Jacketed Confectionery Product with Crystalline Intermediate Layer

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Solution Overview

Problem

Producing confectionery products with a chewy center and a hard shell is challenging due to difficulties in controlling crystallinity and moisture levels, and hard shells can be brittle, making them difficult to package without damage.

Innovation Solution

A method involving an extrusion process where a chewy candy material is mixed and cooled, then coated with a second candy material in a batch roller to form a jacketed confectionery product with a chewy center, an intermediate crystalline layer, and a crunchy hard shell, using sweeteners, texturizers, and nucleating agents to control texture and crystallization.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

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

Engineering Contradiction:

Improvehard shell structureVSAvoidpackaging integrity

Core Design Contradiction:

ShapeVSReliability

Solution Approach 1:

The patent divides the confectionery product into three distinct layers: a chewy center, an intermediate crystalline layer, and a hard shell outer layer. This segmentation allows each layer to perform its specific function while reducing the brittleness problem by distributing mechanical stress across multiple layers rather than concentrating it in a single hard shell.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The intermediate crystalline layer acts as a mediator between the chewy center and the hard shell. This intermediate layer reduces the brittleness of the hard shell by providing a transition zone that absorbs stress, preventing the hard shell from chipping or breaking during packaging and distribution.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Shape

If a hard shell coating is applied to a soft center, then the product has a crunchy texture, but coating control and moisture management become difficult

Engineering Contradiction:

Improvehard shell coatingVSAvoidcoating control

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The patent applies preliminary action by forming the intermediate crystalline layer before applying the final hard shell coating. This intermediate layer is formed with controlled crystallinity during the extrusion process, creating a stable base that facilitates subsequent hard shell coating application and improves overall coating control.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent applies local quality by giving each layer distinct properties: the center remains chewy with high moisture content, the intermediate layer has controlled crystallinity for structural stability, and the outer layer provides hard shell crunch. This localized differentiation of material properties enables precise control over coating behavior and moisture distribution throughout the product.

Inventive Principle:

Principle #3Local quality

3Shape

If multiple layers and coatings are used in confectionary products, then the product has complex texture and structure, but processing difficulties increase especially in controlling crystallinity and moisture levels

Engineering Contradiction:

Improvemultiple layers structureVSAvoidprocessing complexity

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The patent merges multiple functions into a single extrusion process that simultaneously forms the chewy center, intermediate crystalline layer, and hard shell outer layer. By combining these layers into one continuous extrusion operation rather than separate coating steps, the process simplifies moisture and crystallinity control while maintaining the complex multi-layer structure.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent uses composite materials with different crystalline structures and moisture contents in each layer. The intermediate layer specifically uses a crystalline structure that is stable during processing, which simplifies the overall control of crystallinity and moisture levels throughout the multi-layer product by providing a structurally stable middle layer.

Inventive Principle:

Principle #40Composite materials

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 method allows for the production of confectionery products with a consistent chewy center and crunchy hard shell, enabling effective coating and packaging while maintaining texture and preventing brittleness, ensuring the product remains intact during distribution.

Implementation Method 1

The first candy material is cooled after exiting the extrusion mixing device

Methodology Applied

Scientific EffectCooling: Cooling

Implementation Method 2

an intermediate layer comprising sweetener and flavour which is at least partially crystalline

Methodology Applied

Scientific EffectCrystallization: Crystallisation

Implementation Method 3

using sweeteners, texturizers, and nucleating agents to control texture and crystallization

Methodology Applied

Scientific EffectNucleation: Nucleation

Data Source

PatentEP2117336B1Method of preparing a coated confectionary product

Publication Date: 2017.08.23 WM WRIGLEY JR CO

Figure 1~3
Figure 4

AI summary

A method of producing a confectionary product includes providing a chewy material including a first sweetener and a fat. The chewy material is mixed in a mixing device and metered through a pumping device. A candy material including a second sweetener is disposed around the chewy material to form a jacketed confectionary material. The jacketed confectionary material is formed into a confectionary product.