Editor Joseph Clarke speaks with BCH Operations Director, Stuart Grogan, about how manufacturers are embracing advanced forming and extrusion technologies to meet the demand for indulgent and visually striking confectionery
Consumer demand for unique and indulgent experiences has driven the evolution of confectionery production technologies, enabling greater customisation and intricate product designs. According to GlobaData Consumer Survey Insights, the Sensory & Indulgence megatrend is gaining importance as consumers seek both comfort and excitement in their purchases. Social media and digital engagement have further amplified this trend, making visually striking and immersive confectionery products more desirable.
Research by Lumina Intelligence highlights that 63% of UK sweet consumers are looking for a greater variety of flavours, with a quarter specifically interested in more exotic options. Morli Shah, Group Solution Specialist – Confectionery, TNA Solutions, advises that “confectionery producers must adapt by incorporating flexible forming technologies that allow them to create memorable, eye-catching products that stand out in a competitive market.”
Thanks to tecent advancements in forming machinery, there have been significant improvements in precision and consistency in confectionery production, particularly for starch mogul systems. “These systems are known for their exceptional flexibility, enabling manufacturers to produce a diverse range of confectionery products—including gummies, jellies, marshmallows, fondant crèmes, aerated masses, centre-in-shell products, nutraceuticals, and liquorice—on a single production line,” says Morli Shah, adding: “The ability to create such variety stems from precision-engineered moulds, which are pressed into the starch bed to form cavities that shape the liquid confectionery mixture. The accuracy of these moulds ensures uniformity in size, shape and intricate design details.”
At ProSweets and ISM 2025, I had the opportunity to catch up with some of the industry’s leading experts in forming and extrusion. One of the most intriguing discussions was with BCH Ltd, where I explored their innovative solutions for liquorice production. Despite evolving confectionery trends, liquorice remains a staple in the industry, with strong consumer demand driving continuous innovation. The forming and extrusion process plays a crucial role in achieving the distinctive texture, consistency, and shape of liquorice products, ensuring both efficiency and quality in large-scale production. This precision engineering is key to meeting market expectations—something BCH has refined through its advanced technologies and expertise.
Forming and Extrusion Liquorice Production
Over the years, forming and extrusion technology for confectionery, particularly liquorice, has advanced significantly. Traditionally, liquorice was a simple product, often limited to a single colour and flavour. However, modern consumers expect more variety, and manufacturers are responding by introducing a broader spectrum of colours and flavours.
According to Stuart Grogan, Operations Director at BCH, the company has embraced these evolving trends by developing the DMS 6 colour and flavour system. “We prioritised giving our customers the flexibility to explore and create innovative products,” he explains. This system allows manufacturers to keep pace with market trends, ensuring that their offerings remain exciting and relevant.
In addition, there has been a growing focus on natural ingredients, a trend that was evident at ISM/ProSweets 2025. Many new product launches are highlighting formed and extruded shapes such as spaghetti and co-extruded pieces, now marketed with an emphasis on healthier and natural components. BCH recognises that such advancements are crucial for manufacturers aiming to stay ahead in a rapidly changing confectionery landscape.
When it comes to consumer demands, preferences are shifting towards healthier alternatives, and this trend is shaping the future of extruded confectionery. Products with reduced sugar content and those made with natural ingredients are in high demand.
“BCH is adapting its technology to meet these evolving needs by continually developing its independent cooking, forming, and extrusion equipment,” says Grogan. This approach enables a controlled process that operates at significantly lower pressures and temperatures than traditional methods, making it easier to process delicate and sensitive products. This technological evolution ensures manufacturers can meet consumer demand without compromising on quality or production efficiency.
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Joseph Clarke
Editor, International Confectionery
Tel: +44 (0) 1622 823 920
Email: [email protected]
