bed, with each tray capable of holding hundreds to thousands of jelly beans.

2. Syrup Filling

Hot syrup is filled into the grooves, with the starch responsible for absorbing water and setting the shape.

3. 24–48 Hour Drying Period

Temperature and humidity are controlled at 22–26℃ and humidity at 40–55% to effectively prevent the jelly beans from collapsing.

III. Panning: Giving Jelly Beans a Glossy Sheen and a Crispy Shell

The iconic shell of jelly beans comes from panning, the most experience-intensive step in the entire production process.

Key Steps

1. Pre-coating
   A thin layer of syrup is sprayed on first to seal the core and prevent moisture absorption.
2. Layered Sugar Addition
   Fine sugar is added to the panning pan, allowing the jelly bean shell to gradually form.
3. Раскраска
   Brands can choose natural colorings (such as beet red, spirulina blue) or synthetic colorings.
4. Drying and Color Setting
   Each layer of sugar needs to be dried; the entire shell formation typically takes 2–4 hours.

Data and Precautions

• A shell thickness of 0.3–0.6 mm is recommended for optimal flavor without being too hard.
• Improper humidity control can lead to common problems such as “sticking” and “whitening” of jelly beans.

IV. Polishing and Packaging: Making Jelly Beans Brighter, More Stable, and Safer for Transport

The high gloss of jelly beans comes from the final polishing and waxing process.

Polishing Steps Include

1. Waxing (usually carnauba wax)

This gives jelly beans a glossy finish and reduces friction damage during transport.

2. High-Speed ​​Polishing Roller

A glossy appearance is achieved after 5–15 minutes of polishing.

Packaging Considerations

• Using PET/PE structure stand-up pouches or cans can extend shelf life.
• In high-temperature regions (Southeast Asia, the Middle East), higher barrier packaging structures are recommended to prevent softening.
• Rainbow Mixes typically consist of 6–12 colors and are among the best-selling retail SKUs.

V. Quality Inspection and Stability Control: Ensuring Every Jelly Bean Meets Standards

High-quality jelly beans require multiple tests, such as:

Common Testing Items

1. Moisture Content: Maintain within the 12%–16% range.

Excessive moisture content can lead to mold, while insufficient moisture results in a hard texture.

2. Color Uniformity Check

Especially when brand-specified colors are used, batch-by-batch comparison is necessary.

3. Hardness Test

Maintaining the optimal balance between a light, crisp outer shell and a soft, supple inner core.

4. Shelf Life Test

Common testing cycles are 30 days, 60 days, and 90 days accelerated testing.

Practical Industry Tips

• If the product is to be exported to the United States, it must meet FDA 21 CFR food contact grade standards.
• If targeting the children’s market, vitamins or fruit juice concentrate can be added as selling points.

Заключение

Making jelly beans is a complicated process that draws on both tradition and modernity: from syrup pour proportions and starch molds to careful coating and polishing, every part of the process affects the final product’s flavor, visual appeal, and shelf life.

As major global brands in the candy industry increasingly search for differentiation, seasonal new launches, and healthy flavor trends, a working knowledge of jelly bean production processes will help brands bring the product to market faster, ensure better assessments of factories and factories align with their production principles, and develop more marketable products in an increasing competitive space.

LeChao Candy: Leading Jelly Bean Manufacturer and Supplier

Конфеты LeChao was established in 1991, and is a modern soft candy manufacturer whose areas of concentration include the research and production of jelly beans, gummy candy, licorice candy, marshmallows, and chocolate candy.

We have advanced manufacturing processes in candy, strong custom flavor options, a rapid quote system, strict quality control processes, global logistics capabilities, and have provided OEM/ODM services for many of the international brands.

Whether you are looking at seasonal candies, gift box candies, bulk candies, or custom candies, Конфеты LeChao will support your success with its professional manufacturing capabilities.