Method for forming confectionery

Abstract

A method of forming a jellied confection includes: providing a jellied confection material having a first solids percentage to a first moisture removal system; removing moisture from the jellied confectionery material having the first solids percentage within the first moisture removal system to form a jellied confectionery material having a second solids percentage; depositing the jelly confectionery material having the second solids percentage into at least one mold; and removing moisture from the jellied confectionery material having the second solids percentage within a second moisture removal system to form a jellied confectionery material having a third solids percentage.

Description

Cross Reference to Related Applications

[0001] This application claims the benefit of U.S. Application No. 63 / 494,939, filed April 7, 2023, and U.S. Application No. 63 / 617,561, filed January 4, 2024, which are incorporated by reference herein in their entirety. TECHNICAL FIELD

[0002] The present disclosure relates generally to a system and method for forming a confectionery, and more particularly to a system and method for forming a jelly confectionery. BACKGROUND

[0003] Jelly confectioneries are typically formed using a baking process in which a jelly slurry is deposited into cavities pressed into starch-based flats. The starch-based flats with jelly deposits are heated / cured in an oven-type environment at about 50°C to 70°C for 30 to 70 hours. As the jelly deposits cure, moisture is removed and structure is created in the individual deposits to form jelly pieces. A skin that is less moisture diffusive than the rest of the jelly deposit is also formed around the surface of the deposit.

[0004] It would be desirable to have a more time-efficient process for forming jelly confectioneries. SUMMARY

[0005] According to one embodiment, a method of forming a jelly confectionery includes: providing a jelly confectionery material having a first percent solids; removing moisture from the jelly confectionery material having the first percent solids within a first moisture removal system to form a jelly confectionery material having a second percent solids; depositing the jelly confectionery material output from the first moisture removal system and having at least the second percent solids into at least one mold; and removing moisture from the jelly confectionery material having at least the second percent solids within a second moisture removal system to form a jelly confectionery material having a third percent solids.

[0006] In addition to one or more of the features described herein, or as an alternative, in further embodiments the jelly confectionery material having the second percent solids is a high solids jelly.

[0007] In addition to one or more of the features described herein, or as an alternative, in further embodiments the second percent solids is between 2% to 10% greater than the first percent solids.

[0008] In addition to one or more of the features described above, or as an alternative, in further embodiments the second solids percentage is at least 4% greater than the first solids percentage.

[0009] In addition to one or more of the features described above, or as an alternative, in further embodiments the third solids percentage is between 1% and 9% greater than the second solids percentage.

[0010] In addition to one or more of the features described above, or as an alternative, in further embodiments the third solids percentage is at least 4% greater than the second solids percentage.

[0011] In addition to one or more of the features described above, or as an alternative, in further embodiments the second solids percentage is between about 79% and about 86%.

[0012] In addition to one or more of the features described above, or as an alternative, in further embodiments the gelatinous confectionery material having the first solids percentage is a low solids gelatin.

[0013] In addition to one or more of the features described above, or as an alternative, in further embodiments the operation of removing moisture from the gelatinous confectionery material having at least the second solids percentage within the at least one mold includes baking the gelatinous confectionery material having at least the second solids percentage.

[0014] In addition to one or more of the features described above, or as an alternative, in further embodiments the first moisture removal system is an extruder.

[0015] In addition to one or more of the features described above, or as an alternative, in further embodiments the extruder includes at least one devolatization section including at least one opening to the ambient environment and the operation of removing moisture from the gelatinous confectionery material having the first solids percentage occurs via the at least one opening.

[0016] In addition to one or more of the features described above, or as an alternative, in further embodiments the extruder includes at least one devolatization section including at least one opening and a vacuum device in communication with the at least one opening. The vacuum device is positioned to actively draw moisture from the gelatinous confectionery material having the first solids percentage and the extruder.

[0017] In addition to one or more of the features described herein, or as an alternative, in further embodiments the first moisture removal system includes a heat transfer device.

[0018] In addition to one or more of the features described herein, or as an alternative, in further embodiments the heat transfer device is a scraped surface heat exchanger.

[0019] In addition to one or more of the features described herein, or as an alternative, in further embodiments the first moisture removal system includes a containment device fluidly coupled to the heat transfer device. The method includes: providing the gelatinous confectionery material having the first solids percentage from an outlet of the heat transfer device to the containment device; and releasing the gelatinous confectionery material having the first solids percentage in an interior of the containment device.

[0020] In addition to one or more of the features described herein, or as an alternative, in further embodiments the operation of removing moisture from the gelatinous confectionery material having the first solids percentage within the first moisture removal system to form a gelatinous confectionery material having a second solids percentage occurs in response to the operation of releasing the gelatinous confectionery material having the first solids percentage in the interior of the containment device.

[0021] In addition to one or more of the features described herein, or as an alternative, in further embodiments the operation of removing moisture from the gelatinous confectionery material having the first solids percentage occurs in response to the operation of continuously renewing an exterior surface of the gelatinous confectionery material having the first solids percentage.

[0022] In addition to one or more of the features described herein, or as an alternative, in further embodiments the interior of the containment device has a low moisture, low pressure environment.

[0023] In addition to one or more of the features described herein, or as an alternative, in further embodiments the gelatinous confectionery material having the third solids percentage is a final gelatinous confectionery having a desired shape.

[0024] In addition to one or more of the features described herein, or as an alternative, in further embodiments the operation of depositing the gelatinous confectionery material having at least the second solids percentage into the at least one mold further includes: depositing the gelatinous confectionery material having at least the second solids percentage at a temperature greater than 100°C.

[0025] According to one embodiment, a method of forming a jelly confectionery comprises depositing a jelly confectionery material having a solids percentage of at least 79% into at least one mold; and baking the jelly confectionery material to form a jelly confectionery material having a final solids percentage.

[0026] In addition to or as an alternative to one or more of the features described above, in further embodiments the percentage solids of the jelly confectionery material deposited into the at least one mould is at least 81%.

[0027] In addition to or as an alternative to one or more of the features described above, in further embodiments, the method comprises reducing the viscosity of the jelly confectionery material having the solids percentage of at least 79%.

[0028] In addition to or as an alternative to one or more of the features described above, in further embodiments, the operation of reducing the viscosity of the jelly confectionery material having the solids percentage of at least 79% comprises: heating the jelly confectionery material having the solids percentage of at least 79%.

[0029] In addition to or as an alternative to one or more of the features described above, in further embodiments the jelly confectionery material having the solids percentage of at least 79% is heated to a temperature greater than 100°C.

[0030] In addition to or as an alternative to one or more of the features described above, in further embodiments, the operation of heating the jelly confectionery material having the solids percentage of at least 79% occurs before the operation of depositing the jelly confectionery material having the solids percentage of at least 79% into the at least one mould.

[0031] In addition to or as an alternative to one or more of the features described above, in a further embodiment, the jelly confectionery material having the solids percentage of at least 79% is deposited into the at least one mold via a deposition nozzle. The method comprises: interrupting the flow of the jelly confectionery material having the solids percentage of at least 79% at the deposition nozzle.

[0032] In addition to one or more of the features described above, or as an alternative, in another embodiment, the operation of interrupting the flow of the jelly confectionery material having the solids percentage of at least 79% at the deposition nozzle includes: breaking off the tail of the jelly confectionery material.

[0033] According to one embodiment, a method of forming a gelatinous confectionery includes: providing a gelatinous confectionery material having a first percent solids; and removing moisture from the gelatinous confectionery material having the first percent solids within a moisture removal system to form a gelatinous confectionery material having a second percent solids. At least a portion of the moisture is removed from the gelatinous confectionery material having the first percent at a rate of at least about 1% per hour.

[0034] In addition to one or more of the features described herein, or as an alternative, in further embodiments at least a portion of the moisture is removed from the gelatinous confectionery material having the first percent at a rate of at least about 2% per hour.

[0035] In addition to one or more of the features described herein, or as an alternative, in further embodiments at least a portion of the moisture is removed from the gelatinous confectionery material having the first percent at a rate of at least about 5% per hour.

[0036] In addition to one or more of the features described herein, or as an alternative, in further embodiments at least 1% of the moisture is removed from the gelatinous confectionery material having the first percent in less than five minutes.

[0037] In addition to one or more of the features described herein, or as an alternative, in further embodiments at least 5% of the moisture is removed from the gelatinous confectionery material having the first percent in less than five minutes.

[0038] In addition to one or more of the features described herein, or as an alternative, in further embodiments the gelatinous confectionery material having the first percent solids is a low solids gelatin and the gelatinous confectionery material having the second percent solids is a high solids gelatin. BRIEF DESCRIPTION OF DRAWINGS

[0039] The accompanying drawings, which are incorporated in and form a part of the specification, illustrate several aspects of the present disclosure and, together with the description, serve to explain the principles of the present disclosure. In the drawings: Figure 1 is a schematic illustration of a system for forming a gelatinous confectionery according to one embodiment; Figure 2 is a schematic illustration of a first moisture removal system including an extruder for forming a gelatinous confectionery according to one embodiment; Figure 3 is a schematic illustration of a first moisture removal system for forming a gelatinous confectionery according to one embodiment; Figure 2 is a schematic illustration of a cross-section of a first moisture removal system for forming a gelatinous confectionery according to one embodiment; Figure 4 is a schematic diagram of a portion of a first moisture removal system for forming a gelatin in accordance with another embodiment; Figure 5 is a schematic diagram of a portion of a first moisture removal system in accordance with an embodiment; Figure 4 is a schematic diagram of a containment device of a first moisture removal system in accordance with an embodiment; Figure 6A is a schematic diagram of a portion of a second moisture removal system for forming a gelatin in accordance with an embodiment; Figure 6B is a schematic diagram of another portion of a second moisture removal system for forming a gelatin in accordance with an embodiment; and Figure 6C is a plan view of a tray having a gelatin material with a final percent solids output from an oven in accordance with an embodiment; and Figure 7 is a graph comparing viscosity and shear rate of a plurality of different gelatin materials having different percent solids at different temperatures in accordance with an embodiment. DETAILED DESCRIPTION

[0040] The embodiments disclosed herein relate to a system and method of forming a gelatin. As used herein, the term "gelatin" is intended to describe a confectionery comprising various sugars and water and at least one of cooked starch, pectin, gelatin, and similar hydrocolloids. The gelatin can also comprise one or more of a colorant, a flavoring agent, and a food acid. Further, the gelatin can transform between various stages during the formation process. Examples of these stages include a low solids gelatin, a high solids gelatin, and a stabilized high solids gelatin as discussed herein. As used herein, the phrase "low solids gelatin" is intended to describe a gelatin having a percent solids of less than 80%, and in some embodiments, a percent solids of less than 78%. In some embodiments, the percent solids of a low solids gelatin is typically, for example, between about 72% and about 78%. As used herein, the phrase "high solids gelatin" is intended to describe a gelatin having a percent solids that is higher than the percent solids associated with a low solids gelatin. A high solids gelatin can have a percent solids of greater than 78%, and in some embodiments, a percent solids of greater than 80%. In some embodiments, the percent solids of a high solids gelatin is typically, for example, between about 82% and about 90%. As used herein, the phrase "stabilized high solids gelatin" is intended to describe a high solids gelatin after gelatin solidification has occurred. Solidification, also referred to as baking, is a process that results in one or more of moisture removal, skin formation, desired gel strength and / or gel texture formation, and sugar inversion. After solidification, the gelatin has a shape that is stable at room temperature.

[0041] Referring toFigure 1 , illustrates a schematic diagram of a system 20 for forming a jelly confectionery. The system 20 for forming a jelly confectionery comprises a first moisture removal system, schematically illustrated at 22, and a second moisture removal system, generally illustrated at 24, located downstream of the first moisture removal system 22 relative to the flow of the jelly confectionery material. As will be described in more detail below, the first or initial moisture removal system 22 is configured to receive a jelly confectionery material J1 having a first solids percentage and form it into a jelly confectionery material J2 having a second or intermediate solids percentage. The second moisture removal system is configured to receive the jelly confectionery material J2 having a second solids percentage and form it into a jelly confectionery material J3 having a third or final solids percentage.

[0042] In one embodiment, the jelly confectionery material J1 having the first solids percentage is a low-solids jelly. However, embodiments are also contemplated herein in which the jelly confectionery material having the first solids percentage is a high-solids jelly. In one embodiment, the jelly confectionery material J3 having the third or final solids percentage is a high-solids jelly. The second or intermediate solids percentage is greater than the first solids percentage and less than the third solids percentage. In one embodiment, the jelly confectionery material J2 provided at the outlet of the first moisture removal system 22 and having the second or intermediate solids percentage is a high-solids jelly having a solids percentage less than the third or final solids percentage.

[0043] Now refer to Figure 2 , illustrates an example of the first moisture removal system 22 in more detail. The first moisture removal system 22 may comprise a device or a combination of devices capable of simultaneously heating and continuously mixing or agitating the jelly confectionery material. In the illustrated non-limiting embodiment, the first moisture removal system 22 is an extrusion system, for example, comprising an extruder 30. As shown, a jelly confectionery material J1 having a first set of properties is provided as input to the extruder 30 and processed within the extruder 30 into a jelly confectionery material J2 having a second set of properties. The first set of properties may include a first solids percentage, and the second set of properties may include a second solids percentage. As previously described, the jelly confectionery material J1 having the first set of properties may be a low-solids jelly, while the jelly confectionery material J2 having the second set of properties may be a high-solids jelly. However, it should be understood that in other embodiments, the jelly confectionery material J1 provided as input to the extruder 30 and the jelly confectionery material J2 output from the extruder 30 may both be low solids jelly or high solids jelly, wherein the second solids percentage of the jelly confectionery material J2 output from the extruder 30 is greater than the first solids percentage of the jelly confectionery material J1 input to the extruder 30.

[0044] In an example embodiment, the extrusion system 22 for processing the gelatinous confectionery material includes a gelatin supply 32, such as but not limited to a batch mixer or tank, that supplies a gelatinous confectionery material J1 having a first set of properties to an extruder 30. In one embodiment, the gelatinous confectionery material J1 provided to the extruder 30 is a slurry or solution. As shown, the gelatinous confectionery material J1 is delivered from the gelatin supply 32 to the extruder 30 via a gelatin delivery device, such as but not limited to an injection line 34 coupled to a gelatin input 36 of the extruder 30. The injection line 34 can be heated to allow the gelatinous confectionery material gel J1 to have a viscosity that is more flowable as it travels through the injection line 34 to the extruder 30. It should be understood that the gelatinous confectionery material J1 can additionally or alternatively be provided to the extruder 30 via a side feed device, hopper, or any other known method for supplying a slurry material or solution to an extruder.

[0045] The gelatinous confectionery material J1 provided by the gelatin supply 32 to the extruder 30 can include all of the gelatin ingredients except for certain temperature sensitive ingredients or shear sensitive ingredients, such as flavorings and possible edible pieces, such as dry crumb. The gelatinous confectionery material J1 in the absence of the mentioned sensitive ingredients can include ingredients such as but not limited to water, glucose, trans-sugar, granulated sugar, starch, and pectin. As will be discussed in more detail below, at least one temperature sensitive ingredient or shear sensitive ingredient can be added to the extruder 30 at one or more downstream sections of the extruder. Such sensitive ingredients include but are not limited to prebiotics, probiotics, vitamins, flavorings, and colorings. Edible pieces, such as but not limited to pieces such as for example nuts, dried fruits, baked good pieces, and candy pieces, can also be added at downstream sections of the extruder 30 or after the gelatinous confectionery material J2 is output from the extrusion point 38 of the extruder 30.

[0046] The extruder 30 can be any type of continuous extruder, such as but not limited to a single screw, twin screw, or planetary roller extruder. In the illustrated non-limiting embodiment, the extruder 30 is a twin screw extruder that includes a first screw 40a that is in close or intermeshing engagement with a second screw 40b. The twin screw extruder 30 can include multiple sections or barrels 42a,..., 42n or a single barrel having multiple zones that can be used for a variety of different extrusion or processing functions. An example method for using the twin screw extruder 30 to process a gelatinous confectionery material J1 having a first percent solids into a gelatinous confectionery material J2 having a second percent solids will be described below. Figure 2 Figure 3 In the illustrated non-limiting embodiment, the extruder 30 is a twin screw extruder that includes a first screw 40a that is in close or intermeshing engagement with a second screw 40b. The twin screw extruder 30 can include multiple sections or barrels 42a,..., 42n or a single barrel having multiple zones that can be used for a variety of different extrusion or processing functions. An example method for using the twin screw extruder 30 to process a gelatinous confectionery material J1 having a first percent solids into a gelatinous confectionery material J2 having a second percent solids will be described below.

[0047] ​As described above, the gelato material J1 is provided to the extruder 30 from the gelato supply 32. The gelato material J1 provided at the input end 36 of the first section 42a has or includes a first percent solids. In exemplary embodiments, the first percent solids is between about 70% and 80% solids, and more particularly about 71%, 72%, 73%, 74%, 75%, 76%, 77%, 78%, 79%, or 80% solids. Thus, in one embodiment, the gelato material J1 having the first percent solids is a low solids gelato. The remaining percent of the gelato material J1 can but need not be water or another liquid. Via the mixing and conveying process that occurs between the input end 36 and the exit / extrusion point 38 of the extruder 30, the gelato material J1 is "dehydrated" to form a gelato material J2 having a desired second percent solids. In exemplary embodiments, the second percent solids associated with the gelato material J2 is between about 79% and 90% solids, and more particularly about 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, or 90% solids. Thus, in one embodiment, the gelato material J2 having the second percent solids is a high solids gelato. As previously noted, although this dehydration process or moisture reduction is described with respect to converting a low solids gelato J1 to a high solids gelato J2, in other embodiments, this process can be used to simply increase the percent solids within a low solids gelato or a high solids gelato, respectively. In Figure 2 and Figure 3 In the exemplary embodiment shown, this dehydration or moisture reduction occurs as follows.

[0048] The first section 42a of the extruder 30 is a raw material / slurry entry section. The gelato material J1 can be provided to the first section 42a in any suitable manner, including but not limited to via an injection line, a hopper, or even a hole formed in the first section 42a. This section is generally not heated, although in some embodiments it can be heated, such as when the gelato material J1 provided to this section is at a relatively heated temperature upon entering the section 42a. For example, the gelato material J1 can be provided to the first section 42a at a temperature equal to or greater than 90°C. From here, the gelato material J1 moves downstream due to the rotating screw geometry to the second section 42b. In exemplary embodiments employing an extruder having a twin screw, the rotating screws 40a, 40b continuously move the gelato material J1 through the flow path of the extruder 30 defined by each of the successive barrels or sections 42a-n in combination, all the way to the output end or extrusion point 38 at which the gelato material J2 has the second percent solids.

[0049] For ease of understanding, the gelatinous confectionery material is generally referred to as J1 as it flows through the first removal system 22 until it becomes a gelatinous confectionery material J2 having a second solids percentage. However, it should be understood that the solids percentage of the gelatinous confectionery material J1 gradually increases from the first solids percentage to the second solids percentage within the first removal system 22. Thus, the gelatinous confectionery material disposed at a location between the inlet of the first removal system 22 and where the gelatinous confectionery material reaches the second solids percentage J2, although referred to as J1, also has a solids percentage between the first solids percentage and the second solids percentage, respectively.

[0050] Similar to the multiple segments of the extruder 30 shown in the exemplary embodiment of Figure 2 and Figure 3 The first and second segments 42b are generally conveying segments in which the gelatinous confectionery material J1 moves downstream, mixes, and in some embodiments, is heated via an extruder heating system or heating device. In such extruders, at least one conveying segment, such as segment 42b, generally heats the gelatinous confectionery material J1 to a temperature of between about 95°C and 150°C, such as between about 95°C and 145°C, between about 95°C and 140°C, between about 95°C and 135°C, between about 95°C and 130°C, between about 95°C and 125°C, between about 95°C and 120°C, between about 100°C and 150°C, between about 100°C and 145°C, between about 100°C and 140°C, between about 100°C and 135°C, between about 100°C and 130°C, between about 100°C and 125°C, between about 100°C and 120°C, between about 105°C and 150°C, between about 105°C and 145°C, between about 105°C and 140°C, between about 105°C and 135°C, between about 105°C and 130°C, between about 105°C and 125°C, between about 105°C and 120°C, between about 110°C and 150°C, between about 110°C and 145°C, between about 110°C and 140°C, between about 110°C and 135°C, between about 110°C and 130°C, between about 110°C and 125°C, between about 110°C and 120°C, between about 115°C and 150°C, between about 115°C and 145°C, between about 115°C and 140°C, between about 115°C and 135°C, between about 115°C and 130°C, between about 115°C and 125°C, or between about 115°C and 120°C. In one embodiment, the heated moisture within the gelatinous confectionery material J1 remains liquid within the second segment 42b. The gelatinous confectionery material J1 is conveyed from the second segment 42b through the screws 40a, 40b to the third segment 42c.

[0051] In Figure 2 and Figure 3 In the exemplary embodiment illustrated, the third section 42c is a devolatilization barrel or section in which moisture (such as vaporized moisture) is removed from the gelatinous confectionery material Jl to at least begin increasing its percent solids to raise from the first percent solids to the second percent solids, as discussed above. Of course, while the exemplary embodiments discussed herein describe the third section 42c as a first devolatilization section of the extruder 30, it should be understood that any section of the extruder 30 can be configured as a devolatilization section. Moreover, embodiments in which additional sections of the extruder 30 are located upstream of the first devolatilization section are within the scope of the present disclosure.

[0052] In one embodiment, the single barrel or section (such as, for example, the third section 42c) is the only devolatilization or moisture removal section of the extruder 30. In such embodiments, the amount of moisture removed within the only devolatilization section is sufficient to transform the gelatinous confectionery material Jl having the first percent solids into the gelatinous confectionery material J2 having the increased second percent solids that will ultimately be discharged from the extruder 30. In other embodiments, the section 42c is one of a plurality of devolatilization sections arranged along the extruder 30, as is the case in the exemplary embodiments of Figure 2 and Figure 3 In such embodiments, moisture can be removed in a consistent manner (e.g., the percent solids is increased by 2% in each successive devolatilization barrel or section) or in an inconsistent manner (e.g., where the percent solids is increased by a different percentage in each successive devolatilization barrel or section).

[0053] In one embodiment, the devolatilization section has a free volume at or slightly above atmospheric pressure (in embodiments where a vacuum device is not connected to the devolatilization section). Reduced pressure to the devolatilization section can occur as a result of the configuration of one or more screws of the extruder 30. In one embodiment, at least one screw 40a, 40b of the extruder 30 is configured to draw the gelatinous confectionery material Jl from the devolatilization section faster than the gelatinous confectionery material Jl is provided to the devolatilization section.

[0054] Similar to the conveying sections, such as the second section 42b, at least one devolatilization section, such as, for example, the third section 42c, can also include a heating system to heat the gelatinous confectionery material J1 to a temperature of about 105°C to 135°C, such as between about 105°C and 130°C, between about 105°C and 125°C, between about 105°C and 120°C, between about 110°C and 135°C, between about 110°C and 130°C, between about 110°C and 125°C, between about 110°C and 120°C, between about 115°C and 135°C, between about 115°C and 130°C, between about 115°C and 125°C, or between about 115°C and 120°C, to convert or maintain the moisture of the gelatinous confectionery material J1 as vapor. In one embodiment, substantially all or a majority of the vaporization of the moisture within the gelatinous confectionery material J1 occurs within the at least one devolatilization section. As the moisture at the surface of the gelatinous confectionery material J1 facing the free volume is heated, the moisture vaporizes and flows into the free volume. Due to the continuous rotation of the screws 40a, 40b, new surfaces of the gelatinous confectionery material J1 are continuously exposed to the free volume, resulting in the continuous release of vaporized moisture from the gelatinous confectionery material J1. In this manner, the vaporized moisture does not need to travel through the gelatinous confectionery material J1 to escape into the free volume.

[0055] It should be noted that, Figure 2 and Figure 3 The third section 42c illustrated in the exemplary embodiment of Figure 2 The opening 44 allows at least some of the vaporized moisture within the devolatilization section to escape from the gelatinous confectionery material J1 and the extruder 30. The fifth section 42e and the sixth section 42f can also be devolatilization sections of the first type having openings 44. Similar to the third section 42c, these sections 42e and 42f can also include a heating system to heat the gelatinous confectionery material J1 to a temperature of about 105°C to 135°C, and more specifically to about 110°C to 120°C, to heat the moisture, as discussed above, with the openings 44 likewise allowing the vaporized moisture to escape therethrough. However, it should be understood that each devolatilization section can have a different temperature profile. Moreover, the devolatilization sections need not have the same temperature profile as the conveying sections.

[0056] As Figure 2 and Figure 3In the illustrated non-limiting embodiment, the gelatinous confectionery material J1 is conveyed along the downstream path of the extruder 30 from the third section 42c to the fourth section 42d. The fourth section 42d can be a conveying and heating section like, for example, the second section 42b. The gelatinous confectionery material J1 is conveyed from the fourth section 42d via the screws 40a, 40b to a fifth section 42e and a sixth section 42f, which, as discussed above, can function as first-type devolatilization sections. The gelatinous confectionery material J1 is then moved on its downstream path to a seventh section 42g, which can be another conveying and heating section like sections 42b and 42d. The gelatinous confectionery material J1 is conveyed from the seventh section 42g via the screws 40a, 40b to an eighth section 42h. In one embodiment, the eighth section 42h is configured as a second-type devolatilization section, which will be discussed in more detail below with reference to the eleventh section 42k. A ninth section 42i and a tenth section 42j are located downstream of section 42h and can function as conveying and heating sections like sections 42b, 42d, and 42g.

[0057] The gelatinous confectionery material J1 is conveyed from the tenth section 42j via the screws 40a, 40b to the eleventh section 42k, which, in the illustrated non-limiting embodiment, is also a second-type devolatilization section like section 42h. As discussed herein, the second-type devolatilization sections are similar to the first-type devolatilization sections. However, instead of containing only openings 44 to the ambient atmosphere like the first-type devolatilization sections, the second-type devolatilization sections, such as sections 42h and 42k, contain openings 46 that are coupled to vacuum devices 48. In the illustrated non-limiting embodiment, each section configured as a second-type devolatilization section can contain a respective vacuum device, such as, for example, devices 48a and 48b. However, embodiments in which multiple sections configured as second-type devolatilization sections are fluidly coupled to the same vacuum device are also within the scope of the present disclosure. The vacuum device or devices 48a, 48b can be operable to actively draw off vaporized moisture from the free volumes of the second-type devolatilization sections of the extruder 30. In example embodiments, these vacuum devices 48a, 48b remove moisture from the devolatilization sections through the respective openings 46. The pressure resulting from the application of the vacuum devices can be any pressure from atmospheric pressure to full vacuum (zero pressure). The application of the vacuum devices 48a, 48b to the second devolatilization sections can increase the rate at which moisture is evaporated and removed from the gelatinous confectionery material J1 within these sections.

[0058] As discussed above, the second type of devolatilization section (e.g., sections 42h, 42k) can remove an amount of moisture that produces the same increase in solids percentage as the increase found in the first type of devolatilization section. In fact, even though the vacuum devices 48a, 48b can produce more efficient moisture removal than that found in the first type of devolatilization section, the solids percentage of the jelly confectionery material J1 can increase at the same rate therein due to the reduced moisture present at the downstream locations of the vacuum devices 48a, 48b relative to the upstream locations of the first type of devolatilization section. Of course, the vacuum devices associated with the second type of devolatilization section (e.g., sections 42h, 42k) can also increase the solids percentage in the jelly confectionery material J1 at a greater rate than in the first type of devolatilization section, or can simply be modified to remove moisture at any level that achieves any desired rate of increase.

[0059] exist Figure 2 and Figure 3 In the exemplary embodiment of the present invention, there are two further conveying and heating sections downstream of the eleventh section 42k. These two conveying and heating sections 421 and 42m function like sections 42b, 42d, 42g, 42i and 42j. Section 42n is the fourteenth and final section shown in the exemplary embodiment. This section 42n includes an opening 46 and a vacuum device 48c and serves as a second type of devolatilization section similar to section 42k. Section 42n is the output section including the extrusion point 38 of the extruder 30, from which the jelly confectionery material J2 having a second solids percentage is output. Thus, in Figure 2 and Figure 3 In the exemplary embodiment of the present invention, it is in the final section 42n of the extruder 30 that moisture has been removed to the extent that the jelly confectionery material is converted to a jelly confectionery material J2 having a second solids percentage. It will be appreciated that in some embodiments, the jelly confectionery material J1 within the extruder 30 is converted from a low solids jelly to a high solids jelly at a location upstream of the final devolatilization section.

[0060] As the jelly confectionery material J2 exits the extruder die, some additional, unintentional devolatilization or further moisture removal may occur at the outlet or extrusion point 38 of the extruder 30. Thus, in embodiments where the outlet 38 of the extruder 30 is positioned downstream of the final devolatilization section, the outlet 38 may be the final location where moisture is removed from the jelly confectionery material to form the jelly confectionery material J2 having the second solids percentage. In one embodiment, the extruder outlet is connected to a constrained tube (not shown). In such embodiments, final devolatilization may occur as the jelly confectionery material J2 passes through the outlet end of the constrained tube.

[0061] The extruder 30 is described above with reference to an exemplary number of barrels or sections 42a-42n as shown. However, it should be understood that this is merely an example of a system that can be used. Any number of barrels or sections of the extruder 30 having any suitable arrangement are contemplated herein. For example, the extruder 30 can include an entry section, a downstream exit section, and any number of mixing sections, conveying sections, first type devolatilization sections, and second type devolatilization sections therebetween. Further, it should be understood that one or more of the conveying sections, first type devolatilization sections, and second type devolatilization sections can be arranged in any suitable order along the extruder 30. The entry section and exit section can also function as a conveying section and / or a devolatilization section (first type or second type), with any number of sections functioning as one or both of a conveying section and a devolatilization section disposed between (including no sections between) the entry section and the exit section. Further, it should be understood that any of the sections positioned between the entry section and the exit section can be capable of heating or cooling the gummy confectionery material disposed therein. The conveying sections and devolatilization sections of the first type or second type can be disposed upstream and downstream of one another between the entry section and the exit section of the extruder 30. Further, after being conveyed through at least one devolatilization section, the gummy confectionery material within the extrusion system 22 can be converted to a gummy confectionery material J2 having a desired second percent solids at any point along the extruder 30, with the gummy confectionery material J2 merely being moved / conveyed to the exit section for extrusion without further devolatilization (or any significant further devolatilization prior to exiting / extruding from the extruder).

[0062] Ingredients sensitive to one or more of temperature, shear, and volatility (also referred to herein as "sensitive ingredients") can optionally be added to the gelatinous confectionery material within the extruder 30, such as, for example, via an inlet other than the inlet 36. When added within the extruder 30, the at least one sensitive ingredient can be added at a location downstream of the formation of the gelatinous confectionery material J2 having the desired second solids percentage, such as, for example, within the final delivery section of the extruder 30. In one embodiment, the addition of sensitive ingredients within the extruder 30 occurs downstream of all devolatilization of the gelatinous confectionery material J1. For example, any volatile sensitive ingredients should be added downstream of the final devolatilization section to maintain the integrity of those ingredients. Any sensitive ingredients added at or upstream of the devolatilization section should be non-volatile to prevent some of their volatile ingredients from being lost within the devolatilization section. Alternatively or in addition, one or more sensitive ingredients, as well as non-sensitive ingredients, can be added to the gelatinous confectionery material J2 downstream of the final delivery section and / or the outlet 38 of the extruder 30, such as, for example, within a constrained tube fluidly coupled to the outlet of the extruder 30. These ingredients can be mixed with the gelatinous confectionery material J2 having the desired second solids percentage via any suitable mechanism, including but not limited to a static or dynamic agitator.

[0063] In traditional baking methods, the heat directed to the surface of the low solids gelatin to assist in devolatilization creates a surface "crust" around at least a portion of the resulting gelatinous confectionery (a region with a different moisture diffusion rate, typically less than the remainder of the mixture). This surface crust typically has a moisture diffusion rate that is two orders of magnitude lower than the moisture diffusion rate of the remainder of the gelatinous confectionery. This low moisture diffusion rate at the surface is one of the primary reasons that the gelatinous confectionery material must be heated for an extended period of time to form a gelatinous confectionery having the desired solids percentage.

[0064] Because the screws 40a, 40b of the extruder 30 are continuously rotating as the gelatinous confectionery material J1 is delivered through the extruder 30, new portions of the gelatinous confectionery material J1 are continuously brought to the surface. This continuous renewal of the surface of the gelatinous confectionery material J1 or the gelatinous confectionery material J2 is particularly important within the at least one devolatilization section. It is the continuous exposure of new portions of the gelatinous confectionery material J1 to the free volume within the at least one devolatilization section that allows moisture at the surface of the gelatinous confectionery material J1 to evaporate and be removed therefrom. It should be understood that during the dehydration or moisture removal process, the solids percentage of the gelatinous confectionery material J1 can transition from a low solids gelatin to a high solids gelatin before becoming the gelatinous confectionery material J2 having the desired second solids percentage.

[0065] The skin that would not form within the extruder 30 as described with respect to the traditional baking process because as the frozen gel confectionery material flows through the extruder 30 and particularly through one or more devolatilization sections, the surface of the frozen gel confectionery material J1 is constantly renewed. Moreover, it should be noted that the frozen gel confectionery material present within the extruder 30 can comprise a material composition having a uniform moisture diffusivity across its entire cross-sectional area, such as taken in a plane perpendicular to the direction of flow of the frozen gel confectionery material. In fact, due to the mixing and surface renewal discussed above, a substantially uniform moisture diffusivity across the entire cross-sectional area can not only be present in the frozen gel confectionery material J2 at the exit 38 of the extruder 30, but can be present in the frozen gel confectionery material J1 throughout the residence time within the extruder 30.

[0066] In exemplary embodiments, the residence time of the frozen gel confectionery material (in the form of a low solids gel, and in some embodiments, in the form of a high solids gel) in the extruder 30 from input to extrusion output is between about thirty seconds to about five minutes, such as less than four minutes, less than three minutes, less than two minutes, less than one minute, between about one minute and about four minutes, between about one minute and three minutes, or between about one minute and about two minutes. Moreover, one or more of the screws 40a, 40b of the extruder 30 has an axial length L measured parallel to the axis of rotation of the one or more screws between the entrance of the screw tip having an inner diameter D and the extrusion point. The ratio of length to diameter L / D can be at least 3: 1, or in other embodiments, can be at least 4: 1, 5: 1, 6: 1, 7: 1, 8: 1, 9: 1, 10: 1. In some embodiments, the ratio L / D is between 12: 1 and 20: 1, such as 12: 1, 13: 1, 14: 1, 15: 1, 16: 1, 17: 1, 18: 1, 19: 1, and 20: 1. Moreover, in one embodiment, the rotational speed of the one or more screws of the extruder can be between about 25 rpm and about 500 rpm.

[0067] Reference is now made to Figure 4Another example of a first moisture removal system 22 for forming a gummy candy J2 having a second percent solids is illustrated. As shown, the first moisture removal system 22 includes a scraped surface heat exchanger 60. Although the scraped surface heat exchanger 60 is illustrated in a substantially vertical orientation, it should be understood that embodiments in which the scraped surface heat exchanger 60 has another configuration, such as for example, a horizontal configuration, are also within the scope of the present disclosure. As shown, the scraped surface heat exchanger 60 includes a hollow cylindrical outer housing 62 that surrounds an annular channel 64. A rotor 66 is centrally located within the interior of the annular channel 64 and includes one or more blades 68 that extend outwardly from the rotor 66 via arms 70. As the rotor 66 rotates within the annular channel 64 about an axis, the interior surface 72 of the annular channel 64 is continuously engaged and “scraped” by the at least one blade 68 extending from the rotor 66.

[0068] The gummy candy material J1 having the first percent solids is provided to the annular channel 64 of the scraped surface heat exchanger 60. In one embodiment, the gummy candy material J1, such as from a gummy candy material supply 75, is delivered to an inlet 74 of the annular channel 64. Although the inlet 74 is illustrated as being disposed at a first lower end of the scraped surface heat exchanger 60, it should be understood that in other embodiments, the inlet can be located at another position around the scraped surface heat exchanger 60. Similar to the previous embodiments of the first moisture removal system described above, the gummy candy material J1 provided to the scraped surface heat exchanger 60 can be a low solids gummy that includes a first percent solids that is between 70% solids to 80% solids, and more specifically, 71%, 72%, 73%, 74%, 75%, 76%, 77%, 78%, or 79% solids. The remaining percent of the gummy candy material J1 provided to the scraped surface heat exchanger 60 can be, but is not necessarily, water or another liquid.

[0069] As the gelatinous confectionery material J1 flows through the annular passageway 64 toward the outlet 76 (such as, for example, disposed at the second opposite end of the scraped surface heat exchanger 60), the gelatinous confectionery material J1 is heated. In one embodiment, a heat exchange medium M (such as steam, air, oil, or another suitable medium) is circulated within the outer housing 62. Heat from the heat exchange medium M is transferred through the walls of the outer housing 62 to the gelatinous confectionery material J1. In one embodiment, the amount of heat transferred to the gelatinous confectionery material J1 within the scraped surface heat exchanger 60 is controlled such that the gelatinous confectionery material J1 at the outlet 76 has a temperature equal to or greater than the boiling point of water (at standard temperature and pressure). In one embodiment, the gelatinous confectionery material J1 at the outlet 76 has a temperature between 95 °C and 150 °C (such as between about 95 °C and 145 °C, between about 95 °C and 140 °C, between about 95 °C and 135 °C, between about 95 °C and 130 °C, between about 95 °C and 125 °C, between about 95 °C and 120 °C, between about 100 °C and 150 °C, between about 100 °C and 145 °C, between about 100 °C and 140 °C, between about 100 °C and 135 °C, between about 100 °C and 130 °C, between about 100 °C and 125 °C, between about 100 °C and 120 °C, between about 105 °C and 150 °C, between about 105 °C and 145 °C, between about 105 °C and 140 °C, between about 105 °C and 135 °C, between about 105 °C and 130 °C, between about 105 °C and 125 °C, between about 105 °C and 120 °C, between about 110 °C and 150 °C, between about 110 °C and 145 °C, between about 110 °C and 140 °C, between about 110 °C and 135 °C, between about 110 °C and 130 °C, between about 110 °C and 125 °C, between about 110 °C and 120 °C, between about 115 °C and 150 °C, between about 115 °C and 145 °C, between about 115 °C and 140 °C, between about 115 °C and 135 °C, between about 115 °C and 130 °C, between about 115 °C and 125 °C, or between about 115 °C and 120 °C).

[0070] As the gelatinous confectionery material J1 is heated, the rotation of the rotor 66 and the resulting scraping of the interior surface 72 of the annular channel 64 continuously mixes the gelatinous confectionery material J1. This mixing facilitates uniform heating of the gelatinous confectionery material J1. Although the gelatinous confectionery material J1 is heated within the scraped surface heat exchanger 60, the first solids percentage of the gelatinous confectionery material J1 provided at the outlet 76 thereof can be substantially the same as the first solids percentage of the gelatinous confectionery material J1 provided to the inlet 74 of the scraped surface heat exchanger 60. Thus, the first solids percentage of the gelatinous confectionery material J1 can remain approximately constant as the gelatinous confectionery material J1 is heated within the scraped surface heat exchanger 60. Further, it should be appreciated that embodiments using another machine or heat transfer device capable of heating the gelatinous confectionery material J1 in place of the scraped surface heat exchanger are within the scope of the present disclosure. Examples of such heat transfer devices include, but are not limited to, coil ovens and heat exchangers, and in such embodiments, the gelatinous confectionery material J1 can be configured to continuously move or flow through the heat transfer device. In one embodiment, the gelatinous confectionery material J1 is moving through any suitable heat transfer device having non-laminar flow.

[0071] With continued reference to Figure 4 and further reference to Figure 5 , the first moisture removal system 22 additionally includes a containment device 80, such as, for example, a storage tank. The containment device 80 can include a body 82 having an inlet 84 and an outlet 86 and a substantially hollow interior 88 connected to the inlet 84 and the outlet 86. In the illustrated, non-limiting embodiment, the inlet 84 is formed at a first, upper end of the body 82 and the outlet 86 is formed at a bottom end of the body 82. However, embodiments are also contemplated herein in which the inlet 84 and / or the outlet 86 are formed at another location about the body 82, such as, for example, a sidewall.

[0072] In one embodiment, the environment within the hollow interior 88 of the storage tank 80 is a low moisture environment, such as a gaseous environment having low humidity. A vent or opening 90 can be formed in a wall of the storage tank 80. At least some of the vaporized moisture within the free volume of the storage tank 80 can escape through the vent 90. In some embodiments, the hollow interior 88 of the storage tank 80 can be operably coupled to a vacuum device 92, such that the environment within the hollow interior 88 is a low pressure environment. The vacuum device 92 is operable to actively draw vaporized moisture from the hollow interior 88 of the storage tank 80. The pressure within the hollow interior 88 resulting from the application of the vacuum device 92 can be any pressure from atmospheric pressure to full vacuum (zero pressure).

[0073] As shown, the heated gummy confectionery material J1 is provided from the outlet 76 of the scraped surface heat exchanger 60 to the inlet 84 of the storage tank 80 either directly or via a conduit 78. The temperature of the gummy confectionery material J1 can be substantially the same at the inlet 84 of the storage tank 80 and the outlet 76 of the scraped surface heat exchanger 60. However, embodiments in which a small amount of heat is transferred from or to the gummy confectionery material J1 during travel between the outlet 76 and the inlet 84, such as for example due to conduction or convection to the ambient atmosphere, are also within the scope of the present disclosure. In embodiments in which heat is lost between the scraped surface heat exchanger 60 and the storage tank 80, the temperature of the gummy confectionery material J1 at the inlet 84 of the storage tank 80 can be equal to or higher than the boiling point of water (at standard temperature and pressure).

[0074] Within the storage tank 80, the flowable gummy confectionery material J1 is configured to fall from the inlet 84 to the outlet 86, such as via gravity. In some embodiments, a nozzle 94 is disposed at or directly adjacent to the inlet 84 of the storage tank 80. The nozzle 94 can be angled relative to the longitudinal axis of the storage tank 80 to direct the heated gummy confectionery material J1 toward the interior surface 96 of the sidewall of the storage tank 80. In one embodiment, the nozzle 94 is configured to divide the flow of heated gummy confectionery material J1 at the inlet 84 into multiple streams, thereby increasing the surface area of the heated gummy confectionery material J1 within the storage tank 80.

[0075] As the gummy confectionery material J1 is released from the inlet 84 into the hollow interior 88 of the storage tank 80, liquid moisture located at or near the outer surface of the gummy confectionery material J1 that is in contact with the surrounding atmosphere evaporates and releases or expels gases from the gummy confectionery material J1. Furthermore, as the gummy confectionery material J1 accelerates and one or more streams of the gummy confectionery material J1 thin as they fall via gravity, new surfaces of the gummy confectionery material J1 are continuously exposed, resulting in the continuous release of water vapor from the surfaces of the gummy confectionery material J1 until it reaches the bottom of the containment device 80. This continuous exposure of new surfaces of the gummy confectionery material J1, which results in the continuous release of moisture therefrom, is a form of continuous renewal similar to the mixing achieved within the extruder 30 in the embodiments of Figure 2 and Figure 3 In one embodiment, the gummy confectionery material J2 having the desired second percent solids, such as for example a high solids gummy, is collected at the bottom of the storage tank 80 and output from the storage tank 80 via the outlet 86. Furthermore, the water or moisture released from the gummy confectionery material can be collected in a separate portion of the storage tank or can be removed therefrom, for example via the vent 90 as previously described.

[0076] As the jelly confectionery material J1 falls, the continuous removal of water vapor causes the jelly confectionery material J1 to be "dehydrated" to form a jelly confectionery material J2 having a desired second solids percentage, such as, for example, a high-solids jelly. In an exemplary embodiment, the jelly confectionery material J2 collected within the containment device 80 has a second solids percentage that is between about 79% solids and 90% solids, and more specifically, about 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, or 90% solids. The jelly confectionery material J2 provided at the outlet 86 of the containment device 80 will not include a skin as previously described herein.

[0077] One or more parameters associated with the jelly confectionery material J1 at the inlet of the containment apparatus 80 or associated with the operation of processing equipment (such as, for example, the containment apparatus 80, the scraped surface heat exchanger 60, and / or the vacuum apparatus 92) may be controlled to achieve a desired second solids percentage of the jelly confectionery material J2 at the outlet 86 of the containment apparatus 80. Examples of such parameters include, but are not limited to, the flow rate at which the jelly confectionery material J1 is provided to the inlet 84, the axial (vertical) distance that water is removed from the jelly confectionery material J1 (e.g., the distance between the inlet 84 and the outlet 86 of the containment apparatus 80), the temperature of the jelly confectionery material J1, the temperature of the environment within the containment apparatus 80, and the pressure or vacuum level within the containment apparatus 80.

[0078] Although only a single containment device 80 is illustrated, it should be understood that in other embodiments, the first moisture removal system 22 may include multiple containment devices arranged in series with respect to the flow of the jelly confectionery material. In such embodiments, the jelly confectionery material provided at the outlet 86 of the last containment device in the series may be jelly confectionery material J2 having the second solids percentage.

[0079] Similar to the above Figure 2 to Figure 3The described embodiments, sensitive ingredients such as, but not limited to, those discussed above, can optionally be added to the gelatinous confectionery material at a location within or downstream of the containment device 84. Alternatively or in addition, one or more sensitive ingredients such as, for example, non-volatile temperature sensitive ingredients, can be added to the gelatinous confectionery material J1 at the inlet 84 of the containment device 80, within the conduit 78 extending between the scraped surface heat exchanger 60 and the inlet 84, within the annular channel 64 of the scraped surface heat exchanger 60 such as at or near its outlet 76 once the gelatinous confectionery material J1 has been heated to the desired temperature, or even within the gelatinous confectionery material J1 upstream of the scraped surface heat exchanger 60. However, embodiments are also contemplated herein in which the sensitive ingredients are added downstream of the containment device 80 such as to the gelatinous confectionery material J2.

[0080] Regardless of the configuration of the first moisture removal system 22, the gelatinous confectionery material J2 having the second set of parameters output from the first moisture removal system can be provided to the second moisture removal system 24. Although only a single first moisture removal system is exemplified and described herein, it will be appreciated that some embodiments can include multiple first moisture removal systems arranged in series upstream of the second moisture removal system 24. In embodiments including multiple first moisture removal systems, the gelatinous confectionery material J1 having a first percent solids is provided at the inlet of the most upstream first moisture removal system 22, and the gelatinous confectionery material provided at the outlet of the upstream moisture removal system will have an intermediate percent solids between the first and second percent solids. Thus, this gelatinous confectionery material having the intermediate percent solids will be provided at the inlet of another first moisture removal system 22. The gelatinous confectionery material output from the most downstream first moisture removal system 22 will have the second percent solids J2.

[0081] The gelatinous confectionery material provided at the outlet of the second moisture removal system 24 will be a gelatinous confectionery material J2 having a third or final set of parameters. In some embodiments, the gelatinous confectionery material J3 will be output from the second moisture removal system 24 as a final gelatinous confectionery. In such embodiments, the final gelatinous confectionery can be the desired size and shape, and ready to be packaged. However, in other embodiments, one or more additional processes can be applied to the gelatinous confectionery before the gelatinous confectionery is a final gelatinous confectionery ready to be packaged.

[0082] In Figure 6A to Figure 6CIn the illustrated non-limiting embodiment, the second moisture removal system 24 includes at least one tray 100 having one or more cavities 102 formed therein. Each of the cavities 102 can be considered a mold. The cavities 102 can have a three-dimensional shape that corresponds to the desired shape of the final gummy confectionery. The cavities 102 can be covered by a layer of starch, or in some embodiments, the tray 100 itself can be a starch-based flat plate having one or more cavities 102 formed therein.

[0083] The deposition nozzle 104 is configured to deliver a predetermined amount of the gummy confectionery material J2 having the second set of parameters into each of the plurality of cavities 102. Once the cavities 102 are filled with the gummy confectionery material J2, the tray 100 is positioned within the oven 110 for a predetermined period of time (see Figure 6B ). In one embodiment, the hold time between filling the cavities 102 and moving the tray 100 forward toward the oven 110 is between 0.05 seconds to 1 second. Within the oven 110, heated air A can be forced to flow over and around the cavities 102, causing further moisture to be removed from the gummy confectionery material located therein to form a gummy confectionery material J3 having a third percent solids (see Figure 6C ). This process of filling the molds or cavities 102 with the gummy confectionery material and solidifying the gummy confectionery material within the oven can also be referred to herein as "baking." In one embodiment, the interior 112 of the oven 110 can be heated to a temperature of about 70°C, and the at least one mold 102 can be positioned within the oven 110 for a suitable length of time, such as between about 10 hours and about 70 hours. In some embodiments, the mold 110 is positioned within the oven 110 for less than 24 hours, and in some cases, less than 23 hours, less than 22 hours, less than 21 hours, less than 20 hours, less than 19 hours, less than 18 hours, less than 17 hours, less than 16 hours, less than 15 hours, less than 14 hours, less than 13 hours, or even less than 12 hours, ranging all the way down to 1 hour or less. It should be appreciated, however, that the temperature of the oven 110 and the time required to solidify the gummy confectionery material within the oven 110 can vary not only based on the desired third set of parameters of the resulting gummy confectionery material J3, but also based on the second set of parameters of the second gummy confectionery material J2 provided to the oven. By removing a portion of the moisture from the gummy confectionery material prior to solidifying the gummy confectionery material within the oven 110, the total time that the gummy confectionery material is positioned within the oven 110 to form a gummy confectionery material J3 having the same final percent solids is reduced.

[0084] A skin can form on the gelato material within the cavity 102 during the curing process. Various adjustments can be made to the composition of the gelato material, the processing parameters associated with the first moisture removal system, and / or the processing parameters associated with the second moisture removal system to increase or decrease the skin of the final gelato.

[0085] In existing systems, the percent solids of the gelato material provided to the depositing nozzle and the cavity is typically between about 75% and 76%. However, the gelato material J2 provided to the second moisture removal system 24 with the second set of parameters has a percent solids between about 79% and about 86%. Due to this increased percent solids, the gelato material J2 can have a greater viscosity than the gelato material provided to the depositing nozzle in existing systems. When the gelato material with the increased viscosity is provided to the same depositing nozzle used in existing systems, difficulties in pumping the gelato material and tailing can occur. Tailing refers to an extra amount of gelato material output from the depositing nozzle that does not directly enter the cavity. Instead, this material or "tail" can extend upward from the cavity or can connect adjacent cavities to one another.

[0086] To address the potential problems of pumping and tailing caused by the increased viscosity of the gelato material J2 with the second percent solids, the temperature of the gelato material J2 with the second percent solids can be increased. Referring to Figure 7 , a graph illustrating the viscosity of a first gelato material and a second gelato material at different temperatures over a range of shear rates is illustrated. Three lines identified as control slurry (standard brix) represent a first gelato material with a first percent solids, such as the percent solids associated with gelato materials currently deposited via existing processes. The three lines represent the viscosity of the first gelato material at different temperatures 85°C, 95°C, and 105°C, respectively. The graph additionally provides three lines identified as control slurry (higher brix). These lines represent a second gelato material at the same three temperatures. The second gelato material has the same composition as the first gelato material; however, the percent solids of the second gelato material is greater than the percent solids of the first gelato material. In one embodiment, the second gelato material has a second percent solids comparable to the gelato material J2 described herein.

[0087] As can be seen by comparing the line associated with the first gelato material (standard brix) at a particular temperature and the corresponding line associated with the second gelato material (higher brix) at the same temperature, for shear rates less than 1000 s -1The viscosity of the second gummy confectionery material at any shear rate increases significantly. However, as the temperature of the second gummy confectionery material increases, the viscosity of the second gummy confectionery material at the same shear rate decreases. Thus, the temperature of the second gummy confectionery material can be controlled to achieve a second gummy confectionery material having a viscosity that is nearly equal to the viscosity of the first gummy confectionery material for a given shear rate.

[0088] In the existing system, the gummy confectionery material having a percent solids between about 75% and 76% is output from the depositing nozzle at a temperature between about 85°C and about 90°C. This combination of temperature and percent solids results in an acceptable depositing viscosity without creating too much sucrose inversion prior to depositing. In one embodiment, the gummy confectionery material J2 output from the first water removal system and having a second percent solids, such as between about 79% and about 86%, is discharged from the same depositing nozzle 104 at a temperature greater than 100°C, such as between about 100°C and about 115°C. As described above, at this temperature, the viscosity of the gummy confectionery material J2 having the second percent solids can compensate for the higher percent solids. For example, the viscosity of the gummy confectionery material J2 having the second percent solids can be within, such as for example, 10% of the viscosity of the gummy confectionery material having a percent solids between about 75% and 76% at a temperature between about 85°C and about 90°C. The gummy confectionery material J2 having the second percent solids can be heated via a heating system (not shown) located at the depositing nozzle, or alternatively or additionally, at a location upstream of the depositing nozzle. To achieve this elevated temperature, the heating system can be configured to use oil instead of water to transfer heat to the gummy confectionery material J2.

[0089] With continued reference to Figure 7Alternatively or in addition, to raise the temperature of the gelatinized confectionery material J2, the shear rate can be controlled (such as, for example, increased or decreased) to achieve the desired viscosity of the gelatinized confectionery material J2 being deposited. As an alternative to controlling the viscosity of the gelatinized confectionery material J2, one or more parameters associated with the operation of the deposition nozzle 104 can be adjusted to accommodate the increased viscosity of the gelatinized confectionery material J2 output from the first moisture removal system 22. Examples of such parameters include, but are not limited to, back suction and deposition speed. For example, the deposition speed of the gelatinized confectionery material J2 can be between 10 mm / second and 500 mm / second. At this speed, the deposition nozzle 104 can be used to fill between 10 and 50 trays per minute. However, embodiments having deposition speeds or total number of trays filled per minute outside of the given range are also within the scope of the present disclosure. In one embodiment, the configuration of the deposition nozzle 104 used to deposit the gelatinized confectionery material J2 having the second percent solids can be changed relative to the deposition nozzle of existing systems. For example, the axial length of the deposition nozzle 104, the inner diameter of the deposition nozzle 104 at the outlet, and / or the change in inner diameter over the axial length of the deposition nozzle 104 can be adjusted. In one embodiment, the shape of the deposition nozzle 104 is cylindrical or conical and has a nozzle inner diameter between 1.5 mm and 4.5 mm. Alternatively or in addition, at least a portion of the interior surface 106 of the deposition nozzle 104 can include one or more coatings. In some embodiments, a separate device 108 for interrupting the flow of the gelatinized confectionery material at the outlet of the deposition nozzle 104 can be included. The device 108 can be a heating element operable to break the tail of the gelatinized confectionery material J2 at the outlet of the deposition nozzle 104. In one embodiment, the device 108 is a mechanical cutting device operable to break the tail of the gelatinized confectionery material at the outlet of the deposition nozzle 104. However, any suitable device 108 is also within the scope of the present disclosure.

[0090] The systems for forming gelatinized confections as exemplified and described herein are operable to form the gelatinized confectionery material, the gelatinized confection, or the final gelatinized confection in a reduced amount of time. For example, forming a gelatinized confection by baking a gelatinized confectionery material having a percent solids between 73% and 78.5% typically requires 16 hours to 70 hours depending on the size, weight, shape, dimensions, and thickening agent, if any, included in the composition. The product temperature during the steady state conditions of the baking process is typically between 50 °C and 75 °C for starch-based gelatinized confections and between 20 °C and 60 °C for gelatin-containing gelatinized confections. Additionally, the resulting gelatinized confection typically has a percent solids between 80% and 88.5%.

[0091] However, when forming a gelatinous confectionery using the two-step process described herein, a significant time reduction is achieved. The percent solids of the gelatinous confectionery material provided thereto typically increases by at least 1% during the first moisture removal process. In some embodiments, the percent solids of the gelatinous confectionery material typically increases between 2% and 10%, such as at least 4%, at least 5%, and in some embodiments, for example, about 6% during the first moisture removal process. This increase in the percent solids of the gelatinous confectionery material is achieved in less than 5 minutes, and in some embodiments, in less than 3 minutes, less than 90 seconds, or even between 30 seconds and 60 seconds. For example, the gelatinous confectionery material can be held within the containment device 80 for less than one minute. Thus, the rate of moisture removal from the gelatinous confectionery material during at least a portion of the manufacturing process is greater than or equal to about 1% per hour. For example, the rate of moisture removal during at least a portion of the manufacturing process can be greater than or equal to about 2% per hour, about 3% per hour, about 4% per hour, and about 5% per hour. In some embodiments, the rate of moisture removal during a portion of the manufacturing process is greater than or equal to about 10% per hour, about 11% per hour, about 12% per hour, about 13% per hour, about 14% per hour, and about 15% per hour.

[0092] During the second moisture removal process, the percent solids of the gelatinous confectionery material provided thereto typically increases between 1% and 9%, for example, at least 4%, and in some embodiments, for example, about 6%. As previously described, this increase in the percent solids of the gelatinous confectionery material can occur in less than 24 hours. Because the rate of moisture removal from the gelatinous confectionery material during at least a portion of the manufacturing process is increased as compared to a typical gelatinous confectionery manufacturing process, the total time required to form the gelatinous confectionery material is reduced. Further, the total energy required to form a final gelatinous confectionery from a gelatinous confectionery material J1 having a first percent solids is significantly reduced, such as by significantly reducing the time the gelatinous confectionery material spends in an oven.

[0093] The term“about” is intended to encompass a degree of error in measurement that is associated with the particular quantifying equipment available at the time the application is submitted. For example,“about” can include a range of ± 8% or 5% or 2% of a given value.

[0094] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms“a,”“an” and“the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms“comprises,”“comprising,”“includes” and / or“including,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0095] While the present disclosure has been described with reference to one or more exemplary embodiments, those skilled in the art will understand that various changes in form and detail can be made thereto without departing from the scope of the present disclosure. Furthermore, to the extent that the prior art knowledge has been incorporated into the present disclosure, such is for enhancement of understanding of the present disclosure then presently known, but not to limit the present disclosure in any way. The application is thus intended to cover all alternatives, modifications and equivalents that can be included within the scope of the present disclosure as defined by the following claims.

Claims

1. A method of forming a jelly confectionery, the method comprising: providing a jelly confectionery material having a first solids percentage; removing moisture from the jelly confectionery material having the first solids percentage in a first moisture removal system to form a jelly confectionery material having a second solids percentage; depositing the jelly confectionery material output from the first moisture removal system and having at least the second solids percentage into at least one mold; as well as Moisture is removed from the jelly confectionery material having at least the second solids percentage in a second moisture removal system to form a jelly confectionery material having a third solids percentage.

2. The method of claim 1, wherein the jelly confectionery material having the second solids percentage is a high solids jelly.

3. The method of claim 1, wherein the second solids percentage is between 2% and 10% greater than the first solids percentage.

4. The method of claim 1, wherein the second percent solids is at least 4% greater than the first percent solids.

5. The method of claim 1, wherein the third percent solids is between 1% and 9% greater than the second percent solids.

6. The method of claim 1, wherein the third percent solids is at least 4% greater than the second percent solids.

7. The method of claim 1, wherein the second percent solids is between about 79% and about 86%.

8. The method of claim 1, wherein the jelly confectionery material having the first solids percentage is a low solids jelly.

9. The method of claim 1 , wherein removing moisture from the jelly confectionery material having at least the second solids percentage within the at least one mold further comprises: The jelly confectionery material having at least the second solids percentage is baked.

10. The method of claim 1, wherein the first moisture removal system is an extruder.

11. The method of claim 10, wherein the extruder further comprises at least one devolatilization section comprising at least one opening to the surrounding environment, the removing of moisture from the jelly confectionery material having the first solids percentage occurring through the at least one opening.

12. The method of claim 10, wherein the extruder further comprises at least one devolatilization section comprising at least one opening and a vacuum device in communication with the at least one opening, the vacuum device being positioned to actively draw moisture from the jelly confectionery material having the first solids percentage and the extruder.

13. The method of claim 1, wherein the first moisture removal system comprises a heat transfer device.

14. The method of claim 13, wherein the heat transfer device is a scraped surface heat exchanger.

15. The method of claim 13, wherein the first moisture removal system further comprises a containment device fluidly coupled to the heat transfer device, the method further comprising: providing the jelly confectionery material having the first solids percentage from the outlet of the heat transfer device to the containment device; as well as The jelly confectionery material having the first solids percentage is released into the interior of the containment device.

16. The method of claim 15, wherein removing moisture from the jelly confectionery material having the first solids percentage within the first moisture removal system to form a jelly confectionery material having a second solids percentage occurs in response to releasing the jelly confectionery material having the first solids percentage into the interior of the containment device.

17. The method of claim 16, wherein removing moisture from the jelly confectionery material having the first solids percentage occurs in response to continuously renewing an exterior surface of the jelly confectionery material having the first solids percentage.

18. The method of claim 15, wherein the interior of the containment device has a low moisture, low pressure environment.

19. The method of claim 1, wherein the jelly confectionery material having the third solids percentage is a finished jelly confectionery having a desired shape.

20. The method of claim 1, wherein depositing the jelly confectionery material having at least the second solids percentage into the at least one mold further comprises: The jelly confectionery material having the second solids percentage is deposited at a temperature greater than 100°C.

21. A method of forming a jelly confectionery, the method comprising: depositing a jelly confectionery material having a solids percentage of at least 79% into at least one mold; as well as The jelly confectionery material is baked to form a jelly confectionery material having a final solids percentage.

22. A method according to claim 21 wherein the percentage solids of the jelly confectionery material deposited into the at least one mould is at least 81%.

23. The method according to claim 21, further comprising: reducing the viscosity of said jelly confectionery material having said percentage of solids of at least 79%.

24. The method of claim 23, wherein reducing the viscosity of the jelly confectionery material having the solids percentage of at least 79% comprises heating the jelly confectionery material having the solids percentage of at least 79%.

25. The method of claim 24, wherein the jelly confectionery material having the solids percentage of at least 79% is heated to a temperature greater than 100°C.

26. The method of claim 24, wherein said heating of said jelly confectionery material having said solids percentage of at least 79% occurs before said depositing of said jelly confectionery material having said solids percentage of at least 79% into said at least one mould.

27. The method of claim 21 , wherein the jelly confectionery material having the solids percentage of at least 79% is deposited into the at least one mold via a deposition nozzle, the method further comprising: The flow of the jelly confectionery material having the solids percentage of at least 79% is interrupted at the depositing nozzle.

28. The method of claim 27, wherein said interrupting said flow of said jelly confectionery material having said solids percentage of at least 79% at said deposition nozzle further comprises: The tail of the jelly confectionery material is cut off.

29. A method of forming a jelly confectionery, the method comprising: providing a jelly confectionery material having a first solids percentage; removing moisture from the jelly confectionery material having the first solids percentage in a moisture removal system to form a jelly confectionery material having a second solids percentage, wherein at least a portion of the moisture is removed from the jelly confectionery material having the first solids percentage at a rate of at least about 1% per hour.

30. The method of claim 29, wherein at least a portion of the moisture is removed from the jelly confectionery material having the first percentage at a rate of at least about 2% per hour.

31. The method of claim 29, wherein at least a portion of the moisture is removed from the jelly confectionery material having the first percentage at a rate of at least about 5% per hour.

32. The method of claim 29, wherein at least 1% of the moisture is removed from the jelly confectionery material having the first percentage in less than five minutes.

33. The method of claim 29, wherein at least 5% of the moisture is removed from the jelly confectionery material having the first percentage in less than five minutes.

34. The method of claim 29, wherein the jelly confectionery material having the first solids percentage is a low solids jelly and the jelly confectionery material having the second solids percentage is a high solids jelly.

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