Dough-like Confectionery Coating for Rapid Layer Formation
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Solution Overview
Problem
The conventional production of hard coated confectionery products, such as chewing gum, requires numerous layers of coating material and a lengthy process due to the use of water-laden solutions, which is time-consuming and inefficient.
Innovation Solution
A dough-like confectionery material with a low water content, comprising solid particulates and a diffusion controller, is used to form layers or regions, allowing for rapid formation and application, eliminating the need for multiple layers and reducing processing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional hard panning procedure with multiple thin layers of coating material is used, then desirable crunchy hard coating is achieved, but production time becomes excessively long (six hours or more)
Solution Approach 1:
The invention merges multiple thin coating layers into a single thick coating layer applied in one operation. Instead of building up 40-60 thin layers through repetitive spraying and drying cycles, the dough-like confectionery material is applied as a single thick layer that achieves the desired crunchy coating quality, thereby reducing production time from six hours or more to a single application cycle
Solution Approach 2:
The invention changes the physical and chemical parameters of the coating material from a liquid sugar syrup (high water content) to a dough-like confectionery material (low water content). This parameter change allows the material to be applied as a thick layer in a single operation rather than requiring multiple thin layers, thus resolving the contradiction between coating quality and production time
2Ease of manufacture
If water-laden coating solutions are used in conventional hard panning, then coating material can be applied, but extensive drying operations are required
Solution Approach 1:
The invention changes the water content parameter of the coating material from high (water-laden sugar syrup) to low (dough-like confectionery material). This parameter change eliminates the need for extensive drying operations while maintaining ease of manufacture, as the dough-like material can be applied directly without requiring prolonged drying cycles
3Manufacturing precision
If multiple thin layers of coating material are applied to achieve hard crunchy coating, then coating quality is improved, but process complexity increases
Solution Approach 1:
The invention merges the function of multiple thin coating layers into a single thick coating layer application. Instead of requiring a complex repetitive process of spraying and drying 40-60 layers, the dough-like material is applied in one operation, thereby simplifying the coating process while maintaining the desired hard crunchy coating quality
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 approach enables the production of confectionery products with desirable crunchy characteristics in less time, maintaining quality and flexibility in forming hard or soft layers, while reducing the need for extensive drying operations.
Implementation Method 1
The liquid phase includes a liquid and a diffusion controller that controls the diffusion of the liquid and its contact with the solid particulates
Data Source
AI summary
A dough-like confectionery material contains a solid particulate, a liquid, and a diffusion controller. The dough-like confectionery material is an effective replacement for panned coatings, and it can be applied to an edible substrate, such as candy or chewing gum to form a layered confection. Methods and apparatus for forming layered confections are also described.