Advanced encapsulation process for controlled release of active ingredients from chewing gum

Abstract

To provide an advanced encapsulation process for controlled release of an active ingredient from chewing gum.SOLUTION: The present disclosure relates generally to ingredients used in edible compositions, and more particularly, to individual pieces and methods of forming individual pieces of ingredients of edible compositions. A chewing gum component for use in a chewing gum composition is provided that includes a component body and a plurality of regions of at least one active component encapsulated within an encapsulating material. A plurality of regions are disposed within the component body. Less than 15% of the average active ingredient concentration within the component body is in contact with the outer surface of the component body.SELECTED DRAWING: None

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE The present disclosure relates generally to ingredients used in edible compositions, and more particularly to individual pieces and methods of forming individual pieces of ingredients of edible compositions. [Background technology]

[0002] A conventional method for preparing one or more active ingredients for use in edible foods involves forming an extrudate in which one or more active ingredients are encapsulated. The extrudate is then cooled by convection to a temperature at which it can be broken into small pieces and then ground into powder. When the extrudate is crushed, the pieces formed are non-uniform in shape and size. As a result, different amounts of energy are required to grind each piece into particles of the desired size, making the milling operation inefficient.

[0003] Therefore, there is a need for a system and method that allows for the continuous and efficient preparation of active ingredients for use in edible foods. Summary of the Invention [Means for solving the problem]

[0004] According to one embodiment of the present invention, there is provided a chewing gum component for use in a chewing gum composition, comprising a component body and a plurality of regions of at least one active ingredient encapsulated within an encapsulating material, the plurality of regions being disposed within the component body, and less than 15% of the average active ingredient concentration within the component body being in contact with an exterior surface of the component body.

[0005] In addition to or in the alternative to one or more of the above features, in a further embodiment, less than 10% of the average active ingredient concentration within the component body is in contact with the exterior surface of the component body.

[0006] In addition to or in the alternative to one or more of the above features, in further embodiments, the body has a longest dimension of less than 1000 micrometers.

[0007] In addition to or in the alternative to one or more of the above features, in a further embodiment, the cross section of the body is generally circular.

[0008] In addition to or as an alternative to one or more of the above features, in a further embodiment, the encapsulating material is water-insoluble.

[0009] According to another embodiment, there is provided a chewing gum component for use in a chewing gum composition, comprising a plurality of component bodies, each of which comprises a plurality of regions of at least one active ingredient encapsulated within an encapsulating material, the regions being disposed within the component body, and the plurality of component particles having a size distribution with a standard deviation of less than 50% of the average longest dimension of each of the plurality of particles.

[0010] In addition to or in the alternative to one or more of the above features, in a further embodiment, the plurality of component bodies has a narrow size distribution with a standard deviation of less than 10% of the average longest dimension of each of the plurality of component bodies.

[0011] In addition to or in the alternative to one or more of the above features, in a further embodiment, each of the plurality of component bodies has a longest dimension of less than 1000 micrometers.

[0012] According to another embodiment, there is provided a chewing gum component for use in a chewing gum composition, comprising a component body and multiple regions of at least one active ingredient encapsulated within an encapsulating material, the multiple regions being disposed within the component body, wherein the at least one active ingredient has a release profile of less than about 10% per minute within 1 minute after exposing the component body to a dissolving liquid.

[0013] In addition to or in the alternative to one or more of the above features, in further embodiments, the profile of the at least one active ingredient is less than about 3% / minute within 1 minute after exposing the component body to a dissolving liquid.

[0014] In addition to or in the alternative to one or more of the above features, in further embodiments, the profile of the at least one active ingredient is continuously linear for at least 30 minutes after exposing the component body to a dissolving liquid.

[0015] According to another embodiment, a chewing gum component for use in a chewing gum composition is provided, comprising a component body and multiple regions of at least one active ingredient encapsulated within an encapsulating material. The amount of the at least one active ingredient is configured to dissolve less than 10% upon exposure to water for 3 minutes or less. This amount is determined by placing the component body in a container of water at a temperature of 21-23°C. The container has a rotatable element operable at a rotational speed of 350 rpm.

[0016] In addition to, or in the alternative to, one or more of the above features, less than 5% of the at least one active ingredient is configured to dissolve upon exposure to water within 3 minutes.

[0017] According to another embodiment, a method for producing an edible product includes forming an extrudate of a first component, the first component including multiple regions of at least one active ingredient encapsulated within an encapsulating material. The extrudate is then cut into a plurality of spaced-apart pieces, each of which contains less than 10% of the at least one active ingredient, the amount of which is configured to dissolve upon exposure to water for three minutes or less. Determining that the amount of at least one active ingredient in each of the plurality of pieces is configured to dissolve upon exposure to water for three minutes or less includes adding the extrudate to a container of water having a temperature of 21-23°C and rotating a rotatable element located within the container at a rotational speed of 350 rpm.

[0018] According to another embodiment, there is provided a method for producing an edible material, comprising forming an extrudate of a first component. The extrudate is cut into a plurality of spaced pieces, each of which has a longest dimension of less than 1000 micrometers. A gum is formed containing the plurality of pieces as an ingredient.

[0019] In addition to or as an alternative to one or more of the above features, in a further embodiment, the extrudate is cut into the plurality of small pieces at regular intervals.

[0020] In addition to or as an alternative to one or more of the above features, in a further embodiment, the extrudate is cut into said plurality of small pieces at regular intervals.

[0021] In addition to or in the alternative to one or more of the above features, in a further embodiment, each of the plurality of particles is substantially uniform in size.

[0022] In addition to or in the alternative to one or more of the above features, in further embodiments, the longest dimension is between about 200 micrometers and about 700 micrometers.

[0023] In addition to or in the alternative to one or more of the above features, in a further embodiment, the first component is a composition comprising a region of one or more active ingredients encapsulated within an encapsulating material.

[0024] In addition to or in the alternative to one or more of the above features, in a further embodiment, the active ingredient comprises at least one sweetener.

[0025] In addition to or in the alternative to one or more of the above features, in a further embodiment, the encapsulant material is polyvinyl acetate.

[0026] In addition to or in the alternative to one or more of the above features, in a further embodiment, the extrudate is cut using a cutting device configured to rotate about an axis positioned substantially parallel to the direction of movement of the extrudate.

[0027] In addition to or in the alternative to one or more of the above features, in a further embodiment, cutting the extrudate includes feeding the extrudate to a pelletizer having a wheel including a plurality of blades, the wheel configured to rotate about an axis disposed substantially perpendicular to a direction of travel of the extrudate.

[0028] In addition to or in the alternative to one or more of the above features, in further embodiments, less than 1% of the particles of the active ingredient are ruptured by the plurality of blades during the cutting.

[0029] In addition to or in the alternative to one or more of the above features, in further embodiments, none of the particles of the active ingredient are ruptured by the plurality of blades during the cutting.

[0030] In addition to or in the alternative to one or more of the above features, in a further embodiment the edible material is a chewing gum.

[0031] According to another embodiment, there is provided a method of making a composition comprising forming an extrudate of a first component and cutting the extrudate of the first component into a plurality of spaced apart first pieces, the plurality of first pieces having a first release profile, and forming an extrudate of a second component and cutting the extrudate into a plurality of spaced apart second pieces, the plurality of second pieces having a second release profile.

[0032] In addition to, or as an alternative to, one or more of the above characteristics, in further embodiments, the first release profile and the second release profile are different.

[0033] In addition to or in the alternative to one or more of the above features, in further embodiments, the first component comprises a first active ingredient and the second component comprises a second active ingredient, wherein the first active ingredient and the second active ingredient are substantially identical.

[0034] In addition to or in the alternative to one or more of the above features, in further embodiments, the first component comprises a first active ingredient and the second component comprises a second active ingredient, wherein the first active ingredient and the second active ingredient are different.

[0035] In addition to or in the alternative to one or more of the above features, in a further embodiment, the composition is a chewing gum.

[0036] In addition to or in the alternative to one or more of the above features, in a further embodiment, the composition is a pharmaceutical agent.

[0037] According to another embodiment, a method for customizing the dissolution rate of an edible material is provided, comprising providing a plurality of pieces of a first component, the plurality of pieces of the first component including at least a first encapsulated active ingredient having a first release profile, and providing a plurality of pieces of a second component, the plurality of pieces of the second component including at least a second encapsulated active ingredient having a second release profile, the second release profile being different from the first release profile, and mixing the plurality of pieces of the first component and the plurality of pieces of the second component.

[0038] In addition to or in place of one or more of the above features, in a further embodiment, the plurality of small pieces of the first component and the plurality of small pieces of the second component are substantially the same size.

[0039] In addition to or as an alternative to one or more of the above features, in a further embodiment, the plurality of small pieces of the first component and the plurality of small pieces of the second component are different in size.

[0040] In addition to or in the alternative to one or more of the above features, in further embodiments, the first encapsulated active ingredient and the second encapsulated active ingredient are the same.

[0041] In addition to or in the alternative to one or more of the above features, in further embodiments, the first encapsulated active ingredient and the second encapsulated active ingredient are different.

[0042] In addition to or in the alternative to one or more of the above features, in a further embodiment, the composition is a chewing gum.

[0043] In addition to or in the alternative to one or more of the above features, in a further embodiment, the composition is a pharmaceutical agent.

[0044] In addition to or in place of one or more of the above features, in a further embodiment, the encapsulating material of the plurality of particles of the first component and the encapsulating material of the plurality of particles of the second component have different molecular weights.

[0045] According to another embodiment, a method for producing an edible product includes providing an active ingredient to an extruder and providing an encapsulated ingredient to the extruder. The active ingredient and the encapsulated ingredient are mixed in the extruder to form a composition. The composition is passed through a melt screen filter having openings less than 500 micrometers and extruded from the extruder.

[0046] In addition to or in the alternative to one or more of the above features, in a further embodiment, extruding the composition from the extruder includes extruding the composition through an extrusion die having exit holes of 200 to 1000 micrometers.

[0047] In addition to or in the alternative to one or more of the above features, in a further embodiment, extruding the composition from the extruder includes extruding the composition through an extrusion die having exit holes of 200 to 800 micrometers.

[0048] According to another embodiment, a system for forming an encapsulated active ingredient includes a continuous extruder configured to receive and mix an active ingredient and an encapsulation ingredient to form an encapsulated composition, an extruder die disposed in a downstream extension of the extruder, and a melt screen filter having openings less than 500 micrometers disposed upstream of the extruder die.

[0049] According to another embodiment, a method of forming a composition includes forming an extrudate of the composition, wherein the composition includes a water-soluble component, and cooling the extrudate with water.

[0050] In addition to or as an alternative to one or more of the above features, in a further embodiment the extrudate comprises a water soluble active ingredient encapsulated within a matrix that is not water soluble. The present invention provides, for example, the following items. (Item 1) 1. A chewing gum component for use in a chewing gum composition, comprising: a component body; a plurality of regions of the component body comprising at least one active ingredient encapsulated within an encapsulating material; A chewing gum component wherein less than 15% of the average active ingredient concentration within said component body is in contact with the exterior surface of said component body. (Item 2) 2. The chewing gum component of claim 1, wherein less than 10% of the average active ingredient concentration within the component body is in contact with the outer surface of the component body. (Item 3) 2. The chewing gum component of claim 1, wherein the body has a longest dimension of less than 1000 micrometers. (Item 4) 4. The chewing gum component of claim 3, wherein the cross section of the body is generally circular in shape. (Item 5) 4. The chewing gum component according to claim 3, wherein the encapsulating material is water-insoluble. (Item 6) 1. A chewing gum component for use in a chewing gum composition, comprising: 1. A chewing gum component comprising a plurality of component bodies, each of the plurality of bodies comprising a plurality of regions of at least one active ingredient encapsulated within an encapsulating material, the plurality of regions being disposed with the component bodies, the plurality of component bodies having a size distribution with a standard deviation of less than 50% of the average longest dimension of each of the plurality of bodies. (Item 7) 7. The chewing gum component of claim 6, wherein the plurality of component bodies have a narrow size distribution with a standard deviation of less than 10% of the average longest dimension of each of the plurality of component bodies. (Item 8) 7. The chewing gum component of claim 6, wherein each of the plurality of component bodies has a longest dimension of less than 1000 micrometers. (Item 9) 1. A chewing gum component for use in a chewing gum composition, comprising: a component body; a plurality of regions of at least one active ingredient encapsulated within an encapsulating material, the plurality of regions being disposed within the component body; A chewing gum component, wherein the release profile of said at least one active ingredient is less than 10% per minute within 1 minute after exposing said component body to a dissolving liquid. (Item 10) 10. The chewing gum component of claim 9, wherein the release profile of the at least one active ingredient is less than 3% / min within 1 minute after exposing the component body to a dissolving liquid. (Item 11) 10. The chewing gum component of claim 9, wherein the release profile of the at least one active ingredient is continuously linear for at least 30 minutes after exposing the component body to a dissolving liquid for 2 minutes. (Item 12) 1. A chewing gum component for use in a chewing gum composition, comprising: a component body; a plurality of regions of the component body comprising at least one active ingredient encapsulated within an encapsulating material; A chewing gum component, wherein the amount of the at least one active ingredient is configured to dissolve less than 10% within 3 minutes of exposure to water, the amount being determined by placing the component body in a container of water at a temperature of 21-23°C, the container having a rotatable element operable at a rotational speed of 350 rpm. (Item 13) 13. The chewing gum component according to claim 12, wherein less than 5% of the at least one active ingredient is configured to dissolve within 3 minutes of exposure to water. (Item 14) 1. A method for producing an edible material, comprising: forming an extrudate of a first component, said first component comprising a plurality of regions of at least one active ingredient encapsulated within an encapsulating material; cutting the extrudate into a plurality of spaced pieces, wherein an amount of the at least one active ingredient in each of the plurality of pieces is configured to dissolve within 3 minutes of exposure to water, said amount being less than 10%; Determining the amount of the at least one active ingredient in the plurality of pieces configured to dissolve within 3 minutes of exposure to water comprises: adding the extrudate to a container of water, the water having a temperature of 21-23°C; and rotating a rotating element located within the vessel at 350 rpm. (Item 15) 1. A method for producing an edible material, comprising: forming a first component extrudate; cutting the extrudate into a plurality of spaced pieces, the plurality of pieces having a longest dimension of less than 1000 micrometers; forming a gum containing said plurality of pieces as ingredients. (Item 16) Item 16. The method of claim 15, wherein the extrudate is cut into the plurality of small pieces at regular intervals. (Item 17) Item 18. The method of item 15, wherein the extrudate is cut into the plurality of small pieces at irregular intervals. Item 19. The method of item 15, wherein each of the plurality of small pieces is substantially uniform in size. Item 16. The method of item 15, wherein the longest dimension is between 200 micrometers and 700 micrometers. (Item 20) Item 16. The method of item 15, wherein the first component is a composition comprising a region of one or more active ingredients encapsulated within an encapsulating material. (Item 21) Item 22. The method according to Item 20, wherein the one or more active ingredients include at least one sweetener. 21. The method of claim 20, wherein the encapsulating material is polyvinyl acetate. (Item 23) Item 16. The method according to item 15, wherein cutting the extrudate comprises feeding the extrudate to a cutting device rotatable about an axis arranged substantially parallel to a direction of movement of the extrudate. (Item 24) Item 16. The method of item 15, wherein cutting the extrudate comprises feeding the extrudate to a pelletizer having a wheel including a plurality of blades, the wheel configured to rotate about an axis disposed substantially perpendicular to a direction of travel of the extrudate. (Item 25) 25. The method of claim 24, wherein less than 1% of the particles of the active ingredient are ruptured by the plurality of blades during the cutting. (Item 26) 25. The method of claim 24, wherein none of the particles of the active ingredient are ruptured by the plurality of blades during the cutting. (Item 27) Item 16. The method according to item 15, wherein the edible material is chewing gum. (Item 28) 1. A method of making a composition, comprising: forming a first component extrudate; cutting the extrudate of the first component into a plurality of spaced first pieces, the plurality of first pieces having a first release profile; forming a second component extrudate; and cutting the extrudate of the second component into a plurality of second pieces at spaced intervals, the plurality of second pieces having a second release profile. (Item 29) 29. The method of claim 28, wherein the first release profile and the second release profile are different. (Item 30) 29. The method of claim 28, wherein the first component comprises a first active ingredient and the second component comprises a second active ingredient, and the first active ingredient and the second active ingredient are substantially the same. (Item 31) 29. The method of claim 28, wherein the first component comprises a first active ingredient and the second component comprises a second active ingredient, the first active ingredient being different from the second active ingredient. (Item 32) 29. The method of claim 28, wherein the composition is a chewing gum. (Item 33) 29. The method of claim 28, wherein the composition is a pharmaceutical agent. (Item 34) 1. A method for customizing the dissolution rate of an edible material, comprising: providing a plurality of pieces of a first component, the plurality of pieces of the first component including at least a first encapsulated active ingredient having a first release profile; providing a plurality of pieces of a second component, the plurality of pieces of the second component comprising at least a second encapsulated active ingredient having a second release profile, the second release profile being different from the first release profile; mixing the plurality of pieces of a first component with the plurality of pieces of a second component. (Item 35) Item 35. The method of item 34, wherein the plurality of small pieces of the first component and the plurality of small pieces of the second component are substantially similar in size. (Item 36) Item 35. The method of item 34, wherein the plurality of small pieces of the first component and the plurality of small pieces of the second component are different in size. (Item 37) 35. The method of claim 34, wherein the first encapsulated active ingredient and the second encapsulated active ingredient are the same. (Item 38) 35. The method of claim 34, wherein the first encapsulated active ingredient and the second encapsulated active ingredient are different. (Item 39) 35. The method of claim 34, wherein the composition is a chewing gum. (Item 40) 35. The method of claim 34, wherein the composition is a pharmaceutical agent. (Item 41) Item 35. The method of claim 34, wherein the encapsulating material of the plurality of particles of the first component and the encapsulating material of the plurality of particles of the second component have different molecular weights. (Item 42) 1. A method for producing an edible material, comprising: providing an active ingredient to an extruder; providing an encapsulated ingredient to said extruder; mixing the active ingredient and the encapsulated ingredient in the extruder to form a composition; passing the composition through a melt screen filter having openings less than 500 micrometers; and extruding said composition from said extruder. (Item 43) Item 43. The method of claim 42, wherein extruding the composition from the extruder comprises extruding the composition through an extrusion die having exit holes of 200 to 1000 micrometers. (Item 44) Item 43. The method of claim 42, wherein extruding the composition from the extruder comprises extruding the composition through an extrusion die having exit holes of 200 to 800 micrometers. (Item 45) 1. A system for forming an encapsulated active ingredient, comprising: a continuous extruder configured to receive and mix the active ingredient and the encapsulation ingredient to form an encapsulated composition; an extrusion die disposed in a downstream region of the extruder; a melt screen filter having openings less than 500 micrometers positioned upstream of the extrusion die. (Item 46) 1. A method of forming a composition, comprising: forming an extrudate of the composition, the composition including a water soluble component; and cooling the extrudate with water. (Item 47) 47. The method of claim 46, wherein the extrudate comprises a water-soluble active ingredient encapsulated within a matrix that is not water-soluble. [Brief explanation of the drawings]

[0051] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several aspects of the disclosure and, together with the description, serve to explain the principles of the disclosure.

[0052] [Figure 1] FIG. 1 is a perspective view of a piece of a first component for use with edible materials, according to one embodiment.

[0053] [Figure 2] FIG. 2 is a schematic diagram of an extruder for forming a first component extrudate according to one embodiment.

[0054] [Figure 3A] FIG. 2 is a schematic diagram of a system for forming pieces of the first component of FIG. 1, according to one embodiment.

[0055] [Figure 3B] FIG. 2 is a schematic diagram of a system for forming pieces of the first component of FIG. 1, according to one embodiment.

[0056] [Figure 4] 1 is a schematic diagram of portions of a gum making system according to one embodiment.

[0057] [Figure 5] FIG. 2 is a cross-sectional view of a finished gum product including multiple pieces of a first component, according to one embodiment.

[0058] [Figure 6] 1 is a graph of the dissolution curve of encapsulated aspartame, according to one embodiment.

[0059] [Figure 7] 1 is another graph of the dissolution curve of encapsulated aspartame, according to one embodiment.

[0060] The detailed description explains, by way of example, embodiments of the present invention, together with advantages and features, with reference to the drawings. DETAILED DESCRIPTION OF THE INVENTION

[0061] The following disclosure details particular embodiments of the present invention, providing ingredient pieces, including encapsulated compositions, particularly for use in chewing gum and other such confections.

[0062] The edibles discussed herein include any type of edible product, including, but not limited to, chewing gum (at any stage, including elastomers, partially finished bases, finished chewing gum bases, and finished chewing gums), confections (which may be synonymous with chewing gum and candy), sweet and savory biscuits and cakes, nuts, and cereals. For ease of description, the edibles will be referred to as chewing gums in the remainder of this description. Certain compositions of chewing gum may have a non-uniform texture and / or a multi-layered composition.

[0063] As used herein, products referred to as "chewing gum" or "gum" include, but are not limited to, compositions ranging from and including compounded elastomers to finished gums, which may include compounded elastomers with some compounding aids, masterbatch gum base, compounded elastomers with some subsequent gum ingredients, compounded elastomers with some gum base ingredients and some subsequent gum ingredients, gum base, gum base with some subsequent gum ingredients, masterbatch finished gum, and finished gum.

[0064] Before describing the various systems and methods according to the present invention, it is useful to discuss the general composition of several typical stages of chewing gum manufacture where encapsulation may be used, i.e., the finished gum.

[0065] As used herein, "finished chewing gum" or "finished gum" generally refers to chewing gum that is ready for preparation for distribution to consumers. Thus, the finished gum may still require tempering, forming, molding, packaging, and coating. However, from a compositional standpoint, the chewing gum itself is generally complete. Not all finished gums have the same ingredients or the same amounts of individual ingredients. By varying the ingredients and ingredient amounts, the texture, flavor, and sensation, among other things, can be altered to provide different properties to meet user needs.

[0066] As is generally known, finished gum typically comprises a water-soluble bulk portion, a water-insoluble gum base portion, and one or more flavoring agents. The water-soluble portion dissipates over time during chewing. The gum base portion is retained in the oral cavity throughout the chewing process. Finished gum is defined as chewing gum that is ready for consumption by the user.

[0067] As used herein, "finished chewing gum base" or "finished gum base" refers to a chewing gum containing a sufficient combination of gum base ingredients that need only be combined with subsequent gum ingredients to form a finished gum. A finished gum base is a viscoelastic material containing at least a high-viscosity component, an elastic component, and a softener component. For example, a typical gum base may contain an elastomer, at least some fillers, resins and / or plasticizers, polyvinyl acetate, and a softener (such as an oil, fat, or wax). An elastomer simply formulated without the addition of any softeners is not considered usable in a finished gum structure, for example, because it would be difficult, if not impossible, to chew, and therefore is not a finished gum base. In one embodiment, the viscosity of the finished gum base, or the extrudate exiting the extruder described further below, is from about 75 Pascal-seconds to about 140,000 Pascal-seconds.

[0068] As used herein, "incomplete chewing gum base" or "incomplete gum base" refers to a chewing gum that includes a gum base component or combination of gum base components that must be combined with additional gum base components and subsequent non-base gum components to form a finished gum. An incomplete gum base includes at least an elastic component and will require the addition of at least a thickener component and / or a softener component to form a finished gum base.

[0069] Insoluble gum bases in the form of finished gum bases generally contain ingredients that fall into the following categories: elastomers, elastomer plasticizers (resins or solvents), plasticizers, fats, oils, waxes, softeners, and fillers. Further discussion of representative ingredients within each category is provided below. Gum bases may comprise 5-95% by weight of the finished gum, more typically 10-50% by weight of the finished gum, and most commonly 20-30% by weight of the finished gum.

[0070] The water-soluble portion of the finished gum, referred to in this disclosure as the subsequent ingredient (because it is added after the finished gum base is produced), may include subsequent gum ingredients that fall into the following categories: softeners, bulk sweeteners, intense sweeteners, flavorings, acids, additional fillers, functional ingredients, and combinations thereof. Softeners are added to gum to optimize the chewability and mouthfeel of the gum. Softeners, also known as plasticizers, plasticizers, or emulsifiers, generally comprise about 0.5-15% by weight of the finished gum. Bulk sweeteners comprise 5-95% by weight of the finished gum, more typically 20-80% by weight of the finished gum, and most commonly 30-60% by weight of the finished gum. Intense sweeteners may also be present and are generally used in conjunction with sugarless sweeteners. When used, high intensity sweeteners typically comprise 0.001 to 5% by weight of the finished gum, preferably 0.01 to 3% by weight of the finished gum. Typically, high intensity sweeteners are at least 20 times sweeter than sucrose.

[0071] Flavoring agents should generally be present in the gum in an amount ranging from about 0.1 to 15% by weight of the finished gum, preferably from about 0.2 to 5% by weight of the finished gum, and most preferably from about 0.5 to 3% by weight of the finished gum. Natural and artificial flavoring agents may be used and combined in any sensory acceptable manner. If an acid is included, it typically comprises from about 0.001 to 5% by weight of the finished gum. Optional ingredients such as colorants, functional ingredients, and additional flavoring agents may also be included in the gum.

[0072] Referring now to the drawings, during the formation of gum or other edible material, first component pieces 20 may be mixed with one or more other ingredients, such as in a gum manufacturing system, to form a finished gum product. FIG. 1 shows an example of one of the first component pieces 20 in greater detail. The pieces 20 generally have diameters of less than 1000 micrometers, e.g., between 200 and 700 micrometers. In one embodiment, each of the pieces 20 is substantially identical in size. As a result, pieces 20 typically used in a gum batch, such as a 10-pound batch of pieces 20, have a narrow size distribution with a standard deviation of less than 50%, more specifically less than 10%, of their average longest dimension. The illustrated first component pieces 20 have a generally circular cross-section and may be spherical or cylindrical in shape, although pieces 20 having other shapes are also contemplated herein. For example, the particles 20 may have any shape such that the ratio of their largest dimension to their smallest dimension is less than 3:1, or alternatively less than 2:1.

[0073] In the illustrated non-limiting embodiment, first component pieces 20 may comprise a composition containing both an "active ingredient" and an "encapsulated ingredient," with the active ingredient being surrounded or encapsulated by the encapsulated ingredient. In some embodiments, the active ingredient may be relatively sensitive to high-energy mixing environments (such as the heat and shear forces that may be associated with some types of mixing). Any active ingredient typically used in edible materials is within the scope of the present disclosure, for example, but not limited to, high-intensity sweeteners (including natural and synthetic sweeteners), food acidulants, and various ingredients (including texture modifiers, colorants, salts, oral care ingredients, and other ingredients). Any encapsulated ingredient typically used in edible materials, for example, but not limited to, a polymer or resin, is also contemplated in forming first component pieces 20. In some embodiments, the encapsulated ingredient is water-insoluble. In other embodiments, the encapsulated ingredient may be water-soluble.

[0074] For example, the active ingredient may include, but is not limited to, sweeteners and food acidulants.The sweeteners used can be selected from a wide range of substances, including water-soluble sweeteners, water-soluble artificial sweeteners, water-soluble sweeteners derived from natural water-soluble sweeteners, dipeptide-based sweeteners, and protein-based sweeteners, and mixtures thereof.Although not limited to specific sweeteners, representative categories and examples include: (a) water-soluble sweeteners, such as dihydrochalcones, monellin, stevioside, glycyrrhizin, saccharin salts, i.e., saccharin sodium or calcium salts, cyclamate salts, acesulfame salts, such as sodium, ammonium, or calcium salts of 3,4-dihydro-6-methyl-1,2,3-oxathiazin-4-one-2,2-dioxide, 3,4 (b) potassium salt of dihydro-6-methyl-1,2,3-oxathiazin-4-one-2,2-dioxide (acesulfame K), saccharin and the free acid form of monatin, (c) dipeptide sweeteners, such as L-aspartic acid derived sweeteners, for example, L-aspartyl-L-phenylalanine methyl ester (aspartame) and L-α-aspartyl-N-(2,2,4,4-tetramethyl-3-thietanyl)-D-alaninamide hydrate (acesulfame K), L-aspartyl-L-phenylglycerin and methyl ester of L-aspartyl-L-2,5-dihydrophenylglycine, methyl esters of L-aspartyl-2,5-dihydro-L-phenylalanine; aspartyl-L-(1-cyclohexene)-alanine, neotame, and advantame; (c) water-soluble sweeteners obtained from chlorinated derivatives of common sugars (sucrose), such as Reb-A, for example, naturally occurring water-soluble sweeteners of chlorodeoxysugar derivatives, such as chlorodeoxysucrose or chlorodeoxygalactosucrose derivatives, known under the trade name sucralose; (examples of chlorodeoxysucrose and chlorodeoxygalactosucrose derivatives include 1-chloro-1'-deoxysucrose; 4-chloro-4-deoxy-α-D-galactopyranosyl-α-D-fructofuranoside; or 4-chloro-4-deoxygalactosucrose;4-chloro-4-deoxy-α-D-galactopyranosyl-1-chloro-l-deoxy-β-D-fructofuranoside, or 4,1'-dichloro-4,1'-dideoxygalactosucrose; 1',6'-dichloro-1',6'-dideoxysucrose; 4-chloro-4-deoxy-α-D-galactopyranosyl-1,6-dichloro-1,6-dideoxy-β-D-fructofuranoside, or 4,1',6'-trichloro-4,1',6'-trideoxygalactosucrose; 4,6-dichloro-4,6-dideoxy-α-D-galactopyranosyl-6-chloro-6-deoxy-β-D-fructofuranoside, or or 4,6,6'-trichloro-4,6,6'-trideoxygalactosucrose; 6,1',6'-trichloro-6,1',6'-trideoxysucrose; 4,6-dichloro-4,6-dideoxy-α-D-galacto-pyranosyl-1,6-dichloro-1,6-dideoxy-γ-β-D-fructofuranoside; or 4,6,1',6'-tetrachloro-4,6,1',6'-tetradeoxygalactosucrose, 4,6,1',6'-tetradeoxy-sucrose, and mixtures thereof; or (d) other protein-based sweeteners such as Saumaocaus danielli (thaumatin I and II) and thallium. Food acidulants may include citric acid, malic acid, fumaric acid, tartaric acid, lactic acid, and adipic acid.

[0075] Encapsulation of an active ingredient can protect the active ingredient from dissolution upon contact with water or saliva, thereby extending the relative shelf life of the active ingredient in the finished gum product. Furthermore, encapsulation of an active ingredient can also protect the active ingredient during the remainder of the manufacturing process. Because the edible components to be encapsulated may be sensitive to temperature, mixing, extrusion, or other factors, encapsulation allows for efficient handling and protection of these sensitive components during production. This protection of the active ingredient is achieved by mixing the active ingredient(s) with the encapsulating ingredient(s). In practice, the at least one encapsulated active ingredient composition defined herein comprises at least one active ingredient, such as those discussed above, mixed with one or more encapsulating ingredient(s), such as those discussed immediately below, for production or extrusion.

[0076] Examples of encapsulating materials / components include polymers or resins, the properties of which control the release characteristics and protection of the encapsulated active ingredient. In some embodiments, the encapsulating material may be polyvinyl acetate, polyethylene, cross-linked polyvinylpyrrolidone, polymethyl methacrylate, polylactic acid, polyhydroxyalkanoate, ethyl cellulose, polyvinyl acetate phthalate, polyethylene glycol ester, methacrylic acid-co-methyl methacrylate, polyvinyl acetate-vinyl alcohol copolymer, or any other component suitable for polymer matrix-type encapsulation.

[0077] As discussed above, it may be desirable to encapsulate certain ingredients or components used in edible products such as pharmaceuticals or chewing gum. Such compositions described herein include at least one active ingredient or component that is protected and released in a specific release profile, and at least one additional encapsulating component, such as, but not limited to, a polymer or resin.

[0078] It is desirable to have a uniform release of the active ingredient. Since the active ingredient is typically water-soluble, the surface material dissolves quickly when exposed to saliva. The inner material dissolves more slowly. Therefore, the less active component on the surface will have a more uniform release. In addition, a uniform size distribution of the components will result in a more uniform release.

[0079] Referring again to FIG. 1 , an exemplary first component piece 20 includes multiple regions containing an active ingredient 22, such as one or more liquid or powdered sweeteners, disposed within an encapsulating material 24 and positioned between the center and an outer surface 26 of the piece 20. The encapsulating material may be, for example, polyvinyl acetate having a molecular weight of 8,000 to 200,000, more specifically, 12,000 to 100,000. In one embodiment, the multiple regions of active ingredient 22 are water-soluble, while the encapsulating material 24 is not. Within each of the multiple pieces 20, the regions of active ingredient 22 are generally uniformly distributed throughout the encapsulating material 24. By forming the component pieces 20 when the material is soft and malleable, the regions of active ingredient 22 within each piece 20 remain generally entire. As a result, the region of active ingredient 22 is fully encapsulated within the encapsulating material 24 such that a limited portion of the region of active ingredient 22 is exposed, for example, immediately beneath or generally adjacent to the exterior surface 26 of each particle 20. In one embodiment, less than 20%, less than 15%, less than 10%, and more particularly less than 1% of the average active ingredient concentration within each particle 20 is exposed to or directly adjacent to the exterior surface 26 of each particle 20. In addition, the portion of any region of active ingredient 22 defined by the encapsulating material 24 that extends partially beyond the exterior surface 26 of each particle 20 has a distance of less than 20% of the longest dimension of the particle 20. To determine the amount of active ingredient exposed to or directly adjacent to the exterior surface 26 of each particle 20, a regression line is drawn for the latter half of the dissolution release curve corresponding to the particle 20. The percentage of dissolved active ingredient at the point where the curve deviates from the regression line is the amount of active ingredient in contact with the exterior surface of the component body.

[0080] Typically, encapsulation of an active ingredient 22 (e.g., flavor, sweetener, etc.) results in delayed release of a major amount of the active ingredient 22 during consumption of an edible product, such as a gum structure, containing the encapsulated active ingredient. This initial release generally occurs in response to a release trigger, such as by rupturing the encapsulated active ingredient particles due to chewing, crunching, or dissolving the encapsulated ingredient via saliva or solvents in the digestive tract. However, in pharmaceutical applications, a chemical catalyst, such as stomach acid, may be configured to degrade the encapsulation material 24 and expose the active ingredient 22 contained therein.

[0081] Because the majority of the area of ​​the active ingredient 22 is generally not exposed at the outer surface 26 of the piece 20, the release or dissolution of the active ingredient is significantly slower than the release of a conventionally encapsulated active ingredient. For example, referring to Figures 6 and 7, a piece 20 described herein having a first active ingredient, such as aspartame, has about 10% or less dissolution after 36 minutes. However, a conventional piece of the same encapsulated first active ingredient has about 30% or 50% dissolution after the same length of time. In addition, the release profile of the piece 20 described herein may be linear or near-linear, whereas a conventional piece of the same encapsulated first active ingredient initially has an asymptotic release profile.

[0082] A typical chewing life of a gum is, for example, about 30 minutes. It is important that the active ingredient be present during the chewing life so that the consumer experiences the effect of the active ingredient throughout the entire chew. If the release rate of the active ingredient is too high, the active ingredient in the chewing gum will be consumed in less than 30 minutes. If the active ingredient lasts for 30 minutes, the release rate of the active ingredient should be less than about 3% / min. If data related to the release rate are measured at 20-second intervals, the difference between consecutive data points should be less than about 1%. An exemplary graph shown in FIG. 6 illustrates the rate of active ingredient release as a function of time. As shown, the slope of the curve for the encapsulated active ingredient described herein (the inventive technology), labeled "Technology S" in the figure, is less than 10% / min, more specifically less than 5% / min, and less than 3% / min, and this rate is reached in less than 1 minute of exposure. For the curve representing a conventionally encapsulated active ingredient, entitled "2G," the slope of the curve does not reach a rate of less than 3% / min until about 4 minutes have elapsed. Similarly, the curve relating to another conventionally encapsulated active ingredient, entitled "3G," achieves a dissolution rate of less than 3% / min after about 2 minutes. Additionally, while the conventional technology has an initial release rate of about 7% / 20 seconds, the process described herein has an initial rate of less than 1% / 20 seconds.

[0083] The dissolution rate of the encapsulated active ingredients described herein is measured using a Distek Dissolution Machine Model 2100C. Prior to conducting the test, the water ultraviolet (UV) absorption correction and the analytical wavelength associated with the active ingredient must be determined. To measure the water ultraviolet (UV) absorption correction, one of the tanks is filled with approximately 200 mL of deionized water and one or more UV probes are inserted therein. The UV probes are configured to measure the spectrum used for the water UV absorption correction. The analytical wavelength is the wavelength at which the active ingredient has maximum absorbance. In embodiments where the active ingredient is aspartame, the analytical wavelength is 200 nm; in embodiments where the active ingredient is citric acid, the analytical wavelength is 210 nm; and in embodiments where the active ingredient is acesulfame K, the analytical wavelength is 227 nm.

[0084] To measure dissolution rate, the machine's paddle rotation speed is set to approximately 350 rpm, and approximately 500 mL of deionized water is filled into the machine's glass chamber. Once the water in the chamber reaches a temperature of approximately 21-23°C, the encapsulated active ingredient is weighed and then added to the water. The amount of active ingredient in the encapsulated active ingredient added to the water should be similar to the amount of active ingredient added to 200 mL of deionized water, with a linear response to the concentration level at the corresponding analytical wavelength. For example, if the active ingredient is aspartame, the concentration level at the selected wavelength is approximately 0.275 g / L; if the active ingredient is citric acid, the concentration level at the selected wavelength is approximately 7.5 g / L; and if the active ingredient is acesulfame K, the concentration level at the selected wavelength is approximately 0.175 g / L. Once the encapsulated active ingredient is added to the water, dissolution rate data should be collected, for example, approximately every 20 seconds. Data collection is initially continued for 35 minutes, or until the total percentage of active ingredient dissolution exceeds 50%.

[0085] In one embodiment, the first component is formed by mixing the active ingredient 22 and the encapsulated ingredients in an extruder 30 to form an extrudate 32. A schematic diagram of one example of an extruder is shown in more detail in Figure 2. In the illustrated non-limiting embodiment, the extruder 30 is a twin-screw extruder comprising one or more substantially hollow barrels 34 having substantially identical first and second screws (not shown) mounted therein. However, other types of extruders 30, such as, for example, planetary roller extruders and single-screw extruders, are within the scope of the present invention.

[0086] The extruder die 36 is fluidly connected to the extrusion end 38 of one or more barrels 34, from which the composition containing the encapsulated active ingredient is separated. The die preferably has a shape complementary to the die 36. The die preferably has a plurality of small diameter exit holes, e.g., 200-1000 micrometers, which can be easily clogged by large particles. A melt pump or other gear pump 40 may be disposed between the extrusion end 38 and the extrusion die 36. The melt pump 40 is configured to receive the unformed composition from the extrusion end 38 and supply the unformed composition to the extrusion die 36 at a desired pressure, thereby assisting in the extrusion of the encapsulated composition.

[0087] In one embodiment, a melt screen or filter 42 with a very fine mesh is positioned between the melt pump 40 and the extrusion die 36. This filter 42 typically requires high pressure to force the polymer through the thin openings formed therein. As the composition is forced through the small openings in the filter 42 by the high pressure generated by the melt pump 40, particles or agglomerates are broken down and dispersed. This results in a dramatic reduction in die clogging and the formation of an improved polymer matrix or encapsulated composition. In one embodiment, the melt screen filter 42 has openings of about 0.500 mm or less, such as about 0.200 micrometers in size, or about 0.125 mm in size, and the pump 40 pressure is about 4000 to about 5000 psi. However, other configurations of the filter 42 and pump 40 are also contemplated herein.

[0088] 3A, the first component extrudate 32 may be formed into a plurality of pieces 20 as the extrudate 32 exits the die 36. A cutting device 44, such as, for example, a rotating set of knives on a hub, may be located generally adjacent the die exit so that a desired length of extrudate 32 is output during each cycle of the cutting device. The composition may be cooled, for example, with high velocity air or water, after and / or during formation into the plurality of pieces 20.

[0089] In another embodiment shown in FIG. 3B , the first component is formed into a plurality of pieces 20 by continuously feeding the extrudate 32 from the extruder 30, such as via a conveyor 45, to a downstream cutting mechanism 44. The cutting mechanism 44 may be configured to cut and / or shape the continuously fed extrudate 32 thereto at regular intervals to form a plurality of pieces 20 of substantially the same size and shape. However, embodiments in which the extrudate 32 is fed at irregular intervals and / or in which the plurality of pieces 20 are not substantially the same size and shape are also contemplated herein. In the illustrated non-limiting embodiment, the cutting mechanism 44 includes a rotary cutter having a plurality of blades 46 extending outwardly therefrom. The rotary cutter is configured to rotate about an axis R oriented generally perpendicular to the direction of travel of the extrudate 30. As the extrudate moves toward the cutting mechanism 44, the blades successively cut the ends of the extrudate 32 to form a plurality of individual pieces 20. A narrow size distribution of the plurality of pieces 20 may be achieved by maintaining constant the output rate from the extruder 30 and the rotational speed of the rotary cutter. While a particular cutting mechanism 44 for forming the first component pieces 20 is shown and described herein, other methods are within the scope of this disclosure. In one embodiment, cutting of the extrudate 32 into the plurality of pieces 20 occurs when the extrudate 32 exceeds the glass transition temperature.

[0090] Additionally, extruder 30 may be configured to output multiple ropes, including a first rope configured to be formed into a plurality of first pieces and a second rope configured to be formed into a plurality of second pieces. The multiple ropes may be provided simultaneously to the same cutting mechanism 44 or to different cutting mechanisms. Regardless of whether the first and second ropes of extrusion 32 are provided to the same cutting mechanism 44 or separate cutting mechanisms 44, the size and / or shape of the first pieces need not be the same or similar to the size and / or shape of the second pieces.

[0091] The release profile of the pieces 20 varies in part based on the dimensions of the plurality of pieces 20. Thus, the release profile of the pieces 20, and thereby the dimensions of the pieces 20, may be adjusted by modifying one or more parameters used during the formation of the pieces 20. For example, in embodiments in which the pieces 20 are formed by cutting an extruded encapsulated composition, the release profile may be altered by adjusting one or more of the size of the die exit holes, the rate at which the composition is extruded through the extruder 30, and the rotational speed of the rotary cutter 34. In one embodiment, each of the plurality of pieces 20 has a uniform release rate over an initial period of time, such as from 5 minutes to 20 minutes.

[0092] As previously mentioned, the pieces 20 may be fed into a portion of a downstream gum manufacturing system 50, such as, for example, a mixer 52 shown in Figure 4, where the pieces 20 are added as one of multiple ingredients used to form a gum product. In such an embodiment, the individual pieces 20 are added as a whole and remain substantially intact in the final gum product such that the pieces 20 may be visible when viewing a cross section of the final gum product 54, as shown in Figure 5.

[0093] When one or more pieces 20 are used as an ingredient in a final gum product, such as gum product 44, the release profile of the final gum product depends on the release profile of the encapsulated active ingredient incorporated therein of the multiple pieces 20. In one embodiment, the pieces 20 incorporated into final gum product 44 have a substantially uniform release profile.

[0094] Alternatively, a mixture of pieces 20 with different release profiles may be included in the final gum product to customize the release profile of the entire gum piece when the gum is chewed. For example, the mixture of pieces 20 may include pieces 20 that vary in size, distribution, and / or one or more active ingredients encapsulated therein. By including pieces 20 with different release profiles in the gum product, the encapsulated active ingredients in the gum product 44 are released in a gradual manner. This can extend the total time a user can detect one or more encapsulated active ingredients by chewing the final gum product 44. As a result of this improved control over the release profile of the pieces 20, the amount of encapsulated active ingredient(s) included in the final gum product 44 can be reduced. Additionally, reducing the amount of encapsulated active ingredient(s) 22 in the final gum product 44 can also result in a reduction in the amount of other ingredients added to the final gum product 44.

[0095] The pieces 20 of the first component of the edible compositions described herein have a slower and more uniform dissolution rate. Additionally, the narrow size distribution of the pieces 20 allows for more precise control of the release profile of an edible product comprising the pieces 20. Producing pieces 20 of a desired size and shape eliminates the need for additional milling or grinding.

[0096] All references, including publications, patent applications, and patents, cited in this specification are herein incorporated by reference to the same extent as if each individual reference was individually and specifically indicated to be incorporated by reference and was set forth in its entirety herein.

[0097] The use of the terms "a," "an," and "the," and similar referents, in the context of describing the present invention (particularly in the context of the claims which follow), shall be construed to encompass both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms "comprising," "having," "including," and "containing" are intended to be open-ended unless otherwise noted. The terms "including, but not limited to," "subject to," "object to," "object to object ...

[0098] Illustrative embodiments of the invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those embodiments may become apparent to those skilled in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.

Claims

1. A method for manufacturing chewing gum, To form a chewing gum base, Forming multiple small pieces of the encapsulated composition, The plurality of small pieces of the encapsulated composition are mixed with the chewing gum base. Includes, Each of the plurality of small pieces of the encapsulated composition is The constituent body and; Multiple regions of the constituent body, each containing at least one active ingredient encapsulated within the encapsulation material Includes, A method wherein less than 15% of the average concentration of the active ingredient in the plurality of small pieces of the encapsulated composition is in contact with the outer surface of the plurality of small pieces.

2. The method according to claim 1, wherein less than 10% of the average active ingredient concentration in the plurality of small pieces of the encapsulated composition is in contact with the outer surface of the plurality of small pieces.

3. The method according to claim 1, wherein the main body of the component has a maximum dimension of less than 1,000 micrometers.

4. The method according to claim 3, wherein the cross-section of the main body of the component is generally circular in shape.

5. The method according to claim 3, wherein the encapsulating material is water-insoluble.

6. Forming the plurality of small pieces of the encapsulated composition The active ingredient and the encapsulating component are mixed in an extruder to form an extruded product, When the extruded material exceeds its glass transition temperature, the extruded material is cut into the plurality of small pieces using cutters at regular intervals. The method according to claim 1, including the method described in claim 1.

7. The method according to claim 6, further comprising moving the extruded material from the extruder to the cutter via a conveyor in order to form the plurality of small pieces of the encapsulated composition.

8. The method according to claim 7, wherein the cutter rotates about an axis perpendicular to the direction of movement of the extruded material.

9. The method according to claim 1, wherein each of the plurality of small pieces is substantially uniform in size.

10. The method according to claim 6, wherein the active ingredient and the encapsulating ingredient mixed in the extruder pass through a molten screen filter having an opening of less than 500 micrometers.

11. The method according to claim 10, wherein the molten screen is positioned upstream of the extruder die of the extruder.

12. The method according to claim 11, further comprising applying pressure to the active ingredient and the encapsulating component mixed in the extruder via a pump to pass the active ingredient and the encapsulating component mixed in the extruder through the molten screen.

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