Systems and methods for manufacturing gummy puffs

A system for manufacturing gummy puffs, the system comprising:

• a) a gummy unit, the gummy unit comprising:
• i. a grinder assembly for grinding raw material of gummy puffs;
• ii. one or more mixers for mixing the raw material received from the grinder assembly;
• iii. a mogul unit for receiving the raw material from the one or more mixers, the mogul unit includes:
• 1. a plurality of depositor modules, wherein each of the plurality of depositor module includes a plurality of trays for receiving the raw material followed by stacking of the plurality of trays;
• 2. a starch buck module for molding the raw material received from the plurality of trays and removing excess starch from the raw material by a starch removal unit, wherein the starch removal unit includes:
• a cover placed on the plurality of trays to receive the raw material from the depositor module, wherein the raw material adheres to the surface of the cover;
• and
• a plurality of air jets to provide compressed air for removing the starch from the raw material adhered to the cover;
• 3. a stacker module for stacking and cooling the raw material received from the starch buck module;
• b) a freeze-drying unit for receiving the raw material from the stacker module, the freeze drying unit comprises:
• i. a puffing unit for puffing the gummy by lowering the vapor pressure;
• ii. a stabilizing unit for stabilizing the gummy puffs by continuously freezing followed by annealing the gummy puffs received from the puffing unit;
• and
• iii. a drying unit for drying the gummy puffs from the stabilizing unit, wherein the drying unit comprises:
• a primary drying unit at a first temperature, wherein the primary drying unit sublimates water molecules within the gummy puffs at a pre-defined pressure;
• and
• a secondary drying unit at a second temperature lower than the first temperature, wherein the secondary drying unit disintegrates any physio-chemical interactions between the water molecules and the ice crystals,
• further wherein drying the gummy puffs from the drying unit forms the gummy puffs.

A method of manufacturing dehydrated gummy puffs, the method comprising:

• a) mixing raw materials of the gummy puffs in one or more mixers of a compounding unit to form a blended mixture of the raw materials,
• b) pouring the blended mixture of the raw materials via a nozzle in a plurality of trays of a depositor module received from the mixers,
• c) allowing the blended mixture to settle in plurality of trays of the depositor module,
• d) shaping the blended mixture in a molding unit of a starch buck module received from the depositor module,
• e) removing excess starch from the molded blended mixture in a starch removal unit by passing compressed air through plurality of air jets on the molded blended mixture, further wherein the molded blended mixture adheres to a cover placed on the molded blended mixture received from the molding unit,
• f) stacking and cooling the molded blended mixture received from the starch buck module in a stacking module,
• g) puffing the cooled blended mixture by lowering the vapor pressure thereby increasing the surface area of the blended mixture;
• h) stabilizing the puffed blended mixture by continuously freezing followed by annealing the puffed blended mixture received from the pre-treatment unit;
• i) sublimating water molecules within the puffed blended mixture at a pre-defined pressure and temperature;
• j) disintegrating any physio-chemical interactions between the water molecules and the ice crystals, further wherein drying the puffed blended mixture to form the gummy puffs.

A method of manufacturing gummy puffs by using of manufacturing gummy puffs, the method comprises:

• a) grinding raw materials of the gummy puffs in a grinder assembly to form grinded raw materials;
• b) mixing the grinded raw materials of the gummy puffs received from the grinding assembly in one or more mixers to form a blended mixture of the gummy puffs,
• c) pouring the blended mixture of the gummy puffs via a nozzle in a plurality of trays of a depositor module received from the mixers via a conveyor belt,
• d) allowing the blended mixture to settle in plurality of trays of the depositor module,
• e) shaping the blended mixture filled trays in a molding unit of a starch buck module received from the depositor module,
• f) removing excess starch from the molded blended mixture in a starch removal unit by passing compressed air through plurality of air jets on the molded blended mixture, further wherein the blended mixture adheres to a cover placed on the blended mixture filled trays received from the molding unit,
• g) reconditioning the excess starch in a re-circulating starch reconditioning system by filtering, drying, and cooling the excess starch received from the starch buck module;
• h) reusing the reconditioned starch by transferring the reconditioned starch to the depositor module;
• i) stacking and cooling the molded blended mixture in a stacking module received from the starch buck module,
• j) puffing the cooled blended mixture by lowering the vapor pressure thereby increasing the surface area of the blended mixture;
• k) stabilizing the puffed blended mixture in a stabilizing unit by continuously freezing followed by annealing the puffed blended mixture received from the puffing unit;
• l) sublimating water molecules within the puffed blended mixture in a primary drying unit at a pre-defined pressure and temperature received from the stabilizing unit;
• m) disintegrating any physio-chemical interactions in a secondary drying unit between the water molecules and the ice crystals received from the primary drying unit, further wherein drying the puffed blended mixture to form the gummy puffs.