Methena's fully automatic cone marshmallow production line integrates quantitative accuracy, sugar stability, and production changeover efficiency into a single continuous line. Sugar boiling, gelatin mixing, aeration and whipping, quantitative pouring, filling and sauce injection, powdering, and powder recycling are all connected in series by a PLC program. Pouring accuracy is ±0.2 grams, temperature control accuracy is ≤±1℃, and sugar specific gravity changes within 30 seconds when switching between 0.18 and 1.0. Two capacity options, 150 kg/h and 500 kg/h, cover the mass production needs of startups to medium-sized factories.
In-depth Process Analysis: Continuous Operation from Sugar Boiling to Recycling
The entire production line's operation is broken down into six steps based on material flow.
Step 1: Syrup Boiling.
White sugar and glucose syrup are fed into the boiling tank according to the specified ratio. A 16 kW heating system heats 250 liters of material per batch to the process temperature. The heating rate determines the final viscosity of the syrup, and the thermal efficiency here directly affects the stability of the entire line's cycle time.
Step 2: Gelatin Mixing and Insulated Storage.
The boiled syrup and gelatin solution are mixed and then transferred to an insulated tank. The tank uses a heavy-duty three-layer insulation structure, combined with active heating to maintain a uniform temperature of the sugar solution and prevent premature cooling, solidification, and pipe blockage.
Step 3: Aeration and Whipping.
The mixed sugar solution enters a whipping machine, continuously aerated and stirred at high speed under a 3 kW drive. The whipping machine is equipped with an independent cooling circulation loop to dynamically offset the frictional heat generated by continuous stirring, keeping the sugar temperature within a precisely controlled range and forming a uniform and delicate cloud-like texture.
Step 4: Quantitative Casting and Filling.
After whipping, the sugar is pumped into a temporary storage tank, and then the cones are filled using an integrated casting head. The double-layer co-extrusion head simultaneously injects jam, syrup, or chocolate liquid through the inner core nozzle while pouring the outer layer of marshmallows, allowing both materials to form simultaneously and preventing filling leakage. The conveyor line height is adjustable, compatible with mini cones to larger sizes.
Step 5: Dusting and Anti-sticking.
After demolding, the finished product is coated with an automatic dusting device, serving both anti-sticking and decorative functions. Colored sugar powder can be added to enhance the appearance.
Step 6: Powder Recycling and Post-Production Connection.
Excess powder is recycled and reused in real time through a closed-loop screening and spiral conveyor system, reducing powder consumption by at least 5%. After being conveyed and sorted, the finished product is connected to the packaging machine for sealing and bagging, eliminating the need for manual contact with the sugar throughout the entire process.
Parameter | MET-ACMP |
Line model | MET-ACMP |
Process scope | Sugar cooking, gelatin mixing, aeration whipping, precision depositing, center-filling, powder dusting, powder recovery |
Throughput options | 150 kg/h / 500 kg/h |
Dosing accuracy | ±0.2 g |
Temperature control | ≤±1°C |
Specific gravity range | 0.18–1.0, 30-second changeover |
Yield rate | ≥99% |
Voltage | 380V three-phase (220V optional) |
Total installed power | Approx. 75 kW (all stations combined) |
Main unit dimensions (depositing system) | 4800×1300×1600 mm |
Packing gross weight | Approx. 600 kg (main unit standard packing) |
Control system | PLC touch control |
Contact material | SUS304 food-grade stainless steel |
Core electrical/pneumatic components | Siemens, Schneider, Phoenix Contact, SMC (Japan) |
Continuous fault-free operation | 720 hours |
Design life | 8–10 years |
Certifications | ISO 9001, ISO 14001, ISO 45001, CE, BSCI, ETL |
Station Details (standard 150 kg/h configuration; parameters per actual configuration)
Station | Voltage | Power | Capacity Parameter | Dimensions (mm) |
Sugar cooking tank | 380V | 16 kW | 250 L | 1080×1200×1100 |
Insulated storage tank | 380V | 16 kW | 250 L | 1080×1200×1100 |
Aeration whipping machine | 380V | 3 kW | 150 kg/h | 1280×600×1400 |
Chiller unit | 380V | 10 kW | 5 HP refrigeration | 1200×950×1200 |
Integrated depositing system | 380V | 30 kW | 40–150 kg/h | 4800×1300×1600 |
Fully Automated Cotton Candy Cone Production Line Engineering Design
Cooking Tank:
Rapid heating shortens the sugar cooking cycle and optimizes syrup viscosity, providing stable output for continuous production. Thermal efficiency is the core indicator for this station: slow heating means batch-to-batch fluctuations in syrup viscosity, causing a loss of benchmark for specific gravity control in the downstream whipping process.
Insulated Tank:
A three-layer insulation structure isolates heat exchange with the environment, combined with a hot water circulation jacket on the outer wall of the pipeline, preventing syrup solidification and pipe blockage at the source. The material conveying pump and pipelines are equipped with independent hot water circulation insulation, a key design feature for uninterrupted continuous production.
Whipping Machine:
Responsible for shaping the sugar body. An independent cooling circulation loop continuously removes the frictional heat from high-speed stirring, a structure not found in ordinary models: whipping machines without a cooling loop experience sugar temperature rise during continuous operation, resulting in specific gravity drift and increased product collapse rate.
Chiller Unit:
Provides circulating water for temperature control at the whipping and cooling stations. A pneumatic valve automatically manages the circulating cooling of tap water, triggering an alarm when the preset temperature is reached, thus completing the temperature control closed loop.
Integrated casting system.
The core of the entire line's precision. Quantitative casting and filling are completed simultaneously at the same die head, with a casting volume of ±0.2 grams; the height-adjustable conveyor line is compatible with different specifications of wafer cones, and no changeover is required. The powder spreading and spiral recovery mechanism are integrated in the discharge section, allowing for powder recycling.
Core electrical and pneumatic components are sourced from Siemens, Schneider Electric, Phoenix Contact, and SMC Japan. This provides the structural support for 720 hours of continuous trouble-free operation and is the underlying guarantee for an 8-10 year design life of the entire machine.
Large-scale production in casual snack factories.When puffed food factories and candy factories add egg cone marshmallows to their product line, a 500 kg/h configuration can be integrated with existing packaging sections to form complete production capacity. Finished products can be stored at room temperature, eliminating the need for a cold chain, resulting in low logistics costs for distribution channels.
Flexible production of multiple SKUs in candy factories.Solid-color classic, two-color spiral, molten filling, sculpted shapes, and colored sprinkles can be switched on the same production line. The 30-second adjustable specific gravity allows for small-batch, multi-variety orders without sacrificing overall line speed.
Holiday gifts and OEM orders.Customized production cycles for New Year's goods, Children's Day, and wedding favors are concentrated. The combination of rapid changeover and convenient filling system material changes makes it suitable for undertaking OEM/ODM orders from brand owners.
Q1: What cone marshmallow products can this line produce?Plain classic domes, two-tone twisting swirls, liquid-filled jam cores, sculpted flower toppings, colored sprinkle dusting, and flat wafer cup fills. Multi-variety production runs on one line through PLC settings and mold changeover.
Q2: How does the line handle different wafer cone sizes?The conveyor carries a height-adjustable mechanism, and carrier trays are custom-engineered per cone specification. From pocket mini-cones to oversized formats, changeover is a mechanism adjustment, not a line replacement.
Q3: Can the pipelines clog with solidified syrup?Transfer pumps and pipelines carry independent hot-water circulation jackets, and the storage tank's three-layer structure actively insulates, eliminating premature solidification by design. Routine hot-water circulation flushing after shutdown keeps the lines clear.
Q4: Will the marshmallow collapse or melt during high-speed continuous production?The whipping machine's independent cooling loop continuously counteracts friction heat, holding sugar temperature inside a micro-controlled band. Texture remains stable and aerated under continuous high-speed operation.
Q5: How long does cleaning take during color or flavor changeover?Quick-release pipeline connections and polished SUS304 contact surfaces resist residue buildup, compressing washdown downtime and keeping flavor crossover at zero.
Q6: What throughput configurations are available?Two tiers: 150 kg/h and 500 kg/h, with station parameters matched per configuration. Select by target daily output and shift schedule, reserving roughly 20% capacity buffer.
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