U.S. patent application number 12/608329 was filed with the patent office on 2010-04-01 for method and apparatus for uniformly adding particulates to a coating on comestibles, and products produced thereby.
This patent application is currently assigned to Wm. Wrigley Jr. Company. Invention is credited to Kevin M. Fistek, Eugeniusz Kowalewski, Roger C. Parrish, Michael P. Russell, Julius W. Zuehlke.
Application Number | 20100077956 12/608329 |
Document ID | / |
Family ID | 32987426 |
Filed Date | 2010-04-01 |
United States Patent
Application |
20100077956 |
Kind Code |
A1 |
Zuehlke; Julius W. ; et
al. |
April 1, 2010 |
METHOD AND APPARATUS FOR UNIFORMLY ADDING PARTICULATES TO A COATING
ON COMESTIBLES, AND PRODUCTS PRODUCED THEREBY
Abstract
A process for applying particulates to a large number of
comestible cores during the production of comestible cores so as to
have a generally uniform application of particulates on each coated
core involves the steps of placing a batch of comestible cores in a
coating apparatus; applying aliquots of coating syrup while the
cores are tumbled in the coating apparatus to build up a coating on
the cores; dividing a predetermined total amount of the
particulates to be applied to the coated cores into at least three
portions of approximately equal size; and applying each of the
portions of particulates to the coated cores simultaneously from
multiple, spaced apart, particulate distributors in the coating
apparatus while the coated cores are being tumbled. Preferably the
particulate applicator comprises a number of venturi eductors equal
to the number of particulate distributors; a pneumatic hose
connected between each venturi eductor and each particulate
distributor; and a vibratory pan for holding a quantity of
particulates and causing the particulates to vibrate and flow at a
uniform rate into each venturi eductor. The process is particularly
were suited to uniformly apply speckle particulates to produce
coated chewing gum or other confectionery cores with a uniform
number of speckles on each core.
Inventors: |
Zuehlke; Julius W.;
(Chicago, IL) ; Fistek; Kevin M.; (Homer Glen,
IL) ; Parrish; Roger C.; (Naperville, IL) ;
Russell; Michael P.; (Evergreen Park, IL) ;
Kowalewski; Eugeniusz; (Poznan, PL) |
Correspondence
Address: |
WRIGLEY & DREYFUS 28455;BRINKS HOFER GILSON & LIONE
P.O. BOX 10395
CHICAGO
IL
60610
US
|
Assignee: |
Wm. Wrigley Jr. Company
|
Family ID: |
32987426 |
Appl. No.: |
12/608329 |
Filed: |
October 29, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10536670 |
May 27, 2005 |
|
|
|
PCT/US2004/028732 |
Sep 2, 2004 |
|
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12608329 |
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Current U.S.
Class: |
118/19 |
Current CPC
Class: |
G06F 16/173
20190101 |
Class at
Publication: |
118/19 |
International
Class: |
A23G 3/26 20060101
A23G003/26 |
Claims
1. An apparatus for producing coated comestible cores with
particulates in the coating comprising: a) a coating apparatus for
holding and tumbling comestible cores during a coating operation;
b) at least one syrup applicator for applying a coating syrup to
the cores within the coating apparatus; c) a source of particulates
comprising a vibratory pan, and d) a plurality of spaced apart,
particulate distributors placed within the coating apparatus, each
of the particulate distributors being connected to the supply of
particulates.
2. The apparatus of claim 1 wherein the coating apparatus comprises
a rotating drum having an internal drum length of at least 4 feet,
and the particulate distributors are placed within the drum so as
to uniformly distribute particulates to the cores while the drum is
rotating.
3. The apparatus of claim 1 wherein the particulates are delivered
pneumatically to the particulate distributors, each distributor
being connected to a separate pneumatic hose.
4. The apparatus of claim 3 wherein the vibratory pan feeds
particulates into venturi eductors, with each eductor being
connected to a different pneumatic hose.
5. The apparatus of claim 1 wherein the vibratory pan comprises
dividers that divide a quantity of particulates to be applied to
one batch of cores within the coating apparatus into a number of
portions equal to the number of particulate distributors.
6. The apparatus of claim 2 wherein the drum is about 8 to about 12
feet in length and the plurality of particulate distributors
comprise at least 5 distributors.
7. The apparatus of claim 1 wherein each particulate distributor is
located between about 18 inches and about 32 inches from another
particulate distributor.
8. The apparatus of claim 2 wherein the drum is at least 2 feet in
internal diameter.
9. The apparatus of claim 1 wherein the source of particulates
comprises colored particulates that produce a speckled appearance
on the coated comestible.
10. The apparatus of claim 1 wherein each particulate distributor
comprises a hose having a discharge outlet within the coating
apparatus and each discharge outlet includes a conical
diverter.
11. An apparatus for producing coated comestible cores with
particulates in the coating comprising: a) a rotating drum for
holding and tumbling comestible cores during a coating operation;
b) at least one syrup applicator for applying coating syrup to the
cores within the rotating drum; c) a plurality of spaced apart,
particulate distributors placed within the drum; and d) a source of
particulates that is controlled so as to supply particulates
simultaneously to each of the particulate distributors so as to
uniformly distribute particulates to the cores while the drum is
rotating, the source of particulates being connected to the
particulate distributors by a plurality of separate pneumatic hoses
which convey the particulates in a suspended form from the source
of particulates to the drum.
12. The apparatus of claim 11 wherein the rotating drum is designed
for minimal longitudinal movement of the cores while the cores are
being coated with particulates.
13. An apparatus for automatically coating comestible cores with a
coating having particulates therein, the apparatus comprising: a) a
coating apparatus for holding and tumbling comestible cores during
a coating operation; b) at least one syrup applicator for applying
coating syrup to the cores within the coating apparatus; c) a
controller connected to the at least one syrup applicator that
controls the application of syrup in separate aliquots; d) at least
one particulate distributor placed within the coating apparatus
connected to a supply of particulates; and e) a controller
connected to the particulate supply that automatically activates
the supply of particulates to the at least one particulate
distributor at a predetermined time after a predetermined aliquot
of syrup has been applied.
14. The apparatus of claim 13 wherein the at least one particulate
distributor comprises at least four spaced apart distributors.
15. The apparatus of claim 13 wherein the at least one particulate
distributor distributes speckle particulates after the last
application of coating syrup.
16. The apparatus of claim 1 further comprising a number of venturi
eductors equal to the number of particulate distributors, and a
pneumatic hose connected between each venturi eductor and each
particulate distributor; and the vibratory pan causes the
particulates to vibrate and flow at a uniform rate into each
venturi eductor.
17. An apparatus for dividing a quantity of particulates into
generally equal portions for uniform application to a batch of
coated comestible cores comprising: a) a sloped vibratory pan; and
b) one or more dividers in the pan, each running generally parallel
with the direction of slope, defining a plurality of lanes between
the one or more dividers and the sides of the pan.
18. The apparatus of claim 17 further comprising an adjustable
height gate associated with each lane to control the rate at which
particulates enter the lane as the pan is vibrating.
19. The apparatus of claim 18 wherein each gate height may be
adjusted independently.
20. The apparatus of claim 17 further comprising a venturi eductor
associated with each lane to entrain particulates from that lane
into a flowing air stream.
21. The apparatus of claim 18 further comprising a pneumatic hose
connected to each venturi educator and an air supply tank to which
each of the pneumatic hoses is connected to supply uniform air
pressure to each venturi eductor.
Description
REFERENCE TO EARLIER FILED APPLICATIONS
[0001] The present application claims the benefit of the filing
date under 35 U.S.C. .sctn.121 of U.S. patent application Ser. No.
10/536,670, filed May 25, 2005, which is a nationalization of PCT
Patent Application Serial No. PCT/US2004/028732, filed Sep. 2,
2004, both of which are hereby incorporated by reference in their
entirety.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to methods of uniformly
applying particulate material onto comestible cores and to coated
comestible products with uniformly applied particulates, and more
particularly to methods and apparatus for uniformly adding speckle
particulates to a sugar or sugarless coating on comestibles, such
as chewing gum pellets, and products produced thereby.
[0003] Coated chewing gum and other comestible products are well
known. Some products are made with a sugar coating, and others are
made with a sugarless coating. For example, products that are
designed to not promote tooth decay do not use fermentable sugars
in the product, or in coatings on the product. Instead, sugarless
sweeteners such as sorbitol, maltitol, xylitol, erythritol,
lactitol, hydrogenated isomaltulose and others are used in the
product.
[0004] It is also known to provide speckles on the chewing gum
coating. For example, PCT Patent Publication No. WO 02/19834
discloses speckled, coated chewing gums. The speckles may be used
to signal that the product comprises an oral care active. The
speckles are discrete speckles which are easily visible against a
background opaque coating. Flaked speckle material, such as
"Insoluble Edible Glitter" from Watson Food Co., West Haven, Conn.,
is dry sprayed onto the outermost opaque layer of the coated gum
before the layer is dry.
[0005] Even though coated products with speckles on the outer
coating have thus been suggested, for a product to be commercially
successful, there must be a process for making the product
inexpensively on a commercial scale. Also, with a speckled product,
it is desirable that the speckles have a uniform, even though
random, distribution over the surfaces of the products in the batch
of coated products. Not only should the speckles be uniformly
distributed over the entire surface of the product, but good
process control and quality assurance practices require that the
number of speckles on a product must be fairly uniform from one
product to another within the batch, and from batch to batch. If
consumers see a wide variation in the number of speckles on one
product compared to another product from the same manufacturer,
they are likely to consider that some products are defective,
especially where the number of speckles on the product is
associated in the minds of the consumer with some other
characteristic of the product, such as the level of oral care
active in the product.
[0006] There are other ingredients that would be advantageous if
they could be uniformly added to a coating in particulate form. For
example, some flavors, high-intensity sweeteners, physiological
cooling agents, food acids and medicaments may desirably be
included in a coating, and may normally be supplied in a powder
form. While these materials might be able to be added as part of a
dry charge, there are some particulates that would be best if added
by themselves, and many coating operations do not involve a
dry-charge. These materials may thus need to be applied to the
cores while the coating operation is underway in a very uniform
manner, especially if they are used at low levels.
[0007] Thus, there is a need for an inexpensive process for
repeatedly, uniformly distributing randomly applied particulates,
such as colored speckles, on coated chewing gum and other
comestibles on a large scale basis.
BRIEF SUMMARY OF THE INVENTION
[0008] A method of applying particulates to a coating on a
comestible such that there is a uniform number of randomly applied
particulates throughout a batch of products, and from one batch to
the next, which can be used on large size commercial coating
equipment, has been invented.
[0009] In one aspect, the invention is process for producing a
coated comestible comprising placing a batch of comestible cores in
a coating drum having an internal drum length of at least 4 feet;
applying one or more coating syrups in multiple aliquots, with
drying between applications, to build up a coating on the cores;
and adding a quantity of particulates to the coating drum before
the last applied aliquot of coating syrup has dried, such that the
particulates are uniformly applied across the length of the bed and
stick to the coating on the cores.
[0010] In another aspect, the invention is a process for producing
a batch of coated comestible cores having speckles uniformly
distributed on the coating of each of the cores in the batch,
comprising the steps of adding a batch of comestible cores
containing at least 200 kg of cores to a coating apparatus;
applying aliquots of coating syrup to the cores in the apparatus to
build up a coating on the cores; and while the cores are still wet
from the application of coating syrup, applying about 0.2 to about
2 grams of speckle particulates per 1000 grams of coated cores in
the batch.
[0011] In yet another aspect, the invention is a process for
uniformly applying particulates to coated comestible cores
comprising the steps of placing a batch of comestible cores in a
coating apparatus; applying aliquots of coating syrup to build up a
coating on the cores; and applying particulates to the cores while
they are still wet with coating syrup, the particulates being
applied from multiple, spaced apart, particulate distributors
within the coating apparatus, the application of the particulates
occurring simultaneously from each of the multiple particulate
distributors.
[0012] In another aspect, the invention is a process for applying
particulates to a plurality of comestible cores during the
production of coated comestible cores comprising the steps of
placing a batch of cores in a coating apparatus; applying aliquots
of coating syrup while the cores are tumbled in the coating
apparatus to build up a coating on the cores; dividing a
predetermined total amount of particulates to be applied to the
coated cores into at least three portions of approximately equal
size; and applying each of the portions of particulates to the
coated cores simultaneously from a different particulate
distributor in the coating apparatus while the coated cores are
being tumbled.
[0013] Another aspect of the invention is a process for producing
comestible cores with a uniformly colored background coating and
speckle particulates of a contrasting color comprising the steps of
adding a batch of comestible cores to a coating apparatus; applying
aliquots of coating syrup, at least some of which have a light
colored pigment therein, to the cores in successive operations to
build up a light colored coating on the cores; providing a quantity
of speckle particulates that have a contrasting color to the light
colored pigment and a generally uniform size distribution; applying
the quantity of speckle particulates to the cores in the coating
apparatus while the coating syrup is still wet so that the speckle
particulates stick to the light colored coating; and drying the wet
coating syrup with the speckle particulates thereon rapidly after
the speckle particulates are applied to avoid transfer of color
from the speckle particulates on one coated core to the background
coating on other cores in the batch.
[0014] Still another aspect of the invention is batch of at least
1000 kg of coated comestible cores in a coating apparatus, each of
the coated cores having a hard crunchy coating of a first color and
speckles of a second color randomly distributed over the cores, the
cores in the batch having a generally uniform number of speckles
from one coated core to the next.
[0015] In yet another aspect, the invention is an apparatus for
producing coated comestible cores with particulates in the coating
comprising a rotating drum having an internal drum length of at
least 4 feet for holding and tumbling comestible cores during a
coating operation; at least one syrup applicator for applying a
coating syrup to the cores within the rotating drum; and a
plurality of spaced apart, particulate distributors, each connected
to a source of particulates, and placed within the drum, so as to
uniformly distribute particulates to the cores while the drum is
rotating.
[0016] Another aspect of the invention is an apparatus for
producing coated comestible cores with particulates in the coating
comprising a rotating drum for holding and tumbling comestible
cores during a coating operation; at least one syrup applicator for
applying coating syrup to the cores within the rotating drum; a
plurality of spaced apart, particulate distributors placed within
the drum; and a source of particulates that is controlled so as to
supply particulates simultaneously to each of the particulate
distributors so as to uniformly distribute particulates to the
cores while the drum is rotating.
[0017] A further aspect of the invention is an apparatus for
producing coated comestible cores with particulates in the coating
comprising a coating apparatus for holding and tumbling comestible
cores during a coating operation; at least one syrup applicator for
applying a coating syrup to the cores within the coating apparatus;
and a plurality of spaced apart, speckle distributors placed within
the coating apparatus, each of the particulate distributors being
connected to a supply of particulates.
[0018] In another aspect, the invention is an apparatus for
automatically coating comestible cores with a coating having
particulates therein, the apparatus comprising a coating apparatus
for holding and tumbling comestible cores during a coating
operation; at least one syrup applicator for applying coating syrup
to the cores within the coating apparatus; a controller connected
to the at least one syrup applicator that controls the application
of syrup in separate aliquots; at least one particulate distributor
placed within the coating apparatus connected to a supply of
particulates; and a controller connected to the particulate supply
that automatically activates the supply of particulates to the at
least one particulate distributor at a predetermined time after a
predetermined aliquot of syrup has been applied.
[0019] In yet a further aspect, the invention is an apparatus for
applying particulates to a batch of coated comestible cores
comprising a rotating body for holding and tumbling the comestible
cores; at least one syrup applicator for applying coating syrup to
the tumbling cores; and a particulate applicator comprising i) at
least one particulate distributor positioned to distribute
particulates on the tumbling cores; ii) a number of venturi
eductors equal to the number of particulate distributors; iii) a
pneumatic hose connected between each venturi eductor and each
particulate distributor; and vi) a vibratory pan for holding a
quantity of particulates and causing the particulates to vibrate
and flow at a uniform rate into each venturi eductor.
[0020] Another aspect of the invention is an apparatus for dividing
a quantity of particulates into generally equal portions for
uniform application to a batch of coated comestible cores
comprising a sloped vibratory pan; and one or more dividers in the
pan, each running generally parallel with the direction of slope,
defining a plurality of lanes between the one or more dividers and
the sides of the pan.
[0021] In a still further aspect the invention is a process for
assuring quality control of uniformity of speckles on coated
comestible cores in a batch comprising the steps of producing a
batch of coated comestible cores having randomly distributed
speckles over the surfaces of the comestible cores in the batch;
selecting a sample size of at least 50 individual coated cores;
grading each of at least 50 coated cores into one of at least 3
different classifications, each classification having a higher
average number of speckles than the previous classification;
rejecting the batch if over a first predetermined percentage of the
at least 50 individual coated cores are classified in the
classification with the fewest number of speckles; and also
rejecting the batch if over a second predetermined percentage of
the at least 50 individual coated cores are classified in the
classification with the highest number of speckles.
[0022] The ability to make coated products on a large scale, while
at the same time achieving a uniform distribution of particulates
on the products and within batches of the products, provides a
great advantage, in that high quality products can be manufactured
on a profitable basis. In preferred embodiments, relatively
inexpensive and automated equipment is used to the divide
particulates into generally equal portions and feed those portions
into spaced particulate distributors within long coating drums.
These and other advantages of the invention, as well as the
invention itself, will be more easily understood in view of the
attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is a perspective view of a preferred apparatus in
accordance with a first embodiment of the present invention.
[0024] FIG. 2 is a partially broken away perspective view inside a
rotatable drum shown in FIG. 1.
[0025] FIG. 2A is an enlarged elevational view of a particulate
distributor used in the drum of FIG. 2.
[0026] FIG. 3 is a perspective view of the particulate dividing and
feeding equipment used in the apparatus of FIG. 1.
[0027] FIG. 4 is an end elevational view of the equipment of FIG.
3.
[0028] FIG. 5 is a top plan view of the equipment of FIG. 3.
[0029] FIG. 6 is a side elevational view of the equipment of FIG.
3.
[0030] FIGS. 7A-7E depict coated chewing gum pellets with different
levels of speckles applied thereon.
DETAILED DESCRIPTION OF THE DRAWINGS AND PREFERRED EMBODIMENTS
[0031] The present invention will now be further described. In the
following passages, different aspects of the invention are defined
in more detail. Each aspect so defined may be combined with any
other aspect or aspects unless clearly indicated to the contrary.
In particular, any feature indicated as being preferred or
advantageous may be combined with any other feature or features
indicated as being preferred or advantageous. The present invention
will be explained and illustrated with respect to applying speckle
particulates to coated chewing gum pellets. However, it will be
understood that the invention is also applicable to other
particulates and other comestibles that have a coating applied
thereto, including comestible cores comprising a confectionery such
as pressed tablets, and gummy and chewy candies. The term "chewing
gum" as used herein also includes bubble gum and the like. Unless
indicated otherwise, all percentages are given in weight percent.
As used herein, the term "confectioneries" include things (gum,
mints, etc) which would normally be considered as confectionaries
regardless of whether or not they include medicaments.
[0032] There are several unique aspects to the present invention.
Most of them relate to the process and apparatus for applying
particulates, but a large scale batch of products with speckles
uniformly distributed over the coated cores in a random fashion is
also believed to be novel, as well as procedures for determining
quality control of speckle application. The novel process and
apparatus will be described first, and then products and quality
control methods will be discussed. Finally, examples will be given
utilizing the inventive processes and apparatus.
[0033] The preferred embodiments of the invention use commercially
available coating equipment to build up a coating on the cores, but
the equipment is modified to allow for a uniform application of
particulates. The preferred applicator apparatus includes not only
a plurality of particulate distributors within the coating
equipment, but also includes a source of particulates that is
controlled so as to supply particulates simultaneously to each of
the particulate distributors so as to uniformly distribute
particulates to the cores. FIG. 1 depicts an overall layout of an
apparatus for applying particulates to a batch of coated comestible
cores, both the coating equipment and the particulate applicator
apparatus.
[0034] In the background, FIG. 1 shows an open door 12 to a
conventional coating apparatus 10 that has been modified for use in
practicing the present invention. In the foreground, FIG. 1 depicts
the vibratory pan 40 and pneumatic delivery system, which
constitutes the preferred way to supply particulates to the
particulate distributors within the coating apparatus 10. Pneumatic
hoses 50 carry the particulates from the vibratory pan 40 to the
coating apparatus 10.
[0035] The coating apparatus 10 is shown partially broken away in
FIG. 2 to make it easier to see the particulate distributors 20.
While the present invention can be utilized with many different
types of coating apparatus, the preferred coating apparatus
comprises a rotating body, preferably a rotating horizontal drum,
for holding and tumbling comestible cores during the coating
operation. Such a drum will preferably be able to hold a batch of
cores containing at least 200 kg, more preferably at least 500 kg
of cores 14, and most preferably it will be able to hold a batch of
at least 1000 kg of coated comestible cores. The drum will
preferably have an internal drum length of at least 4 feet, more
preferably at least 8 feet, and most preferably the drum is about 8
to about 12 feet in length. The drum will also preferably be at
least 2 feet in internal diameter, and may be as large as 6 feet in
diameter. One preferred type of rotating drum is one that is
designed for minimal longitudinal movement of the cores 14 while
the cores are being coated, especially when the particulate
includes speckle particulates that should not be transferred from
pellet to pellet. Alternatively, the speed of rotation may be
reduced during application of the speckle particulates.
[0036] The coating apparatus 10 includes at least one syrup
applicator for applying coating syrup to the cores within the
rotating drum. The preferred syrup applicators are conventional and
thus not further described. The coating apparatus will preferably
also be able to add a dry charge, which is also conventional.
[0037] The apparatus for producing coated comestible cores with
particulates on the coating comprises at least one particulate
distributor 20 placed within the coating apparatus and positioned
to distribute particulates on the tumbling cores 14. Preferably a
plurality of spaced apart, particulate distributors 20 are
employed. While only three distributors 20 are seen in FIG. 2,
preferably at least four distributors, more preferably at least
five distributors, and most preferably six distributors 20 are
placed within the coating apparatus so as to uniformly distribute
particulates to the cores while the drum is rotating. The preferred
ratio of particulate distributors to drum length is at least one
distributor for every two feet of drum length, and more preferably
one distributor for every 1.5 feet of drum length. Each particulate
distributor 20 is preferably located between about 18 inches and
about 32 inches from another particulate distributor.
[0038] The preferred particulate distributors 20 each comprise a
hose having a discharge outlet within the coating apparatus and
connected to a supply of particulates. As shown in FIG. 2A, the
preferred discharge outlet includes a conical diverter 22 suspended
at the end of the hose 50. Each of the particulate distributors 20
is connected to a separate particulate supply source via a separate
hose 50. In the apparatus of FIG. 2, which has six distributors 20,
there are six hoses 50a-50f. The particulates are thus preferably
delivered pneumatically to the particulate distributors, each
distributor being connected to a separate pneumatic hose, and
thence to a separate particulate supply source.
[0039] While the present invention can be used to apply a variety
of particulate material to a variety of comestible cores, the
invention will be described hereafter as being used to apply
colored speckle particulates, which is the presently preferred use
of the invention. Other materials that may benefit from being
applied with the methods and apparatus described herein include
solid high-intensity sweeteners, solid physiological cooling
agents, solid flavors, granular food acids, and powdered
medicaments, such as powdered caffeine.
[0040] While there are numerous possible ways of separately
supplying each distributor with speckle particulates, it is
preferred that the speckle particulate supply comprise an apparatus
for dividing a quantity of speckle particulates into generally
equal portions for uniform application to a batch of coated
comestible cores. In this fashion, where the coating operation is
carried out in a batch process, the entire quantity of speckle
particulates to be applied to the batch can be weighed out in one
measurement and then applied from different distributors within the
coating apparatus. This assures batch to batch uniformity with
respect to the total number of speckles that will be applied. Of
course different size batches of cores will require proportionately
different amounts of speckle particulates.
[0041] The preferred separate speckle particulate supply sources
are thus provided by the apparatus shown in FIGS. 3-6, which has
two major systems, 1) a sloped vibratory pan 40 with dividers for
holding a quantity of speckle particulates and causing the speckle
particulates to vibrate and flow at a uniform rate, the dividers
dividing the quantity of speckle particulates to be applied to one
batch of cores within the drum into a number of portions equal to
the number of speckle particulate distributors, and 2) an air
system which entrains the speckle particulates in a flowing stream
of air and conveys them pneumatically to the distributors 20.
[0042] As best seen in FIG. 3, the vibratory pan 40 has a holding
section 42 and one or more dividers, preferably five dividers 44,
in the opposite end of the pan from the holding section 42. Each of
the dividers runs generally parallel with the direction of slope,
defining a plurality of lanes 48, preferably six, between the
dividers 44 and the sides 46 of the pan 40. An adjustable height
gate is provided for each lane 48 to control the rate at which
speckle particulates enter the lane from the holding section 42 as
the pan is vibrating. The height of each gate may be adjusted
independently. The gates are provided by strips 49 of metal or
other material supported by crosspiece 43, which in turn is
supported by the frame 41 of the apparatus of FIG. 3. Either the
strips or the crosspiece 43 may be provided with elongated slots,
which allow a screw attaching the strip to the crosspiece to pass
through the slot. The adjustability of the height of the strip 49
makes it easy to set the height of the gate and then tighten the
screw to hold the strip at the desired elevation, and thus control
how much particulate flows into the lane 48 associated with that
gate. The position of the crosspiece 43 on the frame 41 can be
changed, allowing the gates to be established at the beginning of
the lanes 48, or closer to the end of the vibrating pan 40.
[0043] Vibratory pan 40 is vibrated by a vibrator 47 underneath the
pan, best seen in FIGS. 5 and 6. The vibrator is preferably a Model
HS-42 Hi-Speed Vibratory Feeder from Eriez Manufacturing Company
with headquarters in Erie, Pa. Control knob 45 on the vibrator 47
preferably allows control of the amplitude of vibration of pan 40.
However, once the vibrator is tuned for vibration of a given pan 40
and set for a proper amplitude of vibration for feeding speckle
particulates at a desired rate, control knob 45 will not need
further adjustment. The pan 40 may be provided with a hinged cover
(not shown) to prevent objects from falling into the pan 40. Also,
on the outlet of the lanes 48, the pan may be provided with a
catcher to prevent any loose screws from falling with the speckle
particulates off the end of the pan 40.
[0044] The air system includes an air supply, venturi eductors 52
(best seen in FIG. 6), collection tubes 54 and conveyance hoses 50.
The number of venturi eductors 52 is equal to the number of speckle
particulate distributors 20, and each eductor 52 is associated with
one of the lanes 48 and has its own collection tube 54 and is
connected to a different pneumatic conveyance hose 50. Thus, in the
preferred embodiment, there are six eductors 52, six collection
tubes 54, and six conveyance hoses 50. As speckle particulates are
vibrated down the six lanes 48, they fall into the six collection
tubes 54 and are entrained into a flowing air stream. The pneumatic
hose 50 connected to each venturi eductor conveys the speckle
particulates portion falling from the lane 48 associated with that
eductor in a suspended form to a separate speckle particulate
distributor 20.
[0045] Air is supplied to the venturi eductors 52 by six air supply
hoses 56 from an air supply tank 58. The air tank 58 thus supplies
uniform air pressure to each venturi eductor 52. Preferably, the
eductors are 1 inch eductors, and the air in the air supply tank 58
is supplied at a pressure of about 1.5 psi by regulator 59. Should
they be needed, individual valves 57 can be closed on each supply
hose 56.
[0046] It is important that the quantity of speckles flowing down
each lane 48 is generally equal. To get the gates adjusted when the
speckle supply apparatus is first set up, it is beneficial if the
collection tubes 54 can be moved out of the way. Then the speckle
particulates falling off of each lane 48 are manually collected and
weighed. This prevents the speckle particulates from being
transported into the coating apparatus, where they would be more
difficult to collect and measure. The strips 49 can then be moved
up or down as needed, and the process repeated until generally
equal amounts of speckle particulates flow down each lane.
Thereafter the strips should be able to be left in place, as the
gates are adjusted for operation with the vibratory pan 40. To
allow the collection tubes 54 to be moved out of the way, the
preferred apparatus supports the tops of all six collection tubes
54 with a single support 53 that may be disconnected from frame
41.
[0047] After the gates have been adjusted, the system is ready to
be used to produce speckled, coated comestibles. A batch of
comestible cores 14 of a known batch size is placed in the coating
drum 10. One or more coating syrups are applied in multiple
aliquots, with drying between applications, while the cores are
tumbled in the coating apparatus to build up a coating on the
cores. The final aliquot of coating syrup is applied to the coated
cores. A quantity of speckle particulates is added to the coating
drum before the final aliquot of coating syrup has dried, while the
cores are still wet from the application of coating syrup, such
that the speckle particulates are uniformly applied across the
length of the bed and stick to the coating on the cores. The
quantity of speckle particulates is preferably a predetermined
amount based on the known batch size of the cores. This
predetermined total amount of speckle particulates to be applied is
then divided into multiple portions using the vibratory pan 40,
preferably into at least three portions of approximately equal
size, more preferably six portions, prior to its addition to the
drum. Each portion will preferably be within 90-110% of the weight
of the average portion size. In this way a large batch of coated
comestible cores having speckles uniformly distributed on the
coating of each of the cores in the batch can be produced, the
speckle particulates being applied from multiple, spaced apart,
speckle particulate distributors 20 within the coating apparatus
10, each of the portions of speckle particulates being applied to
the coated cores simultaneously from a different speckle
particulate distributor 20 in the coating apparatus while the
coated cores are being tumbled.
[0048] Preferably the speckle particulates are applied over a
period that lasts between about 30 seconds and about 5 minutes,
more preferably between about 1 and about 4 minutes, and most
preferably about 2 minutes. The total amount of speckle
particulates may still be in the process of being divided into the
portions when the first part of each portion starts to be applied
to the cores in the coating apparatus. Preferably the speckle
particulates are applied at a ratio of about 0.2 to about 2 grams,
more preferably between about 0.6 and about 1 gram, of speckle
particulates per 1000 grams of coated cores in the batch. They are
preferably applied such that the application of the speckle
particulates is carried out in less than 1 second per 1000 grams of
coated cores, more preferably less than 0.5 seconds per 1000 grams
of coated cores. Even though at the very beginning and at the tail
end of the speckle particulate application process the rate of
application will build up and then decline, it is preferred that at
least 90% of the total speckle particulates are applied at a
uniform rate of amount per unit of time. Preferably at least 90% of
the speckle particulates are applied at a uniform rate of between
about 0.002 grams/second and about 0.006 grams/second per 1000
grams of coated cores.
[0049] In the preferred process, the comestible cores are produced
with a uniformly light colored background coating, and the speckle
particulates have a contrasting color. This can be accomplished by
applying aliquots of coating syrup having a light colored pigment
therein to the cores in successive operations to build up a light
colored coating on the cores. The coating syrup preferably includes
titanium dioxide as a pigment to produce a white background coating
on the cores. The preferred speckle particulates have a contrasting
color to the light colored pigment color, such as blue, green, red
and purple. More than one color of speckle particulates may be
applied to give a coated product with multiple color speckles. The
preferred coating syrups are aqueous based. Depending on the
coating syrup, the preferred speckle particulates comprise either
poorly water soluble particles, such as sodium alginate and color,
or water soluble particles, such as gum arabic and color. The
sodium alginate particles may be treated with a small amount of
calcium ions to make them less soluble. This material is preferred
when making maltitol coatings. However, gum arabic speckle
particulates are currently preferred when xylitol is used to make
the coating.
[0050] The speckle particulates preferably comprise about 0.2% to
about 2% color, and more preferably about 0.4% to about 1% color.
Preferred water soluble blue speckles, made with gum arabic and
blue #1 dye at a level of about 0.5% dye in the speckles, are
available as WT-7955 from Wixon/Fontarome of St. Francis, Wis.
Another source of blue speckle particulate is "Edible Glitter Blue
F290038" from Watson Foods Co., Inc., 301 Heffernan Drive, West
Haven, Conn. 06516. This material contains gum arabic and FD&C
blue #1. Preferred green speckles are water soluble material made
with gum arabic and blue #1 dye and yellow #5 dyes at a level of
about 0.5% of each dye in the speckles, also available from
Wixon/Fontarome as WT-7955E. The poorly water soluble colors have
about 0.6% color in sodium alginate.
[0051] The speckle particulates stick to the light colored coating.
Preferably the wet coating syrup with the speckle particulates
thereon is rapidly dried after the speckle particulates are applied
to avoid transfer of color from the speckle particulates on one
coated core to the background coating on other cores in the batch.
In this way each of the coated cores has a coating of a first color
and speckles of a second color randomly distributed over the cores.
The cores in the batch have a generally uniform number of speckles
from one coated core to the next.
[0052] One potential problem with producing a highly contrasting
speckle on a light colored background is that if the speckle
particulates include small particles, especially if they are
soluble in the coating solution, the small particles may dissolve
and thus pigment the coating layer. Therefore it is preferred that
the particulates have a generally uniform size distribution so that
the coating conditions can be set to have good adhesion of the
speckle particulate while minimizing dissolution of the particulate
material. Preferably the speckle particulates will have a size
distribution such that less than 30% of the speckle particulates
will pass through a #60 U.S. standard sieve, and at least 90% of
the speckle will pass through a #20 U.S. standard sieve. More
preferably at least 45% of the speckle particulates will be
retained on a #40 U.S. standard sieve, and the longest dimension of
a majority of the speckle particulates will be between about 0.2 mm
and about 0.6 mm. The Watson Foods Edible Glitter Blue F290038 has
a particle size where a minimum of 96% passes through an 8 mesh
sieve, and a maximum of 30% oases through a 30 mesh sieve.
[0053] The preferred coating comprises a hard crunchy coating.
However, the present invention is also applicable to soft panned
coatings, both of which are described in more detail below. The
preferred coatings are made with xylitol or maltitol. The preferred
coated comestible is a confectionery with a mint flavor. The mint
flavor can be in the core, the coating, or both. Of course other
flavors may be used, as described below.
[0054] After the last layer of coating syrup with the speckle
particulate adhered thereto is dried, a wax coating is preferably
applied over the speckle particulates. Such wax coatings are
conventional. However, care must be taken to avoid the wax
application from causing the speckles to smear.
[0055] Preferably the apparatus for coating the comestible cores
automatically applies the speckle particulate at the appropriate
time. Most conventional coating apparatus has a controller 70 (FIG.
1) that allows an operator to program in the various coating
operations, such as the drum rotation speed, the direction and rate
of air flow through the drum, the timing and quantity of syrup
applications, and pause times between each application while drying
air is used, and the application of flavor and dry charge material
when they are used in the coating. The controller is connected to
the syrup applicator(s) and controls the application of syrup in
separate aliquots, thus making it possible to reproduce the
sequence of coating steps necessary to build up the desired coating
on the cores. In the preferred embodiment, the controller 70 is
also connected to the speckle particulate supply, and automatically
activates the supply of speckle particulates to the at least one
speckle particulate distributor at a predetermined time after a
predetermined aliquot of syrup has been applied. For example, the
controller can be programmed to turn on the air supply to the
venturi eductors 52 and start the vibratory pan 40 operating at a
set point in the coating program so that speckle particulate
material is delivered at just the right time when the last aliquot
of coating syrup has been applied but is still wet.
[0056] There are several methods that can be used to determine that
the speckles are uniformly distributed over the coated comestible
cores. One preferred process for assuring quality control of
uniformity of speckles on coated comestible cores in a batch
involves producing a batch of coated comestible cores having
randomly distributed speckles over the surfaces of the comestible
cores in the batch; selecting a sample size of at least 50
individual coated cores; grading each of the coated cores into one
of at least 3 different classifications, each classification having
a higher average number of speckles than the previous
classification; rejecting the batch if over a first predetermined
percentage of the at least 50 individual coated cores are
classified in the classification with the fewest number of
speckles; and also rejecting the batch if over a second
predetermined percentage of the at least 50 individual coated cores
are classified in the classification with the highest number of
speckles. The preferred first and second predetermined percentages
are each 4%. Of course a greater number of coated cores can be used
than 50, and a greater number of classifications than three, can be
used.
[0057] FIGS. 7A-7E show sample coated chewing gum pellets that can
be used in a preferred quality assurance process, which thus has
five classifications. For example, 100 coated cores could be
randomly chosen from a batch. Those coated products would then be
individually sorted and placed into a classification as having a
number of speckles most similar to the sample products used to
establish the classification, such as those shown in FIGS. 7A-7E.
Once the samples were all classified, the batch would be found to
have a uniform speckle distribution if not more than 4 products
were included in the classification corresponding to the sample
with the fewest number of speckles, such as that shown in FIG. 7A;
and not more than 4 products were included in the classification
corresponding with the highest number of speckles, such as that
shown in FIG. 7E.
[0058] Another test for uniformity also uses classifications, but
then looks to see that a certain percentage of the total, such as
60%, 70% or even 80% or more, are within two adjacent
classifications. The higher the percentage, the more uniform the
speckle distribution. For example, a very uniform distribution
would be achieved if at least 80% of the products had a number of
speckles most like those shown in FIGS. 7B and 7C. For a 100
product sample, this could be satisfied if 30 products were in the
category of FIG. 7B and 50 or more of the products were in the
category of FIG. 7C. The batch would also be considered to have a
high uniformity if at least 80% of the products had a number of
speckles most like those shown in FIGS. 7C and 7D, such as 55
products that were closest looking to FIG. 7C and at least 25
products that were closest looking to FIG. 7D. Of course the
classifications can be different than those shown in FIGS. 7A-7E.
It will always be difficult to classify the products from the
samples because some will have a number of speckles that seem to be
right in between two classifications. This may be helped by
including several representative products, perhaps even 10, in the
standard for the classification.
[0059] There are of course other ways to determine uniformity. A
statistical method would be to count the number of speckles on each
coated product in the sample and determine an average and a
standard deviation. For the most part, however, since the goal of
the invention is to make a product that will be pleasing to
consumers, who will judge the product and quality control on visual
perception, the most relevant way to determine if uniform
distribution has been achieved is simply the visual perception from
viewing products in the sample.
[0060] As can be seen from FIGS. 57A-7E, the random distribution of
speckle particulates on coated comestibles can produce widespread
variations. Hence, to achieve reproducible uniformity, especially
in large batches of products made in large scale commercial coating
equipment, it will be necessary to apply the speckle particulate in
a fashion that can be reproduced from one batch to the next, and
that applies the speckle particulates at a uniform rate, preferably
from multiple spaced apart distributors, over a time period when
the cores are wet. This is particularly difficult because
core-to-core transfer of speckles should be avoided. This is
different than many other aspects of the coating operation, where
it is not important that syrup, for example, is evenly distributed
in time or space within the coating apparatus, because the syrup
can flow from one core to the next as the cores tumble. However,
with the application of speckle particulates in a large drum, the
cores must be contacted by the speckle particulates when the cores
reach the surface of the mass of tumbling cores in the drum, and
before they disappear under the next layer of surfacing cores.
[0061] Since the invention is particularly relevant to coated
chewing gum products, the center core and the coating of chewing
gum products will now be discussed.
[0062] In general, a chewing gum composition typically comprises a
water-soluble bulk portion, a water insoluble chewable gum base
portion and typically water-insoluble flavoring agents. The
water-soluble portion dissipates with a portion of the flavoring
agent over a period of time during chewing. The gum base portion is
retained in the mouth throughout the chew.
[0063] The insoluble gum base generally comprises elastomers,
resins, fats and oils, softeners and inorganic fillers. The gum
base may or may not include wax. The insoluble gum base can
constitute approximately 5% to about 95% by weight of the chewing
gum, more commonly the gum base comprises 10% to about 50% of the
gum, and in some preferred embodiments approximately 25% to about
35% by weight, of the chewing gum. In pellet gum center
formulations, the level of insoluble gum base may be much
higher.
[0064] In a particular embodiment, the chewing gum base of the
present invention contains about 20% to about 60% by weight
synthetic elastomer, about 0% to about 30% by weight natural
elastomer, about 5% to about 55% by weight elastomer plasticizer,
about 4% to about 35% by weight filler, about 5% to about 35% by
weight softener, and optional minor amounts (about 1% or less by
weight) of miscellaneous ingredients such as colorants,
antioxidants, etc.
[0065] Synthetic elastomers may include, but are not limited to,
polyisobutylene with GPC weight average molecular weights of about
10,000 to about 95,000, isobutylene-isoprene copolymer (butyl
elastomer), styrene butadiene, copolymers having styrene-butadiene
ratios of about 1:3 to about 3:1, polyvinyl acetate having GPC
weight average molecular weights of about 2,000 to about 90,000,
polyisoprene, polyethylene, vinyl acetate--vinyl laurate copolymers
having vinyl laurate contents of about 5% to about 50% by weight of
the copolymer, and combinations thereof.
[0066] Preferred ranges are: 50,000 to 80,000 GPC weight average
molecular weight for polyisobutylene; 1:1 to 1:3 bound styrene
butadiene for styrene butadiene; 10,000 to 65,000 GBC weight
average molecular weight for polyvinyl acetate, with the higher
molecular weight polyvinyl acetates typically used in bubble gum
base; and a vinyl laurate content of 10 45% for vinyl acetate vinyl
laurate.
[0067] Natural elastomers may include natural rubber such as smoked
or liquid latex and guayule, as well as natural gums such as
jelutong, lechi caspi, perillo, sorva, massaranduba balata,
massaranduba chocolate, nispero, rosindinha, chicle, gutta hang
kang, and combinations thereof. The preferred synthetic elastomer
and natural elastomer concentrations vary depending on whether the
chewing gum in which the base is used is adhesive or conventional,
bubble gum or regular gum, as discussed below. Preferred natural
elastomers include jelutong, chicle, sorva and massaranduba
balata.
[0068] Elastomer plasticizers may include, but are not limited to,
natural rosin esters such as glycerol esters or partially
hydrogenated rosin, glycerol esters of polymerized rosin, glycerol
esters of partially dimerized rosin, glycerol esters of rosin,
pentaerythritol esters of partially hydrogenated rosin, methyl and
partially hydrogenated methyl esters of rosin, pentaerythritol
esters of rosin; synthetics such as terpene resins derived from
alpha pinene, beta pinene, and/or d-limonene; and any suitable
combinations of the foregoing. The preferred elastomer plasticizers
will also vary depending on the specific application, and on the
type of elastomer which is used.
[0069] Fillers/texturizers may include magnesium and calcium
carbonate, ground limestone, silicate types such as magnesium and
aluminum silicate, clay, alumina, talc, titanium oxide, mono-, di-
and tri calcium phosphate, cellulose polymers, such as wood, and
combinations thereof.
[0070] Softeners/emulsifiers may include tallow, hydrogenated
tallow, hydrogenated and partially hydrogenated vegetable oils,
cocoa butter, glycerol monostearate, glycerol triacetate, lecithin,
mono-, di- and triglycerides, acetylated monoglycerides, fatty
acids (e.g. stearic, palmitic, oleic and linoleic acids), and
combinations thereof.
[0071] Colorants and whiteners may include FD&C type dyes and
lakes, fruit and vegetable extracts, titanium dioxide, and
combinations thereof.
[0072] The base may or may not include wax. An example of a wax
free gum base is disclosed in U.S. Pat. No. 5,286,500, the
disclosure of which is incorporated herein by reference.
[0073] In addition to a water-insoluble gum base portion, a typical
chewing gum composition includes a water-soluble bulk portion and
one or more flavoring agents. The water-soluble portion can include
bulk sweeteners, high-intensity sweeteners, flavoring agents,
softeners, emulsifiers, colors, acidulants, antioxidants, and other
components that provide desired attributes.
[0074] Softeners are added to the chewing gum in order to optimize
the chewability and mouth feel of the gum. The softeners, which are
also known as plasticizers and plasticizing agents, generally
constitute between approximately 0.5% to about 15% by weight of the
chewing gum. The softeners may include glycerin, lecithin, and
combinations thereof. Aqueous sweetener solutions such as those
containing sorbitol, hydrogenated starch hydrolysates, corn syrup
and combinations thereof, may also be used as softeners and binding
agents in chewing gum.
[0075] Bulk sweeteners include both sugar and sugarless components.
Bulk sweeteners typically constitute about 5% to about 95% by
weight of the chewing gum, more typically, about 20% to about 80%
by weight, and more commonly, about 30% to about 60% by weight of
the gum. Sugar sweeteners generally include saccharide-containing
components commonly known in the chewing gum art, including but not
limited to, sucrose, dextrose, maltose, dextrin, dried invert
sugar, fructose, galactose, corn syrup solids, and the like, alone
or in combination. Sugarless sweeteners include, but are not
limited to, sugar alcohols such as sorbitol, mannitol, xylitol,
hydrogenated starch hydrolysates, maltitol, hydrogenated
isomaltulose, and the like, alone or in combination.
[0076] High-intensity artificial sweeteners can also be used, alone
or in combination, with the above. Preferred sweeteners include,
but are not limited to, sucralose, aspartame, N-substituted APM
derivatives such as neotame, salts of acesulfame, alitame,
saccharin and its salts, cyclamic acid and its salts, glycyrrhizin,
dihydrochalcones, thaumatin, monellin, and the like, alone or in
combination. In order to provide longer lasting sweetness and
flavor perception, it may be desirable to encapsulate or otherwise
control the release of at least a portion of the artificial
sweetener. Such techniques as wet granulation, wax granulation,
spray drying, spray chilling, fluid bed coating, coacervation, and
fiber extrusion may be used to achieve the desired release
characteristics.
[0077] Combinations of sugar and/or sugarless sweeteners may be
used in chewing gum. Additionally, the softener may also provide
additional sweetness such as with aqueous sugar or alditol
solutions.
[0078] If a low calorie gum is desired, a low caloric bulking agent
can be used. Examples of low caloric bulking agents include:
polydextrose; oligofructose (Raftilose); inulin (Raftilin);
fructooligosaccharides (NutraFlora); palatinose oligosaccharide;
guar gum hydrolysate (BeneFiber); or indigestible dextrin
(Fibersol). However, other low calorie bulking agents can be
used.
[0079] A variety of flavoring agents can also be used, if desired.
The flavor can be used in amounts of about 0.1 to about 15 weight
percent of the gum, and preferably, about 0.2% to about 5% by
weight. Flavoring agents may include essential oils, synthetic
flavors or mixtures thereof including, but not limited to, oils
derived from plants and fruits such as citrus oils, fruit essences,
peppermint oil, spearmint oil, other mint oils, clove oil, oil of
wintergreen, anise and the like. Artificial flavoring agents and
components may also be used. Natural and artificial flavoring
agents may be combined in any sensorially acceptable fashion.
[0080] In general, chewing gum is manufactured by sequentially
adding the various chewing gum ingredients to a commercially
available mixer known in the art. After the ingredients have been
thoroughly mixed, the gum mass is discharged from the mixer and
shaped into the desired form such as rolling sheets and cutting
into sticks, extruding into chunks or casting into pellets, which
are then coated or panned.
[0081] Generally, the ingredients are mixed by first melting the
gum base and adding it to the running mixer. The base may also be
melted in the mixer itself. Color or emulsifiers may also be added
at this time. A softener such as glycerin may also be added at this
time, along with syrup and a portion of the bulking agent. Further
parts of the bulking agent are added to the mixer. Flavoring agents
are typically added with the final portion of the bulking agent.
Other optional ingredients are added to the batch in a typical
fashion, well known to those of ordinary skill in the art.
[0082] The entire mixing procedure typically takes from five to
fifteen minutes, but longer mixing times may sometimes be required.
Those skilled in the art will recognize that many variations of the
above described procedure may be followed.
[0083] After the ingredients are mixed, the gum mass is formed into
pellets or balls. Pellet or ball gum is prepared as conventional
chewing gum but formed into pellets that are pillow shaped, or into
balls. The pellets/balls are used as cores for the coated product.
The cores can be sugar or polyol coated or panned by conventional
panning techniques to make a unique coated pellet gum. The weight
of the coating may be about 20% to about 50% of the weight of the
finished product, but may be as much as 75% of the total gum
product.
[0084] Conventional panning procedures generally coat with sucrose,
but recent advances in panning have allowed use of other
carbohydrate materials to be used in place of sucrose. Some of
these components include, but are not limited to, sugars such as
dextrose, maltose and palatinose; or sugarless bulk sweeteners such
as xylitol, sorbitol, hydrogenated isomaltulose, erythritol,
lactitol, maltitol, and other new polyols (also referred to as
alditols) or combinations thereof. The coating may thus be a sugar
coating or sugarless. These materials may be blended with panning
modifiers including, but not limited to, gum arabic, maltodextrins,
corn syrup, gelatin, cellulose type materials like carboxymethyl
cellulose or hydroxymethyl cellulose, starch and modified starches,
vegetables gums like alginates, locust bean gum, guar gum, and gum
tragacanth, insoluble carbonates like calcium carbonate or
magnesium carbonate and talc. Antitack agents may also be added as
panning modifiers, which allow the use of a variety of
carbohydrates and sugar alcohols to be used in the development of
new panned or coated gum products. Flavors may also be added with
the sugar or sugarless coating to yield unique product
characteristics.
[0085] As noted above, the coating may contain ingredients such as
flavoring agents, as well as dispersing agents, coloring agents,
film formers and binding agents. Flavoring agents contemplated by
the present invention include those commonly known in the art such
as essential oils, synthetic flavors or mixtures thereof, including
but not limited to oils derived from plants and fruits such as
citrus oils, fruit essences, peppermint oil, spearmint oil, other
mint oils, clove oil, oil of wintergreen, anise and the like. The
flavoring agents may be used in an amount such that the coating
will contain from about 0.2% to about 3% flavoring agent, and
preferably from about 0.7% to about 2.0% flavoring agent.
[0086] High-intensity sweeteners contemplated for use in the
coating include but are not limited to synthetic substances,
saccharin, thaumatin, alitame, saccharin salts, aspartame, and N
substituted APM derivatives such as neotame, sucralose and
acesulfame-K. The high-intensity sweetener may be added to the
coating syrup in an amount such that the coating will contain from
about 0.01% to about 2.0%, and preferably from about 0.1% to about
1.0% high-intensity sweetener. Preferably the high-intensity
sweetener is not encapsulated.
[0087] Dispersing agents are often added to syrup coatings for the
purpose of whitening and tack reduction. Dispersing agents
contemplated by the present invention to be employed in the coating
syrup include titanium dioxide, talc, or any other antistick
compound. Titanium dioxide is a presently preferred dispersing
agent of the present invention. The dispersing agent may be added
to the coating syrup in amounts such that the coating will contain
from about 0.1% to about 1.0%, and preferably from about 0.3% to
about 0.6% of the agent.
[0088] Coloring agents are preferably added directly to the syrup
in the dye or lake form. Coloring agents contemplated by the
present invention include food quality dyes. Film formers
preferably added to the syrup include methyl cellulose, gelatins,
hydroxypropyl cellulose, ethyl cellulose, hydroxyethyl cellulose,
carboxymethyl cellulose and the like and combinations thereof.
Binding agents may be added either as an initial coating on the
chewing gum center or may be added directly into the syrup. Binding
agents contemplated by the present invention include gum arabic,
gum talha (another type of acacia), alginate, cellulosics,
vegetable gums and the like, and used at a level of about 1% to
about 12% of the coating.
[0089] The coating is initially present as a liquid syrup which
contains from about 30% to about 80% or 85% of the coating
ingredients previously described herein, and from about 15% or 20%
to about 70% of a solvent such as water. In general, the coating
process is carried out in a rotating pan. Sugar or sugarless gum
center tablets to be coated are placed into the rotating pan to
form a moving mass.
[0090] The material or syrup which will eventually form the coating
is applied or distributed over the gum center tablets. Flavoring
agents may be added before, during and after applying the syrup to
the gum centers. Once the coating has dried to form a hard surface,
additional syrup additions can be made to produce a plurality of
coatings or multiple layers of hard coating.
[0091] In a hard coating panning procedure, syrup is added to the
gum center tablets at a temperature range of from about 100.degree.
F. (38.degree. C.) to about 240.degree. F. (116.degree. C.).
Preferably, the syrup temperature is from about 130.degree. F.
(54.degree. C.) to about 200.degree. F. (94.degree. C.) throughout
the process in order to prevent the polyol or sugar in the syrup
from crystallizing. The syrup may be mixed with, sprayed upon,
poured over, or added to the gum center tablets in any way known to
those skilled in the art.
[0092] In general, a plurality of layers is obtained by applying
single coats, allowing the layers to dry, and then repeating the
process. The amount of solids added by each coating step depends
chiefly on the concentration of the coating syrup. Any number of
coats may be applied to the gum center tablet. Preferably, no more
than about 75-100 coats are applied to the gum center tablets. The
preferred embodiments of the invention contemplates applying an
amount of syrup sufficient to yield a coated comestible containing
about 10% to about 65% coating.
[0093] Those skilled in the art will recognize that in order to
obtain a plurality of coated layers, a plurality of premeasured
aliquots of coating syrup may be applied to the gum center tablets.
It is contemplated, however, that the volume of aliquots of syrup
applied to the gum center tablets may vary throughout the coating
procedure.
[0094] Once a coating of syrup is applied to the gum center
tablets, the present invention contemplates drying the wet syrup in
an inert medium. A preferred drying medium comprises air.
Preferably, forced drying air contacts the wet syrup coating in a
temperature range of from about 70.degree. F. (21.degree. C.) to
about 115.degree. F. (46.degree. C.). More preferably, the drying
air is in the temperature range of from about 80.degree. F.
(27.degree. C.) to about 100.degree. F. (38.degree. C.). The
invention also contemplates that the drying air possesses a
relative humidity of less than about 15 percent. Preferably, the
relative humidity of the drying air is less than about 8
percent.
[0095] The drying air may be passed over and admixed with the syrup
coated gum centers in any way commonly known in the art.
Preferably, the drying air is blown over and around or through the
bed of the syrup coated gum centers at a flow rate, for large scale
operations, of about 2800 cubic feet per minute. If lower
quantities of material are being processed, or if smaller equipment
is used, lower flow rates would be used.
[0096] The present invention also contemplates the application of
powder material after applying an aliquot of coating syrup to help
build up the coating.
[0097] For many years, flavors have been added to a sugar coating
of pellet gum to enhance the overall flavor of gum. These flavors
include spearmint flavor, peppermint flavor, wintergreen flavor,
and fruit flavors. These flavors are generally preblended with the
coating syrup just prior to applying it to the cores or added
together to the cores in one or more coating applications in a
revolving pan containing the cores. Generally, the coating syrup is
very hot, about 130.degree. F. (54.degree. C.) to 200.degree. F.
(93.degree. C.), and the flavor may volatilize if preblended with
the coating syrup too early.
[0098] The coating syrup is preferably applied to the gum cores as
a hot liquid, the sugar or polyol allowed to crystallize, a dry
charge added and the coating then dried with warm, dry air.
Aliquots of syrups are preferably applied in about 30 to 80
applications to obtain a hard shell coated product having an
increased weight gain of about 25% to 75%. A flavor is applied with
one, two, three or even four or more of these coating applications.
Each time flavor is added, several non-flavored coatings are
applied to cover the flavor before the next flavor coat is applied.
This reduces volatilization of the flavor during the coating
process. Dry charge is not used when flavor is applied.
[0099] For mint flavors such spearmint, peppermint and wintergreen,
some of the flavor components are volatilized, but sufficient
flavor remains to give a product having a strong, high impact
flavor. Fruit flavors, that may contain esters, are more easily
volatilized and may be flammable and/or explosive and therefore,
generally these types of fruit flavors are not used in
coatings.
EXAMPLES
Examples 1 and 2
[0100] The following gum formula was made in production equipment
to prepare chewing gum cores for coating:
TABLE-US-00001 Example 1 Example 2 Ingredients in Gum Center Gum
base 30.0% 30.0% Calcium carbonate 14.9% 14.9% Sorbitol 43.3% 43.7%
Glycerin 3.8% 3.8% Sodium polyphosphate 2.0% 2.0% Spearmint flavor
3.0% -- Peppermint flavor -- 2.6% Water 1.0% 1.0% Encapsulated
intense 1.9% 1.9% sweeteners Free aspartame 0.1% 0.1% Total 100.0%
100.0% Ingredients in Coating Center weight 1250 Kg 1250 Kg Coating
weight 660.5 Kg 660.5 Kg Maltitol in syrup form 78.3% 76.2%
Maltitol in powder form 12.2% 12.4% Gum arabic 6.9% 8.2% Spearmint
flavor 1.0% -- Peppermint flavor -- 1.3% Titanium dioxide 0.6% 1.0%
Free aspartame 0.5% 0.5% Green speckles 0.3% -- Blue speckles --
0.2% Carnauba wax 0.1% 0.1% Talc 0.1% 0.1% Total 100.0% 100.0%
[0101] Gum centers were made by conventional manufacturing
processes and formed into 1 gram pillow shaped pellets for coating.
Gum arabic was dissolved in water prior to being added to all of
the coating syrup. In addition, titanium dioxide was dispersed in
water before being added to the coating syrup. Free aspartame was
also added to the coating syrup. Powdered maltitol was added as a
dry charge after each of the first 10 coating applications. The dry
charge was not used during flavor applications. Flavor was applied
in the middle of the coating process. One fourth of the flavor was
applied after each of four syrup applications (half of regular size
applications) and several applications of syrup were applied
between the flavor applications. Another about 10 syrup
applications were made to bring the piece to size. Then smoothing
syrups were used in the last few coats. After the last coating
syrup was applied and before it dried, the green (Example 1) or
blue (Example 2) speckles were added. After the speckles were added
and the last coating application was dried, the wax and talc was
added to polish the products. The total piece weight was 1.52 grams
having a 34.2% coating.
Example 3
TABLE-US-00002 [0102] Ingredients in Gum Center Gum base 33.0%
Calcium carbonate 13.0% Sorbitol 45.2% Glycerin 3.0% Sodium
polyphosphate 2.0% Peppermint flavor 1.7% Color 1.0% Lecithin 0.25%
Encapsulated sweeteners 0.7% Xylitol 0.1% Free aspartame 0.05%
Total 100.0 Coating Level Weight of centers 1250 Kg Weight of
coating 601 Kg Ingredients in Coating Xylitol 88.1% Gum arabic 9.1%
Titanium dioxide 0.8% Peppermint flavor 1.2% Free aspartame 0.3%
Blue speckles 0.3% Talc 0.1% Carnauba wax 0.1% Total 100.0
[0103] Gum centers were made by conventional manufacturing
processes and formed into 1 gram pillow shaped pellets for coating.
Gum arabic was dissolved in water prior to being added to all of
the coating syrup. In addition, titanium dioxide was dispersed in
water before being added to the coating syrup. Free aspartame was
also added to the coating syrup. Flavor was applied in the middle
of the coating process. One fourth of the flavor was applied after
each of four syrup applications (half of regular size applications)
and several applications of syrup were applied between the flavor
applications. About 10 more syrup applications were made to bring
the piece to size, and then smoothing syrups were used in the last
few applications. After the last coating syrup was applied and
before it dried, the blue speckles were added. After the speckles
were added and the last coating application was dried, the wax and
talc was added to polish the products. The total piece weight was
1.52 grams having a 34.2% coating.
[0104] If an automated system using the equipment of FIGS. 1-6 were
used with Example 3, the system might be set up such that after a
30 second spray of the last syrup coating, a 12 second pause
occurs. Then the air supply to the venturi eductors is started, and
2 seconds later the vibratory pan is started, each of these items
being automatically started by the controller where the coating
process is programmed. About 40 seconds after the vibratory pan is
started, speckle particulates begin to flow into the venturi
eductors and are immediately conveyed to the distributors inside
the coating drum, where the air sprays out the end of the hose and
the speckle particulates are deflected by the conical deflectors to
spray out over the bed of tumbling cores. It may take 204 seconds
for the speckle application to be completed. A 4.5 minute drying
time follows, using a 4 rpm pan speed, and 8475 cubic feet/minute
of 75.degree. F. direct flow air.
[0105] The present invention makes it possible to commercially
produce large batches of speckled coated comestible products with a
uniform number of speckles on each product within the batch, as
well as good batch-to-batch consistency. As a result, a company
making such products can sell speckled products with good
uniformity of speckle distribution from one product to the next,
evidencing a high product quality.
[0106] If particulate materials other than speckle particulates are
being applied, or if the speckle particulates are not soluble in
the coating syrup, it may not be necessary to apply the
particulates after the last aliquot of coating syrup is applied.
Instead, the apparatus and method of the present invention will
allow the uniform application of particulate materials between
applications of coating syrup other than after the last
application, or between more than one different applications of
coating syrup in the process of applying a coating to a single
batch of cores.
[0107] It should be appreciated that the methods of the present
invention are capable of being incorporated in the form of a
variety of embodiments, only a few of which have been illustrated
and described above. For example, it can easily be seen that other
particulates could be added to a comestible core using the present
invention. Further, in an earlier embodiment, the vibratory pan 40
was not equipped with dividers and separate lanes. The separation
of particulates into portions occurred as the particulates fell off
the end of the pan into collection tubes feeding the venturi
eductors. In that instance, one plate that could be adjusted in
height from one side to the other was used to get an even
distribution of speckle particulates over the width of the
vibrating pan, instead of individual strips 49 associated with each
lane. Separate screw feeders could be used to provide an equal
supply of speckle particulates over a desired time to each
distributor within the coating apparatus. Another embodiment would
be a long tube that holds the particulate material with either one
continuous or many multiple holes in the tube, covered with a
screen to produce a "salt shaker" effect. The speckles would be
loaded in the tube, which would then be placed right-side-up in the
coating apparatus. At the appropriate time the tube would be
rotated so that the holes were on the bottom and shaken, causing
the speckle particulates to be evenly distributed over the tumbling
cores over a period of time.
[0108] All of the preferred embodiments relate to any or all of the
independently claimed processes and apparatus, taken either singly
or in combination. The invention may be embodied in other forms
without departing from its spirit or essential characteristics. The
described embodiments are to be considered in all respects only as
illustrative and not restrictive, and the scope of the invention,
therefore, indicated by the appended claims rather than by the
foregoing description. All changes that come within the meaning and
range of equivalency of the claims are to be embraced within their
scope.
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