Centre Filled Gummy Production via Low-Temperature One-Shot Encapsulation
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Solution Overview
Problem
Formulating centre filled gummies with active ingredients is challenging due to interference issues with gelation, decomposition, and leakage problems, especially with liquid fillings, which require additional compositions and steps to ensure proper encapsulation and dosing.
Innovation Solution
A method for producing seamless centre filled gummies using a gelatinous shell and filling composition, where the filling is deposited at a lower temperature than the shell, allowing for one-shot encapsulation without a foam layer, preventing gelification issues and ensuring uniform dosage and stability of active ingredients.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If active ingredients are formulated in centre filled gummies using conventional methods, then the gummy provides a tasty and easy-to-swallow delivery form, but the active ingredient interferes with gelation causing gelification problems and decomposition
Solution Approach 1:
The gummy is divided into two distinct parts: an outer gelatinous shell and an inner filling composition. The shell contains gelatin and provides the gelation function, while the filling contains the active ingredient separately. This segmentation prevents the active ingredient from interfering with the gelation process of the shell, solving the gelification problem while maintaining the tasty delivery form.
Solution Approach 2:
A barrier layer or coating is introduced between the active ingredient and the gelatinous shell. This intermediary layer prevents direct contact and chemical interaction between the active ingredient and gelatin, eliminating the interference with gelation and decomposition issues while allowing the gummy to maintain its desirable properties.
2Productivity
If liquid filling is used in centre filled gummies, then the filling provides efficient active ingredient delivery, but the filling leaks out of the gummy requiring additional foam layer and production steps
Solution Approach 1:
The outer shell is designed with optimized gelatin concentration and cross-linking to provide enhanced mechanical strength and sealing properties. This flexible yet strong shell contains the liquid filling effectively without leakage, eliminating the need for additional foam layers while maintaining efficient active ingredient delivery through the liquid filling.
Solution Approach 2:
The viscosity and gel strength parameters of the gelatinous shell are optimized to match the liquid filling properties. By adjusting the gelatin concentration, temperature, and setting time parameters, the shell achieves optimal sealing capability to contain the liquid filling without leakage, simplifying the production process.
3Manufacturing precision
If filling is deposited at high temperature to ensure proper encapsulation, then the shell sets correctly, but the active ingredient decomposes
Solution Approach 1:
The gelatinous shell is prepared and deposited first, allowing it to begin setting at lower temperatures before the filling is added. This preliminary action creates a partial barrier that protects the subsequent filling from high temperature exposure, enabling proper encapsulation without thermal degradation of the active ingredient.
Solution Approach 2:
The deposition and setting process is divided into multiple temperature stages: initial shell deposition at moderate temperature, filling deposition at low temperature, and gradual temperature increase for complete setting. This periodic temperature control ensures proper encapsulation while preventing thermal degradation of the active ingredient.
4Reliability
If foam layer is applied to seal the filling, then leakage is prevented, but an additional composition and production step are required
Solution Approach 1:
The sealing function previously performed by a separate foam layer is merged into the gelatinous shell itself. By optimizing the shell composition and deposition parameters, the shell achieves both structural integrity and leakage prevention in a single component, eliminating the need for additional foam layer application steps.
Solution Approach 2:
The gelatinous shell is designed to self-seal during the setting process through its own gelation properties. As the shell sets, it naturally forms a tight seal around the filling without requiring external foam application, achieving leakage resistance through the shell's inherent properties and reducing production complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables the production of centre filled gummies with a wide range of active ingredients, providing a tasty, chewy, and efficient delivery form with enhanced dosing efficiency and resistance to filling leakage, while avoiding thermal degradation and gelation problems.
Implementation Method 1
the temperature Tinner of the filling composition upon deposition is at most 45° C.
Implementation Method 2
the viscosity of the filling composition upon deposition ranges between 500 and 30000 mPa·s
Implementation Method 3
setting the deposited gelatinous shell composition
Data Source
AI summary
The present invention provides a method for producing a seamless centre filled gummy; wherein the filling comprises at least one active ingredient; the method comprising the steps of: 1) preparing a gelatinous shell composition by a first gelatine product in water to form a first gelatine solution; 2) preparing a filling composition, wherein the filling composition comprises at least one bulking agent and one or more active ingredients dissolved or suspended in said filling composition; 3) depositing the gelatinous shell composition and the filling composition within the same timeframe; 4) setting the deposited gelatinous shell composition; wherein the temperature Tinner of the filling composition upon deposition is at most 45° C., and wherein the viscosity of the filling composition upon deposition ranges between 500 and 30000 mPa·s. The invention further provides seamless centre filled gummy comprising an active ingredient, which may be produced by the inventive method.