Method for preparing delivery system for active ingredient in edible composition

Abstract

The present invention relates to a method for preparing a delivery system for an active ingredient in an edible composition. The present invention provides a method for preparing a first component of an edible composition, the method comprising forming an extrudate of the first component; cooling the extrudate to a first temperature; and further cooling the extrudate to a second temperature, the first temperature being higher than the second temperature.

Description

[0001] This application is a continuation-in-part of PCT International Application PCT / US2016 / 015525, filed January 29, 2016, which entered the Chinese national phase as Chinese Patent Application No. 201680005633.9, entitled "Method for Preparing Delivery System of One or More Active Ingredients in Edible Compositions," filed July 12, 2017. TECHNICAL FIELD

[0002] The present invention relates generally to systems and methods for manufacturing edible compositions, and more particularly to systems and methods for manufacturing a first component for use as an ingredient in edible compositions. BACKGROUND

[0003] Conventional methods for preparing one or more active ingredients for use in edible compositions include forming an extrudate having the active ingredient encapsulated therein. The extrudate is then cooled by convection to a temperature such that the extrudate can be broken into pieces before being ground into a powder. The shape and size of the pieces formed upon breaking of the extrudate are not uniform. Therefore, different amounts of energy are required to grind each piece to obtain particles of a desired size, resulting in an inefficient grinding operation.

[0004] Accordingly, there is a need for systems and methods that can continuously and efficiently prepare active ingredients for use in edible compositions. SUMMARY

[0005] According to one embodiment of the present invention, a method for preparing a first component of an edible composition is provided, the method comprising forming an extrudate of the first component. The extrudate is cooled to a first temperature. The extrudate is further cooled to a second temperature. The first temperature is higher than the second temperature.

[0006] In some embodiments, the method for preparing a first component of an edible composition comprises:

[0007] forming an extrudate of the first component;

[0008] cooling the extrudate to a first temperature; and

[0009] further cooling the extrudate to a second temperature, the first temperature being higher than the second temperature.

[0010] In some embodiments, the first temperature is above a glass transition temperature of the first component.

[0011] In some embodiments, the first temperature is between about 30°C and about 90°C.

[0012] In some embodiments, the second temperature is a temperature below a glass transition temperature of the first component.

[0013] In some embodiments, the second temperature is between about 20 °C and about 35 °C.

[0014] In some embodiments, the extrudate is cooled to the second temperature in a conductive manner.

[0015] In some embodiments, the method further comprises cutting the extrudate cooled to the first temperature into a plurality of substantially identical pieces.

[0016] In some embodiments, each piece comprises a cutting surface having a diameter greater than a thickness of the piece.

[0017] In some embodiments, the ratio of the diameter to the thickness of the cutting surface is greater than 1.

[0018] In some embodiments, the step of cutting the extrudate comprises feeding the extrudate to a pelletizer having a wheel comprising a plurality of teeth extending radially outward, the wheel configured to rotate about an axis arranged substantially perpendicular to a direction of travel of the extrudate.

[0019] In some embodiments, the first component is an encapsulate composition.

[0020] In some embodiments, the step of cooling the plurality of pieces to the second temperature occurs by a cooling mechanism having a conveyance surface defining a vertical spiral path.

[0021] In some embodiments, the method further comprises the step of grinding the plurality of pieces into a powder having particles of a desired size.

[0022] According to another embodiment of the present invention, there is provided a system for preparing a first component of an edible composition, the system comprising an extruder for forming an extrudate of the first component. A conveyance device receives the extrudate output from the extruder and is configured to cool the extrudate to a first temperature. A pelletizer is positioned to receive the extrudate output from the conveyance device. The pelletizer is configured to cut the extrudate into a plurality of substantially identical pieces.

[0023] In some embodiments, the system for preparing a first component of an edible composition comprises:

[0024] an extruder for forming an extrudate of the first component;

[0025] a conveyance device for receiving the extrudate output from the extruder, wherein the conveyance device is configured to cool the extrudate to a first temperature; and

[0026] A pelletizer is disposed to receive the extrudate output from the conveyance device, the pelletizer configured to cut the extrudate into a plurality of substantially identical pieces.

[0027] In some embodiments, the extruder is a twin-screw extruder.

[0028] In some embodiments, the pelletizer includes a wheel having a plurality of teeth extending radially outward therefrom, the wheel configured to rotate about an axis disposed substantially perpendicular to a direction of travel of the conveyance device.

[0029] In some embodiments, each piece includes a cutting surface having a diameter greater than a thickness of the piece.

[0030] In some embodiments, the ratio of the diameter to the thickness of the cutting surface is greater than 1.

[0031] In some embodiments, the system further includes a cooling mechanism configured to receive the pieces and cool the pieces to a second temperature, the second temperature being cooler than the first temperature.

[0032] In some embodiments, the cooling mechanism includes a conveyance surface defining a vertical helical path.

[0033] In some embodiments, a vibration along the conveyance surface is configured to translate movement of the plurality of pieces along the path.

[0034] In some embodiments, a drive motor is operably coupled to the conveyance surface and configured to impart a vibrational force to the conveyance surface.

[0035] In some embodiments, the system further includes a mill disposed downstream of and in series with the cooling mechanism, the mill configured to grind the plurality of pieces into a powder, the powder having particles of a desired size.

[0036] In some embodiments, the first component is an encapsulated composition.

[0037] According to yet another embodiment of the present invention, there is provided a method for preparing a first component of an edible composition, the method including extruding an encapsulated composition. The encapsulated composition is cut into a plurality of substantially identical pieces.

[0038] In some embodiments, the method for preparing a first component of an edible composition includes:

[0039] extruding an encapsulated composition; and

[0040] cutting the encapsulated composition into a plurality of substantially identical pieces.

[0041] In some embodiments, the temperature of the encapsulated composition is above a glass transition temperature of the encapsulated composition at the time the cutting step occurs.

[0042] In some embodiments, the temperature is between about 30°C and about 90°C.

[0043] In some embodiments, each piece comprises a cutting surface having a diameter greater than a thickness of the piece.

[0044] In some embodiments, the ratio of the diameter to the thickness of the cutting surface is greater than 1.

[0045] In some embodiments, the method further comprises cooling the plurality of pieces to a temperature below a glass transition temperature of the encapsulated composition.

[0046] In some embodiments, the plurality of pieces is cooled to a temperature between about 20°C and about 35°C.

[0047] In some embodiments, each of the plurality of pieces is cooled conductively.

[0048] In some embodiments, the step of cooling the plurality of pieces occurs by a cooling mechanism having a conveyance surface defining a vertical spiral path.

[0049] In some embodiments, the method further comprises grinding the plurality of pieces into a powder having particles of a desired size.

[0050] According to another embodiment of the present invention, there is provided a method for preparing a first component of an edible composition, the method comprising extruding an encapsulated composition. The encapsulated composition is cooled to a first temperature, the first temperature being above a glass transition temperature of the encapsulated composition.

[0051] In some embodiments, the method for preparing a first component of an edible composition comprises:

[0052] extruding an encapsulated composition; and

[0053] cooling the encapsulated composition to a first temperature, the first temperature being above a glass transition temperature of the encapsulated composition.

[0054] In some embodiments, the first temperature is between about 30°C and about 90°C.

[0055] In some embodiments, the method further comprises cutting the encapsulated composition into a plurality of substantially identical pieces.

[0056] In some embodiments, each piece comprises a cutting surface having a diameter greater than a thickness of the piece.

[0057] In some embodiments, the ratio of the diameter to the thickness of the cutting surface is greater than 1.

[0058] In some embodiments, the method further includes cooling a plurality of blocks to a second temperature below the glass transition temperature of the encapsulation composition.

[0059] In some implementations, the second temperature is between about 20°C and about 35°C.

[0060] In some implementations, each of the multiple blocks is cooled by conduction.

[0061] In some implementations, the cooling of multiple blocks occurs via a cooling mechanism having a conveying surface that defines a vertical spiral path.

[0062] In some implementations, the method further includes grinding multiple blocks into powder, the powder having particles of the desired size. Attached Figure Description

[0063] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several aspects of the invention and, together with the detailed description, serve to explain the principles of the invention. In the drawings:

[0064] Figure 1 This is a schematic diagram of a system for preparing a first component of an edible composition according to an embodiment of the present invention;

[0065] Figure 2 It is configured for use according to embodiments of the present invention. Figure 1 A cross-sectional view of the extruder in the system;

[0066] Figure 3 It is configured for use according to embodiments of the present invention. Figure 1 A front view of the granulator in the system; and

[0067] Figure 4 This is an example of an extrusion cutting block according to an embodiment of the present invention.

[0068] The following detailed description, in conjunction with the accompanying drawings, illustrates by way of example embodiments, advantages, and features of the present invention. Detailed Implementation

[0069] The following disclosure will describe in detail specific embodiments of the invention, which provide methods and systems for manufacturing encapsulation compositions, particularly for encapsulation compositions for chewable gum base sugars and other such sugar foods.

[0070] The edibles included in the edible extrudates, lumps, and sheets described herein include any type of edible product, such as, but not limited to, chewing gum (at any stage, including elastomers, semi-finished bases, finished chewing gum bases, and finished chewing gum), confectionery (which may be synonymous with chewing gum and candy), sweet and savory biscuits, cakes, nuts, and cereals, etc. For ease of description, in the remainder of this specification, edibles will be referred to as chewing gum. Certain components of chewing gum may have a heterogeneous texture and / or contain a multilayered composition.

[0071] As used herein, products referred to as “chewable gum base” or “gum base” include, but are not limited to, compositions (including composite elastomers and finished gum bases) from complex elastomers to finished gum bases, said compositions may include a complex elastomer plus some complexing additives, a gum base masterbatch, a complex elastomer plus some subsequent gum base components, a complex elastomer plus some gum base components and some subsequent gum base components, a gum base, a gum base plus some subsequent gum base components, finished gum base masterbatch, and finished gum base.

[0072] Before explaining the various systems and methods according to the invention, it is helpful to discuss the basic components of several typical stages in the manufacture of chewable gum bases (i.e. finished gum bases) in which encapsulation can be used.

[0073] The term "finished chewable gum" or "finished gum" used in this article refers to chewable gum that is largely ready for distribution to consumers. Therefore, finished gum may still require temperature conditioning, forming, shaping, packaging, and coating. However, from a compositional point of view, the chewable gum itself is essentially complete. Not all finished gum has the same ingredients or the same amounts of various ingredients. By changing the ingredients and their amounts, texture, flavor compounds, and sensations can be altered to provide different characteristics, thereby meeting consumer needs.

[0074] As is well known, finished chewing gum typically comprises a water-soluble bulk portion, a water-insoluble gum base portion, and one or more flavoring agents. The water-soluble portion dissipates over time during chewing. The gum base portion remains in the mouth throughout the chewing process. Finished chewing gum is defined as chewable gum ready for consumption by consumers.

[0075] As used herein, "finished chewable gum base" or "finished gum base" refers to a chewable gum containing a sufficient combination of gum base components, which only need to be combined with subsequent gum components to form a finished gum. The finished gum base is a viscoelastic material that comprises at least a viscous component, an elastic component, and a softener component. For example, a typical gum base may include an elastomer, and at least some of fillers, resins and / or plasticizers, polyvinyl acetate, and softeners (such as oils, fats, or waxes). For example, an elastomer that has only been blended without any softener will not be a finished gum base because it is difficult to chew (if not impossible to chew) and therefore not considered suitable for a finished gum structure. In one embodiment, as further described below, the viscosity of the finished gum base or the extrudate output from the extruder is between about 75 Pa·s and about 140,000 Pa·s.

[0076] The term "semi-finished chewable gum base" or "semi-finished gum base agent" as used herein refers to a chewable gum base agent containing gum base agent components or a combination of gum base agent components. These gum base agent components need to be combined with other gum base agent components and subsequent non-base gum base agent components to form the finished gum base agent. The semi-finished gum base agent contains at least one elastic component and requires the addition of at least one viscous and / or softening component to form the finished gum base agent.

[0077] Chewable gum bases may include a variety of ingredients belonging to various categories. The systems and methods discussed below can be used to mix any and all known ingredients, including but not limited to the following categories: elastomers, extenders, elastomer plasticizers (including resins), elastomer solvents, plasticizers, fats, waxes, fillers, antioxidants, sweeteners (e.g., extender sweeteners and high-intensity sweeteners), syrups / fluids, flavorings, sensory agents, enhancers, acids, emulsifiers, colorings, and functional ingredients.

[0078] Insoluble gum bases in the form of finished gum bases typically contain components falling into the following categories: elastomers, elastomer plasticizers (resins or solvents), plasticizers, fats, oils, waxes, softeners, and fillers. Further discussion of representative components within each category will follow later. Gum bases can comprise 5 to 95% by weight of the finished gum, more typically 10 to 50% by weight, and most commonly 20 to 30% by weight.

[0079] The water-soluble portion of the finished gum base will be referred to as the subsequent components of this disclosure (because they are added after the manufacture of the finished gum base) and may include subsequent gum base components classified into the following categories: softeners, incrementing sweeteners, high-intensity sweeteners, flavoring agents, acids, additional fillers, functional ingredients, and combinations thereof. To optimize the chewiness and mouthfeel of the gum base, softeners are added. Softeners (also known as plasticizers, emulsifiers, or plasticizers) typically constitute 0.5% to 15% by weight of the finished gum base. Incrementing sweeteners constitute 5% to 95% by weight of the finished gum base, more typically 20% to 80% by weight, and most commonly 30% to 60% by weight. High-intensity sweeteners may also be present and are commonly used in conjunction with sugar-free sweeteners. When high-intensity sweeteners are used, they typically constitute 0.001% to 5% by weight of the finished gum base sugar, and preferably 0.01% to 3% by weight. Typically, high-intensity sweeteners are at least 20 times sweeter than sucrose.

[0080] Flavorings should generally be present in the gum base in an amount ranging from about 0.1% to 15% by weight, preferably from about 0.2% to 5% by weight, and most preferably from about 0.5% to 3% by weight. Natural and artificial flavorings can be used and combined in any perceptible manner.

[0081] When acid is present, it typically constitutes about 0.001% to 5% by weight of the finished gum base sugar.

[0082] Optional ingredients such as colorings, functional ingredients, and additional flavorings can also be included in gum base sugars.

[0083] refer to Figure 1 The system 10 for preparing a first component of an edible composition (e.g., chewable gum) includes an extruder 20 configured to output the first component as an extrudate 12. An example of an extruder 20 used in the systems and methods described below is... Figure 2 The following is shown in more detail. In the illustrated non-limiting embodiment, the extruder 20 is a twin-screw extruder comprising a substantially hollow barrel 22 in which substantially identical first screw 24a and second screw 24b are mounted. However, other types of extruders, such as planetary screw extruders and single-screw extruders, are also within the scope of this invention.

[0084] exist Figure 2 In the twin-screw extruder 20 shown, each of the first screw 24a and the second screw 24b typically extends from the inlet or feed end 26 of the barrel 22 to the outlet or extrusion end 28, and has a central longitudinal axis A and B, respectively.

[0085] Referring now in more detail to screws 24a, 24b, in one embodiment, the diameter of each screw 24a, 24b may be consistent along its length. However, since different parts of the extruder 20 may have different functions, each screw 24a, 24b may have different diameters or configurations at different locations along the length of the extruder 20. For example, a first portion 30 of screws 24a, 24b arranged near the feed end 26 of the extruder 20 may have a first diameter, and a downstream central portion 32 of screws 24a, 24b may have a second, smaller diameter. The first portion 30 may be the feed location, and the central portion 32 may be configured to mix and melt the components within the extruder barrel 22. Screws 24a, 24b include corresponding or interlocking grooves or vanes 34. These vanes 34 facilitate the efficient movement and mixing of the first component flowing through the extruder 20, wherein spaces 35 are provided for the first component so that the first component can flow between the vanes 34 of screws 24a, 24b. The wing 34 may have any desired configuration, including but not limited to variations in the distance and gap between adjacent winglets, winglet shape, and winglet length.

[0086] The extruder 20 includes at least one inlet point 36 for the ingredient to enter the extruder 20, such as an inlet point located near the feed end 26 of the barrel 22 or an inlet point located downstream of the feed end 26. The location of each of these inlet points 36 can be selected depending on the selected application, the ingredient being added, and the form of the added ingredient. Various types of feed inlets 38 can be used at the inlet point 36 to supply the ingredient into the internal volume of the extruder 20. In one embodiment, the feed inlet 38 is a gravity-driven hopper / feeder. Alternatively, the feed inlet 38 can be a side feed inlet configured to supply the ingredient laterally to the side of the extruder 20.

[0087] The extrusion point 40, located at the outlet of the extrusion end 28 of the barrel 22, includes an opening through which the first component flowing through the extruder 20 will ultimately be extruded. Notably, the downstream ends 25 of the screws 24a, 24b are generally located near the extrusion point 40 of the extruder 20. In fact, the downstream ends 25 of the screws 24a, 24b can terminate such that their downstream ends 25 are flush with the extrusion point 40. As is known in the art, the extrusion point 40 is fluidly coupled to an extruder die 42 mounted at the extrusion end 28 of the barrel 22. The extruder die 42 is configured to extrude the first component in one or more desired shapes, such as a rope or a continuous rectangular sheet.

[0088] Furthermore, the extruder 20 may include effective temperature control for a first component mixed therein and extruded therefrom. In one embodiment, the extruder 20 includes a temperature control system 44, such as, but not limited to, a cooling jacket and / or a heating jacket 46 circumferentially disposed around a portion of the barrel 22. The extruder 20 shown and described herein is intended as an example, and other known extruders 20 (such as planetary screw extruders) are within the scope of this invention.

[0089] At least one motor 50 is operatively coupled to the screws 24 of the extruder 20 and configured to rotate the screws 24 about their respective longitudinal axes A, B. The screws 24 can be configured to rotate synchronously or in opposite directions. As the various components enter the extruder 20, the rotation of the screws 24a, 24b produces a directional flow of the components toward the extrusion end 28 of the extruder 20. As the components move away from the feed end 26 of the extruder 20, the rotating screws 24a, 24b mix the components in the flow via movement through the space 35 defined between the teeth 34 of the rotating screws 24a, 24b. As the components are delivered and mixed, the components form a first component. The mixed first component is then provided to the extrusion point 40 adjacent to the downstream end 25 of the screws 24a, 24b. If the extruder die 42 is positioned adjacent to the extrusion end 28 of the barrel 22, the extrudate 12 of the first component is discharged from the extruder 20 in a desired shape complementary to the extruder die 42. In one embodiment, the extrudate 12 is output from the extruder 20 in the form of a rope or strand having a substantially constant cross-sectional area.

[0090] In one embodiment, the extrudate 12 of the first component provided at the extrusion point 40 of the extruder 20 is an encapsulation composition. The encapsulation composition typically comprises an "active" ingredient and an encapsulating ingredient. In some embodiments, the active ingredient may be quite sensitive to high-energy mixing environments, such as heat and shear forces that may be associated with certain types of mixing. Any active ingredient commonly used in edible foods, such as, but not limited to, high-intensity sweeteners (including natural and synthetic sweeteners), food acidifiers, and other ingredients (including texture modifiers, colorants, salts, oral care ingredients, and other ingredients), is contemplated for use with the extruder 20. Any encapsulating ingredient commonly available in edible foods, such as, but not limited to, polymers or resins, is also contemplated for use in the extruder 20.

[0091] For example, active ingredients may include, but are not limited to, sweeteners and food acidifiers. The sweeteners used may be selected from a wide range of materials, including water-soluble sweeteners, water-soluble artificial sweeteners, water-soluble sweeteners derived from naturally occurring water-soluble sweeteners, dipeptide-based sweeteners, and protein-based sweeteners, including mixtures thereof.Not limited to specific sweeteners, representative categories and examples include: (a) water-soluble sweeteners such as dihydrochalcone, indigofera tincture, steviol glycosides, glycyrrhizin, soluble saccharin salts, i.e., sodium or calcium salts of saccharin, cyclosulfonates, butyrylamide salts such as sodium, ammonium, or calcium salts of 3,4-dihydro-6-methyl-1,2,3-oxathiazin-4-one-2,2-dioxide, potassium salts of 3,4-dihydro-6-methyl-1,2,3-oxathiazin-4-one-2,2-dioxide (Acesulfame-K), saccharin in free acid form, and monatin; dipeptide-based sweeteners, such as sweeteners derived from L-aspartic acid, such as L-aspartyl-L-phenylalanine methyl ester (Acesulfame-K); (c) Water-soluble sweeteners derived from naturally occurring water-soluble sweeteners, such as Reb-A, chlorinated derivatives of common sugars (sucrose), such as chlorinated deoxysugar derivatives (such as chlorinated deoxysucrose or chlorinated deoxygalactose derivatives, for example, known by the product name sucralose); Examples of deoxychlorinated sucrose and deoxychlorinated galactosucrose derivatives include, but are not limited to: 1-chloro-1'-deoxysucrose; 4-chloro-4-deoxy-α-D-galactopyranosyl-α-D-fructofuranoside, or 4-chloro-4-deoxygalactosucrose; 4-chloro-4-deoxy-α-D-galactopyranosyl-1-chloro-1-deoxy-β-D-fructofuranoside, or 4,1'-dichloro-4,1'-dideoxygalactosucrose; 1',6'-dichloro-1',6'-dideoxysucrose; 4-chloro-4-deoxy-α-D-galactopyranosyl-1,6-dichloro-1,6-dideoxy-β-D-fructofuranoside, or 4,1',6'-trichloro-4,1',6'-trideoxygalactosucrose; ,6-Dichloro-4,6-dideoxy-α-D-galactopyranosyl-6-chloro-6-deoxy-β-D-fructofuranoside, or 4,6,6'-trichloro-4,6,6'-trideoxygalactosucrose; 6,1',6'-trichloro-6,1',6'-trideoxysucrose; 4,6-dichloro-4,6-dideoxy-α-D-galactopyranosyl-1,6-dichloro-1,6-dideoxy-β-D-fructofuranoside, or 4,6,1',6'-tetrachloro-4,6,1',6'-tetradeoxygalactosucrose; and 4,6,1',6'-tetradeoxysucrose, and mixtures thereof; or (d) other protein-based sweeteners, such as thaumaoccous denielli (Somas I and II) and talin.Food acidifiers may include citric acid, malic acid, fumaric acid, tartaric acid, lactic acid, and adipic acid.

[0092] Encapsulation of the active ingredient provides protection, preventing it from dissolving upon contact with water or saliva, thereby extending the relative shelf life of that component in the finished gum product. Furthermore, encapsulation protects the active ingredient for the remainder of the production process. Since the edible components to be encapsulated may be sensitive to temperature, mixing, extrusion, or other factors, encapsulation allows for the efficient handling and protection of these sensitive components during production. The protection of the active ingredient, as described above, is achieved by mixing the active ingredient with the encapsulating ingredients. In fact, the encapsulation composition defined herein refers to the active ingredient, as described above, mixed with encapsulating ingredients (such as those discussed below) for production and extrusion.

[0093] Examples of encapsulation materials / components include polymers or resins, wherein the characteristics of the polymer or resin determine the release properties and the protection of the active ingredient to be encapsulated. In some embodiments, the encapsulation material may be polyvinyl acetate, polyethylene, cross-linked polyvinylpyrrolidone, polymethyl methacrylate, polylactic acid, polyhydroxyalkanoates, ethyl cellulose, polyvinyl acetate phthalate, polyethylene glycol, methacrylate-co-methyl methacrylate, polyvinyl acetate-vinyl alcohol copolymer, or any other component suitable for polymer-based encapsulation.

[0094] As described above, it may be desirable to encapsulate certain ingredients or components in edible foods (e.g., chewable gum). The encapsulation compositions used herein comprise at least one active ingredient or component to be protected and released with certain release characteristics, and at least one additional encapsulation component, such as, but not limited to, a polymer or resin. After encapsulation, the encapsulation composition can be mixed with other gum components, for example, in a gum manufacturing system, to form a finished gum product.

[0095] During the encapsulation process, one or more active ingredients are supplied to the extruder 20 from an active ingredient source, and one or more encapsulating ingredients are added to the extruder 20 from an encapsulating ingredient source. Alternatively, the active ingredient and encapsulating ingredient from the same source can enter the extruder 20 from the active ingredient feed inlet 38 and the encapsulating ingredient feed inlet 38, respectively. In one embodiment, the active ingredient and encapsulating ingredient can be mixed first and then supplied to the extruder 20 through a single inlet 38. The active ingredient and encapsulating ingredient can be located at the same inlet point 36 or different inlet points 36 of the extruder 20, thereby allowing for different mixing durations of the active ingredient and encapsulating ingredient. The active ingredient and encapsulating ingredient can be added in a molten state or in particulate or raw material form, such as, but not limited to, powder, liquid, or flake materials.

[0096] See you again Figure 1 A conveying device 60, arranged adjacent to the outlet end 28 of the extruder 20, is configured to receive the extrudate 12 and supply it to a pelletizer 70 arranged downstream of and in series with the extruder 20. Furthermore, the conveying device 60 is configured to partially cool the extrudate 12 before conveying it to the pelletizer 70. In one embodiment, the conveying device 60 is configured to cool the extrudate to a temperature above its glass transition temperature, such as between about 30°C and about 90°C. The conveying device 60 may have a cooling system 62 coupled thereto, such that the extrudate 12 is cooled by heat conduction. However, other methods of cooling the extrudate 12, such as blowing cold air over the extrudate 12 arranged on the conveying device 60, are also within the scope of this invention.

[0097] See now Figure 3 An example of a pellet mill 70 is shown in more detail. The pellet mill 70 includes a rotatable wheel 72 having a plurality of substantially identical teeth or blades 74 extending radially outward therefrom. The axis of rotation R of the wheel 72 is oriented generally perpendicular to the direction of travel of the extrudate 12, as indicated by arrow A. As the extrudate 12 moves toward the rotating wheel 72 of the pellet mill 70, the teeth 74 continuously cut adjacent ends of the extrudate 12 to form a plurality of extrudate cut pieces 14.

[0098] In one embodiment, the teeth 74 are equidistantly spaced around the circumference of the wheel 72, such that if the extrudate 12 moves toward the pelletizer 70 at a constant speed, the dimensions, particularly the thickness (denoted by T), of each of the plurality of cut blocks 14 are substantially the same. An example of the cut blocks 14 of the extrudate 12 is shown in... Figure 4 This is shown in more detail below. In one embodiment, the pelletizer 70 is configured such that the thickness of the formed blocks 14, measured parallel to the travel direction A of the extrudate 12, is less than the diameter of the cutting surface 16 of each cut block 14. In one embodiment, the ratio of the diameter of the cutting surface 16 to the thickness of the block 14 is greater than 1.

[0099] In conventional systems, the extrudate is cooled to a temperature below its glass transition temperature, such as about 35°C, before being broken into smaller pieces. At such a temperature, the extrudate is brittle, resulting in multiple pieces of various shapes and sizes. By partially cooling the extrudate to a temperature, for example, above its glass transition temperature, as described in this invention, the extrudate becomes malleable, allowing multiple uniform, substantially homogeneous pieces to be easily formed upon cutting.

[0100] In a non-limiting embodiment illustrated, the pellet mill 70 further includes a funnel 80 disposed directly below the interface between the extrudate 12 and the rotating wheel 72. The funnel 80 is configured to guide the extrudate cut pieces 14 to an adjacent cooling mechanism 82 under gravity. Depending on the size of the cut pieces 14, the outer surface or one of the cut surfaces 16 of each piece 14 will be in direct contact with the cooling mechanism 82. In embodiments where the thickness-to-diameter ratio of each cut piece 14 is limited, the cut pieces 14 are oriented such that one of the cut surfaces 16 of each cut piece 14 is in direct contact with a portion of the cooling mechanism 82 (e.g., its conveying surface).

[0101] The cooling mechanism 82 of the system 10 is configured to further cool the extruded blocks 14 before supplying them to the downstream processor 94. Figure 1 An example of the cooling mechanism 82 shown includes a helical conveyor configured to receive multiple cut pieces 14 of extrudate supplied from a funnel 80. The helical conveyor 82 includes a continuous conveying surface 84, optionally wound around a central axis X to form a vertical helical path. The central axis X may include a tubular structure 86 configured to support the overall structure of the helical conveyor 82. The conveying surface 84 can have any of a variety of shapes, including but not limited to a helical design. Individual sidewalls (not shown) may be attached to or extend from the edge of the conveying surface 84 to accommodate the multiple cut pieces 14 of the extrudate therein. The helical design is advantageous for saving operating space while increasing the overall length of the conveying path because elements of this design include the degree of vertical movement of the cut pieces 14.

[0102] In one embodiment, the helical conveyor 82 generates a vibratory motion to gently throw a plurality of cut blocks 14 forward, for example, along a path defined by a conveyor surface 84, without deforming the shape of the cut blocks 14. Vibratory forces (such as those generated by a drive motor 88 coupled to the helical conveyor 82) can be transmitted to the conveyor surface 84 to generate vibrations along its surface. As the cut blocks 14 of the extrudate are supplied to the conveyor 82, the vibratory forces are applied to the conveyor surface 84 to alter the movement of the cut blocks 14 along its path. In one embodiment, the cut blocks 14 are conveyed to an inlet 90 disposed at the bottom of the conveyor 82, such that the vibratory forces compel the cut blocks 14 upward along the helical path defined by the conveyor surface 84. In another embodiment, the cut blocks 14 are typically supplied to the top of the helical conveyor 82, such that the vibratory forces compel the cut blocks 14 of the extrudate downward along the helical path of the conveyor surface 84.

[0103] As the extruded cutting blocks 14 travel along the conveying surface 84, the blocks 14 are further cooled to a temperature, for example, below the glass transition temperature of the extruded material, such as between about 20°C and about 35°C. In one embodiment, the heat transfer medium includes, but is not limited to, air, water, oil, refrigerant, and other gases and fluids, and is supplied to at least a portion of the screw conveyor 82. Due to the direct contact between each cutting block 14 (e.g., surface 16) and the conveying surface 84, heat can be conducted away from the cutting blocks 14 more efficiently than with conventional cooling mechanisms.

[0104] See you again Figure 1 A processing unit 94, arranged downstream of and in series with the outlet 92 of the cooling mechanism 82, may include a mill. The mill 94 is configured to grind a plurality of cut pieces 14 of the extrudate into a powder containing particles of a desired size. The residence time of the cut pieces 14 in the mill 94 can be any suitable time period required to achieve the desired particle size. After passing through the mill 94, the ground first component 18 can be provided to the mixer of a food-grade manufacturing system, wherein the first component serves as an ingredient in a food-grade composition known in the art.

[0105] By supplying multiple substantially uniform cut pieces 14 of the extrudate to the mill 94, the system 10 for preparing the first component of the edible composition described herein achieves improved consistency and efficiency. Furthermore, by conductively cooling the surface 16 of each cut piece 14 of the extrudate, the energy required to cool the cut pieces 14 of the extrudate to the desired temperature prior to further processing is reduced.

[0106] All references cited in this article, including publications, patent applications and patents, are incorporated herein by reference as if each reference were individually and specifically indicated to be incorporated herein by reference and presented in its entirety.

[0107] In describing the invention (especially in the context of the appended claims), unless otherwise stated herein or the context clearly contradicts it, the use of the terms “a,” “an,” “described,” and similar designations should be understood to encompass both singular and plural meanings. Unless otherwise specified, the terms “comprising,” “having,” “including,” and “containing” should be interpreted as open-ended terms (i.e., meaning “including but not limited to”). Unless otherwise stated herein, descriptions of numerical ranges are intended merely as a concise way of referring individually to each individual value falling within that range, and each individual value is incorporated into this specification as if it were described individually herein. Unless otherwise stated herein or the context clearly contradicts it, all methods described herein can be performed in any suitable order. Unless otherwise stated, the use of any and all examples or exemplary language (e.g., “as”) provided herein is intended merely to better illustrate the invention and not to limit its scope. No language in this specification should be construed as indicating that any non-claimed element is necessary for the implementation of the invention.

[0108] Exemplary embodiments of the invention have been described herein, including the inventors' known best mode for carrying out the invention. Variations of those embodiments will become apparent to those skilled in the art upon reading the foregoing description. The inventors anticipate that those skilled in the art will suitably employ these variations, and the inventors intend that the invention be carried out in ways other than those specifically described herein. Accordingly, the invention includes all modifications and equivalents of the subject matter set forth in the appended claims, subject to applicable law. Furthermore, unless otherwise stated herein or where the context clearly contradicts it, the invention covers any combination of all possible variations of the elements described above.

Claims

1. A method for preparing a chewable gum base composition, wherein the chewable gum base composition comprises a first component, the first component comprising an encapsulation composition, the method comprising: An extrusion of the first component is formed at the extruder; The extrudate is transported from the extruder to a downstream component via a conveying device; The extrudate is actively cooled to a first temperature via a cooling system, the first temperature being below 90°C and above the glass transition temperature of the first component, wherein the step of cooling the extrudate and the step of transporting the extrudate occur simultaneously; The extrudate, cooled to the first temperature, is cut into multiple pieces, wherein the multiple pieces are substantially the same size; The plurality of blocks are further actively cooled to a second temperature via a cooling mechanism, wherein the first temperature is higher than the second temperature, and wherein the second temperature is a temperature below the glass transition temperature of the first component; as well as The encapsulation composition is used as a component in the chewable gum composition.

2. The method according to claim 1, wherein the first temperature is higher than 30°C.

3. The method of claim 1, wherein the second temperature is between about 20°C and about 35°C.

4. The method of claim 1, wherein the extrudate is cooled to the second temperature by conduction.

5. The method of claim 1, wherein the plurality of blocks are identical.

6. The method of claim 5, wherein each block comprises a cutting surface having a diameter greater than the thickness of the block.

7. The method of claim 6, wherein the ratio of the diameter to the thickness of the cut surface is greater than 1.

8. The method of claim 5, wherein the step of cutting the extrudate comprises supplying the extrudate to a pellet mill having a wheel comprising a plurality of radially outwardly extending teeth, the wheel being configured to rotate about an axis arranged substantially perpendicular to the direction of travel of the extrudate.

9. The method of claim 5, wherein the step of cooling the plurality of blocks to the second temperature is performed by a cooling mechanism having a conveying surface defining a vertical helical path.

10. The method according to claim 5, further comprising: The step of grinding the plurality of blocks into powder, wherein the powder has particles of the desired size.

11. The method of claim 1, wherein the encapsulating composition comprises polyvinyl acetate.

12. A system for preparing a chewable gum base composition, wherein the chewable gum base composition comprises an encapsulation composition, the system comprising: An extruder for forming an extrudate of the first component; A conveying device for receiving the extrudate output from the extruder, wherein the conveying device is a cooling system that actively cools the extrudate and simultaneously conveys the extrudate; A pelletizer is configured to receive an extrudate having a first temperature below 90°C and above the glass transition temperature of the extrudate, output from the conveying device, and the pelletizer is configured to cut the extrudate cooled to the first temperature into a plurality of identical blocks. A cooling mechanism that receives the block and actively cools the block to a second temperature, wherein the second temperature is cooler than the first temperature and below the glass transition temperature of the first component; and A processing unit, downstream of the cooling unit, comprising a grinding mill.

13. The system of claim 12, wherein the extruder is a twin-screw extruder.

14. The system of claim 12, wherein the pelletizer includes a wheel having a plurality of teeth extending radially outward therefrom, the wheel being configured to rotate about an axis arranged substantially perpendicular to the direction of travel of the conveying device.

15. The system of claim 12, wherein each block includes a cutting surface having a diameter greater than the thickness of the block.

16. The system of claim 15, wherein the ratio of the diameter of the cut surface to the thickness is greater than 1.

17. The system of claim 12, wherein the cooling mechanism includes a conveying surface defining a vertical helical path.

18. The system of claim 17, wherein vibration along the conveying surface is configured to change the motion of the plurality of blocks along the path.

19. The system of claim 18, wherein a drive motor is operatively coupled to the conveying surface and configured to apply a vibrational force to the conveying surface.

20. The system of claim 12, further comprising: A grinding mill, arranged downstream of and in series with the cooling mechanism, is configured to grind the plurality of blocks into powder having particles of a desired size.

21. The system of claim 12, wherein the encapsulating composition comprises polyvinyl acetate.

22. A method for preparing an edible composition, the method comprising: Extrusion encapsulation composition; The encapsulation composition is actively cooled by a cooling system; The encapsulation composition is cut into a plurality of identical blocks by a rotating blade, wherein each block includes a cutting surface having a diameter greater than the thickness of the block, and the ratio of the diameter of the cutting surface to the thickness is greater than 1, wherein during the cutting step, the temperature of the encapsulation composition is below 90°C and above the glass transition temperature of the encapsulation composition. The plurality of identical blocks are further actively cooled to a temperature below the glass transition temperature of the encapsulation composition via a cooling mechanism; as well as The encapsulation composition is used as a component in the edible composition.

23. The method of claim 22, wherein the temperature is above 30°C.

24. The method of claim 22, wherein the plurality of blocks are cooled to a temperature between about 20°C and about 35°C.

25. The method of claim 22, wherein each of the plurality of blocks is cooled in a conductive manner.

26. The method of claim 22, wherein the step of cooling the plurality of blocks is performed by a cooling mechanism having a conveying surface defining a vertical helical path.

27. The method according to claim 22, further comprising: The plurality of blocks are ground into powder, the powder having particles of the desired size.

28. The method of claim 22, wherein the encapsulating composition comprises polyvinyl acetate.

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