A method of making an edible confectionary product

Abstract

A method of producing an edible product comprising a solid centre and a plurality of coats of a fatty coating material is described. The method comprises providing a solid centre comprising corners and edges and at least one face, coating the centre with an inner coat of fatty coating material comprising simultaneously panning the centre and spraying the fatty coating material on to the centre, panning the coated centre without spraying the fatty coating material to dry the coated centre, applying a first outer coat of fatty coating material to the coated centre comprising simultaneously panning the coated centre and spraying the fatty coating material on to the coated centre, and applying a sugar shell to the coated centre. The method provides an edible product in which the corners of the solid centre support the sugar shell and acts as a shock absorber to prevent the shell breaking during transport and during hot conditions when the coatings of fatty material melt.

Description

[0001] TITLE

[0002] A method of making an edible confectionary product

[0003] Technical Field

[0004] The present disclosure relates to an edible confectionary (or snack) product comprising a solid centre and a coating of fatty material, and a method for the production thereof. In particular, the disclosure relates to confectionary products comprising a fruit centre with a yoghurt or chocolate coating.

[0005] Background

[0006] Coated confectionary products with solid centres (e.g. a nut) and yoghurt or chocolate coatings are available in the marketplace. Some of these products contain probiotic bacteria in the coatings which confer a health benefit to the consumer. Due to the fatty nature of the coating, the product cannot be stored at ambient temperature for too long as the fat in the coating reacts with air to spoil and / or discolour the product. This means that the distribution chain for the product does not involve long transportation / storage times, thus making the distribution of the product in larger countries challenging. In addition, the coatings of fatty material are prone to melting in hot climates which necessitates the use of refrigerated delivery and storage, which is an added cost to the distributor / manufacturer.

[0007] It is an object of the disclosure to overcome at least one of these problems.

[0008] Summary

[0009] The Applicant has addressed this problem by providing a coated confectionary product with a fruit centre, one or more fatty (e.g. yoghurt or chocolate) coatings, and an outer sugar shell. The outer sugar shell inhibits the melting of the fatty coat in hot climates, and protects the fat in the product from oxidisation, thus extending the shelf life of the product thus enabling the distribution chain for the product to be extended geographically and temporally. In one aspect, the solid centre is cuboid and the edible product is rounded, and the corners of the cuboid abut an inside face of the outer sugar shell, supporting the shell in situations where the fatty coating partially melts.

[0010] In one aspect, there is provided a method of producing an edible product comprising a solid centre and a plurality of coats of a fatty coating material, the method comprising the steps of: providing a solid centre of the edible product; coating the solid centre with an inner coat of fatty coating material comprising simultaneously panning the solid centre and spraying the fatty coating material on to the solid centre; panning the coated centre without spraying (e.g. without spraying the coating material) to dry the coated centre; applying a first outer coat of fatty coating material to the coated centre comprising simultaneously panning the coated centre and spraying the fatty coating material on to the coated centre; optionally, applying a second outer coat of fatty coating material to the coated centre comprising simultaneously panning the coated centre and spraying the fatty coating material on to the coated centre; and applying a sugar shell around the coated centre. In any embodiment, the solid centre has a 3-D shape consisting of corners, edges and one or more faces (ideally flat faces). The solid centre may be cuboid, for example.

[0011] The applicant has discovered that when this process is applied with a solid centre having a 3-D shape consisting of corners, edges and one or more faces, the step of panning the centre without spraying causes the coating material to coalesce on the face(s) of the centre, providing a convex coating on the faces. This has the effect of rounding the edible product with the edges and corners remaining visible through the coatings. When the sugar shell is applied to the product, the corners of the solid centre are disposed very close to the surface of the product, and help support the sugar shell in conditions when the fatty coating material under the sugar shell melts and no longer supports the shell. This support is accentuated when the solid centre comprises a fruit or pectin gel as the corners of the centre acts as shock absorbers to absorb stresses when the product is moved around during transportation.

[0012] In any embodiment, the centre has a cuboid shape.

[0013] In any embodiment, the edible product is generally spherical (e.g. no sharp edges or corners).

[0014] In any embodiment, the centre is cuboid and has a first colour and the coating has a second colour that contrasts with the first colour. The first colour may be dark colour (e.g. red or purple). The second colour may be a colour lighter than the dark colour, e.g. white, cream or pink.

[0015] In any embodiment, a surface of the edible product comprises a pattern comprising edges and / or corners of the centre visible through the coating of coating material and sugar shell.

[0016] In any embodiment, the pattern comprises a plurality of lines corresponding to edges of the cuboid centre. In any embodiment, the pattern comprises a plurality of triangular markings corresponding to corners of the cuboid centre.

[0017] In any embodiment, the step of coating the centre with the inner coat comprises a first coating step comprising simultaneously spraying the coating material and panning to form a first inner coat and a second coating step comprising simultaneously spraying the coating material on the first coat and panning to provide a second inner coat.

[0018] In any embodiment, the or each coating step comprises intermittently spraying the coating material.

[0019] In any embodiment, the step of intermittent spraying of the coating material comprises spraying steps separated by non-spraying steps, in which each nonspraying step last for 1 to 10 seconds.

[0020] In any embodiment, one of the coatings, for example the outer coating, comprises probiotic bacteria.

[0021] In any embodiment, the process comprises a step of drying the first outer coat by panning the coated centre without spraying prior to application of the second outer coat.

[0022] In any embodiment, the process comprises applying a final outer coat of a fatty coating material to the coated centre.

[0023] In any embodiment, the process comprises applying 2, 3, 4, 5, 6 or 7 outer coats.

[0024] In any embodiment, the process comprises a drying period between each coating step. The drying step may comprise a resting step comprising panning (e.g. rotation of the drum) without spraying. In any embodiment, the process comprises a drying period after the application of the sugar shell.

[0025] In any embodiment, air is circulated inside the panning apparatus (e.g. panning drum) during one or more of the coating or drying steps.

[0026] In any embodiment, one or more of the coating steps comprises spraying the coating material at a spraying rate of 5 to 10 Hz.

[0027] In any embodiment, the spraying rate applied at each spraying step is gradually reduced from thee first coating step to a final coating step.

[0028] In any embodiment, the solid centre is fruit or pectin based centre.

[0029] In any embodiment, the fatty coating material is selected from yoghurt and chocolate.

[0030] In another aspect, there is provided an edible product comprising: a solid centre; an inner coating of fatty material applied to a surface of the solid centre; an outer coat of fatty material; and an outer sugar shell.

[0031] In any embodiment, the solid centre has a 3-D shape consisting of corners, edges and one or more faces (ideally flat faces). The solid centre may be cuboid, for example. Other 3-D shapes are octahedron, icosahedron, tetrahedron, pentagonal prism. In any embodiment, the fatty material coating at the corners of the solid centre has a thickness of less than 200 pm, 100 pm, 75 pm, 50 pm, 30 pm, 20 pm, 10 pm, 5 pm or 2 pm.

[0032] In any embodiment, the corners of the solid centre abut the outer sugar shell.

[0033] In any embodiment, the fatty material coating at the centre of the or each face of the solid centre has a thickness of at least 1000 pm, 1200 pm, 1500 pm, 2000 pm, or 3000 pm.

[0034] In any embodiment, the edible product is generally spherical (e.g. no sharp edges or corners).

[0035] In any embodiment, the centre is cuboid and has a first colour and the coating of fatty material has a second colour that contrasts with the first colour. The first colour may be dark colour (e.g. red or purple). The second colour may be a colour lighter than the dark colour, e.g. white, cream or pink.

[0036] In any embodiment, a surface of the outer coating of fatty material comprises a pattern comprising edges and / or corners of the centre visible through the coating(s) of fatty material.

[0037] In any embodiment, the pattern comprises a plurality of lines corresponding to edges of the cuboid centre.

[0038] In any embodiment, the pattern comprises a plurality of triangular markings corresponding to corners of the cuboid centre.

[0039] In any embodiment, the solid centre comprises a gel, ideally a fruit or pectin gel. In any embodiment, the fatty material comprises yoghurt, chocolate, caramel, starch- or sugar-based coating.

[0040] In any embodiment, one or more of the coatings of fatty material comprises probiotic bacteria.

[0041] In any embodiment, the solid centre has a cuboid or irregular shape.

[0042] In any embodiment, the edible product comprises one or more intermediate coatings of fatty material.

[0043] Other aspects and preferred embodiments of the invention are defined and described in the other claims set out below.

[0044] Brief Description of the Figures

[0045] Figure 1. Yoghurt wafers in melting tank prior to heating at 60°C and mixing for 30 seconds ever 5 minutes until yoghurt is melted.

[0046] Figure 2. Semi-melted yoghurt wafers in melting tank, prior to total melting.

[0047] Figure 3. Completely melted yoghurt wafers in melting tank.

[0048] Figure 4. Fruit piece cubes with first yoghurt coating.

[0049] Figure 5. Fruit piece cubes with second yoghurt coating.

[0050] Figure 6. Fruit piece cubes after application of third yoghurt coating.

[0051] Figure 7. Final edible product with outer sugar shell. Detailed Description of the Invention

[0052] All publications, patents, patent applications and other references mentioned herein are hereby incorporated by reference in their entireties for all purposes as if each individual publication, patent or patent application were specifically and individually indicated to be incorporated by reference and the content thereof recited in full.

[0053] Where used herein and unless specifically indicated otherwise, the following terms are intended to have the following meanings in addition to any broader (or narrower) meanings the terms might enjoy in the art:

[0054] Unless otherwise required by context, the use herein of the singular is to be read to include the plural and vice versa. The term "a" or "an" used in relation to an entity is to be read to refer to one or more of that entity. As such, the terms "a" (or "an"), "one or more," and "at least one" are used interchangeably herein.

[0055] As used herein, the term "comprise," or variations thereof such as "comprises" or "comprising," are to be read to indicate the inclusion of any recited integer (e.g. a feature, element, characteristic, property, method / process step or limitation) or group of integers (e.g. features, element, characteristics, properties, method / process steps or limitations) but not the exclusion of any other integer or group of integers. Thus, as used herein the term "comprising" is inclusive or open- ended and does not exclude additional, unrecited integers or method / process steps.

[0056] As used herein, the term “edible product” refers to a product suitable for oral administration to human and animals, for example a food product, a confectionary product, a snack, a nutritional / food supplement, a supplemented food, or a pharmaceutical product. Examples include coated nut, fruit pieces, fruit and / or nut clusters, coated caramels, fruit gels, coated gummies, lozenges. As used herein, the term “centre” refers to the centre of the food product that is coated in a fatty material. The centre is usually solid, e.g. a solid fruit piece or a gelled edible material such as a fruit gel. Examples of centres include fruit gels, nuts, fruit pieces, and nut clusters, for example dried fruits pieces, peanut brittle pieces, roasted nuts, pretzel balls I plant protein balls I malted milk balls, raisins, macadamia, hazelnuts, gelatin gum pieces, fruit loops, caramels, pectin, cashews, pistachios, corn flakes, fruit clusters and fruit & nut clusters. In any embodiment, the centre has a 3-D shape comprises corners, edges and flat faces. Examples include cubes, cuboids, prisms (e.g. triangular prism, pentagonal prism, hexagonal prism, etc) pyramids (e.g. square, hexagonal, etc), tetrahedron, octahedron, dodecahedron, etc.

[0057] As used herein, the term “fruit gel” typically refers to a product made from fruit pulp or containing fruit or fruit extracts that is heated and then allowed to cool and gel in a shaped mold to form a shaped fruit gel. The fruit gel may be any shape, such as cuboid, round, oval, pyramidical. The fruit gel may comprise pectin or a different gelling agent.

[0058] As used herein the term “fatty material” refers to a food material that is solid at room temperature and configured for phase transition to a liquid upon heating. Examples include yoghurts and chocolate. The fatty material may contain added sugar or sweeteners, preservatives, colouring agents and the like. Generally, the fatty material comprises at least 20%, 25% or 30% fat (w / w).

[0059] As used herein, the term “panning” refers to a well-known process in which a material is coated onto a solid centre by moving the centre while simultaneously applying a coating material to the centre. The process is usually performed in a rotating drum, with or without the circulation of air or other atmosphere modification, the frequency of rotation may be modified to compensate for the weight of the product increasing the process as coating is added to the material. Panning a product results in the application of a coating to the product, and the process parameters can be modified to achieve a partial or complete coating and various levels of moisture in the applied coat.

[0060] As used herein, the term “probiotic” refers to live beneficial bacteria and / or yeasts that naturally live in your body. Probiotics help keep your body healthy and working well, including fighting off bad bacteria when you have too much of it, helping you feel better. The probiotics employed in the invention may comprise a combination of different probiotics. Though there are many types of bacteria that can be considered probiotics, there are two specific types of bacteria that are common probiotics found in stores. These include Lactobacillus and Bifidobacterium. The term includes spore-forming and non-spore forming bacteria. The probiotic may be added to the coating material or applied to a surface of the solid centre. In addition to probiotics, other active agents may be added to the edible product, for example a micronutrient such as a vitamin or mineral, or a prebiotic like non-digestible fibre.

[0061] As used herein, the term “sugar shell” refers to a thin shell of sugar that encapsulates the coated centre. It is often formed by isomaltose which is heated and applied to the coated centres by panning, and then dried to form the hard shell. Typically, the sugar shell comprises a plurality of coats of sugar. Typically, the sugar shell is applied in a process comprising simultaneously panning the coated centre and spraying a sugar solution on to the outer coat of fatty material. Typically, the process comprises atomising spraying of the sugar solution. Typically, the process comprises a plurality of panning / spraying steps, for example 5 to 50, 10 to 40, 20 to 40. Typically, the process is performed in a rotating perforated drum. Typically, the drum is rotated at 20-50 Hz. Typically the process comprises a drying step after one or more (or each) of the panning / spraying steps. Typically, the or each drying step comprises applicating of cold air (e.g. 15-20°C) to the product during the panning process. Typically the cold air has a relative humidity of 25-50 RH. Typically, the or each drying step last for 5-12 minutes. Typically, the sugar solution is 60-75% or 63-70% Brix. Typically, the sugar shell coating process comprises atomised spraying of 50 to 150 Kg, preferably 100 to 125 Kg, of sugar solution on to 4500 Kg of the coated centres. Exemplification

[0062] The invention will now be described with reference to specific Examples. These are merely exemplary and for illustrative purposes only: they are not intended to be limiting in any way to the scope of the monopoly claimed or to the invention described. These examples constitute the best mode currently contemplated for practicing the invention.

[0063] Flavoring Yoghurt wafer

[0064] 1 . Add 400 lbs yoghurt into the melting tank at 60 °C and mix for 30 seconds every 5 minutes. Figure 1

[0065] 2. Wait 30 minutes until a certain amount of yoghurt is melted and turn on mixer to promote even melting at 60 °C. Figure 2

[0066] 3. Wait 60 minutes until all the yogurt wafers are melted completely and lower the heating temperature to 55 °C. Figure 3

[0067] 4. Add 8 lbs strawberry flavor and mix evenly for half an hour in the melting ensuring the flavored yogurt temperature does not exceed 55 °C. Flavor ratio is 2%.

[0068] 5. Pump flavored yogurt to storage tank at 45 °C .

[0069] 6. Check the temperature of yogurt inside the storage tank every two hours to ensure temperature does not exceed 45 °C.

[0070] Adding Strawberry Fruit Pieces with Yoghurt Coating

[0071] 1 . Turn of cold air and fan of panning machine.

[0072] 2. Set temperature of the HVAC system at 10°C and check the displayed temperature on the PLC. should read 10°C-13°C.

[0073] 3. Set humidity of HVAC system at 35 and check the displayed humidity on the

[0074] PLC - should read 35-45.

[0075] 4. Start drum forward rotation. 5. Add boxes of strawberry fruit pieces into the drum.

[0076] 6. Prepare 2.5 lbs probiotic, e.g. L. Rhamnosus 001 in an alcohol - cleaned, water-free container.

[0077] First Coating Step

[0078] Use the following conditions to complete the first coating step.

[0079] Spraying pump speed 7 Hz.

[0080] 1.

[0081] 2.

[0082] Ensure the edge of the fruit centre is exposed after this step, with no yoghurt peeling off the corners. The temperature of the partly coated product at this stage is 23-24°C.

[0083] See Figure 4.

[0084] Second Coating Step

[0085] Use the following conditions to complete the second coating step.

[0086] Spraying pump speed 7 Hz.

[0087] 1.

[0088] Ensure the edge of the fruit centre is exposed after this step, with no yoghurt peeling off the corners.

[0089] See Figure 5

[0090] 2.

[0091] Third Coating Step

[0092] Use the following conditions to complete the third coating step. Spraying pump speed 7 Hz.

[0093] 1.

[0094] Add 2.5 lbs of probiotic powder during this step.

[0095] 2. Stop spraying at the 10thminute for gap drying 1 minute and then continue spraying.

[0096] Stop spraying when the individual weight is 1 .25g-1 .28g, or the total weight of 10 pieces is 12.5-12.8 g.

[0097] See Figure 6

[0098] Release the probiotic yoghurt covered fruit pieces

[0099] 1 . Rotate with 100 Hz air with drum speed 10 Hz for 5-10 minutes.

[0100] 2. Release the product when the temperature of the product is at most 21 °C.

[0101] 3. Release the products.

[0102] 4. After the drum rotates for one cycle, discharge and control the releasing speed.

[0103] 5. Collect the products and allow them to settle until the temperature of the product is 17°C-19 °C.

[0104] Application of Sugar Shell

[0105] 1 . Sugar solution with brix 63-70% should be prepared in advance and the temperature of it needs to be cooled down below 32°C before use. The cooking temperature for sugar solution cannot exceed 70°C for long heating time otherwise caramelized sugar solution will impact the color of sugar shell.

[0106] 2. The sugar shell is made I developed through layers of thin sugar shells added up. 3lb solution or more is sprayed through atomized spraying pattern to the surface of a total of 400lb or more yogurt balls. The cold air is turned on with a condition of 15-20°C temperature and 25-50RH Humidity. 5-12 mins of cold air drying inside a perforated drum system is required to remove the moisture from sugar shell and make it dry and smooth. The drum speed is set in either forward or reverse direction and between 20-50Hz. The 3lb dose should be repeated at least five times so that the bottom sugar layer is even and smooth. 3. After five times, 5lb or more sugar solution is added per cycle to speed up the bulk volume building process. At least 25 sugar adding cycles should be followed to hit the target weight.

[0107] 4. After the product is released from the machine, it should be stored in a resting room with conditions 50°F / 50°C for at least 6 hours so that the crunchy texture is developed.

[0108] The final product should be smooth and in matt texture; fruit pieces on yogurt balls are fully covered by sugar shell (Figure 7).

[0109] Equivalents

[0110] The foregoing description details presently preferred embodiments of the present invention. Numerous modifications and variations in practice thereof are expected to occur to those skilled in the art upon consideration of these descriptions. Those modifications and variations are intended to be encompassed within the claims appended hereto.

Claims

CLAIMS:1 . A method of producing an edible product comprising a solid centre and a plurality of coats of a fatty coating material, the method comprising the steps of: providing a solid centre that is cuboid; coating the solid centre with an inner coat of fatty coating material comprising simultaneously panning the centre and spraying the fatty coating material on to the centre; panning the coated centre without spraying to dry the coated centre; applying a first outer coat of fatty coating material to the coated centre comprising simultaneously panning the coated centre and spraying the fatty coating material on to the coated centre; optionally, applying a second outer coat of fatty coating material to the coated centre comprising simultaneously panning the coated centre and spraying the fatty coating material on to the coated centre; and applying a sugar shell to the coated centre.

2. A method according to Claim 1 in which the edible product is generally spherical.

3. A method according to Claim 1 or 2 in which the centre is a first colour and the coating is a second colour that contrasts with the first colour.

4. A method according to any preceding Claim, in which the step of coating the solid centre with the inner coat comprises a first coating step comprising simultaneously spraying the coating material and panning to form a first inner coatand a second coating step comprising simultaneously spraying the coating material on the first coat and panning to provide a second inner coat.

5. A method according to Claim 1 in which the or each coating step comprises intermittently spraying the coating material.

6. A method according to Claim 5 in which the step of intermittent spraying of the coating material comprises spraying steps separated by non-spraying steps, in which each non-spraying step lasts for 1 to 10 seconds.

7. A method according to any preceding Claim in which the process comprises a step of drying the first outer coat by panning the coated centre without spraying prior to application of the second outer coat.

8. A method according to any preceding Claim, in which the coating material is selected from yoghurt and chocolate.

9. A method according to any preceding Claim, in which the centre is selected from a fruit gel and a dehydrated fruit piece.

10. A method according to any preceding Claim, in which one of the coats of coating material comprises a heat-sensitive agent.11 . A method according to Claim 10, in which the heat sensitive active agent comprises an encapsulated probiotic bacteria.

12. A method according to any preceding Claim in which the method comprises applying a third outer coat of a coating material.

13. A method according to any preceding Claim comprising an inner coat of coating material and at least 3 outer coats of coating material.

14. An edible product comprising: a solid centre having a cuboid shape; an inner coating of fatty material applied to a surface of the solid centre; an outer coat of fatty material; and an outer sugar shell. in which the solid centre is cuboid and in which the fatty material coating at the corners of the solid centre has a thickness of less than 200 pm.

15. An edible product according to Claim 16, in which the corners of the solid centre abut the outer sugar shell.

16. An edible product according to Claim 14 or 15, in which the fatty material coating at the centre of each face of the solid centre has a thickness of at least 1500 pm.

17. An edible product according to any of Claims 14 to 16, in which: the solid centre comprises a gel; and the fatty material comprises yoghurt.

18. An edible product according to any of Claims 14 to 17, in which one or more of the coatings of fatty material comprises probiotic bacteria or a micronutrient.

19. An edible product according to any of Claims 14 to 17, in which a surface of the solid centre comprises probiotic bacteria or a micronutrient.

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