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Vandal Gummy, Red, by WhisBe |
That reminded me of my visit to their Forest Park factory, a dozen years ago, and I dug it out of the archives.
Do you know how they make gummy bears? Of course you don't. You probably think they use metal molds to form the little squishy ursine confections. Ha! Of course not. The actual process is . . . Well, I'm not sure I should tell you. Because it's so staggeringly cool, maybe it should be a secret only a few of us really plugged-in cool guys know about. . .
I didn't learn the secret of gummy bears until I went through Ferrara Pan Candy Co. in Forest Park. A dream of mine, to visit the home of Lemonheads and Red Hots and Atomic Fire Balls (There's an un-PC candy name for ya!) and gummy bears and sour gummy worms, which are made . . . no, no, not yet!
The production line is vertical—that is, it uses gravity to cut down on the need for pumps. Sugar and corn syrup and flavorings and colorings start at the fifth floor, then are blended and mixed and cooked on lower levels, which feature tons and tons of a certain white granular staple.
"One thing you've got to have is lots of sugar," said John Conversa, the plant manager, showing off one of a pair of two-story sugar silos, 16 feet across. "I believe this one holds 600,000 pounds."
Sugar—or more precisely, our government's shortsighted and punitive sugar tariffs—have driven many Chicago candy companies to Mexico.
Family-owned Ferrara Pan stays here, although it does have factories south of the border, and its more, shall we say, sugar-intensive candies are made there, such as Atomic Fire Balls, which are basically pure sugar with a heart of plutonium-239 (joking; they only taste that way).
Not that sugar aplenty isn't being used at Forest Park; the factory goes through 200,000 pounds—the contents of a single rail car—every day.
The dynamics of the plant are interesting enough to fill up three columns. Parts look just like a ship's engine, all pipes and retorts and gauges. What they're basically doing is removing moisture, taking liquid ingredients and cooking and drying them until the result is a miniature distillate of sweetness and flavor.
Much of that flavor is sourness, which means acidity, and, as Conversa says, "Acid is very hygroscopic," meaning it draws water, so keeping tabs on the water content of the candy is very important.
An extra 2 percent of moisture is the difference between a jelly bean that will sit happily on the shelf for years and one that will immediately begin to break down—"sweat" is the candy maker's term. Sweating candy is bad.
Jelly beans, incidentally, are built up like pearls, around a center, a process known lyrically as "engrossment."
They actually use three different types of sugar, increasing in fineness, to get the hard sheen on the outside, the way you would switch to finer sandpaper to finish a wooden desk.
But I was going to tell you how they mold gummy bears. No, not a metal mold—imagine trying to pry a warm, sticky gummy worm out of THAT. No, they take corn starch, mixed with a bit of oil to make it clump like wet snow.
Machines spread the beige starch in a low tray, then take a plate bearing hundreds of little steel bears and press their shapes into the starch, the way wet sand forms footprints. Then the trays slide under hundreds of little spigots—the whole place is automated—and the nozzles blurp just enough sweet/sour liquid to fill each bearlike impression. The candies are set aside to harden, then the trays are flipped over, the nascent gummy bears have their cornstarch steamed off, and are on their way to be packaged for their rendezvous with your mouth.
Like most kids, I have an innate preference for the chocolate family of candies. But going through Ferrara Pan gave me appreciation for the whole sour/gummy subgenus.
They truly are a wonder and, more so, a Chicago wonder.
Do you know how they make gummy bears? Of course you don't. You probably think they use metal molds to form the little squishy ursine confections. Ha! Of course not. The actual process is . . . Well, I'm not sure I should tell you. Because it's so staggeringly cool, maybe it should be a secret only a few of us really plugged-in cool guys know about. . .
I didn't learn the secret of gummy bears until I went through Ferrara Pan Candy Co. in Forest Park. A dream of mine, to visit the home of Lemonheads and Red Hots and Atomic Fire Balls (There's an un-PC candy name for ya!) and gummy bears and sour gummy worms, which are made . . . no, no, not yet!
The production line is vertical—that is, it uses gravity to cut down on the need for pumps. Sugar and corn syrup and flavorings and colorings start at the fifth floor, then are blended and mixed and cooked on lower levels, which feature tons and tons of a certain white granular staple.
"One thing you've got to have is lots of sugar," said John Conversa, the plant manager, showing off one of a pair of two-story sugar silos, 16 feet across. "I believe this one holds 600,000 pounds."
Sugar—or more precisely, our government's shortsighted and punitive sugar tariffs—have driven many Chicago candy companies to Mexico.
Family-owned Ferrara Pan stays here, although it does have factories south of the border, and its more, shall we say, sugar-intensive candies are made there, such as Atomic Fire Balls, which are basically pure sugar with a heart of plutonium-239 (joking; they only taste that way).
Not that sugar aplenty isn't being used at Forest Park; the factory goes through 200,000 pounds—the contents of a single rail car—every day.
The dynamics of the plant are interesting enough to fill up three columns. Parts look just like a ship's engine, all pipes and retorts and gauges. What they're basically doing is removing moisture, taking liquid ingredients and cooking and drying them until the result is a miniature distillate of sweetness and flavor.
Much of that flavor is sourness, which means acidity, and, as Conversa says, "Acid is very hygroscopic," meaning it draws water, so keeping tabs on the water content of the candy is very important.
An extra 2 percent of moisture is the difference between a jelly bean that will sit happily on the shelf for years and one that will immediately begin to break down—"sweat" is the candy maker's term. Sweating candy is bad.
Jelly beans, incidentally, are built up like pearls, around a center, a process known lyrically as "engrossment."
They actually use three different types of sugar, increasing in fineness, to get the hard sheen on the outside, the way you would switch to finer sandpaper to finish a wooden desk.
But I was going to tell you how they mold gummy bears. No, not a metal mold—imagine trying to pry a warm, sticky gummy worm out of THAT. No, they take corn starch, mixed with a bit of oil to make it clump like wet snow.
Machines spread the beige starch in a low tray, then take a plate bearing hundreds of little steel bears and press their shapes into the starch, the way wet sand forms footprints. Then the trays slide under hundreds of little spigots—the whole place is automated—and the nozzles blurp just enough sweet/sour liquid to fill each bearlike impression. The candies are set aside to harden, then the trays are flipped over, the nascent gummy bears have their cornstarch steamed off, and are on their way to be packaged for their rendezvous with your mouth.
Like most kids, I have an innate preference for the chocolate family of candies. But going through Ferrara Pan gave me appreciation for the whole sour/gummy subgenus.
They truly are a wonder and, more so, a Chicago wonder.
—Originally published in the Sun-Times, Oct. 30, 2006