Method of making multi-texture confectionery block

Abstract

Multi-texture confectionery pieces, such as soft granules used in cereals, are prepared by combining the granules with an unaerated soft confection slurry to form a pumpable dough / granule slurry. The pumpable confectionery / pellet slurry is then combined with the cooled aerated soft cotton slurry. By first forming a confectionery / particle slurry in unaerated form and then combining with an aerated soft cotton slurry, the resulting combined slurry remains aerated while the incorporated particles remain intact. The resulting foam product is then extruded into a desired shape, cut into confectionery pieces and dried, effective to form desired multi-texture confectionery pieces.

Description

Technical Field

[0001] The present invention generally relates to the preparation of aerated confectionery products and, more particularly, to incorporating particles in forming a multi-textured confectionery mass. Background Art

[0002] Aerated confectionery is a popular food product. Some aerated confectionery contains a fat component while other aerated confectionery is substantially free of a fat component. An exemplary fat-free aerated confectionery is the common marshmallow. Both larger and smaller sized versions of such marshmallow products are common. It is well known that marshmallows are soft and pliable when fresh but become stale and harden as they lose moisture. In fact, pre-dried aerated confectionery is also well known. These products (especially smaller or bite-sized products) are typically added to certain popular ready-to-eat (“RTE”) breakfast cereals (e.g., Lucky brand ready-to-eat cereal). Due to their small size (i.e., typically having 3 to 6 pieces per gram), these dried aerated confectionery marshmallow products are sometimes colloquially referred to as “marshmallow bits” or “marbits”. The marbits are pre-dried to the low water activity (0.1 - 0.4) of the ready-to-eat cereal prior to mixing with other cereal pieces to reduce unnecessary migration of moisture from the marbits to the other cereal pieces. These dried marshmallow pieces exhibit a desirable crispy, brittle eating quality where the dried confectionery is hard and crunchy rather than soft or chewy.

[0003] Although there are many types of marshmallow products on the market, their preparation methods generally fall into two main categories: extruded marshmallows and deposited or starch - shelled marshmallows. In both types, syrup, structuring agent, and whipping agent are the main components. Generally, gelatin is used both as a whipping agent to form an aerated foam and as a structuring agent to solidify the foam. Typically, the syrup is heated to dissolve solids, boiled to reduce moisture, cooled, and then combined with gelatin to form a slurry. The slurry is then aerated to form a foam. Optionally, colorants and flavorants are added to the foam immediately after aeration, although in some embodiments, these adjuvants are added to the syrup before aeration. A particular marshmallow product can be formed into its final shape by an extrusion process. That is, after aeration, the foam is extruded through a die to form a rope, where the die imparts the desired outer peripheral shape to the rope. The rope is typically allowed to stand briefly to solidify and can be dusted or coated with starch before being cut into the desired size. For dry marshmallows, the method can additionally include one or more drying steps. See, for example, U.S. Patent No. 3,345,186, titled "Method of Making A Dehydrated Confection," issued October 3, 1967, and U.S. Patent No. 4,785,551, titled "Method of Drying Confection Pieces," issued November 2, 1988, both of which are incorporated herein by reference.

[0004] Consumer food products require constant innovation to maintain popularity. For those consumer food products targeted at children, innovation and change are even more important. Thus, while crunchy or brittle dry marshmallow confectionery pieces suitable for addition to ready - to - eat cereals have been popular, it is still desirable to provide dry marshmallow confectionery pieces with a variety of textures to enhance the overall eating experience. Summary of the Invention

[0005] The present invention relates to the production of multi - texture confectionery pieces. More specifically, the present invention relates to a particular method for incorporating particles in a confectionery piece (such as a soft pellet). According to the present invention, particles (e.g., alginate - based particles) are combined with an un - aerated marshmallow slurry to form a pumpable confectionery / particle slurry or "dough". The pumpable confectionery / particle slurry is then combined with a cooled, aerated marshmallow slurry. By first forming the confectionery / particle slurry and then combining it with the aerated marshmallow slurry after the marshmallow slurry has been aerated and cooled, the resulting foam product surprisingly remains aerated while the incorporated particles remain intact. The resulting foam product is then extruded into the desired shape, cut into confectionery pieces, and dried, thus effectively forming the desired multi - texture confectionery pieces.

[0006] Other objects, features, and advantages of the present invention will become more apparent from the following detailed description of the preferred embodiments of the present invention in conjunction with the accompanying drawings, in which like reference numerals refer to like components in several views. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Figure 1 is a schematic view of a manufacturing method for continuously producing multi-textured candy pieces according to the present invention. DETAILED DESCRIPTION

[0008] The detailed embodiments of the present invention are disclosed herein. However, it should be understood that the disclosed embodiments are merely examples of the present invention, and the present invention can be embodied in various and alternative forms. The accompanying drawings are only schematically shown and not drawn to scale, and some features may be simplified or generalized to only show specific stages or components. Therefore, the specific structural and functional details disclosed herein should not be construed as restrictive, but only as a representative basis for teaching those skilled in the art to adopt the present invention. Additionally, any specific numerical values listed herein include a margin of error of + / - 5%. Thus, a mass of 10.0 grams includes masses between 9.50 grams and 10.5 grams. Similarly, a range of 8.00 grams - 12.0 grams includes masses between 7.60 grams and 12.6 grams. The term "about" increases the margin of error to 10%. For numerical values expressed as percentages, the margin of error refers to the base value. In other words, "about 20%" refers to 18% - 22% rather than 10% - 30%.

[0009] Generally, the production of multi-textured confectionery pieces according to the present invention involves: 1) preparing an unpumped confectionery / particle slurry;

[0010] 2) introducing the pumpable confectionery / particle slurry into an incoming, aerated and cooled marshmallow slurry to form an aerated combined slurry; 3) producing an aerated extrudate from the combined slurry; 4) cutting the extrudate into confectionery pieces; and 5) drying the confectionery pieces to form multi-textured confectionery pieces. The multi-textured confectionery pieces can then be incorporated into food products, such as ready-to-eat cereals, cereal bars, or other snack products. Preferably, the multi-textured confectionery pieces constitute soft granules sized to have about 3 - 6 pieces per gram. Although the present invention does not focus on forming the marshmallow slurry that is aerated and cooled prior to blending with the unpumped confectionery / particle slurry, certain details of these steps are provided below for completeness.

[0011] Marshmallows can be prepared by a variety of different methods and from a variety of different ingredients, depending on the desired properties. Generally, marshmallows contain a sugar component, a foaming or whipping component, and a structuring component. Typically, based on dry weight, marshmallows contain 50%-95% of the sugar component (preferably 70%-90%), 0.05%-15% of the foaming or whipping component (preferably 1%-4%, and most preferably about 2.5%), and 0.5% to 20% of the structuring component (preferably 1%-6%, and most preferably about 2.5%).

[0012] The sugar component can include disaccharides such as sucrose; monosaccharides such as glucose, dextrose, and fructose; oligosaccharides; or mixtures thereof. As used herein, "oligosaccharide" is a molecule containing 2 to 20 sugar units linked by glycosidic bonds. Soluble fiber inulin and corn syrup are two examples rich in oligosaccharide components.

[0013] The foaming or whipping component can include protein-based whipping agents such as soy protein, egg white, sodium caseinate, whey protein, gelatin, or mixtures thereof. Suitable non-protein whipping agents include low molecular weight surfactants (e.g., sodium dodecyl sulfate ("SLS"), lecithin), polymers (e.g., methylcellulose ("MC"), hydroxypropyl methylcellulose ("HPMC"), propylene glycol alginate ("PGA")), or mixtures thereof.

[0014] The structuring component can include gelatin; hydrocolloids such as pectin; modified starches; gums such as guar gum and carrageenan; or mixtures thereof. Thus, gelatin can be used as both the foaming component and the structuring component (and is typically the only foaming agent and structuring agent).

[0015] If desired, marshmallows can additionally include one or more ingredients to improve their appearance, flavor, nutritional value, and / or other sensory attributes.

[0016] Typically, the sugar component is heated to dissolve the solids, boiled to reduce the moisture, cooled, and then combined with the foaming component and the structuring component to form a slurry. The slurry (which is introduced at 100 in the schematic diagram) is then aerated at 110 to form a foam. Optionally, colorants and flavorings are added to the foam immediately after aeration, although in some known arrangements, these adjuvants are added before aeration. The foam is then directed through a pump 115 (e.g., at about 120 psi - 140 psi) to a foam cooling unit 120, where the cooled confectionery foam is present at 140. Figure 1

[0017] ​During this operation, a confectionery / particle slurry is also prepared at 130. In a preferred form of the invention, particles (such as alginate-based particles) are combined with an un-aerated confectionery slurry (in one form of the invention the same slurry as present at 100) to produce a pumpable confectionery / particle slurry, or a "dough" as given when the slurry is un-aerated. At this point, it should be appreciated that the percentage of particles can vary, but is preferably provided to form a suspension of about 20%-50%, and more preferably 20%-30%, for example, 20 grams of particles to 80 grams of un-aerated confectionery slurry. Generally, to maintain the desired suspension (solids dispersed and suspended in the confectionery mass), a large additional volume of slurry is required to form a higher liquid content. In addition to the amount of particles, the type of particles can also vary. Most preferably, the particles employed do not tend to absorb water (hydrophobic) and can be solid particles, encapsulated liquids or gels, or combinations thereof. By way of example, the particles can take the form of cereal grains, including potato chips, confectionery candies, alginates or internal liquids or gels encapsulated in a shell to present different fruit or other flavors and burst flavors upon chewing. Generally, the particles themselves can present different flavors, textures, visual appearances and mouthfeels, while potentially being configured to allow some leaching of colorants or flavorants.

[0018] The pumpable (again, un-aerated for flow purposes) confectionery / particle slurry is pumped to be combined at 145 with a cooled confectionery foam from the foam cooling unit 120. For this purpose, a low shear pump 150 is employed. More specifically, the pump 150 preferably constitutes a low shear positive displacement pump, such as a rotary piston or vacuum assisted multi-screw type pump. In any case, the un-aerated pumpable confectionery / particle slurry is combined with an aerated confectionery slurry or foam to produce a combined slurry. Although the ratio of the combined slurry can vary, a preferred embodiment employs an addition rate of about 1:3 to add the confectionery / particle slurry to the aerated confectionery slurry. The combined slurry, which is itself aerated, flows at about 50 psi to 70 psi to the inlet of a booster pump 160, where the booster pump 160 also preferably constitutes a positive displacement pump. The booster pump 160 raises the pressure to about 100 psi and directs the combined slurry to an extruder 175, which produces a shaped extrudate in the form of a string 180 that is directed onto a conveyor 185. The string 180 having the desired shape determined by the extruder 175 is then preferably conveyed under a starch waterfall at 190 and then cut by a cutter 200 to produce multi-textured confectionery pieces, such as dual-textured soft pellets, which are then directed through a drying unit 210. Importantly, these pieces are multi-textured, meaning they include two or possibly more different textures, as the particles remain intact throughout the described process.

[0019] At the drying unit 210, in the case of preparing soft pellets, the multi-textured confectionery pieces are dried in one or more drying steps to a moisture content that provides an aw (water activity) in the range of 0.1 - 0.4, preferably 0.15 - 0.25, throughout each resulting soft pellet (i.e., at the center of each soft pellet). w ) Products dried to such aw values are particularly suitable for addition to or use in dry, shelf - stable ready - to - eat products such as ready - to - eat cereals, beverages such as hot chocolate (added to dry cocoa powder or directly to the hot chocolate beverage), oatmeal (including instant oatmeal) or other dried products for hot cereal gruels (e.g., hot cereal flours), cereal bar products, granola and health bars, dried fruit bars, candy bars, dry mixes for baked goods, and various other snack products. Due to their low aw, the dried marshmallows themselves can also be used as confectionery.

[0020] During the drying process, the pieces are not heated to a degree sufficient to cause caramelization of the sugar components. To cause caramelization, the pieces themselves need to reach a certain temperature, which depends on the ingredients selected, particularly the sugar components. In other words, a high air temperature alone will not cause caramelization if the pieces are not heated for a long enough time to raise their temperature to the caramelization temperature. In an exemplary drying process, the pieces are dried at a temperature in the range of 70 °C - 80 °C. For the purposes of the present invention, drying the pieces does not include spoiling the pieces. Instead, the drying mentioned involves an active step and is carried out before packaging, distribution, and sale. Additionally, at least in the case of preparing soft pellets, the drying can result in multi - textured confectionery pieces having an aw in the range of 0.1 - 0.4.

[0021] At this point, the dried multi - textured confectionery pieces can be packaged or incorporated into the desired food products. As mentioned above, ready - to - eat cereals and cereal bars represent exemplary preferred uses of the multi - textured confectionery pieces of the present invention. As mentioned above, the actual percentage and / or formulation of the granules can vary according to the present invention to produce a variety of products that differ in texture, appearance, taste, mouthfeel, etc. for the consumer. Most importantly, the granules remain intact during processing and make it into the final product.

[0022] Based on the above, it should be apparent that the present invention provides novel dried multi - textured confectionery pieces, as well as a method for producing such products. Although certain preferred embodiments of the present invention have been set forth, it should be understood that various changes or modifications can be made without departing from the spirit of the present invention. Generally, the present invention is only intended to be limited by the scope of the following claims.

Claims

1. A method for preparing a multi-textured confectionery food mass, the method comprises: supplying an aerated confectionery slurry; supplying a non-aerated confectionery and particulate slurry, the non-aerated confectionery and particulate slurry comprising particles suspended in a non-aerated confectionery mass; combining the aerated confectionery slurry with the non-aerated confectionery and particulate slurry to form an aerated combined slurry; extruding the combined slurry to produce an extrudate; and cutting the extrudate into multi-textured confectionery pieces, the multi-textured confectionery pieces comprising the intact particles from the non-aerated confectionery and particulate slurry.

2. The method according to claim 1, wherein the particles constitute about 20%-50% of the non-aerated confectionery and particulate slurry.

3. The method according to claim 2, wherein the particles constitute about 20%-30% of the non-aerated confectionery and particulate slurry.

4. The method according to claim 1, wherein the particles are hydrophobic.

5. The method according to claim 1, wherein the particles constitute cereal grains, confectionery sweets, alginates or an internal liquid or gel encapsulated in a shell.

6. The method according to claim 5, wherein the particles comprise an encapsulated flavoring liquid or gel.

7. The method according to any one of claims 1 to 6, wherein supplying the aerated confectionery slurry comprises: pumping the aerated confectionery slurry through a cooling unit before combining the aerated confectionery slurry with the non-aerated confectionery and particulate slurry.

8. The method according to any one of claims 1 to 6, wherein supplying the non-aerated confectionery and particulate slurry comprises: pumping the non-aerated confectionery and particulate slurry into the aerated confectionery slurry at a ratio of about 1:

3.

9. The method according to claim 8, the method further comprises: after combining the aerated confectionery slurry with the non-aerated confectionery and particulate slurry to form the combined slurry, guiding the combined slurry through a pump to an extruder to form the extrudate.

10. The method according to any one of claims 1 to 6, the method further comprises drying the confectionery pieces.

11. The method according to claim 10, the method further comprises adding the confectionery pieces to a dry, shelf-stable ready-to-eat cereal product.

12. The method according to claim 10, the method further comprises adding the confectionery pieces for use in beverages, hot cereal, snacks or candy bars and / or for a dry blend for baked goods.

13. A method for preparing a multi-textured food confectionery piece, the method comprises: introducing a non-aerated confectionery and particulate slurry into an aerated and cooled stream of confectionery slurry to form an aerated combined slurry; extruding the combined slurry into strings; cutting the strings into confectionery pieces; and drying the confectionery pieces, wherein the particles from the non-aerated confectionery and particulate slurry are dispersed and suspended in the confectionery mass.

14. The method according to claim 13, wherein the particles constitute about 20%-50% of the non-aerated confectionery and particulate slurry.

15. The method according to claim 14, wherein the particles constitute about 20%-30% of the non-aerated confectionery and particulate slurry.

16. The method according to claim 13, wherein the particles are hydrophobic.

17. The method according to claim 13, wherein the particles comprise cereal grains, confectionery, alginates, or an internal liquid or gel encapsulated in a shell.

18. The method according to any one of claims 13 to 17, wherein the non-aerated confectionery and particle slurry are introduced by pumping the non-aerated confectionery and particle slurry into the aerated and cooled confectionery slurry stream at a ratio of about 1:

3.

19. The method according to any one of claims 13 to 17, the method further comprising adding the confectionery pieces to a dry, shelf-stable ready-to-eat cereal product.

20. The method according to any one of claims 13 to 17, the method further comprising adding the confectionery pieces for use in beverages, hot cereals, snacks or candy bars and / or for dry blends for baked goods.

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