Double-layered, crunchy gum pellets

Abstract

A coated confectionery is disclosed, comprising a confectionery core and a shell surrounding the confectionery core, wherein the shell comprises a soft coating comprising at least one layer of a first soft coating material and at least one layer of a second soft coating material, the first soft coating material being a soft coating syrup containing maltitol and the second soft coating material being a soft coating powder containing isomalt, and a hard coating comprising at least one layer of a hard coating material, the hard coating material being a hard coating syrup containing maltitol, the soft coating forming at least 25% of the total weight of the shell.

Description

Technical Field

[0001] The present disclosure generally relates to confectionery, and more particularly to systems and methods for providing coatings for confectionery.

Background Art

[0002] [[ID=1,2,3,4,5,6]]Coated confectionery such as coated candies and coated chewing gums are popular confectionery products. Typically, coated confectionery is prepared by a panning coating process that consumes both time and energy. Conventional methods for forming a coating on confectionery are described in the background section of U.S. Patent No. 7,810,446. For example, a conventional batch-type panning process generally requires about 6 to 8 hours to coat confectionery. The total coating time depends on many factors such as the equipment, the amount of desired coating, and the nature of the ingredients.

[0003] In a conventional chewing gum coating process, a conditioned chewing gum center (also known as a chewing gum core) is coated with a sweetener and / or sugar syrup. The sweetener syrup is applied in a continuous layer, for example, by spraying the sweetener syrup onto the chewing gum core. In the conventional method, after one layer of the sweetener syrup is applied, the layer is completely dried before the next layer of the sweetener syrup is applied. The sweetener syrup layer crystallizes to form a hard coating or shell around the center of the chewing gum. Applying multiple sweetener syrup layers sequentially is a time-consuming and energy-intensive process because each sweetener syrup layer needs to be dried and crystallized before the next layer can be applied.

[0004] Considering the challenges mentioned above, it should be noted that there is a need to provide a new method for rapidly coating chewing gum cores. This novel method must be quick, require little energy, and do not adversely affect the quality of the final product in terms of its sensory characteristics, appearance, and feel. [Overview of the project]

[0005] According to one embodiment, a coated confectionery is disclosed, comprising a confectionery core and a shell surrounding the confectionery core, wherein the shell comprises a soft coating comprising at least one layer of a first soft coating material and at least one layer of a second soft coating material, the first soft coating material being a soft coating syrup containing maltitol and the second soft coating material being a soft coating powder containing isomalt, and a hard coating comprising at least one layer of a hard coating material, the hard coating material being a hard coating syrup containing maltitol, the soft coating forming at least 25% of the total weight of the shell.

[0006] In addition to or alternative to one or more of the features described above, in further embodiments, the hard coating forms at least 55% of the total weight of the shell.

[0007] In addition to or as an alternative to one or more of the above-described features, in further embodiments, the confectionery core is chewing gum.

[0008] In addition to or as an alternative to one or more of the features described above, in further embodiments, the soft coating syrup also includes gum arabic and water.

[0009] In addition to or as an alternative to one or more of the above-described features, in further embodiments, the soft coating syrup is 20% to 60% maltitol.

[0010] In addition to or as an alternative to one or more of the above-described features, in further embodiments, the soft coating syrup is 10% to 30% gum arabic.

[0011] In addition to or as an alternative to one or more of the above-described features, in further embodiments, the soft coating syrup is 45% water.

[0012] In addition to or as an alternative to one or more of the above-described features, in further embodiments, the soft coating syrup is 10% to 70% water.

[0013] In addition to or as an alternative to one or more of the features described above, in further embodiments, the soft coating includes a soft coating weight, and the soft coating weight is 5% to 25% of the weight of the confectionery core.

[0014] In addition to or alternative to one or more of the above-described features, in further embodiments, at least one layer of the flexible coating material is two layers of flexible coating syrup, and at least one layer of the second coating material is two layers of flexible coating powder.

[0015] In addition to or as an alternative to one or more of the features described above, in further embodiments, two layers of soft coating syrup and two layers of soft coating powder are applied alternately.

[0016] In addition to or as an alternative to one or more of the above-described features, in further embodiments, the hard coating syrup also includes water.

[0017] In addition to or as an alternative to one or more of the above-described features, in further embodiments, the hard coating syrup is 60% to 90% maltitol.

[0018] In addition to or alternative to one or more of the above-described features, in further embodiments, the combined weight of the soft coating and the hard coating is 20% to 60% of the weight of the core.

[0019] In addition to or alternative to one or more of the features described above, in further embodiments, the confectionery core is conditioned between the application of a soft coating and the application of a hard coating.

[0020] In another embodiment, a method for forming a coated confectionery is disclosed, the method comprising providing a confectionery core and forming a soft coating around the outer surface of the confectionery core, wherein forming the soft coating includes applying a soft coating syrup containing maltitol and applying a soft coating powder containing isomalt, and forming a hard coating around the soft coating, wherein forming the hard coating includes applying a hard coating syrup containing maltitol, and the soft coating forms at least 25% of the total weight of the shell.

[0021] In addition to or alternative to one or more of the above-described features, in further embodiments, the length of time required to form the hard coating is at least twice the length of time required to form the soft coating.

[0022] In addition to or alternative to one or more of the above-described features, in further embodiments, the length of time required to form the hard coating is at least four times the length of time required to form the soft coating.

[0023] In addition to or alternative to one or more of the above-described features, in further embodiments, the length of time for forming the soft coating is less than 30 minutes.

[0024] In addition to or alternative to one or more of the above-described features, in further embodiments, the length of time for forming the hard coating is at least 2 hours.

[0025] In addition to or as an alternative to one or more of the above-described features, in further embodiments, the confectionery core is chewing gum.

[0026] In addition to one or more of the above features, or alternatively, in a further embodiment, forming the soft coating includes applying a soft coating syrup around the outer surface of the confectionery core.

[0027] In addition to one or more of the above features, or alternatively, in a further embodiment, forming the soft coating further includes applying a soft coating powder around the soft coating syrup.

[0028] In addition to one or more of the above features, or alternatively, in a further embodiment, the rate of weight gain per hour achieved during the formation of the soft coating is at least twice the rate of weight gain per hour achieved during the formation of the hard coating.

[0029] In addition to one or more of the above features, or alternatively, in a further embodiment, moisture is removed by evaporation during the formation of the hard coating.

[0030] In addition to one or more of the above features, or alternatively, in a further embodiment, the method further includes forming a confectionery core, and no conditioning of the confectionery core is performed between forming the confectionery core and forming a soft coating around the confectionery core.

[0031] In addition to one or more of the above features, or alternatively, in a further embodiment, the soft coating syrup also includes gum arabic and water.

[0032] In addition to one or more of the above features, or alternatively, in a further embodiment, the soft coating syrup is 20% - 60% maltitol.

[0033] In addition to one or more of the above features, or alternatively, in a further embodiment, the soft coating syrup is 10% - 30% gum arabic.

[0034] In addition to or as an alternative to one or more of the above-described features, in further embodiments, the soft coating syrup is 45% water.

[0035] In addition to or as an alternative to one or more of the above-described features, in further embodiments, the soft coating syrup is 10% to 70% water.

[0036] In addition to or as an alternative to one or more of the features described above, in further embodiments, the soft coating includes a soft coating weight, and the soft coating weight is 5% to 25% of the weight of the confectionery core.

[0037] In addition to or alternative to one or more of the features described above, in further embodiments, forming a soft coating includes applying two layers of soft coating syrup and applying two layers of soft coating powder.

[0038] In addition to or as an alternative to one or more of the features described above, in further embodiments, two layers of soft coating syrup and two layers of soft coating powder are applied alternately.

[0039] In addition to or as an alternative to one or more of the above-described features, in further embodiments, the hard coating syrup also includes water.

[0040] In addition to or as an alternative to one or more of the above-described features, in further embodiments, the hard coating syrup is 60% to 90% maltitol.

[0041] In addition to or alternative to one or more of the above-described features, in further embodiments, the combined weight of the soft coating and the hard coating is 20% to 60% of the weight of the core.

[0042] In addition to or alternative to one or more of the above-described features, in further embodiments, the temperature of the soft coating syrup during the formation of the soft coating around the confectionery core is 30°C to 70°C.

[0043] In addition to or as an alternative to one or more of the features described above, in further embodiments, the method further includes conditioning the confectionery for 24 to 48 hours between the formation of the soft coating and the formation of the hard coating.

[0044] In addition to or alternative to one or more of the above-described features, in further embodiments, the temperature of the hard coating syrup during the formation of the coating is approximately 70°C. [Brief explanation of the drawing]

[0045] The accompanying drawings incorporated herein and forming part thereof embody several aspects of this disclosure and, together with this description, help to illustrate the principles of this disclosure. In the drawings, [Figure 1] This is a cross-sectional view of a confectionery product according to one embodiment. [Figure 2] This is a schematic diagram of a system for manufacturing confectionery according to one embodiment.

[0046] For a detailed explanation, embodiments of the present disclosure, along with their advantages and features, will be described by illustration with reference to the drawings. [Modes for carrying out the invention]

[0047] Referring here to Figure 1, an example of a confectionery 20 according to one embodiment of the present disclosure is shown. As shown, the confectionery 20 includes a core 22 formed from any suitable confectionery composition. As used herein, the term “confectionery composition” is intended to include any edible product containing a sweetening component. Confectionery compositions may further include sugars, syrups, sugar alcohols, honey, and pharmaceutical preparations made using sweet foods such as candy or pastry. Confectionery compositions are well known in the art and include soft candies, chewing candies, hard candies, chewing gum, chocolate (including, for example, milk chocolate, dark chocolate, white chocolate, and semi-sweet chocolate), and lozenges. In one embodiment, the confectionery core is a chewing gum composition comprising an elastomer base.

[0048] A shell 24, comprising both a soft coating 26 and a hard coating 28, is formed concentrically around the confectionery core 22, surrounding the core 22. The soft coating 26 is located directly adjacent to the confectionery core 22, while the hard coating 28 is positioned around the outside of the soft coating 26, surrounding it. In one embodiment, the soft coating 26 forms about 25% to 45% of the total weight of the shell, and the hard coating 28 forms about 55% to 75% of the total weight of the shell. Soft coatings 26 forming at least 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40%, 41%, 42%, 43%, 44%, or 45% of the total shell weight are contemplated herein, as are hard coatings forming at least 55%, 56%, 57%, 58%, 59%, 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, or 75% of the total shell weight.

[0049] The flexible coating 26 comprises one or more layers formed by at least a first flexible coating material and one or more layers of a second coating material. In an exemplary embodiment, the first flexible coating material applied to the core 22 is a flexible coating syrup containing a sugar alcohol, maltitol. The layer of this flexible coating syrup is first applied directly to the core 22, uniformly and completely surrounding it. In addition to maltitol, the flexible coating syrup may contain gum arabic and water. In an exemplary embodiment, the flexible coating syrup contains 20% to 60% maltitol, 10% to 30% gum arabic, and 10% to 70% water. Non-limiting examples may include 40% maltitol, 15% gum arabic, and 45% water, and any maltitol proportion of at least 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, 50%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59%, or 60% is also intended herein.

[0050] Following the application of the aforementioned layer of soft coating syrup, a second soft coating material is uniformly applied around the first layer of soft coating syrup. This second soft coating material is a powder containing isomalt (hereinafter referred to as soft coating powder). The soft coating powder adheres to the soft coating syrup and forms a first aggregate layer around the core 22, which is the material that forms the soft coating 26.

[0051] In an exemplary embodiment, an additional layer of soft coating syrup is uniformly applied around the first aggregate layer (surrounding the first aggregate layer), and then an additional layer of soft coating powder is applied to the additional layer of soft coating syrup. These additional layers of soft coating syrup and soft coating powder form an additional aggregate layer around the core. Further alternating layers of soft coating syrup and soft coating powder can be applied to form further aggregate layers until a desired weight of total soft coating 26 (25% to 45% of the total shell) is achieved. In an exemplary embodiment, all of this total weight of the soft coating layers is also at least 13% of the weight of the original core, and has a weight of at least 5%, 6%, and 7%. All of the following percentages are intended herein: 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 15%, 20%, 21%, 22%, 23%, 24%, or 25%. In exemplary embodiments, at least 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, or 20% of the weight of the soft coating 26 is soft coating syrup, while at least 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, or 90% of the soft coating is soft coating powder.

[0052] After a desired amount / weight of soft coating 26 is formed around the core 22, a hard coating 28 is formed around the soft coating 26, so that the soft coating is uniformly and completely surrounded by the hard coating 28. The hard coating 28 is a hard coating syrup containing maltitol and water. In exemplary embodiments, the hard coating syrup contains at least 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, 75%, 76%, 77%, 78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, or 90% maltitol. The hard coating syrup is applied to the soft coating 26 in a first layer and dried, and then applied in subsequent layers until the combined weight of the soft coating 26 and the hard coating 28 (e.g., the entire shell 24) is 20% to 60% of the weight of the original core 22.

[0053] As described above, the soft coating syrup containing maltitol may contain gum arabic in a desired proportion. Separately from, or in addition to, gum arabic, the soft coating syrup may also contain one or more other binders, including, but not limited to, pea starch, xanthan gum, carboxymethylcellulose, methylcellulose, hydroxypropylmethylcellulose, starch, modified starch, inulin, konjac, chitosan, tragacanth, karaya, gatti, larch, carrageenan, alginate, chemically modified alginate, agar, guar, locust bean, psyllium, cod, gelan, curdlan, plantain, gelatin, and pectin. These binders help to adhere the soft coating syrup to the core 22. The hard coating syrup may contain gum arabic in a desired proportion and / or one or more of the other binders described above. Such agents help the hard coating adhere to the soft coating surface. The hard coating syrup may also contain other additives such as colorants and / or flavorings.

[0054] Emulsifiers may also be present in soft-coating syrups and hard-coating syrups. Suitable emulsifiers such as polysorbate (polyoxyethylene sorbitan ester), glyceryl monostearate, lecithin, fatty acid monoglycerides, diglycerides, propylene glycol monostearate, sugar esters, polyglycerol fatty acid esters, polyglycerol polyricinoleate (PGPR), and monoglycerides may be used in the syrup, but are not limited to these. Suitable polysorbates for use in syrups include, but are not limited to, one or more of polysorbate 20, polysorbate 40, polysorbate 60, and polysorbate 80. In some embodiments, the emulsifier used is polysorbate 60.

[0055] Referring here to Figure 2, a system 60 and method for rapidly coating confectionery cores are illustrated and described in more detail. The method generally involves forming a soft coating 26, as discussed above, around the outer surface of one or more confectionery cores 22. As previously stated, the soft coating comprises one or more aggregate layers comprising both a soft coating syrup containing maltitol and a soft coating powder containing isomalt. After the formation of the soft coating 26, a hard coating 28, as described above, is formed around the outside of the soft coating 26 by applying a hard coating syrup containing maltitol. Referring here to Figure 2, a system and method for rapidly coating an unmodified confectionery core 22 are shown. In this embodiment, the confectionery core 22 is not cooled or modified before the application of the soft coating 26. The system 60 shown in the exemplary embodiment of Figure 2 generally includes forming a soft coating 26 around a confectionery core 22 at a first coating station 62 and optionally a second coating station 64, and forming a hard coating 28 around the soft coating 26 at a hard coating station 80 located downstream of the first coating station 62 and optionally the second coating station 64.

[0056] The confectionery cores 22 supplied to the coating system 60 are manufactured upstream of the system 60 in a standard manner. During manufacturing, chewing gum of a desired composition may be mixed, then formed into a sheet of a desired thickness, then notched and cut to form multiple fragments or cores 22. Once the sheet into which the cores 22 are cut is formed, no further adjustment is required. In other words, the chewing gum sheet may be formed without any adjustment and sent to the coating system 60. Once the sheet is cut into cores 22, the chewing gum is ready to be transported to the coating system 60 to begin the coating process. As a result, the confectionery cores 22 supplied to the first drum coating station 62 are at a normal processing temperature.

[0057] As shown in Figure 2, the flow of the confectionery core 22 is supplied to the system 60 via a chute 72 connecting the feeder 70 to the first coating station 62. In the illustrated non-limiting embodiments, one or more alternating layers of soft coating syrup and soft coating powder may be applied around the outside of the confectionery core 22 at the first drum coating station 62 to form part or all of the soft coating 26. If the soft coating is only partially formed at the first drum coating station 62, a second gum coating station 64 may be used to apply additional alternating layers of soft coating syrup and soft coating powder to the existing one or more aggregate layers applied at the first drum coating station 62. The entire soft coating 26 (including all aggregate layers) may be applied at the first coating station 64, but for ease of explanation, the system and process will be described below as including any second drum coating station 64 where the application of the layers of soft coating 26 is completed. After the soft coating 26 is completed, one or more layers of hard coating syrup can be applied around the outside of the soft coating 26 at the hard coating station 80.

[0058] In exemplary embodiments, the first coating station 62 and the second coating station 64 each include a first rotating drum 74 and a second rotating drum 76. These drums 74, 76 are identical in both stations 62, 64, and the drums 74, 76 of each station may be fixed to each other via any well-known fixing or locking mechanism connecting the drum surfaces and / or the structures supporting the drums, but the drums 74, 76 may rotate and tilt independently. The first drum 74 defines the first drum volume, and the second drum 76 defines the second drum volume. The first and second drum volumes are connected by inserting the end of the first drum 74 into the portion of the second drum 76 that tapers toward its inlet opening, allowing the confectionery core 22 to flow from the first drum 74 to the second drum 76. By inserting the end of the first drum 74 into the entrance of the second drum 76, an annular portion is formed between the first drum 74 and the second drum 76.

[0059] In an exemplary embodiment, the first drum 74 of the first drum coating station 62 receives confectionery cores 22 from the feeder 70 via a chute 72. Once inside the first drum of the first drum coating station 62, soft coating syrup can be injected into the drum volume. This soft coating syrup can be supplied to this volume via one or more nozzles inside the first drum 74. In one embodiment, the soft coating syrup may be applied via one or more high-pressure spray nozzles, standard drip / flow nozzles, or orifices in each drum. The use of high-pressure spray nozzles provides adjustability of both droplet size and spray pattern without compromising the desired flow. Of course, the syrup may also be supplied manually through the same opening into which the chute 72 supplies the cores 22.

[0060] As described above, the water content of the soft coating syrup may be about 45% in the exemplary embodiment. The temperature of the soft coating syrup is about 40°C for optimal diffusion and distribution, but may be effective at any of the following temperatures: 30°C, 31°C, 32°C, 33°C, 34°C, 35°C, 36°C, 37°C, 38°C, 39°C, 40°C, 41°C, 42°C, 43°C, 44°C, 45°C, 46°C, 47°C, 48°C, 49°C, 50°C, 51°C, 52°C, 53°C, 54°C, 55°C, 56°C, 57°C, 58°C, 59°C, 60°C, 61°C, 62°C, 63°C, 64°C, 65°C, 66°C, 67°C, 68°C, 69°C, or 70°C. If one or more nozzles are used to deliver the soft coating syrup into the interior or volume of the first drum 74, a spray application time of at least 30, 40, 50, or 60 seconds may be desirable for uniform distribution of the layer of soft coating syrup from the nozzles, or the spray may be metered and continuous in a continuous flow coating process. The first layer of this soft coating syrup preferably seals each of the cores 22 as they are mixed in the first drum 74 (the drum 74 can rotate and coat the cores 22 during this time, whether or not the syrup is supplied via spray nozzles).

[0061] After or during the application of the first layer of the soft coating syrup, cold process air may be blown into the first drum coating station 62 onto the first layer of the soft coating syrup and / or onto the confectionery core 22 (this is optional). The temperature of the process air during the application of the first syrup is generally lower than in conventional systems. The tendency of the first layer of the soft coating syrup to adhere may correlate with the temperature of the process air. When the first layer of the soft coating syrup comes into contact with the surface of the confectionery core 22, the temperature of the first layer of the soft coating syrup decreases due to exposure to process air, allowing gelling to begin. As a result, the first layer of the soft coating syrup can adhere more closely to the outer surface of the confectionery core 22 and cool without drying.

[0062] Following the application of the first coating of syrup, the core 22 (now coated with syrup) can be fed from the first drum 74 to the second drum 76. In exemplary embodiments, this can be achieved via a mechanism that positions the drums 74, 76 at different angles to each other. For example, the first drum 74 may be positioned at a downward angle to the second drum 76 so that the gum core 22, having received the first layer of coating syrup, can simply flow into the second drum 76 by gravity.

[0063] As described above, the application of the soft coating powder containing isomalt is applied after the application of the first layer of soft coating syrup. The soft coating powder can be applied in the first drum 74 of the first drum coating station 62, but in the embodiment of Figure 2, one or more layers of the soft coating powder are applied in the second drum 76. In an exemplary embodiment, a tube can be supplied to the annular portion formed between the first drum 74 and the second drum 76, thereby supplying the powder to the second drum 76 by gravity or metering. While inside the second drum 76, the rotation of the second drum 76 allows the layer of soft coating powder to be applied to the core 22 (coated with the first syrup layer). This application of the powder containing isomalt forms a first aggregated layer on the core 22, as described above.

[0064] The second drum 76 may include a nozzle for injecting the soft coating syrup (or may simply have soft coating syrup supplied to its internal volume via a tube or nozzle supplied to the annular portion). As described above, alternating layers of soft coating syrup and soft coating powder may be applied within the second drum 76 until the desired weight and / or thickness of the aggregated layer is reached. As described above, the entire soft coating may be applied via drums 74, 76 of the first drum coating station 62. However, in the exemplary embodiment of Figure 2, an additional aggregated layer is applied at the second drum coating station 64, where the soft coating layer is completed.

[0065] The partially soft-coated cores 22 may be transported via a conveyor 82 to a second drum coating station. In an exemplary embodiment, the cores 22 are transported from the first drum coating station 62 to the second drum coating station without any adjustments ("adjustments" should be defined throughout this description as intentional dwelling in a storage area, which may include temperature and / or humidity control). Upon entering the second coating station 64, the drums 74, 76 apply additional coagulation layers to the cores 22 received from the first drum coating station 62 in the same manner as the drums 74, 76 of the first drum coating station 62. As described above, these cores 22 from the first coating station 62 include a partially soft coating with one or more coagulation layers. The cores 22 with the partially soft coating receive an additional syrup coating in the first drum 74 of the second drum coating station 64. They are then transported to a second drum 76 (again via the angling of the first drum 74, as in the exemplary embodiment, the first drum coating station 62), where the powder is applied to create an additional agglomerated layer. Additional alternating layers of soft coating syrup and soft coating powder can also be applied within this second drum 76. Agglomerated layers are applied, whether via the first layer of soft coating powder applied within the second drum 76 of the second drum coating station 64, or via the additional alternating layers of syrup and powder, until the soft coating 26 is completed and the desired weight and / or thickness of the agglomerated layer is reached. The application of the entire soft coating 26 to the core 22 can be done in 20 minutes or less (whether the application is completed at a single coating station or at the first drum coating station 62 and the second drum coating station 64, as shown in the exemplary embodiment of Figure 2).

[0066] In the illustrated, non-limiting embodiments, it should be understood that the volume of the second drum 76 is greater than the volume of the first drum 74, for example, by the larger diameter and / or length of the second drum 76 compared to the first drum 74. As a result, during transport of the core 22 from the inlet of the first drum 74 to the outlet of the second drum 76, the core 22 may have a longer residence time in the second drum volume than in the first drum volume. This longer residence time in the second drum may provide more time for adding powder, as well as additional alternating powder and syrup layers (e.g., to create a coagulated layer). However, other configurations, such as when the drum volumes are the same, or when the volume of the first drum is greater than the volume of the second drum, are also within the scope of this disclosure. Such coating stations are contemplated herein, but are not limited to those described in more detail in U.S. Patent Application No. 14 / 119,935, which is incorporated herein by reference in its entirety.

[0067] As described above, after the application of the soft coating 26, the confectionery cores 22 can be collected (for example, in a tray) and placed in a conditioning chamber, schematically shown in C, for a desired period. The air-conditioned chamber C has controlled temperature and humidity. By placing the confectionery cores 22 with the soft coating 26 in the conditioning chamber C for a desired time, the hardness of both the core 22 and the soft coating 26 is increased. As described above, the conditioning in the conditioning chamber C continues for 24 to 48 hours, which can harden the aggregated layer of the soft coating 26, making it more dimensionally robust and stable. In addition, some partial crystallization of the aggregated layer of the soft coating 26 may occur in the conditioning chamber C, which helps the soft coating material adhere to the core 22.

[0068] After conditioning, the confectionery core 22 is served to a hard coating station 80, where hard coating syrup can be applied around the soft coating 26 to form a hard coating 28. In exemplary embodiments, the hard coating station 80 may be a batch mixer as shown in Figure 2. The formation of the hard coating 28, also referred to as "finishing," involves applying one or more layers of hard coating syrup over the soft coating 26. In exemplary embodiments, treated air having a temperature of about 20°C to about 50°C can be directed towards the hard coating station 80 to rapidly dry the hard coating syrup that will form the hard coating 28 during the finishing / hard coating stage. This treated air can help remove moisture from the hard coating syrup through evaporation.

[0069] The application of the hard coating 28 can form a smooth and homogeneous surface and achieve desirable sensory characteristics of the finished confectionery, such as crunchiness, color, and flavor. In one embodiment, the formation of the hard coating 28 takes about 4 hours.

[0070] In exemplary embodiments, the hard coating syrup includes one or more colorants configured to produce the desired appearance of the confectionery 20. Furthermore, one or more flavoring agents may be added to the soft coating layer (syrup or powder) and / or applied to the outside of the soft coating 26 before or during the initial formation of the hard coating 28. If flavoring agents are added during the formation of the hard coating 28, such flavoring agents may be included in the first layer to which the hard coating syrup is applied.

[0071] In exemplary embodiments, the hard coating syrup is applied at a temperature of at least 70°C to allow all solids to dissolve in the syrup. The hard coating syrup may contain small amounts of additives, in addition to flavoring agents such as colorants, and small amounts of gum arabic or other hydrophilic colloids (1-4%) to help adhere to the outside of the soft coating 26. After applying the layer of hard coating syrup that forms the hard coating, the syrup may be dried by a forced airflow to the hard coating station 80. The layer of hard coating syrup may be applied 20-60 times and then dried until the hard coating 28 is formed to the desired weight and thickness.

[0072] Using the above-described method for applying a soft coating and a hard coating to the core 22, a crunchy coated confectionery 20 can be produced in less than approximately 5 hours. In one embodiment, the time required to form the soft coating 26 is less than half the time required to form the hard coating 28. The novel methods described herein offer a significant time reduction compared to conventional batch panning methods. This overall time reduction is achieved by replacing a portion of the hard coating 28 with the soft coating 26 by the systems and processes described herein. In exemplary embodiments, a time reduction of 20–40% compared to conventional batch panning coating methods can be achieved by the disclosed processes.

[0073] The rate at which the soft coating 26 is applied to the confectionery core 22, or more specifically, the rate of weight increase per hour achieved during the application of the soft coating 26, is approximately twice (or more) the rate of weight increase per hour achieved during a conventional panning process. Furthermore, since the hard coating 28 can be applied in a similar manner to a conventional panning process, the rate of weight increase per hour achieved while applying the soft coating 26 to the confectionery core 22 is at least twice the rate of weight increase per hour achieved while applying the hard coating 28 to the confectionery core 22.

[0074] Furthermore, it was determined that confectionery 20 coated by the described rapid coating method has substantially the same texture, hardness, and sensory properties as conventional hard bread coated confectionery. Confectionery 20 including soft coatings 26 and hard coatings 28 as described herein has a hardness similar to that of confectionery formed using conventional panning processes. Hardness is defined as the maximum force applied to the outer surface of confectionery 20. In some embodiments, rapidly coated confectionery has at least 80% of the hardness of conventional hard bread coated confectionery having a similar or identical coating composition and the same total coating thickness at 100% coating penetration, and the hardness was measured within two days of the production of the rapidly coated confectionery. More specifically, it was found that rapidly coated confectionery has at least 90% of the hardness of conventional hard bread coated confectionery having the same total coating thickness at 100% coating penetration, and the hardness was measured within two days of the production of the rapidly coated confectionery.

[0075] With respect to confectionery 20 having a shell 24 in which approximately 25-45% of the total weight of the shell is formed by a soft coating 26 and approximately 55-75% of the total weight of the shell is formed by a hard coating 28, the aesthetic and hardness results described herein are unexpected. Layering of multiple coating materials, including a soft coating 26 containing maltitol syrup and isomalt powder and a hard coating 28 containing maltitol syrup, is expected to form a shell 24 having less desirable sensory attributes, such as an undesirable outer surface with less crunchiness or almost no crunchiness compared to conventional hard-coated confectionery. However, unexpectedly, confectionery 20 having a soft coating 26 and a hard coating 28 as described herein generally has a uniform and smooth outer surface with similar or even improved hardness compared to conventional hard-panned confectionery.

[0076] Furthermore, it should be noted that the combination of maltitol soft coating syrup and isomalt soft coating powder with maltitol hard coating syrup resulted in a shell 24 with a smooth, uniform, and good-textured coating with the desired hardness. This was surprising because, theoretically, using the same polyol throughout the coating / shell should result in a more stable and uniform product with a good texture. Polyols are expected to crystallize faster when the same polyol is used throughout the shell, and the presence of other polyols, if present, is expected to inhibit crystallization. However, despite this expectation, it was found here that two different polyols (specifically, maltitol soft and hard coating syrups and isomalt soft coating powder) resulted in a shell 24 with a uniform and smooth outer surface exhibiting similar or even improved hardness compared to conventionally hard-panned confectionery. In fact, using different polyols unexpectedly yielded better results than using the same polyol.

[0077] This specification discloses the present invention, including best modes, using examples, and enables those skilled in the art to construct and use the present invention. The scope of patentability of the present invention is defined by the claims and may include other embodiments that a person skilled in the art could conceive. Such other embodiments shall be within the scope of the claims if they have structural elements that are not different from the language of the claims, or if they include equivalent structural elements that are substantially indistinguishable from the language of the claims.

[0078] All cited patents, patent applications, and other documents are incorporated herein by reference in their entirety. However, if any terminology in this application conflicts with, or is inconsistent with, any terminology in the incorporated references, the terminology in this application shall prevail over any conflicting terminology in the incorporated references.

[0079] All scopes disclosed herein include endpoints, which can be combined independently of each other. Each scope disclosed herein constitutes a disclosure of any point or sub-scope that lies within the disclosed scope.

[0080] The terms “a,” “an,” and “the,” and the use of similar references in the context describing this invention (particularly in the context of the following claims), shall be construed as encompassing both singular and plural unless otherwise stated herein or unless there is a clear inconsistency in the context. Furthermore, it should be noted that terms such as “first,” “second,” etc., in this specification are used to distinguish one element from another, rather than to indicate any order, quantity, or importance. The modifier “about” used in relation to quantity includes the stated value and has a meaning that is clearly understood from the context (for example, the stated quantity includes the degree of error associated with measuring a particular quantity).

Claims

1. Coated confectionery, Confectionery core, The confectionery core includes a shell, and the shell is A soft coating comprising at least one layer of a first soft coating material and at least one layer of a second soft coating material, wherein the first soft coating material is a soft coating syrup containing maltitol and the second soft coating material is a soft coating powder containing isomalt, and A hard coating comprising at least one layer of a hard coating material, wherein the hard coating material is a hard coating syrup containing maltitol, A coated confectionery in which the soft coating forms at least 25% of the total weight of the shell.

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

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

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

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

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

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

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

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

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

11. The coated material according to claim 10, wherein the two layers of the soft coating syrup and the two layers of the soft coating powder are applied alternately.

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

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

14. The coated confectionery according to claim 1, wherein the total weight of the soft coating and the hard coating is 20% to 60% of the weight of the core.

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

16. A method for forming a coated confectionery, wherein the method provides a confectionery core, Forming a soft coating around the outer surface of the confectionery core, wherein forming the soft coating includes applying a soft coating syrup containing maltitol and applying a soft coating powder containing isomalt. Forming a hard coating around the soft coating, wherein forming the hard coating includes applying a hard coating syrup containing maltitol, A method wherein the soft coating forms at least 25% of the total weight of the shell.

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

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

19. The method according to claim 16, wherein the length of time for forming the soft coating is less than 30 minutes.

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

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

22. The method according to claim 16, wherein forming the soft coating comprises applying the soft coating syrup around the outer surface of the confectionery core.

23. The method according to claim 22, wherein forming the soft coating further comprises applying the soft coating powder around the soft coating syrup.

24. The method according to claim 16, wherein the rate of weight increase per hour achieved during the formation of the soft coating is at least twice the rate of weight increase per hour achieved during the formation of the hard coating.

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

26. The method according to claim 16, further comprising forming a confectionery core, wherein no conditioning of the confectionery core is performed between forming the confectionery core and forming the soft coating around the confectionery core.

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

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

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

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

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

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

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

34. The method according to claim 33, wherein the two layers of the soft coating syrup and the two layers of the soft coating powder are applied alternately.

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

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

37. The method according to claim 16, wherein the total weight of the soft coating and the hard coating is 20% to 60% of the weight of the core.

38. The method according to claim 16, wherein during the formation of the soft coating around the confectionery core, the temperature of the soft coating syrup is 30°C to 70°C.

39. The method according to claim 16, further comprising conditioning the confectionery for 24 to 48 hours between the formation of the soft coating and the formation of the hard coating.

40. The method according to claim 16, wherein the temperature of the hard coating syrup is approximately 70°C during the formation of the hard coating.

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