Confectionary Coating with Intermediate Crystalline Layer

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Solution Overview

Problem

Producing confectionary products with a chewy center and a hard shell coating poses challenges in controlling crystallinity and moisture levels, and packaging such products without damaging the hard shell is difficult due to brittleness.

Innovation Solution

A method involving a chewy material with a higher water activity than a candy material, where nucleating sites are created in the candy material to allow water migration and partial crystallization, resulting in a confectionary product with a chewy center, an intermediate crystalline coating, and a crunchy hard shell outer layer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If a hard shell coating is applied to a chewy center, then the product has a desirable crunchy texture, but the hard shell becomes brittle and difficult to package without damage

Engineering Contradiction:

Improvehard shell textureVSAvoidhard shell integrity during packaging

Core Design Contradiction:

ShapeVSReliability

Solution Approach 1:

The patent divides the coating into multiple layers: an intermediate coating layer containing amorphous sweetener that can absorb moisture, and an outer hard shell layer. This segmentation allows the intermediate layer to act as a buffer that absorbs stress and prevents the hard shell from becoming brittle during packaging.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The intermediate coating layer serves as a mediator between the chewy center and the hard shell. It contains amorphous sweetener that can migrate and crystallize, providing a transition zone that reduces the brittleness of the hard shell and prevents chipping or breaking during packaging.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Shape

If a hard shell coating is applied to a soft chewy center, then the product has a crunchy outer layer, but processing difficulties arise in controlling crystallinity and moisture levels

Engineering Contradiction:

Improvecoating structureVSAvoidcrystallinity and moisture control

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The patent applies an intermediate coating layer before the hard shell coating. This intermediate layer contains amorphous sweetener that is prepared in advance to absorb excess moisture and control crystallization, making the subsequent hard shell coating process easier to control and reducing processing difficulties.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent changes the physical state parameter of the sweetener from crystalline to amorphous in the intermediate coating layer. This parameter change allows the intermediate layer to absorb moisture and control crystallization, thereby controlling the overall crystallinity and moisture levels during processing.

Inventive Principle:

Principle #35Parameter changes

3Strength

If the candy material crystallizes completely, then the coating becomes hard and crunchy, but it becomes brittle and difficult to package

Engineering Contradiction:

Improvecoating hardnessVSAvoidpackaging durability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent applies partial crystallization rather than complete crystallization of the candy material. The intermediate coating layer contains amorphous sweetener that partially crystallizes, providing a balance between hardness and flexibility, thereby maintaining packaging durability while achieving the desired crunchy texture.

Inventive Principle:

Principle #16Partial or excessive action

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 confectionary products with a desirable texture, allowing the candy material to crystallize and become chewier over time, while maintaining a crunchy outer layer and preventing the hard shell from becoming brittle during packaging.

Implementation Method 1

Water is allowed to migrate from the chewy material to the candy material

Methodology Applied

Scientific EffectWater migration: Diffusion

Implementation Method 2

The amorphous candy material is allowed to crystallize at least in part

Methodology Applied

Scientific EffectCrystallization: Crystallisation

Data Source

PatentUS8048470B2Coated confectionary product

Publication Date: 2011.11.01 WM WRIGLEY JR CO

AI summary

A method of producing a confectionary product includes providing a chewy material and a candy material. The candy material includes a sweetener and is at least in part amorphous. The water activity of the chewy material is greater than the water activity of the candy material. The chewy material and the candy material are disposed adjacent to each other. Nucleating sites are created in the candy material. Water is allowed to migrate from the chewy material to the candy material. The amorphous candy material is allowed to crystallize at least in part.