Dual structure crunchy gum pellet

Abstract

Disclosed is a coated confectionery, including a confectionery core and a shell surrounding the confectionery core, the shell including a soft coating including at least one layer of a first soft coating material, and at least one layer of a second soft coating material, the first soft coating material being a soft coating syrup including maltitol, and the second soft coating material being a soft coating powder including isomalt, and a hard coating including at least one layer of a hard coating material, the hard coating material is a hard coating syrup including maltitol, wherein the soft coating forms at least 25% of a total weight of said shell.

Description

[0001] DUAL STRUCTURE CRUNCHY GUM PELLET

[0002] FIELD

[0003] The disclosure relates generally to a confectionery, and more particularly, to a system and method for providing coating of the confectionery.

[0004] BACKGROUND OF THE INVENTION

[0005] Coated confectioneries, such as coated candies and coated chewing gums, are popular confectionery products. Typically, coated confectioneries are prepared via a panned coating process which is both time and energy consuming. Conventional methods of forming a coating on a confectionery are described in the background section of US Patent No. 7,810,446. For example, a conventional batch-type panning process commonly requires about 6-8 hours to coat a confectionery. Total coating time depends on a number of factors, such as, equipment, amount of desired coating, nature of ingredients etc.

[0006] In conventional chewing gum coating processes, a conditioned chewing gum center (also known as a chewing gum core) is coated with sweetener and / or sugar syrups. The sweetener- syrup is applied in successive layers, for example by spraying the sweetener-syrup on the chewing gum core. In conventional methods, after one layer of sweetener-syrup is applied, the layer is allowed to completely dry before the next layer of sweetener-syrup is applied. The sweetener-syrup layers crystallize and form a hard coating or shell around the chewing gum center. Since each sweetener-syrup layer needs to be dried and crystallized before the next layer can be applied, the sequential application of multiple sweetener-syrup layers is a time-consuming and energy intensive process.

[0007] In view of the above challenges, it is noted that there is a need to provide new methods of rapidly coating chewing gum cores. The new method should be less time-consuming, require less energy, and should not adversely affect the final product quality in terms of sensory attributes and look-and-feel of the product.

[0008] BRIEF DESCRIPTION OF EMBODIMENTS OF THE INVENTION

[0009] According to an embodiment, there is disclosed a coated confectionery, including a confectionery core and a shell surrounding the confectionery core, the shell including a soft coating including at least one layer of a first soft coating material, and at least one layer of a second soft coating material, the first soft coating material being a soft coating syrup including maltitol, and the second soft coating material being a soft coating powder including isomalt, and a hard coating including at least one layer of a hard coating material, the hard coating material is a hard coating syrup including maltitol, wherein the soft coating forms at least 25% of a total weight of said shell.

[0010] In addition to one or more of the features described above, or as an alternative, in further embodiments the hard coating forms at least 55% of the shell total weight.

[0011] In addition to one or more of the features described above, or as an alternative, in further embodiments the confectionery core is a chewing gum.

[0012] In addition to one or more of the features described above, or as an alternative, in further embodiments the soft coating syrup also includes gum arabic and water.

[0013] In addition to one or more of the features described above, or as an alternative, in further embodiments the soft coating syrup is 20%-60% maltitol.

[0014] In addition to one or more of the features described above, or as an alternative, in further embodiments the soft coating syrup is 10%-30% gum arabic.

[0015] In addition to one or more of the features described above, or as an alternative, in further embodiments the soft coating syrup is 45% water.

[0016] In addition to one or more of the features described above, or as an alternative, in further embodiments the soft coating syrup is 10%-70% water.

[0017] In addition to one or more of the features described above, or as an alternative, in further embodiments the soft coating includes a soft coating weight, and the soft coating weight is 5%- 25% of a weight of the confectionery core.

[0018] In addition to one or more of the features described above, or as an alternative, in further embodiments the at least one layer of the soft coating material is two layers of the soft coating syrup, and wherein the at least one layer of the second coating material is two layers of the soft coating powder.

[0019] In addition to one or more of the features described above, or as an alternative, in further embodiments the two layers of the soft coating syrup and the two layers of the soft coating powder are applied in an alternating manner.

[0020] In addition to one or more of the features described above, or as an alternative, in further embodiments the hard coating syrup also includes water.

[0021] In addition to one or more of the features described above, or as an alternative, in further embodiments the hard coating syrup is 60%-90% maltitol.

[0022] In addition to one or more of the features described above, or as an alternative, in further embodiments a combined weight of the soft coating and the hard coating is 20%-60% of a weight of the core.

[0023] In addition to one or more of the features described above, or as an alternative, in further embodiments the confectionery core is conditioned between application of the soft coating and the hard coating.

[0024] According to another embodiment, there is disclosed a method of forming a coated confectionery, the method including providing a confectionery core, forming a soft coating about an exterior surface of the confectionery core, wherein the forming of the soft coating including applying a soft coating syrup including maltitol, and applying a soft coating powder including isomalt, and forming a hard coating about the soft coating, wherein the forming of the hard coating includes applying a hard coating syrup including maltitol, wherein the soft coating forms at least 25% of a total weight of the shell.

[0025] In addition to one or more of the features described above, or as an alternative, in further embodiments a length of time required to form the hard coating is at least double a length of time required to form the soft coating.

[0026] In addition to one or more of the features described above, or as an alternative, in further embodiments the length of time to form the hard coating is at least four times the length of time required to form the soft coating.

[0027] In addition to one or more of the features described above, or as an alternative, in further embodiments the length of time to form the soft coating is less than thirty minutes.

[0028] In addition to one or more of the features described above, or as an alternative, in further embodiments the length of time to form the hard coating is at least two hours.

[0029] In addition to one or more of the features described above, or as an alternative, in further embodiments the confectionery core is a chewing gum.

[0030] In addition to one or more of the features described above, or as an alternative, in further embodiments the forming of the soft coating includes applying the soft coating syrup about the exterior surface of the confectionery core.

[0031] In addition to one or more of the features described above, or as an alternative, in further embodiments the forming of the soft coating further includes applying the soft coating powder about the soft coating syrup.

[0032] In addition to one or more of the features described above, or as an alternative, in further embodiments a percentage of weight gain per hour achieved during formation of the soft coating is at least double a percentage of weight gain per hour achieved during formation of the hard coating.

[0033] In addition to one or more of the features described above, or as an alternative, in further embodiments moisture is removed during formation of the hard coating by evaporation.

[0034] In addition to one or more of the features described above, or as an alternative, in further embodiments the method further includes forming a confectionery core, wherein no conditioning of the confectionery core occurs between forming the confectionery core and the forming the soft coating about the confectionery core.

[0035] In addition to one or more of the features described above, or as an alternative, in further embodiments the soft coating syrup also includes gum arabic and water.

[0036] In addition to one or more of the features described above, or as an alternative, in further embodiments the soft coating syrup is 20%-60% maltitol.

[0037] In addition to one or more of the features described above, or as an alternative, in further embodiments the soft coating syrup is 10%-30% gum arabic.

[0038] In addition to one or more of the features described above, or as an alternative, in further embodiments the soft coating syrup is 45% water.

[0039] In addition to one or more of the features described above, or as an alternative, in further embodiments the soft coating syrup is 10%-70% water.

[0040] In addition to one or more of the features described above, or as an alternative, in further embodiments the soft coating includes a soft coating weight, and the soft coating weight is 5%- 25% of a weight of the confectionery core.

[0041] In addition to one or more of the features described above, or as an alternative, in further embodiments the forming of the soft coating includes applying two layers of the soft coating syrup, and applying two layers of the soft coating powder.

[0042] In addition to one or more of the features described above, or as an alternative, in further embodiments the two layers of the soft coating syrup and the two layers of the soft coating powder are applied in an alternating manner.

[0043] In addition to one or more of the features described above, or as an alternative, in further embodiments the hard coating syrup also includes water.

[0044] In addition to one or more of the features described above, or as an alternative, in further embodiments the hard coating syrup is 60%-90% maltitol.

[0045] In addition to one or more of the features described above, or as an alternative, in further embodiments a combined weight of the soft coating and the hard coating is 20%-60% of a weight of the core.

[0046] In addition to one or more of the features described above, or as an alternative, in further embodiments a temperature of the soft coating syrup is 30°C to 70°C during the forming of the soft coating about the confectionery core.

[0047] In addition to one or more of the features described above, or as an alternative, in further embodiments the method further includes conditioning the confectionery for 24 to 48 hours between the forming of the soft coating and the forming of the hard coating. In addition to one or more of the features described above, or as an alternative, in further embodiments a temperature of the hard coating syrup is around 70°C during the forming of said the coating.

[0048] BRIEF DESCRIPTION OF THE DRAWINGS

[0049] The accompanying drawings incorporated in and forming a part of the specification embodies several aspects of the present disclosure and, together with the description, serves to explain the principles of the present disclosure. In the drawings:

[0050] Figure 1 is a perspective, cross-sectional view of a confectionery according to an embodiment; and

[0051] Figure 2 is a schematic diagram of a system for manufacturing a confectionery according to an embodiment.

[0052] The detailed description explains embodiments of the disclosure, together with advantages and features, by way of example with reference to the drawings.

[0053] DETAILED DESCRIPTION OF THE INVENTION

[0054] Referring now to FIG. 1, examples of a confectionery 20 according to an embodiment of the disclosure are illustrated. As shown, the confectionery 20 includes a core 22 formed from any suitable confectionery composition. The term “confectionery composition” as used herein is intended to include any edible product comprising a sweet component. Confectionery compositions may additionally include medicinal preparations made with sugar, syrup, sugar alcohol, honey, and sweet foods, such as candy or pastry for example. Confectionery compositions are well known in the art and include soft candy, chewy candy, hard candy, chewing gum, chocolate (including milk chocolate, dark chocolate, white chocolate, and semisweet chocolate for example, and lozenges, etc. In one embodiment, the confectionery core is a chewing gum composition, including an elastomer base.

[0055] Formed concentrically around and surrounding the confectionery core 22 is a shell 24 including both a soft coating 26 and a hard coating 28. The soft coating 26 is located directly adjacent the confectionery core 22 and the hard coating 28 is arranged about and surrounding the exterior of the soft coating 26. In one embodiment, the soft coating 26 forms between about 25% and about 45% of the total shell weight, and the hard coating 28 forms about 55-75% of the total shell weight. A soft coating 26 forming at least 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40%, 41%, 42%, 43%, 44%, or 45% of the total shell weight is contemplated herein, as is a hard coating forming at least 55%, 56%, 57%, 58%, 59%, 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, or 75% of the total shell weight. The soft coating 26 includes one or more layers formed by at least a first soft coating material, and one or more layers of a second coating material. In an exemplary embodiment, the first soft coating material applied to the core 22 is a soft coating syrup including the sugar alcohol, maltitol. A layer of this soft coating syrup is first applied directly to the core 22, and surrounds the core 22 completely in a uniform manner. In addition to maltitol, the soft coating syrup may include gum arabic and water. In an exemplary embodiment, the soft coating syrup includes 20%-60% maltitol, 10%-30% gum arabic, and 10%-70% water. A non-limiting example may include 40% maltitol, 15% gum arabic, and 45% water, with a maltitol percentage of at least any of 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, 50%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59%, or 60% also being contemplated herein.

[0056] Following application of the layer of soft coating syrup referenced above, a second soft coating material is applied uniformly about the initial layer of the soft coating syrup. This second soft coating material is a powder including isomalt (referred to as the soft coating powder hereinbelow). The soft coating powder adheres to the soft coating syrup to form a first agglomerate layer about the core 22, with this first agglomerate layer being the material that creates the soft coating 26.

[0057] In an exemplary embodiment, an additional layer of soft coating syrup is applied uniformly about the first agglomerate layer (surrounding the first agglomerate layer), and an additional layer of soft coating powder is then applied to the additional layer of soft coating syrup. These additional layers of soft coating syrup and soft coating powder creates an additional agglomerate layer about the core. Further alternating layers of soft coating syrup and soft coating powder may be applied to create further agglomerate layers until a desirable weight of the total soft coating 26 (25% - 45% of the total shell) is achieved. In an exemplary embodiment, this total weight of all of the soft coating layers is also at least 13% of the weight of the original core, with weights of at least 5%, 6%, 7%. 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 15%, 20%, 21%, 22%, 23%, 24%, or 25% all being contemplated herein. In an exemplary embodiment, at least 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, or 20% of the weight of the soft coating 26 is the soft coating syrup, while at least 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89% or 90% of the soft coating is the soft coating powder.

[0058] After a desirable amount / weight of the soft coating 26 has been formed about the core 22, a hard coating 28 is formed about the soft coating 26 such that the soft coating is completely surrounded by the hard coating 28 in a uniform manner. The hard coating 28 is a hard coating syrup including maltitol and water. In an exemplary embodiment, the hard coating syrup includes at least 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, 75%, 76% 77%, 78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89% or 90% maltitol. The hard coating syrup is applied to the soft coating 26 in a first layer, dried, and then applied in subsequent layers until the combined weight of the soft coating 26 and hard coating 28 (e.g. the entire shell 24) is 20%-60% the weight of the original core 22.

[0059] As previously stated, the soft coating syrup including maltitol may also include gum arabic in a desirable percentage. Separately or in addition to the gum arabic, the soft coating syrup may also include one or more other binding agents such as but not limited to pea starch, xanthan gum, carboxymethyl cellulose, methyl cellulose, hydroxypropylmethyl cellulose, starch, modified starches, inulin, konjac, chitosan, tragacanth, karaya, ghatti, larch, carageenan, alginate, chemically modified alginate, agar, guar, locust bean, psyllium, tara, gellan, curdlan, pullan, gelatin, and pectin. These binding agents assist in adhering the soft coating syrup to the cores 22. The hard coating syrup may also include gum arabic in a desirable percentage, and / or one or more of the other binding agents mentioned above. Such agents help the hard coating adhere to the soft coating surface. The hard coating syrup may also contain other additives, such as color and / or flavor.

[0060] Emulsifiers may also be present in the soft coating syrup and hard coating syrup. Suitable emulsifiers such as but not limited to one or more of polysorbates (polyoxyethylene sorbitan esters), glyceryl monostearate, lecithin, a fatty acid monoglyceride, a diglyceride, propylene glycol monostearate, sugar esters, polyglycerol fatty acid esters, polyglycerol polyricinoleate (PGPR), monoglycerides may be used in the syrups. Suitable polysorbates for us in the syrups include but are not limited to one or more of polysorbate 20, polysorbate 40, polysorbate 60, and polysorbate 80. In some embodiments, the emulsifier used is polysorbate 60.

[0061] With reference now to FIGS. 2, a system 60 and method of rapidly coating a confectionery core is illustrated and described in more detail. The method generally includes forming the soft coating 26 as discussed above about the exterior surface of one or more confectionery cores 22. As previously discussed, the soft coating includes one or more agglomerate layers including both the soft coating syrup with maltitol, and the soft coating powder with isomalt. After formation of the soft coating 26, the hard coating 28 as discussed above is then formed about the exterior of the soft coating 26 via application of the hard coating syrup with maltitol. Referring to FIG. 2, a system and method for rapidly coating a non- conditioned confectionery core 22 is illustrated. In this embodiment, the confectionery cores 22 are not cooled or conditioned before application of the soft coating 26. The system 60 as shown in the exemplary embodiment of FIG. 2 generally includes forming a soft coating 26 about a confectionery core 22 at a first coating station 62, and optionally a second coating station 64, and forming a hard coating 28 about the soft coating 26 at a hard coating station 80 arranged downstream from the first coating station 62 and optional second coating station 64.

[0062] The confectionery cores 22 provided to the coating system 60 are manufactured in a standard manner upstream of the system 60. During manufacture, chewing gum of a desirable composition may be mixed and then formed into a sheet of a desired thickness, which is then scored and cut to form a plurality of pieces or cores 22. Once the sheet from which the cores 22 are cut is formed no further conditioning need occur. In other words, the sheet of chewing gum may be formed and sent to the coating system 60 without any conditioning occurring. Once the sheet is cut into the cores 22 the chewing gum is ready for transport to the coating system 60 to begin the coating process. As a result, the confectionery cores 22 provided to the first drum coating station 62 are at a normal processing temperature.

[0063] As shown in FIG. 2, a flow of confectionery cores 22 is provided to the system 60 via a chute 72 that connects the feeder 70 to the first coating station 62. In the illustrated, non-limiting embodiment, one or more alternating layers of soft coating syrup and soft coating powder may be applied about the exterior of the confectionery cores 22 in the first drum coating station 62 in order to form some or all of the soft coating 26. In the event that the soft coating is only partially formed in the first drum coating station 62, the second gum coating station 64 may be employed to apply additional alternating layers of soft coating syrup and soft coating powder to the existing agglomerate layer or layers that were applied in the first drum coating station 62. While the entire soft coating 26 (with all agglomerate layers) may be applied in the first coating station 64, for ease of description the system and process will be described henceforth as including the optional second drum coating station 64, in which application of the layers of soft coating 26 is completed. Following completion of the soft coating 26, one or more layers of the hard coating syrup may be applied about an exterior of the soft coating 26 in the hard coating station 80.

[0064] In an exemplary embodiment, the first coating station 62 and second coating station 64 each include a first rotating drum 74 and a second rotating drum 76. These drums 74, 76 are the same in both of the stations 62, 64, and the drums 74, 76 of each station may be fixed relative to each other via any known affixing or locking mechanisms that connect surfaces of the drums and / or structures supporting the drums, though the drums 74, 76 but may rotate and incline independently. The first drum 74 defines a first drum volume and the second drum 76 defines a second drum volume. The first and second drum volumes communicate via insertion of an end of the first drum 74 into a portion of the second drum 76 that tapers down to an inlet opening thereof, allowing the confectionery cores 22 to flow from the first drum 74 into the second drum 76. This insertion of the end of the first drum 74 into the inlet of the second drum 76 also forms an annulus between the first and second drums 74, 76.

[0065] In an exemplary embodiment, the first drum 74 of first drum coating station 62 receives confectionery cores 22 from the feeder 70 via the chute 72. Once in the first drum of the first drum coating station 62, soft coating syrup may be injected into the drum volume. This soft coating syrup may be provided to this volume via one or more nozzles at an interior of the first drum 74. In one embodiment, the soft coating syrup may be applied via one or more high pressure spray nozzles, standard drip / flow nozzles, or orifices in the respective drum. Use of high pressure spray nozzles provides adjustability in both droplet size and spray pattern, without compromising the required flow. Of course, the syrup may also be provided manually at the same opening into which the chute 72 provides the cores 22.

[0066] As is discussed above, the water content of the soft coating syrup may, in an exemplary embodiment, be around 45%. The temperature of the soft coating syrup is around 40°C for optimum spreading and distribution, but may be effective at any of at least 30°C, 31°C, 32°C, 33°C, 34°C 35°C, 36°C, 37°C, 38°C, 39°C, 40°C, 41°C, 42°C, 43°C, 44°C, 45°C, 46°C, 47°C,

[0067] 48°C, 49°C, 50°C 51°C, 52°C, 53°C, 54°C, 55°C, 56°C, 57°C, 58°C, 59°C, 60°C, 61°C, 62°C,

[0068] 63°C, 64°C, 65°C, 66°C, 67°C, 68°C, 69°C, or 70°C. If one or more nozzles are employed for delivering the soft coating syrup to the interior or volume of the first drum 74, a spray application time of any of at least 30 seconds, 40 second, 50 second or 60 seconds may be desirable for uniform distribution of a layer of the soft coating syrup from the nozzles, or the spray may be metered and continuous in a continuous flow coating process. This first layer of the soft coating syrup desirably seals each of the cores 22, as they are also mixed in the first drum 74 (the drum 74 may rotate and coat the cores 22 for this amount of time whether the syrup is provided via a spray nozzle or not).

[0069] Following or during application of the first layer of the soft coating syrup, cool process air may be blown into the first drum coating station 62 over the first layer of soft coating syrup and / or the confectionery cores 22 (though this is optional). The temperature of the process air during the application of the first syrup is generally lower than in conventional systems. The adhesion tendency of the first layer of soft coating syrup may correlate to the temperature of the process air. When the first layer of soft coating syrup contacts the surface of the confectionery cores 22, a temperature of the first layer of soft coating syrup may drop due to exposure to the process air, and cause j edification to begin. As a result, the first layer of soft coating syrup is more able to stick and cool on the exterior surface of the confectionery cores 22 without drying.

[0070] Following application of the first coating of syrup, the cores 22 (which are now coated with syrup) may be fed from the first drum 74 to second drum 76. In an exemplary embodiment, this may be achieved via a mechanism that positions the drums 74,76 at different angles relative to each other. For example, the first drum 74 may be disposed at a downward angle relative to the second drum 76, such that gum cores 22 that have received the first layer of coating syrup may simply flow via gravity into the second drum 76.

[0071] As is noted above, application of the soft coating powder including isomalt is applied following application of the first layer of the soft coating syrup. While soft coating powder could be applied in first drum 74 of the first drum coating station 62, in the exemplary of FIG. 2 one or more layers of soft coating powder are applied in the second drum 76. In an exemplary embodiment, a tube may be fed into the annulus formed between the first and second drums 74, 76, whereby the tube feeds powder via gravity or metering into the second drum 76. While in the second drum 76, a layer of soft coating powder may be applied to the cores 22 (coated with the first syrup layer) via rotation of the second drum 76. This application of powder including isomalt forms a first agglomeration layer on the cores 22, as discussed above.

[0072] The second drum 76 may also include nozzles for injecting soft coating syrup (or simply have soft coating syrup supplied to an interior volume thereof via a tube or nozzle fed into the annulus). As discussed above, alternating layers of soft coating syrup and soft coating powder may be applied in the second drum 76 until a desirable weight and / or thickness of agglomeration layers is reached. As noted above, the entire soft coating may be applied via the drum 74, 76 of the first drum coating station 62. However, in the exemplary embodiment of FIG. 2, additional agglomeration layers are applied in the second drum coating station 64, in which the soft coating layer is completed.

[0073] The cores 22 with a partial soft coating may be transported to the second drum coating station via a conveyor 82. In an exemplary embodiment, the cores 22 are transported from the first drum coating station 62 to the second drum coating station without any conditioning (“conditioning should be defined throughout the description as intentional residency in a storage area that may include temperature and / or humidity regulation). Once in the second coating station 64, the drums 74, 76 apply additional agglomeration layers to the cores 22 as received from the first drum coating station 62 in the same manner as the drums 74, 76 of the first drum coating station 62. As noted above, these cores 22 from the first coating station 62 include a partial soft coating with one or more agglomeration layers. The cores 22 with a partial soft coating receive an additional syrup coating in the first drum 74 of the second the second drum coating station 64. They are then transported to the second drum 76 (again via an angling of the first drum 74 like in the first drum coating station 62 in an exemplary embodiment), where powder is applied to create an additional agglomeration layer. Additional alternating layers of soft coating syrup and soft coating powder may also be applied in this second drum 76. Whether via the first layer of soft coating powder applied in the second drum 76 of the second drum coating station 64, or via additional alternating layers of syrup and powder, agglomeration layer(s) will be applied until the soft coating 26 is completed and a desirable weight and / or thickness of agglomeration layers is reached. Application of the total soft coating 26 to the cores 22 may take 20 minutes or less (whether application is completed in either just a single coating station or in the first and second drum coating stations 62, 64 as shown in the exemplary embodiment of FIG. 2).

[0074] It should be appreciated that in the illustrated, non-limiting embodiment, the volume of the second drums 76 is greater than that of the first drum 74, such as via a greater diameter and / or length of the second drums 76 relative to the first drums 74. As a result, during transport of the cores 22 from an inlet in the first drum 74 to an outlet of the second drum 76, the cores 22 may have a longer residence time in the second drum volume than the first drum volume. This greater residence time in the second drum may provide for more time for adding powder, as well as additional alternating powder and syrup layers (e.g. creating agglomeration layers). However, other configurations, such as where the drum volumes are the same or where the first drum volume is greater than the second drum volume are also within the scope of the disclosure. A coating station, such as but not limited to those further described in United States Patent Application No. 14 / 119,935, which is herein incorporated by reference in its entirety, is contemplated herein.

[0075] As noted above, after application of the soft coating 26, the confectionery cores 22 may be collected (such as in trays for example) and placed in a conditioning room, illustrated schematically at C, for a desired period of time. The conditioning room C has at least one of a controlled temperature and humidity. By positioning the confectionery cores 22 having the soft coating 26 within the conditioning room C for a desired period of time, the hardness of both the core 22 and the soft coating 26 is increased. As is noted above, conditioning in the conditioning room C may last 24 to 48 hours, and allow the agglomerated layers of the soft coating 26 to firm up and become more dimensionally robust and stable. There may also be some partial crystallization of the agglomerated layers of the soft coating 26 occurring in the conditioning room C, which helps the soft coating material to adhere to the cores 22.

[0076] After being conditioned, the confectionery cores 22 are provided to the hard coating station 80 where the hard coating syrup may be applied about the soft coating 26 to form a hard coating 28. In an exemplary embodiment, the hard coating station 80 may be more of a batch style mixer such as that shown in FIG. 2. Formation of the hard coating 28, also referred to as “finishing,” includes applying one or more layers of the hard coating syrup over the soft coating 26. In an exemplary embodiment, processed air having a temperature between about 20°C and about 50°C may be directed into the hard coating station 80 to rapidly dry the hard coating syrup that forms the hard coating 28 during the finishing / hard coating phase. This processed air may aid in removal of moisture from the hard coating syrup via evaporation.

[0077] Application of the hard coating 28 may form a smooth homogeneous surface, as well as achieve desirable sensory properties of a finalized confectionery, such as crunch, color, and flavor for example. In one embodiment, formation of the hard coating 28 requires about four hours.

[0078] In an exemplary embodiment, the hard coating syrup includes one or more colorants configured to create a desired appearance of the confectionery 20. Further, one or more flavorants may be added to the soft coating layers (syrup or powder), and / or applied to the exterior of the soft coating 26 prior to or during the initial formation of the hard coating 28. If the flavorants are added during formation of the hard coating 28, such flavorants may be included in an initially applied layer of the hard coating syrup.

[0079] In an exemplary embodiment, the hard coating syrup is applied at a temperature of at least 70°C to allow all solids to be dissolved in the syrup. The hard coating syrup may also contain small additives in addition to flavor such as color and a small amount of gum arabic or other hydrocolloid (1~4%) to help it adhere to the exterior of the soft coating 26. After application of a layer of the hard coating syrup that forms the hard coating, the syrup may be dried via forced airflow into the hard coating station 80. Layers of hard coating syrup may be applied and then dried 20 to 60 times until the hard coating 28 is formed to the desired weight and thickness.

[0080] Using the above method of applying soft and hard coatings to the cores 22, a crunchy coated confectionery 20 may be produced in less than about 5 hours. In one embodiment, formation of the soft coating 26 requires less than half the time required to form the hard coating 28. The new method described herein provides a significant time reduction compared to conventional batch panning methods. This overall reduction in time is achieved by replacing a portion of the hard coating 28 with the soft coating 26 via system(s) and process(es) described herein. In an exemplary embodiment, a 20-40% time reduction over conventional batch panned coating methods may be achieved via the disclosed processes.

[0081] The rate at which the soft coating 26 is applied to the confectionery core 22, or more specifically, the percentage of weight gain per hour achieved during application of the soft coating 26 is approximately double (or more) the percentage of weight gain per hour achieved during a conventional panning process. Further, because the hard coating 28 may be applied in a manner similar to the conventional panning process, the percentage of weight gain per hour achieved during application of the soft coating 26 to a confectionery core 22 is at least double the percentage of weight gain per hour achieved during application of the hard coating 28 to a confectionery core 22.

[0082] It has also been determined that the confectioneries 20 coated by the rapid coating methods described have texture, hardness, and sensory properties substantially similar to conventional hard pan coated confectioneries. A confectionery 20 including a soft coating 26 and a hard coating 28 as described herein, has a hardness similar to the hardness of a confectionery formed using a conventional panning process. Hardness is identified as the maximum force applied to the exterior surface of the confectionery 20. In some embodiments, the rapidly coated confectionery possesses at least 80% of the hardness of a conventional hard pan-coated confectionery having a similar or identical coating composition and the same total coating thickness at 100% penetration of the coating wherein the hardness was measured within two days of producing the rapidly coated confectionery. More specifically, it was found that the rapidly coated confectionery possessed at least 90% of hardness of a conventional hard pan-coated confectionery having the same total coating thickness at 100% penetration of the coating wherein the hardness was measured within two days of producing the rapidly coated confectionery.

[0083] The aesthetic and hardness results as described herein with respect to confectioneries 20 having a shell 24 wherein about 25-45% of the shell total weight is formed by the soft coating 26. and about 55-75% of the shell total weight is formed by the hard coating 28 are unexpected. Layering of multiple coating materials including the soft coating 26 with maltitol syrup and isomalt powder and the hard coating 28 including maltitol syrup is expected to form a shell 24 having less desirable sensory attributes such as an undesirable exterior surface having less crunch or almost no crunch compared to a conventional hard coat confectionery. However, though unexpected, a confectionery 20 with a soft coating 26 and hard coating 28 as described herein generally has a uniform, smooth outer surface with similar or even improved hardness compared to conventional hard-panned confectioneries.

[0084] In addition, it should be noted that it was surprising that a combination of maltitol soft coating syrup and isomalt soft coating powder with a maltitol hard coating syrup resulted in the shell 24 having a smooth, uniform, and well textured coating with a desirable hardness. This was surprising because in theory using the same polyol across the entire coating / shell should lead to a more stable and unform product, with good texture. Polyols crystallize faster when the same polyol is used across shell, and the presence of other polyols would be expected to inhibit crystallization when present. However, tt was discovered here - despite this expectation - that two different polyols (specifically maltitol soft and hard coating syrups and isomalt soft coating powder) resulted in a shell 24 with a uniform, smooth outer surface exhibiting a similar or even improved hardness compared to conventional hard-panned confectioneries. Indeed, using the different polyols unexpectedly achieved better results than using the same polyol.

[0085] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to make and use the invention. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

[0086] All cited patents, patent applications, and other references are incorporated herein by reference in their entirety. However, if a term in the present application contradicts or conflicts with a term in the incorporated reference, the term from the present application takes precedence over the conflicting term from the incorporated reference.

[0087] All ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other. Each range disclosed herein constitutes a disclosure of any point or sub-range lying within the disclosed range.

[0088] The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Further, it should further be noted that the terms “first,” “second,” and the like herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The modifier “about” used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (e.g., it includes the degree of error associated with measurement of the particular quantity).

Claims

CLAIMS1. A coated confectionery, comprising: a confectionery core; and a shell surrounding said confectionery core, said shell including: a soft coating including at least one layer of a first soft coating material, and at least one layer of a second soft coating material, the first soft coating material being a soft coating syrup including maltitol, and the second soft coating material being a soft coating powder including isomalt; and a hard coating including at least one layer of a hard coating material, said hard coating material is a hard coating syrup including maltitol, wherein said soft coating forms at least 25% of a total weight of said shell.

2. The coated confectionery according to claim 1, wherein said hard coating forms at least 55% of said shell total weight.

3. The coated confectionery according to claim 1, wherein said confectionery core is a chewing gum.

4. The coated confectionery according to claim 1, wherein said soft coating syrup also includes gum arabic and water.

5. The coated confectionery according to claim 4, wherein said soft coating syrup is 20%-60% maltitol.

6. The coated confectionery according to claim 4, wherein said soft coating syrup is 10%-30% gum arabic.

7. The coated confectionery according to claim 4, wherein said soft coating syrup is 45% water.

8. The coated confectionery according to claim 4, wherein said soft coating syrup is 10%-70% water.

9. The coated confectionery according to claim 1, wherein said soft coating includes a soft coating weight, and said soft coating weight is 5%-25% of a weight of said confectionery core.

10. The coated confectionery according to claim 1, wherein said at least one layer of said soft coating material is two layers of said soft coating syrup, and wherein said at least one layer of said second coating material is two layers of said soft coating powder.

11. The coated material according to claim 10, wherein said two layers of said soft coating syrup and said two layers of said soft coating powder are applied in an alternatingmanner.

12. The coated confectionery according to claim 1, wherein said hard coating syrup also includes water.

13. The coated confectionery according to claim 1, wherein said hard coating syrup is 60%-90% maltitol.

14. The coated confectionery according to claim 1, wherein a combined weight of said soft coating and said hard coating is 20%-60% of a weight of said core.

15. The coated confectionery according to claim 1, wherein said confectionery core is conditioned between application of said soft coating and said hard coating.

16. A method of forming a coated confectionery, the method comprising: providing a confectionery core; forming a soft coating about an exterior surface of said confectionery core, wherein said forming said soft coating including applying a soft coating syrup including maltitol, and applying a soft coating powder including isomalt; and forming a hard coating about said soft coating, wherein said forming said hard coating includes applying a hard coating syrup including maltitol, wherein said soft coating forms at least 25% of a total weight of said shell.

17. The method according to claim 16, wherein a length of time required to form said hard coating is at least double a length of time required to form said soft coating.

18. The method according to claim 16, wherein said length of time to form said hard coating is at least four times said length of time required to form said soft coating.

19. The method according to claim 16, wherein said length of time to form said soft coating is less than thirty minutes.

20. The method according to claim 16, wherein said length of time to form said hard coating is at least two hours.

21. The method according to claim 16, wherein said confectionery core is a chewing gum.

22. The method according to claim 16, wherein said forming said soft coating includes applying said soft coating syrup about said exterior surface of said confectionery core.

23. The method according to claim 22, wherein said forming said soft coating further includes applying said soft coating powder about said soft coating syrup.

24. The method according to claim 16, wherein a percentage of weight gain per hour achieved during formation of said soft coating is at least double a percentage of weight gain per hour achieved during formation of said hard coating.

25. The method according to claim 16, wherein moisture is removed during formation of said hard coating by evaporation.

26. The method of claim 16, the method further including forming a confectionery core, wherein no conditioning of said confectionery core occurs between forming said confectionery core and said forming said soft coating about said confectionery core.

27. The method according to claim 16, wherein said soft coating syrup also includes gum arabic and water.

28. The method according to claim 27, wherein said soft coating syrup is 20%-60% maltitol.

29. The method according to claim 27, wherein said soft coating syrup is 10%-30% gum arabic.

30. The method according to claim 27, wherein said soft coating syrup is 45% water.

31. The method according to claim 27, wherein said soft coating syrup is 10%-70% water.

32. The method according to claim 16, wherein said soft coating includes a soft coating weight, and said soft coating weight is 5%-25% of a weight of said confectionery core.

33. The method according to claim 16, wherein said forming said soft coating includes applying two layers of said soft coating syrup, and applying two layers of said soft coating powder.

34. The method according to claim 33, wherein said two layers of said soft coating syrup and said two layers of said soft coating powder are applied in an alternating manner.

35. The method according to claim 16, wherein said hard coating syrup also includes water.

36. The method according to claim 16, wherein said hard coating syrup is 60%-90% maltitol.

37. The method according to claim 16, wherein a combined weight of said soft coating and said hard coating is 20%-60% of a weight of said core.

38. The method of claim 16, wherein a temperature of said soft coating syrup is 30°C to 70°C during said forming of said soft coating about said confectionery core.

39. The method of claim 16, further including conditioning the confectionery for 24 to 48 hours between said forming of said soft coating and said forming of said hard coating.

40. The method of claim 16, wherein a temperature of said hard coating syrup is around 70°C during said forming of said hard coating.

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