Advanced encapsulation methods for controlling release of active ingredients for chewing gum

Abstract

An advanced encapsulation method for controlling the release of active ingredients of chewing gum. The invention provides a chewing gum component for a chewing gum composition comprising a plurality of component bodies, each of the plurality of bodies comprising a plurality of regions of at least one active ingredient encapsulated within an encapsulating material, the plurality of regions being disposed with the component body and the encapsulating material defining an outer surface of the component body; wherein the plurality of component bodies have a size distribution with a standard deviation of less than 50% of the average longest dimension of each of the plurality of bodies; and wherein the release profile of the at least one active ingredient is substantially linear after two minutes of exposure of the component body to a dissolving liquid; the plurality of regions of active ingredient are uniformly distributed throughout the component body.

Description

Advanced encapsulation methods for controlling the release of active ingredients in chewable gum.

[0001] This application is a divisional application of Chinese patent application No. 201780082815.0, entitled "Advanced Encapsulation Method for Controlling the Release of Active Ingredients from Chewable Gum Sugars", which was filed on February 8, 2017, under the PCT international application PCT / US2017 / 016979 and entered the Chinese national phase on July 9, 2019. Technical Field

[0002] This disclosure relates in general to ingredients for edible compositions, and more specifically, to individual blocks and methods of forming individual blocks of ingredients for edible compositions. Background Technology

[0003] A conventional method for preparing one or more active ingredients for use in edible products involves forming an extrusion in which one or more active ingredients are encapsulated. The extrusion is then convectively cooled to a temperature such that it breaks into multiple fragments, which are then pulverized into powder. When the extrusion breaks down, the resulting fragments are not uniform in shape and size. Therefore, different amounts of energy are required to grind each fragment to obtain particles of the desired size, resulting in inefficient grinding operations.

[0004] Therefore, there is a need for systems and methods that can continuously and efficiently prepare active ingredients for use in edible foods. Summary of the Invention

[0005] According to one embodiment of the present invention, a chewable gum component for a chewable gum composition is provided, comprising a component body and a plurality of regions including at least one active ingredient encapsulated within an encapsulating material. Less than 15% of the average active ingredient in the component body is in contact with the outer surface of the component body.

[0006] According to another embodiment of the invention, a chewable gum base component for a chewable gum composition is provided, comprising a component body and multiple regions of at least one active ingredient encapsulated within an encapsulating material. The multiple regions are disposed within the component body. Less than 15% of the average active concentration in the component body is in contact with the outer surface of the component body.

[0007] In addition to one or more of the features described above, or as an alternative, in another embodiment, less than 10% of the average active concentration in the component body is in contact with the outer surface of the component body.

[0008] In addition to one or more of the features described above, or as an alternative, in another embodiment, the longest dimension of the body is less than 1000 micrometers.

[0009] In addition to one or more of the features described above, or as an alternative, in other embodiments, the cross-section of the body is typically circular.

[0010] In addition to one or more of the features described above, or as an alternative, in another embodiment, the encapsulating material is insoluble in water.

[0011] According to another embodiment, a chewable gum base component for use in a chewable gum composition is provided, comprising a plurality of component bodies. Each of the plurality of bodies includes a plurality of regions of at least one active ingredient encapsulated within an encapsulation material. The plurality of regions are disposed within the component bodies. The plurality of component blocks have a size distribution with a standard deviation less than 50% of the average longest dimension of each of the plurality of blocks.

[0012] According to another embodiment, a chewable gum base component for use in a chewable gum composition is provided, comprising a plurality of component bodies. Each of the plurality of bodies includes a plurality of regions of at least one active ingredient encapsulated within an encapsulating material. The plurality of regions are disposed of with the component bodies. The plurality of component bodies have a size distribution with a standard deviation less than 50% of the average longest dimension of each of the plurality of bodies.

[0013] According to another embodiment, a chewable gum component for a chewable gum composition is provided, the chewable gum component comprising a plurality of component bodies, each of the plurality of bodies comprising a plurality of regions of at least one active ingredient encapsulated within an encapsulating material, the plurality of regions being disposed of the component body, and the encapsulating material defining the outer surface of the component body, wherein the plurality of component bodies have a size distribution with a standard deviation less than 50% of the average longest dimension of each of the plurality of bodies; and wherein, after the component body is exposed to a dissolving liquid for two minutes, the release profile of the at least one active ingredient is substantially linear; the plurality of regions of the active ingredient are uniformly distributed throughout the component body.

[0014] In addition to one or more of the features described above, or as an alternative, in another embodiment, the plurality of component bodies have a narrow size distribution with a standard deviation of less than 10% of the average longest size of each of the plurality of component bodies.

[0015] In addition to one or more of the features described above, or as an alternative, in another embodiment, the longest dimension of each of the plurality of component bodies is less than 1000 micrometers.

[0016] According to another embodiment, a chewable gum base component for use in a chewable gum composition is provided, comprising a component body and multiple regions of at least one active ingredient encapsulated within an encapsulating material. The multiple regions are disposed within the component body. Within one minute of the component body being exposed to a dissolving liquid, the release profile of the at least one active ingredient is less than about 10% / minute.

[0017] According to another embodiment, a chewing gum component for a chewing gum composition is provided, the chewing gum component comprising a component body; and a plurality of regions of at least one active ingredient encapsulated within an encapsulating material, the plurality of regions being disposed within the component body, the encapsulating material defining the outer surface of the component body; wherein, within one minute of the component body being exposed to a dissolving liquid, the release profile of the at least one active ingredient is less than 10% / min, and wherein, after two minutes of the component body being exposed to a dissolving liquid, the release profile of the at least one active ingredient is substantially linear; the plurality of regions of the active ingredient are uniformly distributed throughout the component body. In addition to one or more of the features described above, or as an alternative, in another embodiment, within one minute of the component body being exposed to a dissolving liquid, the release profile of the at least one active ingredient is less than about 3% / min.

[0018] In addition to one or more of the features described above, or as an alternative, in another embodiment, the curve of the at least one active ingredient is continuously linear for at least 30 minutes after the component body is exposed to the dissolving liquid.

[0019] In addition to one or more of the features described above, or as an alternative, in another embodiment, the curve of the at least one active ingredient is continuously linear for at least 30 minutes after the component body is exposed to the dissolving liquid for two minutes.

[0020] According to another embodiment, a chewable gum base component for use in a chewable gum composition is provided, comprising a component body and multiple regions of at least one active ingredient encapsulated within an encapsulating material. The amount of the at least one active ingredient is configured to dissolve less than 10% within three minutes of exposure to water. This amount is determined by placing the component body in a water container at a temperature between 21°C and 23°C. The container has a rotatable element operable at a rotational speed of 350 rpm.

[0021] According to another embodiment, a chewing gum component for a chewing gum composition is provided, the chewing gum component comprising a component body; and a plurality of regions of the component body comprising at least one active ingredient encapsulated within an encapsulating material defining an outer surface of the component body; wherein the amount of the at least one active ingredient is configured to dissolve less than 10% within 3 minutes of exposure to water, and the amount is determined by placing the component body in a water container at a temperature between 21°C and 23°C, the container having a rotatable element operable at a rotational speed of 350 rpm; and wherein the release profile of the at least one active ingredient is substantially linear after the component body is exposed to the dissolving liquid for two minutes; the plurality of regions of the active ingredient are uniformly distributed throughout the component body.

[0022] In addition to one or more of the features described above, or as an alternative, in another embodiment, less than 5% of at least one active ingredient is configured to dissolve within 3 minutes of exposure to water.

[0023] According to another embodiment, a method for manufacturing an edible substance includes forming an extrusion of a first component. The first component includes multiple regions of at least one active ingredient encapsulated within an encapsulating material. The extrusion is cut into multiple blocks at intervals. The amount of at least one active ingredient in each of the multiple blocks is configured to dissolve within 3 minutes of exposure to water. This amount is less than 10%. The operation of determining the amount of at least one active ingredient in each of the multiple blocks configured to dissolve within 3 minutes of exposure to water includes adding the extrusion to a water container at a temperature between 21°C and 23°C and rotating a rotatable element positioned within the container at a rotational speed of 350 rpm.

[0024] According to another embodiment, a method for manufacturing an edible substance includes forming an extrusion of a first component comprising multiple regions of at least one active ingredient encapsulated within an encapsulating material, the encapsulating material defining the outer surface of the component body; cutting the extrusion into multiple blocks spaced apart, wherein the amount of the at least one active ingredient in each of the multiple blocks is configured to dissolve within 3 minutes of exposure to a dissolving liquid, the amount being less than 10%, and wherein the release profile of the at least one active ingredient is substantially linear after the first component has been exposed to the dissolving liquid for two minutes; wherein determining the amount of the at least one active ingredient in the multiple blocks configured to dissolve within 3 minutes of exposure to the dissolving liquid includes: adding the extrusion to a container of a dissolving liquid having a temperature between 21°C and 23°C; and rotating a rotatable element positioned within the container at 350 rpm; wherein the at least one active ingredient is uniformly distributed within the encapsulating material.

[0025] According to another embodiment, a method for manufacturing an edible substance is provided, the method comprising forming an extrusion of a first component. The extrusion is cut into a plurality of blocks at intervals. The longest dimension of each of the plurality of blocks is less than 1000 micrometers. A gum base sugar comprising the plurality of blocks as components is formed.

[0026] According to another embodiment, a method for manufacturing an edible substance is provided, the method comprising forming an extrusion of a first component comprising a plurality of regions of at least one active ingredient encapsulated within an encapsulating material defining an outer surface of the component body; cutting the extrusion at intervals into a plurality of blocks, wherein the longest dimension of the plurality of blocks is less than 1000 micrometers; and forming a gum base sugar comprising the plurality of blocks as components, wherein the release profile of the at least one active ingredient is substantially linear after the first component is exposed to a dissolving liquid for two minutes; and the at least one active ingredient is uniformly distributed in the encapsulating material.

[0027] In addition to one or more of the features described above, or as an alternative, in another embodiment, the extrudate is cut into the plurality of blocks at regular intervals.

[0028] In addition to one or more of the features described above, or as an alternative, in another embodiment, the extrudate is cut into the plurality of blocks at irregular intervals.

[0029] In addition to one or more of the features described above, or as an alternative, in other embodiments, each of the plurality of blocks is substantially uniform in size.

[0030] In addition to one or more of the features described above, or as an alternative, in another embodiment, the longest dimension is between about 200 micrometers and about 700 micrometers.

[0031] In addition to one or more of the features described above, or as an alternative, in another embodiment, the first component is a composition comprising a region of one or more active ingredients encapsulated within an encapsulating material.

[0032] In addition to one or more of the features described above, or as an alternative, in another embodiment, the active ingredient includes at least one sweetener.

[0033] In addition to one or more of the features described above, or as an alternative, in another embodiment, the encapsulating material is polyvinyl acetate.

[0034] In addition to one or more of the features described above, or as an alternative, in another embodiment, a cutting device is used to cut the extrudate, the cutting device being configured to rotate about an axis arranged substantially parallel to the direction of travel of the extrudate.

[0035] In addition to one or more of the features described above, or as an alternative, in another embodiment, the operation of cutting the extrudate includes supplying the extrudate to a cutting device that rotates about an axis arranged substantially parallel to the direction of travel of the extrudate.

[0036] In addition to one or more of the features described above, or as an alternative, in another embodiment, the operation of cutting the extrudate includes feeding the extrudate to a pelletizer having a wheel comprising a plurality of blades. The pelletizer has a wheel comprising a plurality of blades. The wheel is configured to rotate about an axis arranged substantially perpendicular to the direction of travel of the extrudate.

[0037] In addition to one or more of the features described above, or as an alternative, in another embodiment, less than 1% of the active ingredient particles are broken by the plurality of blades during the cutting operation.

[0038] In addition to one or more of the features described above, or as an alternative, in another embodiment, the particles of the active ingredient are not broken by the plurality of blades during the cutting operation.

[0039] In addition to one or more of the features described above, or as an alternative, in another embodiment, the edible substance is a chewable gum base sugar.

[0040] According to another embodiment, a method for manufacturing a composition is provided, the method comprising forming an extrusion of a first component and cutting the extrusion of the first component into a plurality of first blocks at intervals. The plurality of first blocks have a first release profile. An extrusion of a second component is formed and cut into a plurality of second blocks at intervals. The plurality of second blocks have a second release profile.

[0041] According to another embodiment, a method for manufacturing a composition is provided, the method comprising: forming an extrusion of a first component; cutting the extrusion of the first component at intervals into a plurality of first blocks, the plurality of first blocks having a first release profile, the first encapsulating material defining an outer surface of the first component; forming an extrusion of a second component; and cutting the extrusion of the second component at intervals into a plurality of second blocks, the plurality of second blocks having a second release profile, the second encapsulating material defining an outer surface of the second component, wherein the release profile and / or the second release profile are substantially linear after the first component and / or the second component is exposed to a dissolving liquid for two minutes.

[0042] In addition to one or more of the features described above, or as an alternative, in other embodiments, the first release curve and the second release curve are different.

[0043] In addition to one or more of the features described above, or as an alternative, in another embodiment, the first component comprises a first active ingredient and the second component comprises a second active ingredient. The first and second active ingredients are substantially the same.

[0044] In addition to one or more of the features described above, or as an alternative, in another embodiment, the first component comprises a first active ingredient and the second component comprises a second active ingredient. The first active ingredient and the second active ingredient are different.

[0045] In addition to one or more of the features described above, or as an alternative, in another embodiment, the composition is a chewable gum base sugar.

[0046] In addition to one or more of the features described above, or as an alternative, in other embodiments, the composition is a drug.

[0047] According to another embodiment, a method for customizing the dissolution rate of an edible substance is provided, the method comprising multiple blocks of a first component. The multiple blocks of the first component include at least a first encapsulated active ingredient having a first release profile. Multiple blocks of a second component are provided. The multiple blocks of the second component include at least a second encapsulated active ingredient having a second release profile, which differs from the first release profile. The multiple blocks of the first component and the multiple blocks of the second component are then mixed.

[0048] According to another embodiment, a method for customizing the dissolution rate of an edible substance is provided, the method comprising: providing a plurality of blocks of a first component, the plurality of blocks of the first component comprising at least a first encapsulated active ingredient having a first release profile, the first encapsulation material defining the outer surface of the first component; providing a plurality of blocks of a second component, the plurality of blocks of the second component comprising at least a second encapsulated active ingredient having a second release profile different from the first release profile, the second encapsulation material defining the outer surface of the second component; and mixing the plurality of blocks of the first component and the plurality of blocks of the second component, wherein the release profile and / or the second release profile are substantially linear after the first component and / or the second component is exposed to a dissolving liquid for two minutes.

[0049] In addition to one or more of the features described above, or as an alternative, in another embodiment, the plurality of blocks of the first component and the plurality of blocks of the second component are substantially similar in size.

[0050] In addition to one or more of the features described above, or as an alternative, in another embodiment, the plurality of blocks of the first component and the plurality of blocks of the second component have different sizes.

[0051] In addition to one or more of the features described above, or as an alternative, in another embodiment, the active ingredient in the first encapsulation is the same as the active ingredient in the second encapsulation.

[0052] In addition to one or more of the features described above, or as an alternative, in another embodiment, the active ingredient in the first encapsulation is different from the active ingredient in the second encapsulation.

[0053] In addition to one or more of the features described above, or as an alternative, in another embodiment, the composition is a chewable gum base sugar.

[0054] In addition to one or more of the features described above, or as an alternative, in another embodiment, said composition is a drug.

[0055] In addition to one or more of the features described above, or as an alternative, in another embodiment, the encapsulating materials of the plurality of blocks of the first component and the encapsulating materials of the plurality of blocks of the second component have different molecular weights.

[0056] According to another embodiment, a method for manufacturing an edible product includes feeding an active ingredient and an encapsulating ingredient into an extruder. The active ingredient and the encapsulating ingredient are mixed within the extruder to form a composition. The composition is then passed through a melt screen filter having openings of less than 500 micrometers and extruded from the extruder.

[0057] In addition to one or more of the features described above, or as an alternative, in another embodiment, extruding the composition from an extruder comprises extruding the composition through an extruder die having an outlet orifice between 200 micrometers and 1000 micrometers.

[0058] In addition to one or more of the features described above, or as an alternative, in another embodiment, extruding the composition from an extruder comprises extruding the composition through an extruder die having an outlet orifice between 200 micrometers and 800 micrometers.

[0059] According to another embodiment, the system for forming the encapsulated active ingredient includes a continuous extruder configured to receive and mix the active ingredient and the encapsulating ingredient to form an encapsulating composition. An extruder die is arranged in the downstream section of the extruder, and a melt screen filter having an opening of less than 500 micrometers is arranged upstream of the extruder die.

[0060] According to another embodiment, the method of forming the composition includes forming an extrusion of the composition, the composition comprising a water-soluble component, and cooling the extrusion with water.

[0061] According to another embodiment, a method of forming a composition includes: forming an extrusion of a first component, the first component comprising a plurality of regions of at least one active ingredient encapsulated within an encapsulating material defining an outer surface of the first component; and cooling the extrusion with water, wherein the release profile of the at least one active ingredient is substantially linear after the first component is exposed to a dissolving liquid for two minutes.

[0062] In addition to one or more of the features described above, or as an alternative, in another embodiment, the extrudate includes a water-soluble active ingredient encapsulated within a water-insoluble matrix. Attached Figure Description

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

[0064] Figure 1 is a perspective view of a block of a first component for use in an edible product according to one embodiment;

[0065] Figure 2 is a schematic diagram of an extruder for forming an extrudate of a first component according to one embodiment;

[0066] Figure 3A is a schematic diagram of a system for forming the first component of Figure 1 according to one embodiment;

[0067] Figure 3B is a schematic diagram of a system for forming the first component of Figure 1 according to one embodiment;

[0068] Figure 4 is a schematic diagram of a portion of a gum base sugar manufacturing system according to one embodiment;

[0069] Figure 5 is a cross-sectional view of a final gum base sugar product comprising multiple blocks of a first component according to one embodiment;

[0070] Figure 6 is a dissolution curve of encapsulated aspartame according to one embodiment; and

[0071] Figure 7 is another dissolution curve of encapsulated aspartame according to one embodiment.

[0072] The specific embodiments, advantages, and features of the present invention are illustrated by way of example with reference to the accompanying drawings. Detailed Implementation

[0073] The following disclosure will detail specific embodiments of the invention that provide blocks comprising encapsulation compositions, particularly those used in chewable gum bases and other such confectionery.

[0074] The edibles discussed 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, as well as cakes, nuts, and cereals. For ease of description, in the remainder of this specification, the edibles will be referred to as chewing gum. Some components of chewing gum may have a heterogeneous texture and / or a multilayered composition.

[0075] 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.

[0076] 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.

[0077] The term "finished chewable gum" or "finished gum" as used in this article refers to chewable gum that is generally 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, chewable gum is typically a finished product. 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 and thus meet consumer needs.

[0078] 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.

[0079] 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 includes 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 use in 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.

[0080] The term "semi-finished chewable gum base" as used in this article refers to a chewable gum base comprising: gum base components, and a combination of gum base components that need to be combined with other gum base components and subsequent non-gum base components to form a finished gum base. The semi-finished gum base includes at least one elastic component and requires the addition of at least one viscous and / or softening component to form the finished gum base.

[0081] Insoluble gum bases in the form of finished gum bases typically include 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.

[0082] The water-soluble portion of the finished gum base will be referred to in this disclosure as subsequent ingredients (because they are added after the manufacture of the finished gum base) and may include subsequent gum base ingredients classified into the following categories: softeners, filler sweeteners, high-intensity sweeteners, flavorings, acids, other fillers, functional ingredients, and combinations thereof. Softeners are added to the gum base to optimize its chewiness and mouthfeel. Softeners, also known as plasticizers, emulsifiers, or plasticizers, typically comprise 0.5% to 15% by weight of the finished gum base. Filler sweeteners comprise 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 comprise 0.001% to 5% by weight of the finished gum base sugar, preferably 0.01% to 3% by weight. Typically, high-intensity sweeteners are at least 20 times sweeter than sucrose.

[0083] 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. When acids are included, they typically comprise from about 0.001% to 5% by weight of the finished gum base. Optional ingredients such as colorings, functional ingredients, and additional flavorings may also be included in the gum base.

[0084] Referring now to the accompanying drawings, in the process of forming gum base or other edible products, multiple blocks 20 of a first component can be mixed with one or more other ingredients in a gum base manufacturing system to form a finished gum base product. Figure 1 shows an example of one of the multiple blocks 20 of the first component in more detail. The multiple blocks 20 typically have a diameter of less than 1000 micrometers, such as between 200 and 700 micrometers. In one embodiment, each of the multiple blocks 20 is substantially the same size. Thus, blocks 20 typically used in a batch of gum base (such as ten-pound blocks 20) have, for example, a narrow size distribution with a standard deviation of less than 50% of their average longest dimension, and more specifically, less than 10% of their average longest dimension. The blocks 20 of the first component shown have a generally circular cross-section and can be spherical or cylindrical; however, blocks 20 with other shapes are also considered herein. For example, blocks 20 can have any shape such that the ratio of the largest to the smallest dimension is less than 3:1, or, as another option, less than 2:1.

[0085] In a non-limiting embodiment illustrated, block 20 of the first component comprises a composition containing an "active ingredient" and an "encapsulating ingredient," the active ingredient being surrounded or encapsulated by the 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 typically used in edibles, such as, but not limited to, high-intensity sweeteners (including natural and synthetic sweeteners), food acidifiers, and blending ingredients (including texture modifiers, colorants, salts, oral care ingredients, and other ingredients), is within the scope of this disclosure. Any encapsulating ingredient typically used in edibles, such as, but not limited to, polymers or resins, is also contemplated for forming block 20 of the first component. In some embodiments, the encapsulating ingredient is insoluble in water. In other embodiments, the encapsulating ingredient is soluble in water.

[0086] 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, heliotropein, glycyrrhizin, 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), free acid forms of saccharin, and monatin; (b) dipeptide-based sweeteners such as those derived from L-aspartic acid, such as L-aspartyl-L-phenylalanine methyl ester (aspartame) and L-α-aspartic acid. Aspartoyl-N-(2,2,4,4-tetramethyl-3-thiotrimethylene)-D-alanine amide hydrate (Alitame), methyl esters of L-aspartoyl-L-phenylglycerol and L-aspartoyl-L-2,5-dihydrophenyl-glycine, L-aspartoyl-2,5-dihydro-L-phenylalanine; L-aspartoyl-L-(1-cyclohexene)-alanine, neotame and adventitia; (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 under the product name sucralose); chlorinated Examples of deoxysucrose and deoxygalactosucrose 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.

[0087] Encapsulating the active ingredient protects it from dissolution upon contact with water or saliva, thus extending the relative lifespan of the active ingredient within 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. As described above, the protection of the active ingredient is achieved by mixing one or more active ingredients with one or more encapsulating ingredients. In practice, a composition encapsulating at least one active ingredient as defined herein includes at least one active ingredient such as those discussed above, which is mixed for production or extrusion with one or more encapsulating ingredients (such as those discussed below).

[0088] Examples of encapsulating materials / components include polymers or resins, wherein the properties of the polymer or resin component control the release profile and the protection of the active ingredient to be encapsulated. In some embodiments, the encapsulating material may be polyvinyl acetate, polyethylene, cross-linked polyvinylpyrrolidone, polymethyl methacrylate, polylactide, polyhydroxyalkanoates, ethyl cellulose, polyvinyl acetate phthalate, polyethylene glycol, methacrylate co-methyl methacrylate, polyvinyl acetate-ethynyl alcohol copolymer, or any other component suitable for polymer-based encapsulation.

[0089] As described above, it may be desirable to encapsulate certain ingredients or components in a pharmaceutical or edible (e.g., chewable gum). Such compositions described herein include at least one active ingredient or component to be protected and released according to a specific release profile, and at least one additional encapsulating component, such as, but not limited to, polymers or resins.

[0090] The goal is to achieve uniform release of the active ingredient. Since the active ingredient is typically water-soluble, the material at the surface will dissolve rapidly upon exposure to saliva, while the material inside will dissolve more slowly. Therefore, the component with lower activity at the surface will achieve a more uniform release. Furthermore, a uniform size distribution of the component will result in even more uniform release.

[0091] Referring again to Figure 1, an exemplary block 20 of the first component includes multiple regions having an active ingredient 22 (such as one or more liquid or powdered sweeteners) disposed within an encapsulating material 24 and positioned between the center and outer surface 26 of the block 20. The encapsulating material may be polyvinyl acetate, for example, having a molecular weight between 8,000 and 200,000, and more specifically, between 12,000 and 100,000. In one embodiment, the multiple regions of the active ingredient 22 are water-soluble, but the encapsulating material 24 is insoluble in water. Within each of the plurality of blocks 20, the regions of the active ingredient 22 are generally uniformly distributed throughout the encapsulating material 24. By forming the blocks 20 of the component when the material is soft and malleable, the regions of the active ingredient 22 within each block 20 generally remain integral. Therefore, the region of active ingredient 22 is completely encapsulated within encapsulating material 24 such that a limited portion of the region of active ingredient 22 is exposed at or substantially adjacent to the outer surface 26 of each block 20, for example, just below the outer surface of each block. In one embodiment, less than 20%, less than 15%, less than 10%, and more specifically less than 1% of the average active concentration within each block 20 is exposed at or directly adjacent to the outer surface 26 of each block 20. Furthermore, as defined by encapsulating material 24, any portion of the active ingredient 22 extending beyond the outer surface 26 of each block 20 has a distance less than 20% of the longest dimension of the block 20. To determine the amount of active substance exposed at or directly adjacent to the outer surface 26 of each block, a regression line corresponding to the latter half of the dissolution-release curve for the block 20 was plotted. The percentage of active substance dissolved at points on the curve that deviate from the regression line is the amount of active substance in contact with the outer surface of the component bulk.

[0092] Typically, encapsulation of the active ingredient 22 (e.g., flavoring agent, sweetener, etc.) delays the release of a major amount of the active ingredient 22 during the consumption of edible substances (such as gum sugar structures containing the encapsulated active ingredient). Initial release usually occurs in response to a release-triggered event, such as particle breakage of the encapsulated active ingredient due to chewing or crushing, or dissolution of the encapsulated ingredient in the digestive tract by saliva or solvents. However, in pharmaceutical applications, chemical catalysts, such as gastric acid, can be formulated to break down the encapsulation material 24 and expose the active ingredient 22 contained therein.

[0093] Because most of the active ingredient 22 is not typically exposed to the outer surface 26 of block 20, the release or dissolution of the active substance is significantly slower than that of conventionally encapsulated active ingredients. For example, referring to Figures 6 and 7, block 20 as described herein, containing a first active ingredient (such as aspartame), has a solubility of less than or equal to about 10% after 36 minutes. However, conventional blocks with the same encapsulated first active ingredient have a solubility of about 30% or 50% after the same time period. Furthermore, the release profile of block 20 as described herein can be linear or substantially linear, while conventional blocks with the same encapsulated first active ingredient have an initial, gradual release profile.

[0094] For example, the typical chewing life of chewable gum is about 30 minutes. During this chewing life, it is important that the active ingredient is present so that the consumer can experience the effects of the active substance throughout the chewing process. If the release rate of the active ingredient is too high, the active ingredient in the chewable gum will be consumed in less than 30 minutes. To ensure the active ingredient lasts for 30 minutes, the release rate should be less than about 3% / minute. If data related to the release rate are measured at 20-second intervals, the difference between consecutive data points should be less than about 1%. An exemplary graph shown in Figure 6 illustrates the change in the percentage of active ingredient release over time. As shown, the slope of the curve for the encapsulated active ingredient as described herein, titled "Technology S" (Technology of the Invention), is less than 10% / minute, and more specifically less than 5% / minute and less than 3% / minute, reaching this rate within less than one minute of exposure. Regarding the curve titled "2G" and indicating a conventionally encapsulated active ingredient, the slope of the curve does not reach a rate of less than 3% / minute until approximately four minutes later. Similarly, the curve titled "3G," associated with another conventionally encapsulated active ingredient, reached a dissolution rate of less than 3% / min after approximately 2 minutes. Furthermore, conventional techniques have an initial release rate of approximately 7% / 20 seconds, while the method described herein has an initial rate of less than 1% / 20 seconds.

[0095] The dissolution rate of the encapsulated active ingredient, as described herein, was measured using a Distek dissolution apparatus model 2100C. Prior to performing the test, the correction for the UV absorption of the water and the analytical wavelength associated with the active ingredient were determined. To measure the correction for the UV absorption of the water, approximately 200 mL of deionized water was filled into one of the containers, into which one or more UV probes were inserted. The UV probes were configured to measure the spectrum that would be used for the UV absorption correction of the water. The analytical wavelength refers to the wavelength at which the active ingredient has the maximum absorption. In embodiments where the active ingredient is aspartame, the analytical wavelength is 200 nm; in embodiments where the active ingredient is citric acid, the analytical wavelength is 210 nm; and in embodiments where the active ingredient is acesulfame potassium, the analytical wavelength is 227 nm.

[0096] To measure the dissolution rate, the machine's paddle rotation speed was set to approximately 350 rpm, and the glass chamber was filled with approximately 500 mL of deionized water. Once the water in the chamber reached a temperature between approximately 21°C and 23°C, the encapsulated active ingredient was weighed and subsequently added to the water. The concentration of the encapsulated active ingredient added to the water should be similar to the amount added to 200 mL of deionized water, exhibiting a linear response to concentration levels at the corresponding analytical wavelength. For example, when the active ingredient is aspartame, the concentration level at the selected wavelength is approximately 0.275 g / L; when the active ingredient is citric acid, the concentration level at the selected wavelength is approximately 7.5 g / L; and when the active ingredient is acesulfame K, the concentration level at the selected wavelength is approximately 0.175 g / L. Once the encapsulated active ingredient was added to the water, dissolution rate data, such as approximately every 20 seconds, should be collected. Data collection continued until the first 35 minutes or until the total percentage of active ingredient dissolved exceeded 50%.

[0097] In one embodiment, the first component is formed by mixing the active ingredient 22 and the encapsulating ingredient within an extruder 30 to form an extrudate 32. Figure 2 shows a schematic diagram of an example extruder in more detail. In the illustrated non-limiting embodiment, the extruder 30 is a twin-screw extruder comprising one or more substantially hollow barrels 34 in which a first screw and a second screw (not shown) are mounted. However, other types of extruders 30, such as planetary screw extruders and single-screw extruders, are also within the scope of this invention.

[0098] An extruder die 36 is fluidly coupled to the extrusion end 38 of one or more barrels 34 such that the composition extruded therefrom, including the encapsulated active ingredient, has a shape complementary to the die 36. The die preferably has multiple small-diameter outlet orifices, for example, between 200 and 1000 micrometers, and these orifices are easily clogged by large particles. A melt pump or other gear pump 40 may be positioned between the extrusion end 38 and the extrusion die 36. The melt pump 40 is configured to assist in the extrusion of the encapsulated composition by receiving unformed composition from the extrusion end 38 and supplying it to the extrusion die 36 at the desired pressure.

[0099] In one embodiment, a melt screen or filter 42 with very fine apertures is positioned between a melt pump 40 and an extruder die 36. This filter 42 will typically require high pressure to force the polymer through the tiny openings formed therein. As the high pressure generated by the melt pump 40 forces the composition through the small openings in the filter 42, particles or aggregates are broken up and dispersed. This significantly reduces die clogging and results in an improved polymer matrix or encapsulated composition. In one embodiment, the melt screen filter 42 has an aperture size less than or equal to about 0.500 mm, such as about 0.200 micrometers or about 0.125 mm, and the pressure of the pump 40 is between about 4000 psi and about 5000 psi. However, other configurations of the filter 42 and pump 40 are also considered herein.

[0100] Referring now to Figure 3A, as the extrudate 32 exits from the die 36, the extrudate 32 of the first component can form a plurality of blocks 20. A cutting device 44 (such as a rotating cutter assembly on a hub) can be positioned approximately adjacent to the die exit so that an extrudate 32 of the desired length is output between each cycle of the cutting device. After and / or during the formation of the plurality of blocks 20, the composition can be cooled, for example, with high-speed air or water.

[0101] In another embodiment, as shown in FIG3B, the first component is formed into a plurality of blocks 20 by continuously supplying extrudate 32 from extruder 30 to a downstream cutting mechanism 44 (such as via conveyor 45). The cutting mechanism 44 may be configured to continuously cut and / or shape the extrudate 32 supplied thereon at regular intervals to form a plurality of blocks 20 of substantially the same size and shape. However, embodiments in which the extrudate 32 is supplied at irregular intervals and / or the plurality of blocks 20 are substantially different in size and shape are also contemplated herein. In the illustrated non-limiting embodiment, the cutting mechanism 44 includes a rotary cutter having a plurality of blades 46 extending outwardly therefrom. The rotary cutter is configured to rotate about an axis R oriented substantially perpendicular to the direction of travel of the extrudate 30. As the extrudate moves toward the cutting mechanism 44, the blades continuously cut the ends of the extrudate 32 to form a plurality of individual blocks 20. A narrow size distribution of the plurality of blocks 20 can be achieved by keeping the output rate from the extruder 30 and the rotational speed of the rotary cutter constant. Although a specific cutting mechanism 44 for forming the blocks 20 of the first component has been shown and described herein, other methods are also within the scope of this disclosure. In one embodiment, the extrudate 32 is cut into a plurality of blocks 20 when the extrudate 32 is above the glass transition temperature.

[0102] Furthermore, the extruder 30 can also be configured to output multiple ropes, including first ropes configured to form multiple first blocks and second ropes configured to form multiple second blocks. Multiple ropes can be supplied simultaneously to the same cutting mechanism 44, or alternatively, to different cutting mechanisms. Regardless of whether the first and second ropes of the extrudate 32 are supplied to the same cutting mechanism 44 or separate cutting mechanisms 44, the size and / or shape of the first blocks need not be the same as or similar to the size and / or shape of the second blocks.

[0103] The release profile of block 20 varies in part based on the dimensions of the plurality of blocks 20. Therefore, the release profile of block 20 can be adjusted, and thus the dimensions of block 20 can be adjusted, by changing one or more parameters used during the formation of block 20. For example, in an embodiment where block 20 is formed by cutting and extruding an encapsulating composition, the release profile can be changed by adjusting one or more of the following: the size of the die exit orifice, the rate at which the composition is extruded through extruder 30, and the rotational speed of rotary cutter 34. In one embodiment, each of the plurality of blocks 20 has a uniform release rate during an initial time period (e.g., between 5 minutes and 20 minutes).

[0104] As previously described, block 20 may be provided as part of a downstream gummosis manufacturing system 50, such as mixer 52 as shown in Figure 4, wherein block 20 is added as one of a variety of ingredients for forming the gummosis product. In such embodiments, the individual block 20 is added as a whole and remains substantially intact in the final gummosis product so that block 20 is visible when observing a cross-section of the final gummosis product 54, as shown in Figure 5.

[0105] When one or more blocks 20 are used as an ingredient in a final gum product (such as gum product 44), the release profile of the final gum product will depend on the release profiles of the multiple blocks 20 containing the encapsulated active ingredient. In one embodiment, the blocks 20 incorporated into the final gum product 44 have substantially uniform release profiles.

[0106] Alternatively, a mixture of blocks 20 with different release profiles may be included in the final gummetic product to customize the release profile of the entire gummetic block when chewed. For example, the mixture of blocks 20 may include blocks 20 with different sizes, distributions, and at least one of the one or more active ingredients encapsulated therein. By including blocks 20 with different release profiles within the gummetic product, the encapsulated active ingredients within the gummetic product 44 will be released in stages. Therefore, the total time for which one or more encapsulated active ingredients are detectable by the user when chewing the final gummetic product 44 can be extended. Due to this improved controllability of the release profile of the blocks 20, the amount of encapsulated active ingredients included in the final gummetic product 34 can be reduced. Furthermore, the reduction in the amount of encapsulated active ingredient 22 within the final gummetic product 44 may also result in a reduction in the amount of other ingredients added to the final gummetic product 44.

[0107] The first component block 20 of the edible composition described herein has a slower and more uniform dissolution rate. Furthermore, due to the narrower size distribution of the multiple blocks 20, the release profile of the edible material comprising the multiple blocks 20 can be controlled more precisely. By producing blocks 20 with the desired size and shape, additional grinding or milling is no longer required.

[0108] 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.

[0109] 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 simplified way of individually referring to each individual value falling within that range, and each individual value is incorporated into this specification as if it were individually described 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.

[0110] 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 chewing gum component for use in a chewing gum composition, said chewing gum component comprising: A plurality of component bodies, each of the plurality of component bodies including a plurality of regions of at least one active ingredient encapsulated within an encapsulating material, the plurality of regions being disposed within the component body, and the encapsulating material defining an outer surface of the component body, wherein the plurality of component bodies have a size distribution with a standard deviation less than 50% of the average longest dimension of each of the plurality of component bodies; Less than 20% of the average active concentration of each of the plurality of component bodies is in contact with the outer surface of the component body; and the release curve of the at least one active ingredient is substantially linear after the component body is exposed to the dissolving liquid for two minutes; the plurality of regions of the active ingredient are uniformly distributed throughout the component body.

2. The chewable gum base component according to claim 1, wherein the plurality of component bodies have a narrow size distribution with a standard deviation of less than 10% of the average longest size of each of the plurality of component bodies.

3. A chewing gum component for a chewing gum composition, the chewing gum component comprising a component body; and a plurality of regions of at least one active ingredient encapsulated within an encapsulating material, the plurality of regions being disposed within the component body, the encapsulating material defining an outer surface of the component body; The average active concentration of the component body is less than 20% in contact with the outer surface of the component body; Wherein, within one minute after the component body is exposed to the dissolving liquid, the release curve of the at least one active ingredient is less than 10% / minute, and wherein, after two minutes after the component body is exposed to the dissolving liquid, the release curve of the at least one active ingredient is substantially linear; the plurality of regions of the active ingredient are uniformly distributed throughout the component body.

4. The chewable gum base component according to claim 3, wherein the release curve of the at least one active ingredient is less than 3% / minute within one minute after the component bulk is exposed to the dissolving liquid.

5. The chewable gum base component according to claim 3, wherein the release curve of the at least one active ingredient is continuously linear for at least 30 minutes after the component bulk is exposed to the dissolving liquid for two minutes.

6. A chewing gum component for a chewing gum composition, the chewing gum component comprising a component body; and a plurality of regions of the component body comprising at least one active ingredient encapsulated within an encapsulating material, the encapsulating material defining an outer surface of the component body; The average active concentration of the component body is less than 20% in contact with the outer surface of the component body; The amount of the at least one active ingredient is configured to dissolve less than 10% within 3 minutes of exposure to water, and the amount is determined by placing the component body in a water container at a temperature between 21°C and 23°C, the container having a rotatable element operable at a rotational speed of 350 rpm; and the release curve of the at least one active ingredient is substantially linear after the component body is exposed to the dissolving liquid for two minutes; the plurality of regions of the active ingredient are uniformly distributed throughout the component body.

7. The chewable gum base component according to claim 6, wherein less than 5% of the at least one active ingredient is configured to dissolve within 3 minutes of exposure to water.

8. A method for manufacturing an edible food, the method comprising: An extrusion of a first component is formed, the first component comprising multiple regions of at least one active ingredient encapsulated within an encapsulating material, and the encapsulating material defines the outer surface of the extrusion of the first component; The extrudate is cut into multiple blocks at intervals, wherein the amount of the at least one active ingredient in each of the multiple blocks is configured to dissolve within 3 minutes of exposure to the dissolving liquid, the amount being less than 10%, and wherein less than 20% of the average active concentration in each of the multiple blocks is in contact with the outer surface of the block. Wherein, after the first component is exposed to the dissolving liquid for two minutes, the release curve of the at least one active ingredient is approximately linear; The operation of determining the amount of the at least one active ingredient in the plurality of blocks configured to dissolve within 3 minutes of exposure to the dissolving liquid includes: adding the extrudate to a container of dissolving liquid having a temperature between 21°C and 23°C; And a rotatable element positioned within the container at 350 rpm; the at least one active ingredient is uniformly distributed in the encapsulation material.

9. A method for manufacturing an edible food, the method comprising: An extrusion of a first component is formed, the first component comprising multiple regions of at least one active ingredient encapsulated within an encapsulating material, the encapsulating material defining the outer surface of the extrusion of the first component; The extrudate is cut into multiple blocks at intervals, wherein the longest dimension of the multiple blocks is less than 1000 micrometers; and a gum base sugar is formed comprising the multiple blocks as components, wherein less than 20% of the average active concentration of each of the multiple blocks is in contact with the outer surface of the block; Wherein, after the first component is exposed to the dissolving liquid for two minutes, the release curve of the at least one active ingredient is approximately linear; the at least one active ingredient is uniformly distributed in the encapsulating material.

10. The method of claim 9, wherein each of the plurality of blocks is substantially uniform in size.

11. The method of claim 9, wherein the longest dimension is between 200 micrometers and 700 micrometers.

12. The method of claim 9, wherein cutting the extrudate comprises supplying the extrudate to a cutting device rotatable about an axis arranged substantially parallel to the direction of travel of the extrudate.

13. The method of claim 12, wherein during the cutting operation, less than 1% of the particles of the active ingredient are broken by the cutting device.

14. The method of claim 9, wherein the edible substance is a chewable gum base.

15. A method of manufacturing a composition, the method comprising: The extrudate that forms the first component; The extrudate of the first component is cut at intervals into a plurality of first blocks, the plurality of first blocks having a first release curve, and a first encapsulating material defining the outer surface of the first component; The extrudate forms the second component; And the extrudate of the second component is cut at intervals into a plurality of second blocks, the plurality of second blocks having a second release profile, a second encapsulating material defining the outer surface of the second component, wherein less than 20% of the average active concentration of each of the plurality of first blocks or each of the plurality of second blocks is in contact with the outer surface of the first block or the outer surface of the second block; Wherein, after the first component and / or the second component are exposed to the dissolving liquid for two minutes, the release curve and / or the second release curve are substantially linear.

16. The method of claim 15, wherein the first release curve and the second release curve are different.

17. A method for customizing the dissolution rate of an edible substance, the method comprising: Provide a plurality of blocks of a first component, the plurality of blocks of the first component comprising at least a first encapsulated active ingredient having a first release profile, the first encapsulation material defining the outer surface of the first component; Provide a plurality of blocks of a second component, the plurality of blocks of the second component comprising at least a second encapsulated active ingredient having a second release profile different from a first release profile, the second encapsulation material defining the outer surface of the second component; And a plurality of blocks of the first component and a plurality of blocks of the second component, wherein less than 20% of the average active concentration of each of the plurality of blocks of the first component or each of the plurality of blocks of the second component is in contact with the outer surface of the block of the first component or the outer surface of the block of the second component; Wherein, after the first component and / or the second component are exposed to the dissolving liquid for two minutes, the release curve and / or the second release curve are substantially linear.

18. A method for manufacturing an edible food, the method comprising: The active ingredients are supplied to the extruder; The encapsulation component is supplied to the extruder; The active ingredient and the encapsulating ingredient are mixed in the extruder to form a composition; The composition is passed through a melt sieve filter having an opening of less than 500 micrometers; The composition is extruded from the extruder; The composition from the extruder is cut into multiple blocks at intervals, wherein less than 20% of the average active concentration in each of the multiple blocks is in contact with the outer surface of the block.

19. A system for forming an encapsulated active ingredient, the system comprising: A continuous extruder configured to receive and mix active ingredients and encapsulating ingredients to form an encapsulating composition; An extruder die, the extruder die being arranged in the downstream section of the extruder; A melt screen filter having an opening of less than 500 micrometers and being arranged upstream of the extruder die; And a cutting device that cuts the encapsulation composition from the extruder die into multiple blocks at intervals, wherein less than 20% of the average active concentration in each of the multiple blocks is in contact with the outer surface of the block.

20. A method of forming a composition, the method comprising: An extrusion is formed of a first component, the first component comprising multiple regions of at least one active ingredient encapsulated within an encapsulating material, the encapsulating material defining the outer surface of the first component; The extrudate of the first component is cut into multiple blocks at intervals; and the extrudate is cooled with water, wherein less than 20% of the average active concentration in each of the multiple blocks is in contact with the outer surface of the block; and wherein the release curve of the at least one active ingredient is substantially linear after the first component is exposed to the dissolving liquid for two minutes.

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