How Do Lollipop Machines Make Different Shapes of Lollipops II-Jiangsu Flying Dragon Food Machinery Co., Ltd.

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Comparative Summary Table

Below is a consolidated view comparing all four methods across key aspects:

Method	Detail Level	Production Speed (units/hour)	Changeover Speed	Ideal Run Size	Typical Mold Material
Static (Gravity)	Moderate	≈ 300	(<2 min/plate)	Small → Medium (< 10 000/week)	Aluminum, Silicone
Rotary (Carousel)	Very High	≈ 1 000	(5–10 min)	Medium → Large (10 000–50 000/week)	Hard Anodized Aluminum
Compression (Plunger)	Moderate	≈ 200	(Alignment sensitive)	Small → Medium (< 10 000/week)	Hardened Steel, Aluminum
Injection (Industrial)	Extremely High	≈ 3 000	(Hours)	Very Large (> 50 000/week)	Tool Steel (H13), P20 Steel

Designing a New Shape: Step-by-Step Workflow

Regardless of method, creating a new lollipop shape follows this general progression:

Concept & Sketch
Brainstorm desired shape, size, and any branding elements.
Consider physical constraints (thin sections may break; deep cavities risk air pockets).

3D Modeling (CAD)
Build a digital model (SolidWorks, Fusion 360, or AutoCAD).
Add a draft angle (1–3°) and specify where the stick will be inserted (usually a central boss).

Prototype Mold
For quick proofs-of-concept, use a 3D-printed mold (food-safe resin) or silicone.
Check for proper fill behavior (no trapped air, consistent wall thickness).

Final Mold Fabrication
   CNC Milling (Aluminum/Steel): Common for static or rotary plates.
   EDM (Electrical Discharge Machining): Needed for extreme precision—tiny logos or deep relief.
   Multi-Part Mold Construction: Side slides, inserts, or collapsible cores for undercuts.

Machine Integration & Parameter Tuning

Attach mold to the machine's platen, carousel, or compression station.

Adjust:

   Sugar Temperature (°C/°F)
   Fill Pressure/Speed (for injection or rotary nozzles)
   Cooling Time/Flow
   Ejector Timing
   Test Runs

Produce a small batch (dozens) to verify shape fidelity, wall thickness, and stick alignment.

Inspect for defects:
   Air bubbles around fine details
   Flash or burrs along edges
   Inconsistent stick depth (must be centered and secure)

First-Article Approval
   Measure critical dimensions with calipers (± 0.5 mm typical tolerance).
   Conduct a pull test on the stick (ensure it doesn't pop out under moderate force).
   Perform a quality assessment (appearance, color consistency).

Full-Scale Production
   Monitor reject rate (ideal: < 1 %).
   Schedule regular mold cleaning (every 2–4 hours in high-volume runs).
   Plan for mold refurbishment every 50 000–100 000 cycles (re-polish or re-machine surfaces if wear appears).

Typical Shape Examples & Recommended Methods

Shape	Method	Reasoning/Notes
Classic Round/Disc	Static or Rotary	Simple hemispherical cavity or shallow disc. Static is easiest; rotary helps if volume > 5 000/week.
Heart, Star, Flower	Static or Rotary	Moderate detail (draft angles sufficient). Rotary achieves faster cycles once demand is high.
Corporate Logo (Flat Relief)	Compression or Injection	Compression gives crisp, shallow relief at low volumes; injection needed for thousands with multi-color.
Character/Cartoon Figure	Rotary or Injection	Under-cut features require side cores—rotary with sliding inserts or multi-slide injection molds.
3D Animal/Plastic Figurine	Injection	Complex 3D shape with deep undercuts and side details; injection mold’s sliding cores or collapsible core.

Visual Comparison: Production Speed Chart

Above, you saw a bar chart comparing the approximate production speeds of the four methods:
   Static (Gravity-Fill): ~ 300 units/hour
   Rotary (Carousel): ~ 1 000 units/hour
   Compression (Plunger): ~ 200 units/hour
   Injection (Industrial): ~ 3 000 units/hour

This helps illustrate why, for very large runs or highly detailed designs, rotating or injection systems are favored, whereas small businesses or seasonal artisans often choose static or compression setups.

Key Takeaways

Choose Method by Volume & Detail:

Small, simple orders → Static molding (lowest cost, quick changeover).

Medium volumes with moderate detail → Rotary molding (good balance of speed and detail).

Flat logos or thin layered pops → Compression molding (precise thickness, crisp relief).

Very large runs or highly intricate/colored shapes → Injection molding (highest throughput, multi-layer capabilities).

Draft Angles & Ejection Are Crucial:

Always design molds with a slight taper so candy releases cleanly.

Incorporate reliable ejector pins, spring-loaded sticks, or side slides for undercut areas.

Material Selection Matters:

Aluminum/Steel molds → Faster cooling, longer life, ideal for high-volume.

Silicone or 3D-printed molds → Good for rapid prototyping or very limited runs but slower throughput.

Maintain & Inspect Regularly:

Clean sugar residue every few hours to prevent buildup (“burn backs”).

Check molds for wear (rust, scratches) after tens of thousands of cycles, and re-machine or replace as needed.

Balance Cost vs. Flexibility:

Static and compression presses cost less but have lower throughput and detail.

Rotary and injection molds require higher capital but pay off when volume or branding complexity increases.

With these principles and method comparisons in mind, manufacturers—whether small-batch candy makers or large confectionery factories—can decide how best to produce eye-catching, perfectly shaped lollipops for any occasion.