Method for forming a confectionery

Abstract

A method of forming a jelly confectionery product includes providing a jelly confectionery material having a first percent solids to a first moisture removal system, removing moisture from the jelly confectionery material having the first percent solids in the first moisture removal system to form a jelly confectionery material having a second percent solids, depositing the jelly confectionery material having the second percent solids into at least one mold, and removing moisture from the jelly confectionery material having the second percent solids in a second moisture removal system to form a jelly confectionery material having a third percent solids.

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims the benefit of U.S. Patent Application No. 63 / 494,939, filed April 7, 2023, and U.S. Patent Application No. 63 / 617,561, filed January 4, 2024, which are incorporated herein by reference in their entireties.

[0002] FIELD OF THE INVENTION FIELD OF THE DISCLOSURE The present disclosure relates generally to systems and methods for forming confections, and more particularly to systems and methods for forming jelly confections. [Background technology]

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

[0004] A more time-efficient process for forming jelly confections would be desirable. Summary of the Invention [Means for solving the problem]

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

[0006] In addition to or in the alternative to one or more of the above features, in a further embodiment the jelly confectionery material having the second percentage solids is a high solids jelly.

[0007] In addition to or in the alternative to one or more of the above features, in further embodiments, the second solids percentage is between 2% and 10% greater than the first solids percentage.

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

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

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

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

[0012] In addition to or in the alternative to one or more of the above features, in a further embodiment, the jelly confectionery material having a first percentage of solids is a low solids jelly.

[0013] In addition to or in the alternative to one or more of the above features, in a further embodiment, removing moisture from the jelly confectionery material having at least a second percentage of solids in at least one mold comprises baking the jelly confectionery material having at least a second percentage of solids.

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

[0015] In addition to or in the alternative to one or more of the above features, in a further embodiment, the extruder includes at least one devolatilization section including at least one opening to the ambient environment, and wherein removing moisture from the jelly confectionery material having the first percent solids occurs through the at least one opening.

[0016] In addition to or in the alternative to one or more of the above features, in a further embodiment, the extruder includes at least one devolatilization section including at least one opening and a vacuum device in communication with the at least one opening, the vacuum device positioned to actively draw moisture from the jelly confectionery material having the first percent solids and the extruder.

[0017] In addition to or in the alternative to one or more of the above features, in a further embodiment, the first moisture removal system includes a heat transfer device.

[0018] In addition to or in the alternative to one or more of the above features, in a further embodiment, the heat transfer device is a scraped surface heat exchanger.

[0019] In addition to or in the alternative to one or more of the above features, in a further embodiment the first moisture removal system includes a storage device fluidly coupled to the heat transfer device, and the method includes providing a jelly confectionery material having a first percentage of solids to the storage device through an outlet of the heat transfer device, and discharging the jelly confectionery material having the first percentage of solids into the storage device.

[0020] In addition to or as an alternative to one or more of the above features, in a further embodiment, removing moisture from the jelly confectionery material having a first percent solids in the first moisture removal system to form the jelly confectionery material having a second percent solids occurs in response to releasing the jelly confectionery material having the first percent solids into the interior of the storage device.

[0021] In addition to or in the alternative to one or more of the above features, in a further embodiment, removing moisture from the jelly confectionery material having the first percentage solids occurs in response to continuously refreshing an exterior surface of the jelly confectionery material having the first percentage solids.

[0022] In addition to or as an alternative to one or more of the above features, in a further embodiment, the interior of the storage device has a low moisture, low pressure environment.

[0023] In addition to or in the alternative to one or more of the above features, in a further embodiment the jelly confection material having a third percentage of solids is the final jelly confection having a desired shape.

[0024] In addition to or in the alternative to one or more of the above features, in a further embodiment, depositing the jelly confectionery material having at least a second percentage solids into the at least one mold further comprises depositing the jelly confectionery material having at least a second percentage solids at a temperature greater than 100°C.

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

[0026] In addition to or in the alternative to one or more of the above features, in a further embodiment, the percent solids of the jelly confectionery material deposited in the at least one mold is at least 81%.

[0027] In addition to or in the alternative to one or more of the above features, in a further embodiment, the method comprises reducing the viscosity of a jelly confectionery material having a percent solids of at least 79%.

[0028] In addition to or in the alternative to one or more of the above features, in a further embodiment, reducing the viscosity of the jelly confectionery material having a percent solids of at least 79% comprises heating the jelly confectionery material having a percent solids of at least 79%.

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

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

[0031] In addition to or in the alternative to one or more of the above features, in a further embodiment, a jelly confectionery material having a percent solids of at least 79% is deposited into at least one mold through a deposition nozzle, the method comprising interrupting the flow of the jelly confectionery material having a percent solids of at least 79% at the deposition nozzle.

[0032] In addition to or in the alternative to one or more of the above features, in a further embodiment, interrupting the flow of jelly confection material having a solids percentage of at least 79% at the deposition nozzle comprises breaking off a tail of the jelly confection material.

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

[0034] In addition to or in the alternative to one or more of the above features, in a further embodiment, at least a portion of the moisture is removed from the jelly confectionery material having the first ratio at a rate of at least about 2% per hour.

[0035] In addition to or in the alternative to one or more of the above features, in a further embodiment, at least a portion of the moisture is removed from the jelly confectionery material having the first ratio at a rate of at least about 5% per hour.

[0036] In addition to or in the alternative to one or more of the above features, in a further embodiment, at least 1% of the moisture is removed from the jelly confectionery material having the first proportion in less than 5 minutes.

[0037] In addition to or in the alternative to one or more of the above features, in a further embodiment, at least 5% of the moisture is removed from the jelly confectionery material having the first proportion in less than 5 minutes.

[0038] In addition to or in the alternative to one or more of the above features, in a further embodiment, the jelly confectionery material having the first percentage of solids is a low solids jelly and the jelly confectionery material having the second percentage of solids is a high solids jelly. [Brief explanation of the drawings]

[0039] The accompanying drawings, which are incorporated in and constitute a part of this specification, embody several aspects of the disclosure and, together with the description, serve to explain the principles of the disclosure.

[0040] [Figure 1] FIG. 1 is a schematic diagram of a system for forming a jelly confection, according to one embodiment.

[0041] [Figure 2] FIG. 1 is a schematic diagram of a first moisture removal system including an extruder for forming a jelly confection, according to one embodiment.

[0042] [Figure 3] 3 is a cross-sectional schematic diagram of a first moisture removal system for forming the jelly confection of FIG. 2, according to one embodiment.

[0043] [Figure 4] FIG. 10 is a schematic diagram of a portion of a first moisture removal system for forming a jelly confection according to another embodiment.

[0044] [Figure 5] 5 is a schematic diagram of a storage device of the first moisture removal system of FIG. 4, according to one embodiment.

[0045] [Figure 6A] FIG. 10 is a schematic diagram of a portion of a second moisture removal system for forming a jelly confection, according to one embodiment.

[0046] [Figure 6B] FIG. 10 is a schematic diagram of another portion of a second moisture removal system for forming a jelly confection according to one embodiment.

[0047] [Figure 6C] FIG. 1 is a top view of a tray with jelly confectionery material having a final solids percentage output from an oven according to one embodiment.

[0048] [Figure 7] 1 is a graph comparing the viscosity and shear rate of several different jelly confectionery materials having different percentage solids at different temperatures, according to one embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0049] Embodiments disclosed herein relate to systems and methods for forming jellies. As used herein, the term "jelly" is intended to describe a confectionery containing various sugars and water, as well as at least one of cooked starch, pectin, gelatin, and similar hydrocolloids. Jellies may also contain one or more of colorants, flavors, and food acids. Furthermore, jellies can be transformed between various stages during the formation process. Examples of these stages include low-solids jellies, high-solids jellies, and stable high-solids jellies, as discussed herein. As used herein, the phrase "low-solids jellies" is intended to describe jellies having a percentage of solids of less than 80%, and in some embodiments, less than 78%. In some embodiments, the percentage of solids in low-solids jellies is typically, for example, about 72% to about 78%. As used herein, the phrase "high-solids jellies" is intended to describe jellies having a percentage of solids greater than the percentage of solids associated with low-solids jellies. High solids jellies can have a percent solids of greater than 78%, and in some embodiments, greater than 80%. In some embodiments, the percent solids of high solids jellies is typically, for example, about 82% to about 90%. As used herein, the phrase "stable high solids jelly" is intended to describe a high solids jelly after the jelly has been allowed to harden. Hardening, also known as baking, is a process that results in one or more of water removal, skin formation, formation of a desired gel strength and / or texture, and sugar inversion. After hardening, the jelly has a stable shape at room temperature.

[0050] Referring to Figure 1, a schematic diagram of a system 20 for forming jelly confections is illustrated. The system 20 for forming jelly confections includes a first moisture removal system, generally illustrated at 22, and a second moisture removal system, generally illustrated at 24, located downstream of the first moisture removal system 22 relative to the flow of jelly confection material. As will be explained in more detail below, the first or initial moisture removal system 22 is configured to receive a jelly confection material J1 having a first percentage solids and form it into a jelly confection material J2 having a second or intermediate percentage solids. The second moisture removal system is configured to receive a jelly confection material J2 having a second percentage solids and form it into a jelly confection material J3 having a third or final percentage solids.

[0051] In one embodiment, the jelly confectionery material J1 having the first percent solids is a low solids jelly. However, embodiments in which the jelly confectionery material having the first percent solids is a high solids jelly are also contemplated herein. In one embodiment, the jelly confectionery material J3 having the third or final percent solids is a high solids jelly. The second or intermediate percent solids is greater than the first percent solids and less than the third percent solids. In one embodiment, the jelly confectionery material J2 having the second or intermediate percent solids provided to the outlet of the first moisture removal system 22 is a high solids jelly having a lower percent solids than the third or final percent solids.

[0052] Referring now to FIG. 2, an example of the first moisture removal system 22 is illustrated in more detail. The first moisture removal system 22 may include a device or combination of devices capable of simultaneously heating and continuously mixing or stirring the jelly confectionery material. In the illustrated non-limiting embodiment, the first moisture removal system 22 is an extrusion system including, for example, an extruder 30. As shown, a jelly confectionery material J1 having a first set of properties is provided as input to the extruder 30, where it is processed into a jelly confectionery material J2 having a second set of properties. The first set of properties may include a first percentage of solids, and the second set of properties may include a second percentage of solids. As previously mentioned, the jelly confectionery material J1 having the first set of properties may be a low solids jelly, and the jelly confectionery material J2 having the second set of properties may be a high solids jelly. However, it should be understood that in other embodiments, the jelly confectionery material J1 provided as input to extruder 30 and the jelly confectionery material J2 output from extruder 30 may both be a low solids jelly or a high solids jelly, and the second solids percentage of the jelly confectionery material J2 output from extruder 30 is greater than the first solids percentage of the jelly confectionery material J1 input to extruder 30.

[0053] In the exemplary embodiment, the extrusion system 22 for processing jelly confectionery material includes a jelly supply 32 (such as, but not limited to, a batch mixer or a tank) that supplies a jelly confectionery material J1 having a first set of characteristics to an extruder 30. In one embodiment, the jelly confectionery material J1 provided to the extruder 30 is a slurry or solution. As shown in the drawings, the jelly confectionery material J1 is delivered to the extruder 30 from the jelly supply 32 via a jelly conveying unit, such as, but not limited to, an injection line 34 connected to a jelly input 36 of the extruder 30. The injection line 34 may be heated to allow a more flowable viscosity of the jelly confectionery material J1 as it travels through the injection line 34 to the extruder 30. It should be understood that the jelly confectionery material J1 may additionally or alternatively be provided to the extruder 30 via a side feed, a hopper, or any other known method for feeding a slurry material or solution to an extruder.

[0054] The jelly confectionery material J1 provided to the extruder 30 by the jelly supply 32 may include all jelly ingredients except for certain temperature- or shear-sensitive ingredients, such as flavorings and possibly edible pieces such as dried crumbles. The jelly confectionery material J1 does not include the mentioned sensitive ingredients and may include ingredients such as, but not limited to, water, glucose, invert sugar, granulated sugar, starch, and pectin. As discussed in more detail below, at least one temperature- or shear-sensitive ingredient may be added to the extruder 30 at one or more downstream sections thereof. Such sensitive ingredients include, but are not limited to, prebiotics, probiotics, vitamins, flavors, and colors. For example, edible pieces such as, but not limited to, nuts, dried fruit, baked goods pieces, and candy pieces may also be added at downstream sections of the extruder 30 or after the jelly confectionery material J2 is output from the extrusion point 38 of the extruder 30.

[0055] The extruder 30 may be any type of continuous extruder, including, but not limited to, a single-screw, twin-screw, or planetary roller extruder. In the non-limiting embodiment illustrated in Figures 2 and 3, the extruder 30 is a twin-screw extruder including a first screw 40a adjacent to or intermeshing with a second screw 40b. The twin-screw extruder 30 may include multiple sections or barrels 42a...n, or a single barrel with multiple zones that can be used for multiple different extrusion or processing functions. An exemplary method for processing a jelly confectionery material J1 having a first percent solids content into a jelly confectionery material J2 having a second percent solids content using the twin-screw extruder 30 is described below.

[0056] As described above, jelly confectionery material J1 is provided to the extruder 30 from the jelly supply 32. The jelly confectionery material J1 provided to the input 36 of the first section 42a has or contains a first percentage of solids. In an exemplary embodiment, the first percentage of solids is approximately 70% to 80% solids, more specifically, approximately 71%, 72%, 73%, 74%, 75%, 76%, 77%, 78%, 79%, or 80% solids. Thus, in one embodiment, the jelly confectionery material J1 having the first percentage of solids is a low-solids jelly. The remaining percentage of the jelly confectionery material J1 may, but need not, be water or another liquid. Through a mixing and conveying process that occurs between the input 36 and the exit / extrusion point 38 of the extruder 30, the jelly confectionery material J1 is "dehydrated" to form a jelly confectionery material J2 having a desired second percentage of solids. In an exemplary embodiment, the second percent solids associated with jelly confectionery material J2 is between about 79% and 90% solids, or more specifically, about 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, or 90% solids. Thus, in one embodiment, jelly confectionery material J2 having the second percent solids is a high solids jelly. As noted above, while this dehydration process or moisture reduction is described with respect to converting low solids jelly J1 to high solids jelly J2, in other embodiments, the process may be used simply to increase the percent solids within a low solids jelly or a high solids jelly, respectively. In the exemplary embodiment shown in FIGS. 2 and 3, this dehydration or moisture reduction occurs as follows:

[0057] The first section 42a of the extruder 30 is the ingredient / slurry inlet section. Jelly confectionery material J1 may be provided to the first section 42a in any suitable manner, including but not limited to, via an inlet line, a hopper, or even via holes formed in the first section 42a. This section is typically unheated, but in some embodiments may be heated, such as when the jelly confectionery material J1 provided therein is at a relatively elevated temperature upon entering the section 42a. For example, the jelly confectionery material J1 may be provided to the first section 42a at a temperature of 90°C or greater. From here, the jelly confectionery material J1 is moved downstream into the second section 42b as a result of the rotating screw geometry. In an exemplary embodiment using an extruder having twin screws, rotating screws 40a, 40b continuously move jelly confectionery material J1 through a flow path in extruder 30 defined by each of successive barrel or section combinations 42a-n to an output or extrusion point 38 where jelly confectionery material J2 has a second percent solids content.

[0058] For ease of understanding, the jelly confectionery material will be generally referred to as J1 as it flows through the first removal system 22 until it becomes jelly confectionery material J2 having a second percentage solids. However, it should be understood that the percentage solids of the jelly confectionery material J1 gradually increases from the first percentage solids to the second percentage solids within the first removal system 22. Thus, jelly confectionery material located in a position in the first removal system 22 between the inlet and the position where the jelly confectionery material reaches the second percentage solids J2 will each be referred to as J1, but will have a percentage solids between the first percentage solids and the second percentage solids.

[0059] Similar to the several sections of the extruder 30 shown in the exemplary embodiment of Figures 2 and 3, the first and second sections 42b are typically conveying sections where the jelly confectionery material J1 is moved downstream, mixed, and in some embodiments, heated via an extruder heating system or heating device. In such an extruder, at least one conveying section, such as section 42b, is typically heated to a temperature of, for example, about 95°C to 150°C, e.g., about 95°C to 145°C, about 95°C to 140°C, about 95°C to 135°C, about 95°C to 130°C, about 95°C to 125°C, about 95°C to 120°C, about 100°C to 150°C, about 100°C to 145°C, about 100°C to 140°C, about 100°C to 135°C, about 100°C to 130°C, about 100°C to 125°C, about 100°C to 120°C, about 105°C to 150°C, about 105°C to 145°C, about 10 The jelly confectionery material J1 is heated to a temperature of 5°C to 140°C, about 105°C to 135°C, about 105°C to 130°C, about 105°C to 125°C, about 105°C to 120°C, about 110°C to 150°C, about 110°C to 145°C, about 110°C to 140°C, about 110°C to 135°C, about 110°C to 130°C, about 110°C to 125°C, about 110°C to 120°C, about 115°C to 150°C, about 115°C to 145°C, about 115°C to 140°C, about 115°C to 135°C, about 115°C to 130°C, about 115°C to 125°C, or about 115°C to 120°C. In one embodiment, the heated water in the jelly confectionery material J1 remains liquid in the second section 42b. From the second section 42b, the jelly confectionery material J1 is conveyed by screws 40a, 40b to the third section 42c.

[0060] 2 and 3, the third section 42c is a devolatilization barrel or section where moisture, such as evaporated water, is removed from the jelly confectionery material J1 to at least begin to increase its percent solids, rising from a first percent solids to a second percent solids, as discussed above. Of course, while the exemplary embodiment discussed herein describes the third section 42c as the first devolatilization section of the extruder 30, it should be understood that any section of the extruder 30 may be configured as a devolatilization section. Furthermore, embodiments in which additional sections of the extruder 30 are located upstream of the first devolatilization section are also within the scope of the present disclosure.

[0061] In one embodiment, a single barrel or section, such as third section 42c, is the sole devolatilization or moisture removal section of extruder 30. In such an embodiment, the amount of moisture removed in the sole devolatilization section is sufficient to convert jelly confectionery material J1 having a first percent solids to jelly confectionery material J2 having an increased second percent solids that ultimately exits extruder 30. In other embodiments, section 42c is one of multiple devolatilization sections disposed along extruder 30, as in the exemplary embodiment of Figures 2 and 3. In such an embodiment, moisture may be removed in a consistent manner (e.g., the percent solids increase by 2% in each successive devolatilization barrel or section) or in an inconsistent manner (e.g., the percent solids increase by a different percentage in each successive devolatilization barrel or section).

[0062] In one embodiment, the devolatilization section has a free volume that is at or slightly above atmospheric pressure (in embodiments where a vacuum device is not connected to it). The reduced pressure in the devolatilization section may be achieved as a result of the configuration of one or more screws of the extruder 30. In one embodiment, at least one screw 40a, 40b of the extruder 30 is configured to withdraw jelly confectionery material J1 from the devolatilization section faster than the jelly confectionery material J1 is provided to the devolatilization section.

[0063] Similar to the conveying sections, such as the second section 42b, the at least one devolatilization section, e.g., the third section 42c, may also include a heating system for heating the jelly confectionery material J1 to a temperature of about 105°C to 135°C, e.g., about 105°C to 130°C, about 105°C to 125°C, about 105°C to 120°C, about 110°C to 135°C, about 110°C to 130°C, about 110°C to 125°C, about 110°C to 120°C, about 115°C to 135°C, about 115°C to 130°C, about 115°C to 125°C, or about 115°C to 120°C, to convert or maintain the moisture in the jelly confectionery material J1 as steam. In one embodiment, substantially all or the majority of the evaporation of the moisture in the jelly confectionery material J1 occurs in the at least one devolatilization section. As the moisture on the surface of the jelly confectionery material J1 facing the free volume is heated, the moisture evaporates and flows into the free volume. As a result of the continuous rotation of the screws 40a, 40b, new surfaces of the jelly confectionery material J1 are continuously exposed to the free volume, resulting in a continuous release of evaporated moisture from the jelly confectionery material J1. In this way, the evaporated moisture does not have to pass through the jelly confectionery material J1 to escape into the free volume.

[0064] It should be noted that the third section 42c illustrated in the exemplary embodiment of Figures 2 and 3 is a first-type devolatilization section that simply includes at least one opening to the ambient environment in the wall of the extruder 30, such as opening 44 (Figure 2). Opening 44 allows at least a portion of the evaporated moisture within the devolatilization section to escape from the jelly confectionery material J1 and the extruder 30. The fifth section 42e and the sixth section 42f may also be first-type devolatilization sections having openings 44. Like the third section 42c, these sections 42e and 42f may also include a heating system for heating the jelly confectionery material J1 to a temperature of about 105°C to 135°C, more specifically about 110°C to 120°C, to heat the moisture as discussed above, with opening 44 similarly allowing vapor moisture to escape therethrough. However, it should be understood that each devolatilization section may have a different temperature profile. Furthermore, the devolatilization section need not have the same temperature profile as the conveying section.

[0065] As shown in the non-limiting embodiment of Figures 2 and 3, jelly confectionery material J1 is conveyed from third section 42c to fourth section 42d along a downstream path of extruder 30. Fourth section 42d may be a conveying and heating section, such as second section 42b. From fourth section 42d, jelly confectionery material J1 is conveyed via screws 40a and 40b to fifth section 42e and sixth section 42f, which may function as a first type of devolatilization section, as discussed above. Jelly confectionery material J1 is then moved on its downstream path to seventh section 42g, which may be another conveying and heating section, such as sections 42b and 42d. From seventh section 42g, jelly confectionery material J1 is conveyed via screws 40a and 40b to eighth section 42h. In one embodiment, eighth section 42h is configured as a second type of devolatilization section, discussed in more detail below with reference to eleventh section 42k. Ninth section 42i and tenth section 42j are located downstream of section 42h and may function as conveying and heating sections, like sections 42b, 42d, and 42g.

[0066] From tenth section 42j, jelly confectionery material J1 is conveyed via screws 40a, 40b to eleventh section 42k, which in the illustrated non-limiting embodiment is also a second-type devolatilization section, such as section 42h. Second-type devolatilization sections as discussed herein are similar to first-type devolatilization sections. However, instead of simply including an opening 44 to the ambient atmosphere, as in the first-type devolatilization sections, second-type devolatilization sections (such as sections 42h and 42k) include openings 46 connected to vacuum devices 48. In the illustrated non-limiting embodiment, each section configured as a second-type devolatilization section may include a respective vacuum device, such as devices 48a and 48b. However, embodiments in which multiple sections configured as second-type devolatilization sections are fluidly connected to the same vacuum device are also within the scope of the present disclosure. One or more vacuum devices 48a, 48b are operable to actively draw evaporated moisture from the free volume of the second type devolatilization section of the extruder 30. In an exemplary embodiment, these vacuum devices 48a, 48b remove moisture from the devolatilization section through their respective openings 46. The pressure resulting from application of the vacuum devices can be anywhere from atmospheric pressure to a complete vacuum (zero pressure). Application of the vacuum devices 48a, 48b to the second devolatilization section can increase the rate of evaporation and moisture removal from the jelly confectionery material J1 within these sections.

[0067] As discussed above, a second type of devolatilization section, such as sections 42h and 42k, may remove an amount of moisture that results in the same increase in percent solids as that seen in a first type of devolatilization section. Indeed, even though vacuum devices 48a and 48b may result in more active moisture removal than that seen in a first type of devolatilization section, the percent solids of the jelly confectionery material J1 may increase at the same rate downstream of vacuum devices 48a and 48b relative to the upstream position of the first type of devolatilization section due to the reduced presence of moisture there. Of course, the vacuum devices associated with a second type of devolatilization section, such as sections 42h and 42k, may also increase the percent solids in the jelly confectionery material J1 at a faster rate than the first type of devolatilization section, or may simply be modifiable to remove moisture at any level that achieves any desired increase in rate.

[0068] In the exemplary embodiment of Figures 2 and 3, there are two further conveying and heating sections downstream of the eleventh section 42k. These two conveying and heating sections 42l and 42m function like sections 42b, 42d, 42g, 42i, and 42j. Section 42n, as shown in the exemplary embodiment, is the fourteenth and final section. This section 42n includes an opening 46 and a vacuum device 48c, and functions as a second type of devolatilization section like section 42k. Section 42n is the output section including the extrusion point 38 of the extruder 30, from which the jelly confectionery material J2 having the second solids percentage is output. Thus, in the exemplary embodiment of Figures 2 and 3, in the final section 42n of the extruder 30, moisture has been removed to the point where the jelly confectionery material is converted into the jelly confectionery material J2 having the second solids percentage. It should be appreciated that in some embodiments, the jelly confectionery material J1 in the extruder 30 is converted from a low solids jelly to a high solids jelly at a location upstream of the final devolatilization section.

[0069] As jelly confectionery material J2 exits the extruder die, some additional unintentional devolatilization or further moisture removal may occur at the exit or extrusion point 38 of the extruder 30. Thus, in embodiments where the exit 38 of the extruder 30 is located downstream of the final devolatilization section, the exit 38 may be the final location where moisture is removed from the jelly confectionery material to form jelly confectionery material J2 having a second percent solids. In one embodiment, the extruder exit is connected to a confining pipe (not shown). In such an embodiment, final devolatilization may occur as jelly confectionery material J2 passes through the exit end of the confining pipe.

[0070] The extruder 30 is described above with reference to an exemplary number of barrels or sections 42a-n, as shown. However, it should be understood that this is merely an example of a system that may be used. Extruders 30 having any number of barrels or sections in any suitable arrangement are contemplated herein. For example, the extruder 30 may include an inlet section, a downstream outlet section, and any number of mixing sections, conveying sections, first type devolatilization sections, and second type devolatilization sections therebetween. It should further be understood that one or more conveying sections, first type devolatilization sections, and second type devolatilization sections may be arranged in any suitable order along the extruder 30. The inlet section and outlet section may also function as a conveying section and / or a devolatilization section (first or second type), with any number of sections functioning as one or both of a conveying section and a devolatilization section disposed therebetween (including no sections therebetween). It should further be understood that any of the sections positioned between the inlet section and the outlet section may be capable of heating or cooling the jelly confectionery material disposed therein. The conveying section and the first or second type of devolatilization section may be disposed upstream and downstream of each other between the inlet and outlet sections of the extruder 30. Furthermore, the jelly confectionery material in the extrusion system 22 may be converted to a jelly confectionery material J2 having a desired second percentage solids at any point along the extruder 30 following conveyance through at least one devolatilization section, and the jelly confectionery material J2 is simply moved / conveyed to the outlet section for extrusion without further devolatilization (or any significant further devolatilization prior to exit / extrusion from the extruder).

[0071] Ingredients that are sensitive to one or more of temperature, shear, and volatility, also referred to herein as "sensitive ingredients," may optionally be added to the jelly confectionery material in extruder 30, such as through an inlet other than inlet 36. If added in extruder 30, at least one sensitive ingredient may be added downstream of the formation of jelly confectionery material J2 having the desired second percent solids, such as in the final conveying section of extruder 30. In one embodiment, the addition of sensitive ingredients in extruder 30 occurs downstream of all devolatilization of jelly confectionery material J1. For example, any volatile sensitive ingredients should be added downstream of the final devolatilization section to maintain the integrity of those ingredients. Any sensitive ingredients added in or upstream of the devolatilization section should be non-volatile to prevent loss of a portion of that volatile component in the devolatilization section. Alternatively or additionally, one or more sensitive and non-sensitive ingredients may be added to the jelly confectionery material J2 in the final conveying section of extruder 30 and / or downstream of outlet 38, such as in a confined pipe fluidly connected to the outlet of extruder 30. These ingredients may be mixed with jelly confectionery material J2 having the desired second percent solids via any suitable mechanism, including, but not limited to, a static mixer or a dynamic mixer.

[0072] In conventional baking processes, heat directed to the surface of a low solids jelly to aid in devolatilization results in a surface "skin" (a region of different moisture diffusivity, typically less than that of the rest of the mixture) around at least a portion of the resulting jelly confection. This surface skin typically has a moisture diffusivity that can be two orders of magnitude lower than that of the rest of the jelly confection. This low moisture diffusivity at the surface is one of the primary reasons that jelly confection materials must be heated for long periods of time to form jelly confections with the desired percent solids.

[0073] Because the screws 40a, 40b of the extruder 30 are continuously rotating as the jelly confectionery material J1 is conveyed through the extruder 30, new portions of the jelly confectionery material J1 are continuously brought to the surface. This continuous renewal of the surface of the jelly confectionery material J1 or J2 is particularly important within the at least one devolatilization section. It is this constant exposure of new portions of the jelly confectionery material J1 to the free volume within the at least one devolatilization section that allows moisture on the surface of the jelly confectionery material J1 to evaporate and be removed therefrom. It should be appreciated that during the dehydration or moisture removal process, the solids percentage of the jelly confectionery material J1 may transform from a low solids jelly to a high solids jelly before becoming the jelly confectionery material J2 having the desired second solids percentage.

[0074] A skin, as described with respect to conventional baking processes, does not form in extruder 30 because the surface of jelly confectionery material J1 is continuously renewed as the jelly confectionery material flows through extruder 30, particularly through one or more devolatilization sections. It is further noted that the jelly confectionery material exiting extruder 30 may comprise a material composition that has a consistent moisture diffusivity throughout its cross-sectional area as taken in a plane perpendicular to the direction of flow of the jelly confectionery material. Indeed, a substantially consistent moisture diffusivity throughout the cross-sectional area may be present not only in jelly confectionery material J2 at exit 38 of extruder 30, but also in jelly confectionery material J1 throughout its residence time within extruder 30, due to the mixing and surface renewal discussed above.

[0075] In exemplary embodiments, the jelly confectionery material (in the form of a low solids jelly, and in some embodiments a high solids jelly) has a residence time in the extruder 30 from input to extrusion output of about 30 seconds to about 5 minutes, e.g., less than 4 minutes, less than 3 minutes, less than 2 minutes, less than 1 minute, about 1 minute to about 4 minutes, about 1 minute to about 3 minutes, or about 1 minute to about 2 minutes. Further, one or more of the screws 40a, 40b of the extruder 30 has an axial length L measured parallel to the axis of rotation of the one or more screws between the entrance at the screw tip and the point of extrusion, and has an inner diameter D. The length to diameter ratio L / D can be at least 3:1, or in other embodiments, at least 4:1, 5:1, 6:1, 7:1, 8:1, 9:1, 10:1. In some embodiments, the ratio L / D is from 12:1 to 20:1, e.g., 12:1, 13:1, 14:1, 15:1, 16:1, 17:1, 18:1, 19:1, and 20:1. Additionally, in one embodiment, the rotational speed of one or more screws in the extruder can be from about 25 rpm to about 500 rpm.

[0076] Referring now to FIG. 4 , another example of a first moisture removal system 22 for forming a jelly confection J2 having a second percent solids is illustrated. As shown, the first moisture removal system 22 includes a scraped-surface heat exchanger 60. While the scraped-surface heat exchanger 60 is illustrated in a substantially vertical orientation, it should be understood that embodiments in which the scraped-surface heat exchanger 60 has another configuration, such as a horizontal configuration, are also within the scope of the present disclosure. As shown, the scraped-surface heat exchanger 60 includes a hollow cylindrical outer shell 62 surrounding an annular passage 64. A rotor 66 is centrally located within the annular passage 64 and includes one or more blades 68 extending outwardly therefrom via arms 70. As the rotor 66 rotates about its axis within the annular passage 64, an inner surface 72 of the annular passage 64 is continuously engaged and “scraped” by the at least one blade 68 extending from the rotor 66.

[0077] A jelly confectionery material J1 having a first percentage of solids is provided to the annular passage 64 of the scraped surface heat exchanger 60. In one embodiment, the jelly confectionery material J1 is delivered to an inlet 74 of the annular passage 64, such as from a jelly confectionery material supply 75. While the inlet 74 is illustrated as being located at a first lower end of the scraped surface heat exchanger 60, it should be understood that in other embodiments the inlet may be located at another location around the scraped surface heat exchanger 60. As with the previous embodiment of the first moisture removal system described above, the jelly confectionery material J1 provided to the scraped surface heat exchanger 60 may be a low solids jelly containing a first percentage of solids between 70% and 80% solids, more specifically 71%, 72%, 73%, 74%, 75%, 76%, 77%, 78%, or 79% solids. The remaining proportion of the jelly confectionery material J1 provided to scraped surface heat exchanger 60 may, but need not, be water or another liquid.

[0078] As the jelly confectionery material J1 flows through the annular passage 64 toward an outlet 76, such as located at the second, opposite end of the scraped surface heat exchanger 60, the jelly confectionery material J1 is heated. In one embodiment, a heat exchange medium M, such as steam, air, oil, or another suitable medium, is circulated within the outer shell 62. Heat from the heat exchange medium M is transferred to the jelly confectionery material J1 through the wall of the outer shell 62. In one embodiment, the amount of heat transferred to the jelly confectionery material J1 within the scraped surface heat exchanger 60 is controlled so that the jelly confectionery material J1 at the outlet 76 has a temperature at or above the boiling point of water (at standard temperature and pressure). In one embodiment, the jelly confectionery material J1 at the outlet 76 is heated to a temperature between 95°C and 150°C, for example between about 95°C and 145°C, between about 95°C and 140°C, between about 95°C and 135°C, between about 95°C and 130°C, between about 95°C and 125°C, between about 95°C and 120°C, between about 100°C and 150°C, between about 100°C and 145°C, between about 100°C and 140°C, between about 100°C and 135°C, between about 100°C and 130°C, between about 100°C and 125°C, between about 100°C and 120°C, between about 105°C and 150°C, between about 105°C and 145°C, between about 105°C and 140°C, The temperature is about 105°C to 135°C, about 105°C to 130°C, about 105°C to 125°C, about 105°C to 120°C, about 110°C to 150°C, about 110°C to 145°C, about 110°C to 140°C, about 110°C to 135°C, about 110°C to 130°C, about 110°C to 125°C, about 110°C to 120°C, about 115°C to 150°C, about 115°C to 145°C, about 115°C to 140°C, about 115°C to 135°C, about 115°C to 130°C, about 115°C to 125°C, or about 115°C to 120°C.

[0079] As the jelly confectionery material J1 is heated, the rotation of the rotor 66 and the resulting scraping of the inner surface 72 of the annular passage 64 continuously mixes the jelly confectionery material J1. This mixing facilitates uniform heating of the jelly confectionery material J1. As the jelly confectionery material J1 is heated in the scraped-surface heat exchanger 60, the first percent solids of the jelly confectionery material J1 provided at its outlet 76 may be substantially the same as the jelly confectionery material J1 provided at the inlet 74 of the scraped-surface heat exchanger 60. Thus, the first percent solids of the jelly confectionery material J1 may remain generally constant as the jelly confectionery material J1 is heated in the scraped-surface heat exchanger 60. Furthermore, it should be understood that embodiments using another machine or heat transfer device capable of heating the jelly confectionery material J1 in place of the scraped-surface heat exchanger are within the scope of this disclosure. Examples of such heat transfer devices include, but are not limited to, coil cookers and heat exchangers, and in such embodiments, the jelly confectionery material J1 may be configured to move or flow continuously through the heat transfer device. In one embodiment, the jelly confectionery material J1 moving through any suitable heat transfer device has a non-laminar flow.

[0080] 4 and with further reference to FIG. 5, first moisture removal system 22 further includes a storage device 80, such as, for example, a holding tank. Storage device 80 may include a body 82 having an inlet 84 and an outlet 86, and a generally hollow interior 88 connected to inlet 84 and outlet 86. In the illustrated non-limiting embodiment, inlet 84 is formed at a first, upper end of body 82, and outlet 86 is formed at a lower end of body 82. However, embodiments in which inlet 84 and / or outlet 86 are formed at other locations around body 82, such as, for example, in a sidewall, are also contemplated herein.

[0081] In one embodiment, the environment within the hollow interior 88 of the holding tank 80 is a low-moisture environment, such as a low-moisture gaseous environment. Vents or openings 90 may be formed in the walls of the holding tank 80. At least a portion of the evaporated moisture within the free volume of the holding tank 80 may escape through the vents 90. In some embodiments, the hollow interior 88 of the holding tank 80 may be operably coupled to a vacuum device 92 such that the environment within the hollow interior 88 is a low-pressure environment. The vacuum device 92 is operable to actively draw evaporated moisture from the hollow interior 88 of the holding tank 80. The pressure within the hollow interior 88 resulting from application of the vacuum device 92 may be anywhere from atmospheric pressure to a complete vacuum (zero pressure).

[0082] As shown, from outlet 76 of scraped surface heat exchanger 60, heated jelly confectionery material J1 is provided, either directly or via conduit 78, to inlet 84 of holding tank 80. The temperature of jelly confectionery material J1 may be substantially the same at inlet 84 of holding tank 80 and outlet 76 of scraped surface heat exchanger 60. However, embodiments in which a small amount of heat is transferred from or to jelly confectionery material J1 during transfer between outlet 76 and inlet 84, such as by conduction or convection to the ambient atmosphere, are also within the scope of this disclosure. In embodiments in which heat is lost between scraped surface heat exchanger 60 and holding tank 80, the temperature of jelly confectionery material J1 at inlet 84 of holding tank 80 may be at or above the boiling point of water (at standard temperature and pressure).

[0083] Within the holding tank 80, the flowable jelly confectionery material J1 is configured to fall, such as by gravity, from the inlet 84 to the outlet 86. In some embodiments, a nozzle 94 is positioned at or directly adjacent to the inlet 84 of the holding tank 80. The nozzle 94 may be angled relative to the longitudinal axis of the holding tank 80 to direct the heated jelly confectionery material J1 toward an inner surface 96 of the sidewall of the holding tank 80. In one embodiment, the nozzle 94 is configured to split the flow of heated jelly confectionery material J1 at the inlet 84 into multiple streams, thereby increasing the surface area of ​​the heated jelly confectionery material J1 within the holding tank 80.

[0084] As the jelly confectionery material J1 is released through the inlet 84 into the hollow interior 88 of the holding tank 80, liquid water located at or near the exterior surface of the jelly confectionery material J1, which is in contact with the ambient atmosphere, evaporates and is released or gases from the jelly confectionery material J1. Furthermore, as the jelly confectionery material J1 accelerates as it falls due to gravity, and one or more streams of the jelly confectionery material J1 thin, new surfaces of the jelly confectionery material J1 are continually exposed, resulting in the continuous release of water vapor from the surface of the jelly confectionery material J1 until the jelly confectionery material J1 reaches the bottom of the storage device 80. This continuous exposure of new surfaces of the jelly confectionery material J1, which causes the continuous release of moisture, is a form of continuous renewal, similar to the mixing achieved in the extruder 30 in the embodiment of Figures 2 and 3. In one embodiment, a jelly confectionery material J2 having a desired second solids percentage, such as a high solids jelly, is collected at the bottom of the holding tank 80 and is output from the holding tank 80 via the outlet 86. Additionally, water or moisture released from the jelly confectionery material may be collected in a separate portion of the holding tank or may be removed therefrom via vent 90 or the like, as previously described.

[0085] The continuous removal of water vapor as the jelly confection material J1 falls "dehydrates" the jelly confection material J1 to form a jelly confection material J2 having a desired second solids percentage, such as a high solids jelly. In exemplary embodiments, the jelly confection material J2 collected in the storage device 80 has a second solids percentage of about 79%-90% solids, or more specifically, about 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, or 90% solids. The jelly confection material J2 provided to the outlet 86 of the storage device 80 does not include a coating as previously described herein.

[0086] One or more parameters associated with the jelly confectionery material J1 at the inlet of the storage device 80 or associated with the operation of processing equipment such as, for example, the storage device 80, the scraped surface heat exchanger 60, and / or the vacuum device 92, may be controlled to achieve a desired second percent solids of the jelly confectionery material J2 at the outlet 86 of the storage device 80. Examples of such parameters include, but are not limited to, the flow rate at which the jelly confectionery material J1 is provided to the inlet 84, the axial (vertical) distance over which water is removed from the jelly confectionery material J1, e.g., the distance between the inlet 84 and the outlet 86 of the storage device 80, the temperature of the jelly confectionery material J1, the temperature of the environment within the storage device 80, and the pressure or vacuum level within the storage device 80.

[0087] Although only a single storage device 80 is illustrated, it should be understood that in other embodiments, the first moisture removal system 22 may include multiple storage devices arranged in series with respect to the flow of jelly confectionery material. In such an embodiment, the jelly confectionery material provided to the outlet 86 of the last storage device in the series may be jelly confectionery material J2 having the second percent solids.

[0088] 2-3, sensitive ingredients, such as, but not limited to, those discussed above, may optionally be added to the jelly confectionery material at or downstream of the storage device 84. Alternatively or additionally, one or more sensitive ingredients, such as, for example, non-volatile temperature-sensitive ingredients, may be added to the jelly confectionery material J1 at the inlet 84 of the storage device 80, within the conduit 78 extending between the scraped surface heat exchanger 60 and the inlet 84, within the annular passage 64 of the scraped surface heat exchanger 60, at or near the outlet 76 thereof, for example, once the jelly confectionery material J1 has been heated to a desired temperature, or even within the jelly confectionery material J1 at a location upstream of the scraped surface heat exchanger 60. However, embodiments in which sensitive ingredients are added downstream of one or more storage devices 80, for example, to the jelly confectionery material J2, are also contemplated herein.

[0089] Regardless of the configuration of the first moisture removal system 22, the jelly confectionery material J2 output therefrom, having a second set of parameters, may be provided to a second moisture removal system 24. While only a single first moisture removal system is illustrated and described herein, it should be understood that some embodiments may include multiple first moisture removal systems arranged in series upstream of the second moisture removal system 24. In embodiments including multiple first moisture removal systems, the jelly confectionery material J1 having a first solids percentage will be provided to the inlet of the most upstream first moisture removal system 22, and the jelly confectionery material provided to the outlet of the upstream moisture removal system will have a solids percentage intermediate between the first and second percentages. This jelly confectionery material having an intermediate solids percentage will therefore be provided to the inlet of another first moisture removal system 22. The jelly confectionery material output from the most downstream first moisture removal system 22 will have a second solids percentage J2.

[0090] The jelly confectionery material provided at the outlet of second moisture removal system 24 is jelly confectionery material J2 having a third or final set of parameters. In some embodiments, jelly confectionery material J3 is output from second moisture removal system 24 as the final jelly confectionery. In such embodiments, the final jelly confectionery may be of a desired size and shape and ready to be packaged. However, in other embodiments, one or more additional processes may be applied to the jelly confectionery before it becomes a final jelly confectionery ready to be packaged.

[0091] 6A-6C, the second moisture removal system 24 includes at least one tray 100 having one or more cavities 102 formed therein. Each of the cavities 102 may be considered a mold. The cavities 102 may have a three-dimensional shape corresponding to the desired shape of the final jelly confection. The cavities 102 may be covered by a layer of starch, or in some embodiments, the tray 100 itself may be a starch-based slab having one or more cavities 102 formed therein.

[0092] The deposition nozzle 104 is configured to deliver a predetermined amount of jelly confectionery material J2 having a second set of parameters to each of the plurality of cavities 102. Once the cavities 102 are filled with the jelly confectionery material J2, the tray 100 is positioned in the oven 110 for a predetermined period of time (see FIG. 6B). In one embodiment, the hold time between filling the cavities 102 and moving the tray 100 forward toward the oven 110 is between 0.05 seconds and 1 second. Within the oven 110, heated air A is forced to flow over and around the cavities 102, removing additional moisture from the jelly confectionery material located therein to form a jelly confectionery material J3 having a third solids percentage (see FIG. 6C). This process of filling the molds or cavities 102 with jelly confectionery material and hardening the jelly confectionery material in the oven may also be referred to herein as "baking." In one embodiment, the interior 112 of the oven 110 may be heated to a temperature of about 70°C and the at least one mold 102 may be positioned within the oven 110 for a suitable length of time, such as from about 10 hours to about 70 hours. In some embodiments, the mold 110 is positioned within the oven 110 for less than 24 hours, and in some cases less than 23 hours, less than 22 hours, less than 21 hours, less than 20 hours, less than 19 hours, less than 18 hours, less than 17 hours, less than 16 hours, less than 15 hours, less than 14 hours, less than 13 hours, or even less than 12 hours, 1 hour, or even less than 1 hour. However, it should be understood that the temperature of the oven 110 and the time required to set the jelly confectionery material within the oven 110 may vary based not only on the desired third set of parameters for the resulting jelly confectionery material J3, but also on the second set of parameters for the second jelly confectionery material J2 provided therein. By removing a portion of the moisture from the jelly confectionery material before hardening it in the oven 110, the total time that the jelly confectionery material is placed in the oven 110 is reduced to form a jelly confectionery material J3 having the same final percent solids.

[0093] During the setting process, a skin may form on the jelly confectionery material within the cavities 102. Various adjustments may be made to the composition of the jelly confectionery material, the processing parameters associated with the first moisture removal system, and / or the processing parameters associated with the second moisture removal system to increase or decrease the skin on the final jelly confectionery.

[0094] In existing systems, the percent solids of the jelly confectionery material provided to the deposition nozzle and cavities is typically about 75% to 76%. However, the jelly confectionery material J2 with the second set of parameters provided to the second moisture removal system 24 has a percent solids of about 79% to about 86%. As a result of this increased percent solids, the jelly confectionery material J2 may have a higher viscosity than the jelly confectionery material provided to the deposition nozzle in existing systems. If the increased viscosity jelly confectionery material were provided to the same deposition nozzle used in existing systems, it would be difficult to pump the jelly confectionery material, and tailing may occur. Tailing is when the excess jelly confectionery material output from the deposition nozzle does not enter the cavities directly. Rather, this material, or "tail," may extend upward from the cavities or connect adjacent cavities to each other.

[0095] To address potential pumping and tailing issues due to the increased viscosity of the jelly confectionery material J2 having the second percent solids, the temperature of the jelly confectionery material J2 having the second percent solids can be increased. Referring to Figure 7, a graph is illustrated depicting the viscosity of a first jelly confectionery material and a second jelly confectionery material at different temperatures over a range of shear rates. Three lines identified as "Control Slurry Standard Brix" represent the first jelly confectionery material having a first percent solids, as associated with jelly confectionery materials currently deposited via existing processes. These three lines represent the viscosity of the first jelly confectionery material at different temperatures: 85°C, 95°C, and 105°C, respectively. The graph also provides three lines identified as "Control Slurry - High Brix." These lines represent the second jelly confectionery material at the same three temperatures. The second jelly confectionery material has the same composition as the first jelly confectionery material. However, the percent solids of the second jelly confectionery material is greater than the percent solids of the first jelly confectionery material. In one embodiment, the second jelly confectionery material has a second percent solids comparable to jelly confectionery material J2 described herein.

[0096] As can be seen by comparing the line associated with the first jelly confectionery material (standard Brix) for a particular temperature with the corresponding line associated with the second jelly confectionery material (high Brix) for the same temperature, the viscosity of the second jelly confectionery material is 1000 s -1 The viscosity of the second jelly confectionery material increases significantly for any shear rate less than 1 / 2. However, as the temperature of the second jelly confectionery material increases, the viscosity of the second jelly confectionery material decreases at the same shear rate. Therefore, the temperature of the second jelly confectionery material can be controlled to achieve a second jelly confectionery material with a viscosity approximately equal to that of the first jelly confectionery material for a given shear rate.

[0097] In existing systems, a jelly confectionery material having a percent solids of about 75% to 76% is output from the deposition nozzle at a temperature of about 85°C to about 90°C. This combination of temperature and percent solids provides an acceptable viscosity for deposition without excessive sucrose conversion prior to deposition. In one embodiment, a jelly confectionery material J2 output from the first moisture removal system and having a second percent solids, such as about 79% to about 86%, is discharged from the same deposition nozzle 104 at a temperature greater than 100°C, such as about 100°C to about 115°C. As noted above, at this temperature, the viscosity of the jelly confectionery material J2 having a second percent solids can compensate for the higher percent solids. For example, the viscosity of the jelly confectionery material J2 having a second percent solids at a temperature of about 85°C to about 90°C can be close to, e.g., within 10% of, the viscosity of a jelly confectionery material having a percent solids of about 75% to 76%. The jelly confectionery material J2 having the second solids percentage may be heated via a heating system (not shown) located at the deposition nozzle or alternatively or additionally at a location upstream of the deposition nozzle. To achieve this temperature increase, the heating system may be configured to transfer heat to the jelly confectionery material J2 using oil instead of water.

[0098] Continuing with reference to FIG. 7, alternatively or additionally to increasing the temperature of the jelly confectionery material J2, the shear rate may be controlled, for example, increased or decreased, to achieve a desired viscosity of the deposited jelly confectionery material J2. As an alternative to controlling the viscosity of the jelly confectionery material J2, one or more parameters associated with the operation of the deposition nozzle 104 may be adjusted to accommodate the increased viscosity of the jelly confectionery material J2 output from the first moisture removal system 22. Examples of such parameters include, but are not limited to, suckback and deposition speed. For example, the deposition speed of the jelly confectionery material J2 may be between 10 and 500 mm / sec. At this rate, the deposition nozzle 104 may be used to fill between 10 and 50 trays per minute. However, embodiments having deposition rates or total numbers of trays filled per minute outside the specified range are also within the scope of the present disclosure. In one embodiment, the configuration of the deposition nozzle 104 used to deposit the jelly confectionery material J2 having the second solids percentage may be modified relative to the deposition nozzle of an existing system. For example, the axial length of the deposition nozzle 104, the inner diameter of the deposition nozzle 104 at the outlet, and / or the variation in the inner diameter over the axial length of the deposition nozzle 104 may be adjusted. In one embodiment, the deposition nozzle 104 is cylindrical or conical and has an inner diameter of 1.5 to 4.5 mm. Alternatively, or additionally, at least a portion of the inner surface 106 of the deposition nozzle 104 may include one or more coatings. In some embodiments, a separate device 108 for interrupting the flow of jelly confectionery material at the outlet of the deposition nozzle 104 may be included. The device 108 may be a heating element operable to break the tail of the jelly confectionery material J2 at the outlet of the deposition nozzle 104. In one embodiment, the device 108 is a mechanical cutting device operable to break the tail of the jelly confectionery material at the outlet of the deposition nozzle 104. However, any suitable device 108 is also within the scope of the present disclosure.

[0099] The systems for forming jelly confections as illustrated and described herein are operable to form jelly confection materials, jelly confections, or final jelly confections in a reduced time. For example, forming a jelly confection by baking a jelly confection material having a percent solids of 73-78.5% typically takes 16-70 hours, depending on the size, weight, shape, dimensions, and texturizing agents, if any, included in the composition. The product temperature during steady-state conditions of the baking process is typically 50°C-75°C for starch-based jelly confections and 20°C-60°C for gelatin-containing jelly confections. Furthermore, the resulting jelly confections typically have a percent solids of 80-88.5%.

[0100] However, when forming jelly confections using the two-step process described herein, significant time savings are achieved. During the first moisture removal process, the percent solids of the jelly confection material provided therein typically increase by at least 1%. In some embodiments, the percent solids of the jelly confection material typically increase by 2-10%, e.g., at least 4%, at least 5%, and in some embodiments, about 6%, during the first moisture removal process. This increase in the percent solids of the jelly confection material is achieved in less than 5 minutes, in some embodiments, less than 3 minutes, less than 90 seconds, or even between 30 and 60 seconds. For example, the jelly confection material can remain in the storage device 80 for less than 1 minute. Thus, the rate of moisture removal from the jelly confection material during at least a portion of the manufacturing process is about 1% per hour or greater. For example, the rate of moisture removal during at least a portion of the manufacturing process can be about 2% per hour, about 3% per hour, about 4% per hour, and about 5% per hour or greater. In some embodiments, the moisture removal rate during a portion of the manufacturing process is about 10% / hour, about 11% / hour, about 12% / hour, about 13% / hour, about 14% / hour, and about 15% / hour or greater.

[0101] During the second moisture removal process, the percent solids of the jelly confectionery material provided therein typically increases by 1-9%, e.g., at least 4%, and in some embodiments, e.g., about 6%. This increase in the percent solids of the jelly confectionery material can occur in less than 24 hours, as discussed above. Because the rate at which moisture is removed from the jelly confectionery material during at least a portion of the production process is increased compared to typical jelly confectionery manufacturing processes, the total time required to form the jelly confectionery material is reduced. Furthermore, the total energy required to form the final jelly confectionery from the jelly confectionery material J1 having the first percent solids is significantly reduced, such as by significantly reducing the time the jelly confectionery material spends in an oven.

[0102] The term "about" is intended to include the degree of error associated with measurement of a particular quantity based on equipment available at the time of filing this application. For example, "about" can include a range of ±8%, or 5%, or 2% of a given value.

[0103] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly dictates otherwise. It will be further understood that the terms "comprises" and / or "comprising," when used herein, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0104] While the present disclosure has been described with reference to exemplary embodiments, those skilled in the art will recognize that various changes can be made and equivalents can be substituted for elements thereof without departing from the scope of the disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the essential scope thereof. Therefore, it is intended that the disclosure not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out the disclosure.

Claims

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

2. 10. The method of claim 1, wherein said jelly confectionery material having said second percent solids is a high solids jelly.

3. The method of claim 1, wherein the second percent solids is 2% to 10% greater than the first percent solids.

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

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

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

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

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

9. 10. The method of claim 1, wherein removing moisture from said jelly confectionery material having at least said second percent solids in said at least one mold further comprises baking said jelly confectionery material having at least said second percent solids.

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

11. 11. The method of claim 10, wherein said extruder further comprises at least one devolatilization section including at least one opening to the ambient environment, and wherein said removing moisture from said jelly confectionery material having said first percent solids occurs through said at least one opening.

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

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

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

15. The first moisture removal system further comprises a storage device fluidly coupled to the heat transfer device, and the method further comprises: providing the jelly confectionery material having the first percent solids through the outlet of the heat transfer device to the storage device; 14. The method of claim 13, further comprising: releasing the jelly confectionery material having the first percent solids into the interior of the storage device.

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

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

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

19. 10. The method of claim 1, wherein said jelly confection material having said third percentage solids is a final jelly confection having a desired shape.

20. 10. The method of claim 1, wherein said depositing said jelly confectionery material having at least said second percent solids into said at least one mold further comprises depositing said jelly confectionery material having said second percent solids at a temperature greater than 100°C.

21. 1. A method of forming a jelly confection, comprising: depositing a jelly confectionery material having a solids percentage of at least 79% into at least one mold; and baking the jelly confectionery material to form a jelly confectionery material having a final percent solids.

22. 22. The method of claim 21, wherein the percent solids of the jelly confectionery material deposited in the at least one mold is at least 81%.

23. 22. The method of claim 21, further comprising reducing the viscosity of said jelly confectionery material having a percent solids of at least 79%.

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

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

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

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

28. 28. The method of claim 27, wherein said interrupting the flow of said jelly confection material having a percent solids of at least 79% at said deposition nozzle further comprises breaking off a tail of said jelly confection material.

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

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

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

32. 30. The method of claim 29, wherein at least 1% of the moisture is removed from the jelly confectionery material having the first percentage in less than 5 minutes.

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

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

Images