How are gummy supplements made
The pectin-based process HBM runs in-house at the St. Petersburg, FL gummy facility.
How are gummy supplements made at HBM: pectin and sugar are cooked into a syrup. Actives are dosed in at a controlled temperature. The syrup is deposited into molds at 95-105°C. The gummies then cure, coat, and pack. HBM runs four continuous depositing stations at 300KG/hour each (two run at a time), totaling 600KG/hour and 90,000,000 gummies per month at the St. Petersburg, FL facility. Both sugar and sugar-free clean-label base systems run on the same pectin chemistry. Most US contract manufacturers route gummy production to a partner. HBM does not. Bench sample to commercial run happens under one quality system and one batch record chain.
Gummy manufacturing reads simple on a brochure and gets specific in the plant. The chemistry of pectin, the temperature window at deposition, and the active load percent decide whether a SKU makes it to commercial production. This page walks the actual sequence HBM runs from syrup kitchen to finished bottle.
Step 1: Base syrup cook
Pectin, sugar (or allulose and FOS for sugar-free), water, and tapioca syrup are cooked into a homogeneous mass. Pectin sets via acid and sugar concentration, so the target Brix and pH are held tight. Sugar-free systems run on the same pectin chemistry but use allulose and chicory root fiber. Texture is softer. Flavor masking is harder without sucrose to round bitter actives.
Step 2: Active addition
Actives are dosed into the cooked syrup at a controlled temperature. Pectin deposition runs at 95-105°C. Actives that degrade above 80°C need a heat-stable form, post-deposition coating, or a different delivery format. Average active load runs 10-17% by weight. The theoretical ceiling is 33%, but loads near that figure produce gritty texture and off-flavor.
Step 3: Deposition
The syrup feeds four continuous depositing stations. Each station runs at 300KG/hour. The combined rated throughput is 600KG/hour, or 3,000,000 gummies per day. The depositor extrudes pre-mixed syrup into pre-formed starch or silicone molds at 95-105°C. HBM offers both starch and starchless lines. Starchless uses silicone or polycarbonate molds. Starch deposition uses food-grade corn starch impressions.
Step 4: Cure
Deposited gummies cure in a temperature-controlled room. Pectin sets as the syrup cools and the pH stabilizes. Cure time depends on size, base system, and active load. Standard sizes run from 2g to 6g, with a 3.75g average. Cube and Gum Drop are standard mold shapes. Custom molds are available starting at roughly $20,000.
Step 5: Coating
Cured gummies are coated to prevent sticking and extend shelf life. HBM offers five coating systems: carnauba wax, tapioca starch, wax plus starch, sugar, and custom. Wax delivers a glossy finish and a strong moisture barrier. Starch delivers a matte finish. Sugar coating amplifies sweetness on the surface without changing the base recipe.
Step 6: Packaging
Coated gummies route to two fully automatic packaging lines. The lines output 40,000 60-count units per day, or 1,200,000 60-count units per month. A separate sachet filler runs 50,000 sachets per day. Each unit ships with audit-grade batch records tied to the same quality system that ran the bench sample.
Frequently asked questions
What temperature is gummy syrup deposited at?
HBM deposits pectin gummy syrup at 95-105°C. The temperature window keeps the syrup flowing cleanly into the molds and lets the pectin set as it cools. Actives sensitive to heat above 80°C need a heat-stable form or a post-deposition coating. HBM screens for heat sensitivity at the bench sample stage.
Does HBM use pectin or gelatin?
HBM defaults to pectin. Both the sugar and sugar-free base systems are pectin-set. Pectin is plant-derived, vegan, and tolerates the 95-105°C deposition window. Gelatin is animal-derived and sets via thermal reversal. For nutraceutical SKUs targeting clean-label buyers, pectin matches consumer expectations and gives better heat tolerance for actives.
What is the maximum active load in an HBM gummy?
Average active load at HBM runs 10-17% by weight. The theoretical ceiling is 33%. Loads near that ceiling produce gritty texture, reduced elasticity, and off-flavor. Higher actives also require larger gummy pieces. A 500mg vitamin C dose at 15% active load lands at a 3.33g gummy. HBM rounds that to a 4g deposit-able size.
How many gummies can HBM make per month?
HBM produces 90,000,000 gummies per month at the St. Petersburg, FL facility. That figure reflects four continuous depositing stations running at 300KG/hour each (two run at a time), or 600KG/hour combined. Daily output is 3,000,000 gummies. Packaging capacity runs 1,200,000 60-count bottles per month across two fully automatic lines.
Does HBM run starch or starchless deposition?
HBM runs both. Starch deposition uses food-grade corn starch mold impressions. Gummies are sieved and de-dusted after cure. Starchless deposition uses silicone or polycarbonate molds. The choice depends on mold complexity, allergen control needs, and finish requirements. HBM picks the line at the formulation review stage of the 10-step R&D framework.
Related pages
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