Sugar-Free Hard Dragee Coating via Erythritol and Maltitol
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Solution Overview
Problem
Existing methods for manufacturing hard sugar-free confectionery products face challenges in achieving industrial scalability, good taste, and sensory qualities due to the processing difficulties and adverse effects of sugar replacement substances like maltitol and sorbitol, which can cause laxative effects and flatulence.
Innovation Solution
A sugar-free hard dragee composed of a compressed core and a hard coating, using a mixture of erythritol, isomalt, and D-sorbitol in the core, and D-maltitol and erythritol with non-sugar sweeteners like stevia, aspartame, and sucralose in the coating, ensuring a crystalline, non-sticky, and non-laxative coating that surrounds the core completely.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If sugar replacement substances like maltitol and sorbitol are used in hard dragees, then the desired texture and crystalline coating can be achieved, but laxative effects and flatulence occur when exceeding certain amounts
Solution Approach 1:
The patent changes the concentration parameters of sugar replacement substances by using a mixture of erythritol (30-70 wt%), isomalt (10-40 wt%), and D-sorbitol (10-40 wt%) in the compressed core, and D-maltitol (40-80 wt%) combined with erythritol (10-30 wt%) in the hard coating. This parameter optimization achieves the desired crystalline texture while staying below laxative thresholds.
Solution Approach 2:
The patent uses composite material strategies by combining multiple sugar replacement substances (erythritol, isomalt, D-sorbitol, D-maltitol) with non-sugar sweeteners (stevia/steviol, aspartame, acesulfame, sucralose) in specific ratios. This composite approach allows achieving the desired texture and sweetness while avoiding the harmful laxative effects of single-substance high concentrations.
2Reliability
If non-sugar sweeteners are used to reduce calories, then the health benefits and tooth-friendly properties are achieved, but traditional manufacturing methods cannot be used due to different processing qualities
Solution Approach 1:
The patent optimizes processing parameters including drying the compressed core to 1-5% moisture content, applying multiple coating layers with 20-40% solid content solution, and controlling crystallization conditions. These parameter adjustments enable traditional hard dragee manufacturing methods to work effectively with non-sugar sweetener-containing materials.
Solution Approach 2:
The patent performs preliminary actions by pre-compressing the core mixture containing non-sugar sweeteners into a stable compressed core with controlled moisture content (1-5%) before applying the hard coating. This preliminary compression stabilizes the non-sugar sweetener mixture, making it suitable for subsequent coating processes.
3Shape
If a hard coating is applied to achieve a crispy, non-sticky dragee cover, then the desired sensory quality is achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent merges multiple functions into the hard coating layer: it provides the crispy non-sticky texture, serves as a protective barrier, and delivers sweetness through incorporated non-sugar sweeteners (aspartame, acesulfame-K, sucralose, or steviol). This consolidation simplifies the overall manufacturing process by combining several requirements into a single coating step.
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 solution enables the production of hard sugar-free dragees with excellent processing qualities, tablet hardness, taste, and compatibility, avoiding stomach issues and the cooling effect often associated with sugar-free confectionery, while maintaining industrial scalability.
Implementation Method 1
For the hard coating, a solution, preferably an oversaturated solution, is applied on the core once or multiple times which crystallizes on the core and therefore forms the crystalline coating.
Data Source
AI summary
The subject matter of the invention is a sugar-free hard dragee consisting of a compressed core and a hard coating completely surrounding the compressed core, wherein the hard dragee is sugar-free. The compressed core contains a mixture of erythritol. D-sorbitol and steviol whereas the hard coating contains a mixture of D-maltitol, erythritol and stevia/steviol. The hard dragees according to the invention surprisingly have a good compatibility in spite off the combination of sugar replacement substances and non-sugar sweeteners. Moreover, the compressed cores of the hard dragees according to the invention have a very good compressibility.