Dual-Structure Gum Pellet Coating for Faster Crunchy Shell Formation
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Solution Overview
Problem
Conventional methods for coating confectioneries, such as coated candies and chewing gums, are time-consuming and energy-intensive due to the sequential drying and crystallization of sweetener-syrup layers, which prolongs the coating process and requires low humidity drying temperatures.
Innovation Solution
A method involving a dual structure coating comprising a soft coating forming at least 25% of the shell weight, applied without intermediate drying, followed by a hard coating, where the soft coating is formed using multiple layers of sugar alcohols with controlled temperature and humidity conditioning, significantly reducing the overall coating time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional sequential drying and crystallization of sweetener-syrup layers is used, then the coating forms a hard shell, but the coating process becomes time-consuming and energy-intensive
Solution Approach 1:
The coating process is segmented into two distinct stages: a soft coating stage using sugar alcohol syrup applied without complete drying, followed by a hard coating stage. This segmentation allows the soft coating to form first as a flexible base, then the hard coating is applied on top, eliminating the need for complete drying between layers and reducing total process time while maintaining shell hardness.
Solution Approach 2:
The soft coating is applied as a preliminary layer before the hard coating. This preliminary soft coating layer serves as a foundation that allows subsequent hard coating to be applied without requiring complete drying of the first layer, thereby reducing the time required for sequential drying and crystallization steps.
2Stability of the object's composition
If low humidity hot air is applied during drying at temperatures below melting point, then the chewing gum core is not deformed, but the drying process takes longer
Solution Approach 1:
The patent changes the parameter of coating material composition by using sugar alcohol syrup instead of conventional sweetener syrup. This parameter change allows the coating to be applied at lower temperatures without requiring extensive drying time, as the sugar alcohol syrup forms a soft coating that can be applied wet and then hardened in a subsequent stage, thereby reducing drying time while maintaining core integrity.
3Strength
If multiple sweetener-syrup layers are applied sequentially with complete drying between layers, then a hard coating shell is formed, but the process becomes energy-intensive
Solution Approach 1:
The coating process is segmented into soft and hard coating stages with different material compositions. The soft coating stage uses sugar alcohol syrup applied without complete drying, eliminating the need for energy-intensive drying between layers. The hard coating stage then provides the necessary hardness, achieving the desired shell properties with reduced energy consumption.
Solution Approach 2:
The coating uses composite materials combining sugar alcohol syrup in the soft coating layer with the hard coating layer. This composite structure allows the soft, flexible sugar alcohol layer to be applied without complete drying, reducing energy requirements for drying between layers, while the hard coating provides the necessary structural integrity.
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
The dual structure coating process reduces the total coating time by 20-40% compared to conventional methods while maintaining the sensory attributes and hardness of the final product, achieving a crunchy texture in less than 5 hours.
Implementation Method 1
The soft coating is formed by applying at least one layer of a first coating material about an exterior surface of the confectionery core. The soft coating material includes sugar alcohol and water, and the soft coating forms at least 25% of the total shell weight.
Implementation Method 2
The sweetener-syrup layers crystallize and form a hard coating or shell around the chewing gum center.
Data Source
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AI summary
A method of forming a coated confectionery is provided, comprising: providing a confectionery core; forming a soft coating about an exterior surface of said confectionery core, said soft coating including one or more layers of a first coating material, wherein moisture is at least partially absorbed during formation of said soft coating; and forming a hard coating about said soft coating, said hard coating including one or more layers of a second coating material.