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the Royale factory tour

How do we make our fantastic soft centered sweets? Here's how...

1) BOILING
This is one of the things that sets our sweets apart from modern, mass produced products. We select the finest sugar and glucose syrup and hand-weigh these into the traditional open copper pan. The sugar/glucose mix is then boiled over an open gas flame to a temperature of 150 degrees C. This form of batch open pan gas fire cooking is the only real traditional method of cooking.

2) TIPPING
Once the syrup has reached the correct temperature, it is removed from the flame and carefully tipped onto a cast iron cooling table, where it spreads out until it fills the entire table with a thin "slab" of molten sugar/glucose.

3) MIXING, CUTTING & KNEADING
Once the syrup has settled for a while, the Candy Craftsman adds the secret Royale® formula for the fantastic flavour in our sweets, and mixes this into the syrup.
Once the syrup has solidified where it is in contact with the cooling table, the Candy Craftsman cuts the syrup into two constituent parts - one part will form the outer casing of the lozenges, and the other will form the inner casing to hold the soft centre. Both parts are then kneaded by the Candy Craftsman to ensure that the flavouring formula is evenly distributed around the batch.

4) ADDING THE SOFT CENTRE
Once the mixture has reached the right consistency for forming into the individual lozenges, the two parts are transferred over to a hot table which maintains this consistency. Here, the Candy Craftsman adds the soft centre, which is made separately as it is cooked to a much lower temperature so that it remains soft. The inner and outer casing are stretched out over the table to form two separate square shaped sections.

The soft centre is then placed across the inner casing, which is wrapped around the centre, and then placed into the outer casing, which again is wrapped around the inner casing - this in effect forms a single giant lozenge!

5) EXTRUSION AND SHAPING
The "giant lozenge" is then placed in the forming line for extrusion and final shaping of the individual lozenges. The first stage of this is performed by a "batch roller" which carries out the primary extrusion.
The second stage, secondary extrusion, is performed by a "rope sizer" machine, so called because it extrudes the batch down into a "rope", the diameter of which determines the thickness of the finished lozenges.
This rope is then fed into a revolving "die" which punches the shape of the finished lozenges into the rope. These then travel along a conveyor to be fed onto a revolving carousel cooler.

6) WRAPPING AND PACKING
The lozenges are then transferred onto a high speed automatic wrapping machine to have that familiar waxed twist wrapping added to the outside. The finished sweets are then sent for packing into their individual packets or jars.