People often ask what we do during the nine months of the year when we’re not making maple syrup. While there’s always a long list of maintenance projects, repairs, and improvements to tackle, the majority of our time is spent building inventory for the busy seasons ahead.

To keep up with demand, we process the equivalent of two 40-gallon drums of maple syrup every day. That syrup is transformed into finished products including  jugs of syrup, maple sugar, maple cream, and maple candies.

Most of these products are shipped directly to Amazon fulfillment centers, while about 25% stays here in our refrigerated storage so we can fulfill orders ourselves and keep our shelves stocked during the holiday season and spring sap season.

Below are a few photos from one of our gallon production weeks. Each pallet holds 30 boxes, with four one-gallon jugs per box—that’s 120 gallons of maple syrup per pallet. In total, these pallets represent 1,200 gallons of maple syrup, packaged and ready to head out to customers!

If you’ve ordered an 8oz candy in the past few months, you might have noticed a change in the packaging. It’s hard to believe we’ve been using the original one-piece corrugated boxes for a decade, but it’s finally time for an updated container. Our new two-piece boxes are accompanied by a plastic tray with individual candy slots and a paper-based padding layer. We’ve finally just run out of old one-pound boxes, it will take a month to fully transition to the new boxes. We still have several rolls of labels left, we’ll investigate screen printing the tops once they run out. Check out the gallery below for pictures and a link to the updated product page.

Maple Candy

Making maple candy is a blend of science and art, especially when it comes to our vacuum cooling process. Every step in this process has strict parameters related to temperature, pressure, invert sugar levels, and timing, among others. While our four-headed unit is efficient, even candy pouring can be challenging. Our new packaging (more details in our upcoming blog post) requires tighter tolerances on candy weight, prompting us to develop a solution that guarantees even candy pouring.

We experimented with various screw-in nozzles, 3D printed with high-strength polycarbonate, to achieve the desired result. It took several iterations to perfect the setup, but since a plate of nozzles only takes an hour or two to print and costs less than a dollar, we quickly found the ones that worked best.

Initially, we discovered that the stock nozzles on our machine were too large in diameter, leading to inconsistent flow rates that varied with temperature and pouring speed. By reducing the diameter of each nozzle, we ensured consistent pressure, resulting in a more even flow rate. However, smaller diameters caused excessive pressure, causing syrup to squeeze out of some of the threaded fittings. This issue was easily resolved by lowering the speed of our gear pump, an effortless task since our motor is driven by a variable frequency drive (VFD).

Despite these improvements, the outer two nozzles still poured slightly slower than the middle two. Swapping out the 3.2mm nozzles with 3.3mm ones was the perfect solution. Now, all our candy molds fill at the same rate, resulting in more uniform candies, faster candy-making days, and reduced waste.

Checkout some pictures below as well as a video of the nozzles printing.