Once the marshmallow mixture has been whipped for a while, it’s time to set them and shape them. This is one area where the process for homemade marshmallows and the process for commercially made marshmallows varies the most.
At home, you’ll want to prepare a baking dish by spraying it with non-stick cooking spray and sprinkling the surface with powdered sugar. Then, you’ll pour the mixture into the pan. Like Jell-O, the marshmallows will need time to set, usually about four hours at room temperature. This also allows the marshmallows to form a thin layer that holds everything together. Then, you cut the marshmallows into squares.
In the factory, this process is called extrusion and is very different. A machine is used that forces the marshmallow mixture through circular tubes. While the mixture shoots through the tubes, it’s put under 200 pounds of pressure per square inch. This extreme pressure forces the marshmallows to set without the hours of waiting.
The machine then squeezes the marshmallow mix out into long strips or bands on a conveyor belt. After they get a chance to cool slightly, they then are sliced into the standard, marshmallow-sized pieces everyone knows and loves. Different-sized marshmallows, like mini marshmallows or jumbo marshmallows, will need to be squeezed through different-sized holes.
Some factories don’t use the rope or band method for their marshmallows. Instead, the mixture goes into a different part of the machine that squeezes individual marshmallows out onto the converter belt. Regardless of the method used, the end result is little marshmallow pillows perfect for s’mores, baking, and snacking.