Starchless gummy manufacturer
Pectin-set, silicone mold deposition at our St. Petersburg, FL gummy facility. No corn starch in the process.
HBM is a starchless gummy manufacturer running pectin-set deposition into silicone and polycarbonate molds at its 30,000 sq ft St. Petersburg, FL facility. Four continuous depositing stations run at 300KG/hour each (two run at a time). Combined throughput is 600KG/hour and 90,000,000 gummies per month. Starchless lines remove corn starch from the molding step. That cuts allergen and dust controls, shortens changeover between SKUs, and keeps the surface finish consistent. Both the sugar and the sugar-free clean-label base systems run on starchless equipment. HBM holds 8 certifications, including FDA Registration, NSF, USDA Organic, and Non-GMO Project Verified.
Starchless deposition matters when a brand wants a cleaner ingredient story, a tighter allergen profile, or faster line changeovers. Corn starch molding is the legacy method. It works, and HBM runs it where the SKU calls for it. Silicone and polycarbonate molds skip the starch step entirely. Surface finish stays consistent piece to piece. Cleanup at the end of a run is faster. The trade is mold cost and mold variety, which is where the design conversation starts.
What starchless gummy manufacturing means
Starchless means no food-grade corn starch in the molding step. Traditional gummy lines press impressions into starch-filled trays. The depositor fills those impressions. Gummies cool, then a sieve separates them from the starch bed. Starchless lines replace the starch bed with rigid molds. HBM runs silicone and polycarbonate tooling. The depositor extrudes pectin syrup at 95-105°C directly into the mold cavities. Gummies cool, demold, and move to coating. No starch dust. No starch sieving. No starch storage or allergen segregation tied to the molding step.
Why brands choose starchless
Three reasons come up most often. **Cleaner label and allergen story.** Corn is a common allergen-control flag. Removing starch from the process removes that flag from the SOP, the batch record, and the audit trail. **Faster changeover.** Starch molding requires the starch trays to be conditioned, then reclaimed, then re-conditioned for the next SKU. Silicone molds rinse and reset. That can shave hours off a SKU change. **Consistent surface finish.** Starch leaves a matte, slightly powdery surface. Silicone molds leave a smoother, more uniform face. That matters for SKUs that get a glossy wax coat or a printed package window where the gummy is visible.
The trade: mold cost and mold geometry
Silicone and polycarbonate molds cost more than starch impressions. Custom tooling starts at roughly $20,000 and varies by complexity. Lead time is 4 to 8 weeks. The geometry envelope is also tighter. Minimum gummy weight is about 1.5g. Maximum is about 6.5g before demolding gets unreliable. HBM’s standard mold inventory covers Cube and Gum Drop shapes in the 2g to 6g range, with a 3.75g average. Custom mold work is quoted at the formal preliminary estimate stage and ordered in parallel with the pilot batch.
Base systems on starchless lines
Both HBM base systems run on starchless equipment. **Sugar Clean Label.** Tapioca syrup, cane sugar, water, pectin. Less than 2% natural flavor, natural color, sodium citrate, and citric acid. The most-ordered base. Best flavor masking. **Sugar-Free Clean Label.** FOS (chicory root fiber), allulose, water, pectin. Less than 2% natural flavor, natural color, sodium citrate, and citric acid. Softer set than the sugar version. Harder to mask bitter actives without sugar present. Active load runs 10-17% by weight on average. The theoretical ceiling is 33%. Above 20%, expect texture and flavor trade-offs.
Capacity, MOQ, and lead time
Starchless lines share the same throughput as the rest of HBM’s gummy capacity. Four depositors at 300KG/hour each (two run at a time). 3,000,000 gummies per day. 90,000,000 gummies per month. MOQ is 300,000 units at standard sizes. At smaller mold sizes, MOQ rises to 600,000 units. The formal preliminary estimate lands in 24 hours. Bench samples run 2-4 weeks. Pilot batch runs 2-4 weeks. Commercial production runs 4-8 weeks.
Frequently asked questions
What does starchless gummy manufacturing mean?
Starchless means HBM deposits pectin gummy syrup into silicone or polycarbonate molds. There is no food-grade corn starch in the molding step. The depositor fills mold cavities directly at 95-105°C. Gummies cool, demold, and move to coating. The result is a cleaner allergen profile and faster changeover between SKUs. Both HBM base systems run on starchless equipment.
Is starchless better than starch-molded?
Neither is universally better. Starchless removes corn starch from the process and gives a more consistent surface finish. Starch molding supports a wider range of mold shapes at a lower tooling cost. HBM runs both methods depending on the SKU. The choice happens during formula review and packaging review, before the formal quote. Buyer priorities on label, allergen, and mold geometry decide it.
What is the MOQ for starchless gummies at HBM?
HBM's standard starchless gummy MOQ is 300,000 units. At smaller mold sizes, MOQ rises to 600,000 units. Custom mold tooling is quoted separately. The custom mold cost starts at roughly $20,000 and varies by complexity. Mold lead time runs 4-8 weeks and is typically scheduled in parallel with the pilot batch.
Do starchless lines change the active load limit?
No. Active load on starchless lines averages 10-17% by weight. The theoretical maximum is 33%. The mold type does not change the chemistry. The active interacts with the pectin gel network the same way in either system. Heat-sensitive actives still need the same mitigation steps regardless of whether the mold is starch or silicone. HBM scopes active load at the bench sample stage.
What gummy sizes and shapes are available on starchless equipment?
Standard sizes run 2g, 3g, 4g, 5g, and 6g, with a 3.75g average. Standard mold shapes are Cube and Gum Drop. Custom geometry is available. Minimum gummy weight is about 1.5g. Maximum is about 6.5g before demolding gets unreliable. HBM quotes custom tooling at the formal preliminary estimate stage.