Gummy production line in Spain

Case Study Transforming Gummy Production for a Spanish Confectionery Leader

When a mid-sized Spanish confectionery factory decided to modernize its gummy production line, it faced significant bottlenecks. Manual processes limited output to just 1,200 kilograms per day, with a defect rate of nearly 8%. The company, which supplies gummy products to major retailers across Europe, needed a fully automated solution that could scale without compromising quality. After evaluating multiple suppliers, the factory chose MachineCooperate to design and install a complete gummy production line. The results were transformative: within the first six months, daily output surged to 4,500 kilograms, defect rates dropped below 0.5%, and overall production costs decreased by 32%. The investment paid for itself in just 14 months.

Measurable Improvements in Efficiency and Revenue

The new line from MachineCooperate integrated continuous cooking, depositing, drying, and packaging modules. Automation reduced the need for manual labor by 65%, cutting the workforce from 32 operators to 11 while increasing throughput. The factory’s lead time shrank from 72 hours to 18 hours per batch, enabling faster response to market demand. Revenue climbed by 48% in the first year as the factory captured new orders from international buyers. Annual energy consumption per kilogram of gummy produced fell by 27%, thanks to the line’s energy-efficient design. The client reported a net profit increase of €420,000 in the first year alone.

A direct comparison before and after the MachineCooperate installation illustrates the step-change in performance:

Comprehensive Support Throughout the Procurement Process

MachineCooperate distinguished itself not only through hardware but also through meticulous service. From the initial consultation, the team conducted a full site audit in Barcelona and designed a layout that maximized the factory’s existing floor space. After the line was built and shipped, two senior engineers spent three weeks on-site for installation and commissioning. They provided hands-on training for all 11 operators, covering recipe management, troubleshooting, and preventive maintenance. The factory’s production manager noted that the training reduced the ramp‑up period from an expected six weeks to just nine days.

The client listed the most valuable service elements as:

• A 24/7 multilingual remote support hotline, with average response time under 12 minutes.
• Annual preventive maintenance visits included in the contract, covering calibration of all sensors and lubrication of mechanical parts.
• Customized recipe development for four new gummy varieties (sugar‑free, vitamin‑fortified, sour, and soft chews) to expand the client’s product portfolio.
• Remote software updates and performance optimization reports every quarter.
• A dedicated spare‑parts warehouse in Madrid, guaranteeing delivery within 48 hours for all critical components.

When a minor conveyor belt issue arose during peak season, MachineCooperate dispatched a technician within six hours and resolved the problem in under two hours, preventing any production downtime. This level of responsiveness solidified the client’s trust and led to a contract renewal for three additional lines.

Spain’s Growing Market for Gummy Confectionery

Spain’s gummy segment has experienced robust growth over the past five years, driven by changing consumer preferences and increased distribution. The Spanish confectionery market was valued at approximately €1.8 billion in 2023, with gummy products accounting for nearly 22% of that total. According to industry reports, the gummy category is projected to grow at a compound annual rate of 6.3% through 2030. This expansion is fueled by demand for innovative formats such as functional gummies (with vitamins, minerals, or probiotics), reduced‑sugar offerings, and organic certifications. Spanish consumers, particularly in the 18‑35 age bracket, increasingly view gummies as a convenient snack rather than a purely seasonal treat. Supermarket chains like Mercadona and Carrefour have expanded private‑label gummy lines, creating opportunities for local manufacturers to scale production. However, many Spanish factories still operate legacy equipment that cannot meet the required flexibility or hygiene standards for these new product categories. As a result, producers are actively seeking partners like MachineCooperate that can deliver turnkey lines with high automation and fast changeover capabilities. The Spanish factory featured in this case study now exports 40% of its gummy output to France, Portugal, and Italy, benefiting from the production capacity unlocked by MachineCooperate. With the European gummy market expected to surpass €10 billion by 2028, investments in modern lines are becoming a strategic necessity rather than an option.

For confectionery manufacturers looking to replicate this success, MachineCooperate offers tailored solutions that combine engineering excellence with deep market understanding. The Spanish case demonstrates that partnering with the right equipment provider can deliver double‑digit efficiency gains, substantial revenue growth, and lasting competitive advantage.