The accuracy of fudge counter machines in high-yield environments has been significantly improved by technology. The 2023 Confectionery Packaging Technical Report shows that gummy counter counts 3000-5000 pieces/minute (manual operation is only 200-300 pieces/minute) with an error rate of less than 0.05% (manual error rate of 1%-2%), especially for special-shaped soft candies (e.g., animal shapes, 5-20mm diameter). For example, Germany Bosch “SVI 4000” model through multi-spectral vision recognition (resolution 0.1 mm) and weight compensation program (accuracy ±0.01 grams), multi-specification mixed packaging of gummies (such as gummy bears and vitamin gummies) sorting efficiency of up to 99.8%, output capacity 250,000/hour. Enabled Mars to increase yearly production by 15%.
Technical specifications show gummy counter load capacity and stability are adequate to fulfill the requirement for mass production. Syntegon, Switzerland’s “TCG 500\” series comes with an 8-channel parallel counting module (600 per minute at one channel speed) that accommodates continuous use for 24 hours (temperature fluctuation ±1°C) and motor life of over 100,000 hours (MTBF). In 2022, when Mondelez introduced the device, the conversion time of the production line was reduced from 45 minutes to 5 minutes (for six fudge sizes), and the unit energy consumption was reduced by 22% (power 1.2 kW/h). Experiments revealed that the models fitted with servo motors (torque 5-20 N·m) and flexible vibrating disks can produce high viscosity gummies (surface sugar powder concentration ≥10%), and the adhesion rate of material is reduced from 3% to 0.5%.
In terms of cost, the cycle of return on investment for gummy counter is much better compared to the manual production line. Market data indicate that its procurement price is $50,000 – $150,000 (manual counting equipment less than $5,000), yet labor expense decreases by 80% (annual savings of over $120,000 at $15 an hour). For example, when Hershey’s American plant employed the “WLS-300” model, the efficiency of packaging lines was increased from 75% to 98%, yearly capacity increased by 120 million bags, and net profit was increased by 18%. In addition to the modular design, i.e., the exchangeable conveyor belt, it reduces the cleaning cycle to 10 minutes (compared to 30 minutes for traditional equipment) and is FDA’s HACCP standard compliant (90 percent risk reduction in microbial contamination).
Market trends favor its high-capacity processing feature. By 2024, the global gummy counter market will be $870 million (CAGR 11.3%), of which smart models (with built-in AI quality inspection) will be 35%. ISHIDA’s “CCD-GUMMY” series uses 3D scanning (200 frames per second) and deep learning models to eliminate defective gummy candy in real time (99.9% accuracy), reducing the scrap rate from 0.8% to 0.05%. The European Union “Food Contact Materials Regulation” (EC 1935/2004) requires equipment material resistance against corrosion (pH 2-12), and that of the Italian manufacturer I.M.A. After certification with the stainless steel model (Class 316L), the working life in the acid fudge (pH 3.5) production line is extended to 8 years (5 years for the normal model).
User cases also support its reliability. In 2023, following China’s Want Want Group’s use of gummy counter, the standard deviation of weight (σ) of QQ sugar (15 grams ±0.2 grams per package) fell from 0.15 to 0.03, and the rate of customer complaints fell by 65%. Jamieson, a Canadian firm, applied acoustic detection technology (frequency 40 kHz) to detect sealing defects, cutting the rate of leaky packaging from 0.3% to 0.005%, saving wear costs by $500,000 annually. The data show the reliability of the operation of such equipment in conditions of high temperature and humidity (35°C, RH 80%) is 99.5% (92% for old equipment), which is sufficient for the supply chain demand of tropical areas, and has become the core infrastructure of confectionery large-scale production.