U.S. patent application number 17/313436 was filed with the patent office on 2021-09-09 for chewing gum manufacture.
The applicant listed for this patent is WM. WRIGLEY JR. COMPANY. Invention is credited to Mariano V. ARTIAGA, Scott G. BROWN, Martin R. CERVENKA, Dennis W. RYBOLT.
Application Number | 20210274803 17/313436 |
Document ID | / |
Family ID | 1000005568558 |
Filed Date | 2021-09-09 |
United States Patent
Application |
20210274803 |
Kind Code |
A1 |
CERVENKA; Martin R. ; et
al. |
September 9, 2021 |
CHEWING GUM MANUFACTURE
Abstract
A chewing gum sheet is formed without substantial use of a
powdered non-stick agent by extruding a slab having a tacky surface
of heated chewing gum composition onto a moving conveyor; cooling
the slab on the conveyor sufficiently to cool the surface of the
slab; and passing the slab from the conveyor through at least one
cooled roller to form a chewing gum sheet with predetermined
dimensions.
Inventors: |
CERVENKA; Martin R.;
(Chicago, IL) ; RYBOLT; Dennis W.; (Beecher,
IL) ; BROWN; Scott G.; (Oswego, IL) ; ARTIAGA;
Mariano V.; (Barrington, IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
WM. WRIGLEY JR. COMPANY |
Chicago |
IL |
US |
|
|
Family ID: |
1000005568558 |
Appl. No.: |
17/313436 |
Filed: |
May 6, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14739778 |
Jun 15, 2015 |
11006653 |
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17313436 |
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12988278 |
Nov 19, 2010 |
9055754 |
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PCT/US2009/002406 |
Apr 17, 2009 |
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14739778 |
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61046249 |
Apr 18, 2008 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B29L 2007/002 20130101;
B29C 48/08 20190201; A23G 4/04 20130101; A23G 7/0093 20130101; A23G
4/02 20130101 |
International
Class: |
A23G 4/02 20060101
A23G004/02; B29C 48/08 20060101 B29C048/08; A23G 4/04 20060101
A23G004/04; A23G 7/00 20060101 A23G007/00 |
Claims
1. An apparatus for producing a chewing gum sheet without
substantial use of a powdered non-stick agent, the apparatus
comprising: a. an extruder for extruding a chewing gum mass into a
slab having a tacky surface of heated chewing gum composition; b. a
conveyor for receiving the chewing gum slab; c. an impingement air
flow system for cooling the chewing gum slab upon the conveyor,
wherein the cooled chewing gum slab comprises a center having a
center temperature and wherein the surface temperature of the
cooled chewing gum slab is less than the center temperature,
thereby creating a temperature differential, wherein the
temperature differential is between about 4.degree. F. to
19.degree. F.; d. a forming unit, wherein the temperature
differential is maintained through passing the forming unit; and e.
at least one cooled calender roller with less than or equal to 0.18
weight % non-stick agent based on the slab weight for receiving the
cooled chewing gum slab from the conveyor and forming a chewing gum
sheet with predetermined dimensions, wherein the at least one
cooled calender roller is in a temperature and humidity controlled
environment, and wherein the environmental air around the at least
one cooled calender roller has a dew point above the temperature of
the at least one cooled calender roller.
2. The apparatus of claim 1 in which the impingement air flow
system is for cooling the top and bottom surfaces of the chewing
gum slab.
3. The apparatus of claim 1 further comprising at least one scoring
roller.
4. The apparatus of claim 3 in which the scoring roller scores the
chewing gum sheet laterally and/or longitudinally.
5. The apparatus of claim 1 further comprising a conveyor for
receiving the chewing gum sheet and an impingement air flow system
for cooling the chewing gum sheet upon the conveyor.
6. The apparatus of claim 5 wherein the conveyor is a multi-tier
conveyor.
7. The apparatus of claim 1 further comprising an applicator for
applying non-stick agent to the chewing gum sheet.
8. The apparatus of claim 7 further comprising a tray system for
stacking the chewing gum sheets.
9. The apparatus of claim 1 further comprising a coating system for
separating the chewing gum sheets into individual pieces and
coating the individual pieces.
10. A system for producing chewing gum pieces without substantial
use of a powdered non-stick agent, the system comprising: a. a
mixer for producing a chewing gum mass; b. an extruder for
extruding the chewing gum mass into a slab having a tacky surface
of heated chewing gum composition; c. an impingement air flow
system for cooling the chewing gum slab, wherein the cooled chewing
gum slab comprises a center having a center temperature, wherein
the surface temperature of the cooled chewing gum slab is less than
the center temperature, thereby creating a temperature
differential, and wherein the temperature differential is between
about 4.degree. F. to 19.degree. F.; d. a cooled forming and
scoring unit for manipulating the slab into a chewing gum sheet
with lateral and/or longitudinal scores, wherein the cooled forming
and scoring unit comprises at least one cooled calender roller with
less than or equal to 0.18 weight % non-stick agent based on the
slab weight, wherein the at least one cooled calender roller is in
a temperature and humidity controlled environment, wherein the
environmental air around the at least one cooled calender roller
has a dew point above the temperature of the at least one cooled
calender roller, and wherein the temperature differential is
maintained through passing the cooled forming and scoring unit; and
e. a cooled conveying system for receiving the chewing gum sheet
and cooling the surface of the chewing gum.
11. The system of claim 10 further comprising a cooled conveying
system receiving the chewing gum slab from the extruder and cooling
the surface of the chewing gum.
12. The system of claim 10 wherein the slab is a ribbon.
13. An apparatus for producing a chewing gum sheet without
substantial use of a powdered non-stick agent, the apparatus
comprising: a. an extruder for extruding a chewing gum mass into a
slab having a tacky surface of heated chewing gum composition; b. a
conveyor for receiving the chewing gum slab; c. an impingement air
flow system for cooling the chewing gum slab upon the conveyor; d.
at least one cooled calender roller for receiving the chewing gum
slab from the conveyor and forming a chewing gum sheet with
predetermined dimensions, wherein the at least one cooled calender
roller is in a temperature and humidity controlled environment,
wherein the environmental air around the at least one cooled
calender roller has a dew point above the temperature of the at
least one cooled calender roller, and wherein the at least one
cooled calender roller is maintained at a temperature of from
5.degree. F. to 32.degree. F.; and e. at least one scoring roller
with 0.18 weight % non-stick agent based on the slab weight.
14. The apparatus of claim 13 in which the scoring roller scores
the chewing gum sheet laterally and/or longitudinally.
15. The apparatus of claim 13 further comprising a conveyor for
receiving the chewing gum sheet and an impingement air flow system
for cooling the chewing gum sheet upon the conveyor.
16. The apparatus of claim 15 wherein the conveyor is a multi-tier
conveyor.
17. The apparatus of claim 13 further comprising an applicator for
applying non-stick agent to the chewing gum sheet.
18. The apparatus of claim 17 further comprising a tray system for
stacking the chewing gum sheets.
19. The apparatus of claim 13 further comprising a coating system
for separating the chewing gum sheets into individual pieces and
coating the individual pieces.
20. A system for producing chewing gum pieces without substantial
use of a powdered non-stick agent, the system comprising: a. a
mixer for producing a chewing gum mass; b. an extruder for
extruding the chewing gum mass into a slab having a tacky surface
of heated chewing gum composition; c. a cooled forming and scoring
unit for manipulating the slab into a chewing gum sheet with
lateral and/or longitudinal scores, wherein the cooled forming and
scoring unit comprises at least one cooled calender roller for
forming the chewing gum sheet and at least one scoring roller with
0.18 weight % non-stick agent based on the slab weight, wherein the
at least one cooled calender roller is in a temperature and
humidity controlled environment, wherein the environmental air
around the at least one cooled calender roller has a dew point
above the temperature of the at least one cooled calender roller,
wherein the at least one cooled calender roller is maintained at a
temperature of from 5.degree. F. to 32.degree. F., and wherein the
at least one cooled calender roller has a temperature below
freezing temperature, and wherein ice is on the at least one cooled
calender roller; and d. a cooled conveying system for receiving the
chewing gum sheet and cooling the surface of the chewing gum.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application claiming
priority under 35 U.S.C. .sctn. 120 to co-pending U.S. application
Ser. No. 14/739,778, filed Jun. 15, 2015, which is a continuation
of U.S. application Ser. No. 12/988,278, filed Oct. 15, 2010, which
is a 35 U.S.C. .sctn. 371 national stage application of
PCT/US2009/002406, filed Apr. 17, 2009, and additionally claims
benefit to U.S. Provisional Application No. 61/046,249, filed Apr.
18, 2008, all of which are incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] This invention relates to manufacture of a confectionery
material having a tacky surface such as chewing gum and more
particularly relates to a process and apparatus for manufacture of
chewing gum without substantial use of a rolling compound or
powdered non-stick agent.
[0003] Chewing gum, commercially distributed as pieces such as
sticks, tabs or pillows and which may be coated or filled,
typically is produced by combining chewing gum components including
a gum base, flavors, sweeteners, fillers, and binders; extruding
such combined components into a slab of typically tacky gum
composition material; rolling such slab into a uniform flat sheet
of a desired thickness and width; scoring the uniform flat sheet
into individual pieces; and ultimately packaging the resulting
pieces. During processing, the extruded slab of chewing gum
material must pass through a series of calender and scoring rollers
to produce the ultimate product. In a conventional process, a
rolling compound or powdered non-stick agent must be applied to the
sheet during processing to avoid sticking or fouling of the rollers
by a tacky gum material.
[0004] Use of extensive amounts of a rolling compound or powdered
non-stick agent may cause manufacturing difficulties in controlling
powdered material in the atmosphere, adds to manufacturing cost,
creates difficulties in handling, increases processing time, may
increase volatization of flavors and may create a porous
non-uniform outer surface. A process which could substantially
reduce or eliminate the need to use a rolling compound or powdered
non-stick agent in a gum manufacturing process would be an
improvement in the art.
SUMMARY
[0005] A chewing gum sheet is formed without substantial use of a
powdered non-stick agent by extruding a slab having a tacky surface
of heated chewing gum composition onto a moving conveyor; cooling
the slab on the conveyor sufficiently to cool the surface of the
slab; and passing the slab from the conveyor through at least one
cooled roller to form a chewing gum sheet with predetermined
dimensions.
[0006] According to one aspect, the present disclosure is directed
to an apparatus for producing a chewing gum sheet without
substantial use of a powdered non-stick agent. The apparatus
includes an extruder for extruding the chewing gum mass into a slab
having a tacky surface of heated chewing gum composition, a
conveyor for receiving the chewing gum slab, an impingement air
flow system for cooling the chewing gum slab upon the conveyor,
wherein the cooled chewing gum slab comprises a center having a
center temperature and wherein the surface temperature of the
cooled chewing gum slab is less than the center temperature,
thereby creating a temperature differential, wherein the
temperature differential is between about 4.degree. F. to
19.degree. F., a forming unit, wherein the temperature differential
is maintained through passing the forming unit, and at least one
cooled roller with less than or equal to 0.18 weight % non-stick
agent based on the slab weight for receiving the cooled chewing gum
slab from the conveyor and forming the chewing gum sheet with
predetermined dimensions, wherein the at least one cooled calender
roller is in a temperature and humidity controlled environment, and
wherein the environmental air around the at least one cooled
calender roller has a dew point above the temperature of the at
least one cooled calender roller.
[0007] In accordance with another aspect, the present disclosure is
directed to a system for producing chewing gum pieces without
substantial use of a powdered non-stick agent. The system includes
a mixer for producing a chewing gum mass, an extruder for extruding
the chewing gum mass into a slab having a tacky surface of heated
chewing gum composition, an impingement air flow system for cooling
the chewing gum slab, wherein the cooled chewing gum slab comprises
a center having a center temperature, wherein the surface
temperature of the cooled chewing gum slab is less than the center
temperature, thereby creating a temperature differential, and
wherein the temperature differential is between about 4.degree. F.
to 19.degree. F., a cooled forming and scoring unit for
manipulating the slab into a chewing gum sheet with lateral and/or
longitudinal scores, wherein the cooled forming and scoring unit
comprises at least one cooled calender roller with less than or
equal to 0.18 weight % non-stick agent based on the slab weight,
wherein the at least one cooled calender roller is in a temperature
and humidity controlled environment, wherein the environmental air
around the at least one cooled calender roller has a dew point
above the temperature of the at least one cooled calender roller,
and wherein the temperature differential is maintained through
passing the cooled forming and scoring unit, and a cooled conveying
system for receiving the chewing gum sheet and cooling the surface
of the chewing gum.
[0008] In accordance with still another aspect, the present
disclosure is directed to an apparatus for producing a chewing gum
sheet without substantial use of a powdered non-stick agent. The
apparatus includes an extruder for extruding a chewing gum mass
into a slab having a tacky surface of heated chewing gum
composition, a conveyor for receiving the chewing gum slab, an
impingement air flow system for cooling the chewing gum slab upon
the conveyor, at least one cooled calender roller for receiving the
chewing gum slab from the conveyor and forming a chewing gum sheet
with predetermined dimensions, wherein the at least one cooled
calender roller is in a temperature and humidity controlled
environment, wherein the environmental air around the at least one
cooled calender roller has a dew point above the temperature of the
at least one cooled calender roller, and wherein the at least one
cooled calender roller is maintained at a temperature of from
5.degree. F. to 32.degree. F., and at least one scoring roller with
0.18 weight % non-stick agent based on the slab weight.
[0009] In accordance with still another aspect, the present
disclosure is directed to a system for producing chewing gum pieces
without substantial use of a powdered non-stick agent. The system
includes a mixer for producing a chewing gum mass, an extruder for
extruding the chewing gum mass into a slab having a tacky surface
of heated chewing gum composition, a cooled forming and scoring
unit for manipulating the slab into a chewing gum sheet with
lateral and/or longitudinal scores, wherein the cooled forming and
scoring unit comprises at least one cooled calender roller for
forming the chewing gum sheet and at least one scoring roller with
0.18 weight % non-stick agent based on the slab weight, wherein the
at least one cooled calender roller is in a temperature and
humidity controlled environment, wherein the environmental air
around the at least one cooled calender roller has a dew point
above the temperature of the at least one cooled calender roller,
wherein the at least one cooled calender roller is maintained at a
temperature of from 5.degree. F. to 32.degree. F., and wherein the
at least one cooled calender roller has a temperature below
freezing temperature, and wherein ice is on the at least one cooled
calender roller, and a cooled conveying system for receiving the
chewing gum sheet and cooling the surface of the chewing gum.
BRIEF DESCRIPTION OF THE DRAWING
[0010] FIG. 1 is a schematic view of a manufacturing process
according to this invention utilizing a chewing gum piece
coater.
[0011] FIG. 2 is a view of a chilled calender roller as used in
this invention.
[0012] FIG. 3 is a view of an alternate chilled roller as used in
this invention.
[0013] FIG. 4 is a schematic view of a forming process according to
this invention.
[0014] FIG. 5 is a schematic view of a manufacturing process
according to this invention illustrating trays for collecting
sheets of chewing gum.
[0015] FIG. 6 is a schematic view of a manufacturing process
according to this invention illustrating a single tier post-cooling
unit.
[0016] FIG. 7 is a schematic view of a manufacturing process
according to this invention illustrating trays for collecting
sheets of chewing gum for transport directly to a tempering
room.
[0017] FIG. 8 is a schematic view of a manufacturing process
according to this invention utilizing a forming unit without
pre-scoring cooling or post-scoring cooling.
DESCRIPTION OF THE INVENTION
[0018] In a process, apparatus, and system of this invention, a
slab or sheet of a confectionery material having a tacky surface,
such as a chewing gum material, is processed through forming,
rolling, and scoring without substantial use of a rolling compound
or powdered non-stick agent. Typically, a confectionery material
having a tacky surface under processing conditions is manufactured
as a rolled sheet having a set or predetermined thickness and
width. From such rolled sheet, portions may be separated and
packaged for commercial sale.
[0019] The confectionery material may be any hard candy, soft
candy, chewing gum, or other confectionery substance, or compound
that has a fluid phase or may take a flowable form. In other words,
the confectionery material may be any material that may be heated,
melted, or dissolved to form a syrup, or be dissolved in a liquid
to become flowable as is commonly known in the art. Nonlimiting
examples of suitable confectionery materials that are flowable or
may be placed into a flowable state include syrups, liquids or
solids for making hard candies, soft candies, lollipops, fondants,
toffees, jellies, chewing gums, chocolates, gelatins and nougats.
The confectionery material may include sugar or may be sugar-free.
Coloring may be added to the confectionery substrate as desired.
The confectionery material may also include a pharmaceutical
product or a medicament.
[0020] The preferred confectionery produced according to this
invention is a chewing gum. Typically, a chewing gum material
suitable for use in the process of this invention is composed of a
gum base, flavorings, and sweeteners and may contain other
components such as fillers and binders. Because of the viscoelastic
characteristics of chewing gum materials, these materials are
formed at elevated (above room or ambient) temperatures into sheets
and pieces suitable for commercial sale. Further, chewing gums
having desirable characteristics such as, but not limited to,
flavor release, elasticity, soft texture, typically have a tacky
surface at processing temperature conditions. In order to process
such tacky materials through processing equipment such as rollers,
a powdered non-stick agent (sometimes referred to as a rolling
compound) is applied to prevent the rolled gum mass from sticking
to processing equipment. This is similar to using flour as a
non-stick agent in rolling pie or cookie dough.
[0021] In an embodiment, chewing gum is manufactured in a process
substantially without a non-stick agent. In such process, the
chewing gum is produced, extruded and scored laterally and
longitudinally substantially without application of a non-stick
agent. As referred to herein, "non-stick agent" includes sugar,
sugar alcohols, calcium carbonate, oil and other particulates or
lubricants specifically applied to the surface of chewing gum to
prevent sticking of the chewing gum to processing machinery such as
conveyors, glide plates, and rollers. Typically, the non-stick
agent is in powder form. As further referred to herein, "without
substantial use of a non-stick agent" means less than or equal to
0.18 weight % non-stick agent based upon the slab weight which
exits an extruder.
[0022] In an embodiment of this invention, a chewing gum surface is
cooled to reduce tackiness. The surface may be cooled using chilled
rollers, air, or other cooling apparatus. In an embodiment of this
invention, the surface temperature of gum material exiting a slab
extruder is lowered prior to passing through chilled rollers by
using air or other gas directed to strike the surface of such
material to transfer heat away from the gum material. This type of
air typically is referred to as "impingement air" and preferably
streams of such impingement air are directed at both surfaces of a
moving slab or sheet of gum material during processing.
[0023] The term "tacky" or "tacky surface" refers to a property of
a confectionery such as a chewing gum material in which the surface
of such material is adhesive or gummy to the touch such that
portions of such material will tend to adhere to each other or to
processing equipment parts such as rollers, and "substantial
adhesion" means a condition in which such material joins to
processing equipment parts to an extent that requires stoppage or
interruption in processing, which is referred to as "downtime."
[0024] The term "rollers" includes scoring rollers, calender
rollers, embossing rollers, and other rollers which typically are
rolling cylinders which contact a gum material and function to
form, shape, flatten, score, cut, conduct heat, emboss, otherwise
process, or provide movement to a slab or sheet of such material.
"Scoring rollers" includes circular scoring rollers which score
(e.g., place an indentation into gum material) or cut the chewing
gum longitudinally, cross scoring rollers which score or cut the
chewing gum laterally or forming rollers which score or cut a
chewing gum laterally and longitudinally. "Calender rollers"
(sometimes referred to as "calender rolls") includes rollers which
contact the surface of the chewing gum typically without scoring or
cutting and include rollers which may reduce the thickness of the
chewing gum, reduce surface imperfections upon the chewing gum,
provide embossing, and contact the surface of the chewing gum to
impart heat transfer. "Forming rollers" may include calender
rollers, scoring rollers, embossing rollers, and the like, which
shape or process a gum sheet. The term "rollers" also includes
systems comprising two rollers, a roller and a conveyor, a roller
and a glide plate, and other systems which affect the chewing gum
surface through scoring, cutting, surface thickness or imparting
heat transfer using at least one rotating cylinder. Rollers may
have a non-stick surface coating such as polytetrafluoroethylene
(such as sold under the Teflon.RTM. brand) or polished stainless
steel.
[0025] The terms "chilled rollers" or "cooled rollers" refer to
rollers which have had their surface temperature lowered below
ambient temperature. In an embodiment, the surface temperature is
lowered by circulating coolant liquid through or within the roller.
Typical coolant materials include propylene glycol, ethylene
glycol, and aqueous solutions thereof and salt-containing solutions
such as saline solutions. The temperature of the chilled rollers
typically is below the temperature of the surface of the chewing
gum during processing and may be well below the freezing point of
water. The rollers are cooled sufficiently to maintain the surface
of a chewing gum slab or sheet in a cooled state during the time of
contact between the roller and the slab or sheet as to not require
substantial (and preferably no) powdered non-stick agent.
Typically, the surface of the chilled roller is maintained at a
temperature below 0.degree. C. (32.degree. F.), preferably below
-5.degree. C. (23.degree. F.) and more preferably below -7.degree.
C. (19.degree. F.). The chilled roller should be at a temperature
low enough to have non-stick properties but not so cold as to make
the sheet brittle or otherwise unworkable. The surface of the
chilled roller is typically above -15.degree. C. (5.degree. F.),
preferably above -10.degree. C. (14.degree. F.) and more preferably
above -9.degree. C. (16.degree. F.).
[0026] Typically, the dew point of the air surrounding the chilled
rollers used in this invention is controlled to prevent water
condensation on the chilled rollers.
[0027] The slab of chewing gum composition, which exits an
extruder, is cooled, typically with impingement air, such that
preferably both surfaces of the slab are cooled with respect to the
interior of the slab. A warm center will tend to reheat the surface
without further surface cooling and will produce a slab which is
sufficiently flexible and formable to permit further processing. A
totally cooled slab would be less flexible and more difficult to
process through calender or scoring rollers.
[0028] The slab of extruded chewing gum composition (which is
heated to a temperature consistent with extrusion) is transferred
from an extruder onto a moving conveyor, which functions to
transport the slab to forming rollers. Although typically the slab
passes directly from the extruder exit onto the moving conveyor,
chilled forming rollers may be inserted between the extruder and
the conveyor. Typically, the conveyor is an open web or mesh such
that contact between a heated slab and the typically metallic (such
as stainless steel) conveyor is minimized and the ability for air
flow on both surfaces of the slab is maximized. A typical conveyor
is a continuous roll of an open mesh which moves over transport
rollers. The length of the conveyor is designed to be sufficient
for the surface of the transported slab to be sufficiently cooled
to subsequently pass through a first cooled calender roller.
[0029] In accordance with this invention, the surfaces of the slab
of chewing gum composition are cooled as the slab is conveyed from
the extruder to a series of cooled forming rollers. Typically, the
surfaces are cooled by contact with impingement air directed from
air jets positions above and below the conveyor. Although the
preferable system is for the conveyor to be constructed as a mesh
or open web in order to facilitate impingement air directed at both
surfaces, other systems are possible such as using a cooled
conveyor belt or other systems which permit initial surface cooling
of the chewing gum slab.
[0030] Surface cooling may be controlled such as by the length of
the conveyor system, the temperature of the cooling impingement
air, the velocity of the cooling impingement air, and the linear
speed of the conveyor system. The extent of cooling should be
sufficient to permit the slab to pass through subsequent cooled
forming rollers without undue sticking or fouling without use of a
powdered non-stick agent. Preferably, the transported slab is not
cooled to a low temperature (especially a low temperature
throughout the slab), which makes the slab difficult to process in
the forming rollers.
[0031] Impingement air is not used with powdered non-stick agents
because the non-stick agents would be blown from surface of the
slab, which would cause manufacturing problems. Typically, the
temperature of the slab prior to cooling is between 53.degree. C.
(127.degree. F.) and 37.degree. C. (100.degree. F.). It has been
discovered that cooling impingement air creates a surface
temperature that is cooler than the center of the slab. Typically,
surface temperature may be reduced to less than 50.degree. C.
(122.degree. F.), preferably less than 37.degree. C. (95.degree.
F.), and more preferably less than 33.degree. C. (92.degree. F.).
Typically, the surface of the chewing gum composition slab is
cooled about 2.degree. C. (4.degree. F.) to 10.degree. C.
(19.degree. F.) relative to the center of the slab. The surface is
not reduced to a temperature so cold as to cool the core to a point
at which the temperature of the core becomes unworkable. Typically,
surface temperature should be above 26.degree. C. (80.degree. F.),
preferably above 30.degree. C. (85.degree. F.), and more preferably
above 32.degree. C. (90.degree. F.).
[0032] The chewing gum will not adhere to the processing equipment
if the processing equipment includes non-stick equipment, the
chewing gum is conditioned to prevent adhering to the processing
equipment (i.e. through surface treatments or other conditioning,
or if a non-stick agent is applied to the surface of the tacky
chewing gum. Such non-stick agents include sugar, sugar alcohols,
calcium carbonate, oil, or other particulates. Non-stick agents
used in excess are generally undesirable as they produce
environmental dust, create potential product changeover issues, and
are an additional expense as the non-stick agent may be later
removed prior to coating the chewing gum or packaging the chewing
gum in wrappers. In an embodiment of this invention, a small,
non-substantial, amount of rolling compound may be used to reduce
the tackiness but not completely eliminate tackiness. Typically,
such addition of non-stick agent is in an amount less than or equal
to 0.18 weight % non-stick agent based upon the slab weight which
exits the extruder, preferably less than 0.15 wt % and more
preferably less than 0.10 wt %.
[0033] In an aspect of this invention, the post-extrusion cooling
conveyor cools the surface of the chewing gum to reduce tack yet
leaves the chewing gum pliable to permit easy forming and scoring.
In a relatively short period of time, heat from the core of the
chewing gum will conduct toward the surface; however, at a typical
velocity of the conveyor, the temperature differential is
maintained through the forming rollers.
[0034] After the surface of the chewing gum composition slab has
cooled sufficiently to permit contact with a cooled solid surface
without sticking or fouling, the cooled slab is transferred from a
moving conveyor to a cooled roller, typically a cooled calender
roller and preferably a double roller in which the slab travels
between two moving rollers. Preferably the moving slab does not
contact the static base of the roller apparatus and is transferred
directly from a moving conveyor to the roller. Preferably, the base
of the roller is set below the top level of the conveyor.
Typically, the initial calender roller forms the chewing gum slab
into a uniform sheet with predetermined width and thickness
dimensions depending upon the size of the roller mechanism and the
space between the rollers. One or more cooled calender rollers may
be used.
[0035] Typically, after a uniform sheet of chewing gum is formed,
the sheet passes through one or more (typically two) scoring
rollers, which divide the chewing gum sheet into individual pieces
such as sticks, tabs, pillows, or other segments for further
processing. Typically, only an indentation is made on the sheet for
the pieces, which are separated and processed in a subsequent step.
Preferably, the scoring rollers also are chilled or cooled.
[0036] Further aspects of the processes, systems, and apparatuses
of this invention are described with reference to the figures.
FIGS. 1 and 5-8 illustrate embodiments of Apparatus 10. FIGS. 2 and
3 illustrate embodiments of the chilled rollers and FIG. 4
illustrates an embodiment of the chilled rollers in a closure.
[0037] Apparatus 10 includes a mixer or mixing unit 12, which may
be a continuous mixer. If mixing unit 12 is a continuous mixer, the
continuous mixer may be capable of mixing both chewing gum base and
finished chewing gum composition. Mixing unit 12 may also be a
batch mixer in which finished gum is made from pre-made chewing gum
base. Irrespective of whether the mixing unit 12 continuously
produces chewing gum or batch mixes chewing gum, the mixing unit is
sized at least to accommodate the maximum throughput of
manufacturing apparatus 10. A typical throughput of apparatus 10 is
between 500 and 5500 kg/hour (1100 and 12,000 lbs/hour) and more
preferably between 2750 and 4500 kg/hr (6000 and 10,000
lbs/hour).
[0038] The mixing unit 12 discharges chewing gum to a conveyor 14.
The chewing gum may be in the form of a chewing gum loaf, a
continuous extrudate, a semi-continuous extrudate or other forms or
strands of chewing gum composition. Chewing gum mixed in the mixing
unit has a typical output temperature between 50-53.degree. C.
(122-127.degree. F.). In order to accommodate potential differences
in the temperature and/or rheological properties of chewing gum
exiting mixing unit 12, the chewing gum may reside upon the
conveyor 14 for a period of time typically from 1 minute to 20
minutes. In an embodiment, the conveyor 14 may be exposed to
ambient air (typically about 15-25.degree. C. (59-77.degree. F.)).
Alternatively, the conveyor 14 may be exposed to conditioned air.
The conditioned air is typically between 1.5-10.degree. C.
(35-50.degree. F.), preferably between 3.3-8.3.degree. C.
(38-47.degree. F.) and more preferably between 6-7.degree. C.
(43-45.degree. F.), The conditioned air may also have a relative
humidity between 36 and 40 percent. The term "rheology properties"
includes deformation, flow, and elastic properties. Rheological
properties of chewing gum are influenced by temperature,
crystallization of sugar or polyols, formulation of chewing gum,
and other factors. Chewing gum exiting the conveyor 14 will have a
temperature between 48-53.degree. C. (118-127.degree. F.) with a
typical temperature of between 50-53.degree. C. (122-127.degree.
F.).
[0039] Chewing gum composition enters a forming extruder 20 via a
receiving hopper 22. An extruder screw 24 or extruder screws
receive chewing gum from the hopper 22. The extruder 20 extrudes
the chewing gum through die 26 into a slab. The extruder 20 may be
an extruder as manufactured by Togum (Model 240) or Bosch (Model
1030 and 1050). The extruder 20 may include a water jacket with
water circulating at between typically 48-50.degree. C.
(118-122.degree. F.). Additionally, the extruder adds heat to the
chewing gum by friction. The temperature of the composition in the
extruder is such to permit movement through the extruder but not at
such a high temperature as to volatize flavors or deform upon exit
from the nozzle. Typically the temperature of the composition
exiting the extruder is less than 53.degree. C. (127.degree. F.),
preferably less than 50.degree. C. (122.degree. F.) and still
preferably less than 49.degree. C. (120.degree. F.). Also, the
temperature of the composition exiting the extruder is typically
above 37.degree. C. (98.degree. F.), preferably above 43.degree. C.
(110.degree. F.) and more preferably above 47.degree. C.
(116.degree. F.). The extruder 20 may extrude the chewing gum from
the die 26 at a consistent pressure and temperature. Alternatively,
the extruder 20 may adjust the pressure and temperature based upon
feedback from downstream processes such as conveyors, forming
equipment, etc.
[0040] A slab of chewing gum may be in a regular slab format.
Typically, thickness of a regular slab is 3 to 12 cm (1 to 5 in)
and more preferably between 5 and 10 cm (2 and 4 in). A regular
slab may have a width between preferably 10 and 40 cm (4 and 16 in)
and more typically 20 to 30 cm (8 and 12 in).
[0041] Alternatively, chewing gum may be extruded from die 26 in a
thin slab or ribbon. The thin slab may have a thickness typically
from 0.15 to 3 cm (0.06 to 1.2 in), and more typically, from
approximately 0.4 cm (0.16 in) to approximately 0.5 cm (0.20 in),
0.76 cm (0.30 in) or 1.02 cm (0.40 in). This slab may have a
typical width from approximately 10 cm (4 in) to approximately 70
cm (28 in) wide and more typically from 2.5 to 55 cm (1 to 22 in)
wide. The thickness of the slab may depend upon whether the chewing
gum is to be formed into a chewing gum stick, tab, or pellet.
[0042] In an embodiment, the extruder 20 may be capable of
extruding a slab of chewing gum at a rate between 550 and 5500
kg/hr (1200-12,000 lbs/hr). More specifically, the extruder 20 may
be capable of extruding a thin slab between 2000 and 5000 kg/hr
(4,400 and 11,000 lbs/hr). In an additional embodiment, the
extruder is capable of extruding between 2750 and 4500 kg/hr (6,000
and 9,900 lbs/hr).
[0043] The chewing gum exiting the extruder 20 may have a tacky
surface due to formulation, temperature, rheology or other factors.
Under such processing conditions used in this invention, the
chewing gum may be formed, scored or cut without adhering to the
processing equipment and creating down time.
[0044] The chewing gum exiting the die 26 is transferred to a
conveyor 34. Conveyor 34 is preferably wire mesh which has a
minimum of contact area with the chewing gum. Preferably the
conveyor is a stainless steel open mesh style conveyor. Such
preferred conveyor 34 typically has an area of contact with the
chewing gum of between 10-75 percent of the total conveyor area,
preferably between 25-50 percent of the total conveyor area and
more preferably between 30-40 percent of the total conveyor
area.
[0045] The chewing gum exiting the die 26 may be passed through one
or more calender rolls (not shown) to size the chewing gum or
smooth any surface irregularities. Such calender rolls are
preferably chilled. Chilled rollers controlling the surface
temperature permit tacky slabs or ribbons of chewing gum to pass
between the chilled rollers without adhering to such an extent as
to cause down time. As seen in FIGS. 1, 5, 6 and 7, the conveyor 34
may be adjacent at least one convective cooling unit 36. Convective
cooling unit 36 may be supplied by air from supply system 40.
Supply system 40 may provide conditioned air which is temperature
and relative humidity controlled. The air supply system 40 may be
adjusted to condition the chewing gum slab or the surface of the
chewing gum slab. The conditioned slab is less likely to stick to
conveyor 34, calender rolls 32 or forming unit 50. Alternatively,
as illustrated in FIG. 8, the apparatus 10 may not include a
convective cooling unit.
[0046] The air supply ducts are connected to impingement air
nozzles 38 which direct air onto the conveyor from a range of 240
meters per minute "MPM" (800 feet per minute ("FPM")) to 1200 MPM
(4000 FPM) and more preferably to approximately 900 MPM (3000 FPM).
Impingement air nozzles 38 may be facing a top surface of the
chewing gum slab, a bottom surface of the chewing gum slab
projecting air through conveyor 34, or a combination of both top
and bottom surfaces.
[0047] The area between the extruder die 26 and the forming unit 50
may be generally referred to as a post-extruding cooling unit 30.
The post-extruding cooling unit 30 cools and/or conditions the
chewing gum slab for consistent scoring of the chewing gum pieces.
The post-extruding cooling unit 30 may alter the properties of the
surface of the chewing gum or may completely cool the chewing gum.
In a preferable embodiment, the post-extruding cooling unit 30
cools the surface of the chewing gum to reduce tack yet leaves the
chewing gum pliable to permit easy scoring. Given a relatively
short period of time, heat from the core of the chewing gum will
conduct toward the surface; however, given the velocity of the
conveyor, a temperature differential may be maintained through the
forming unit 50.
[0048] In an embodiment, forming unit 50 may be made up of sizing
rolls or calender rolls 32, cross scoring unit 52 and a circular
scoring unit 54.
[0049] FIG. 2 illustrates a suitable calender roll 32 configuration
for use in this invention. Preferably, the base of the chewing gum
44 is maintained on the same plane when passed from mesh conveyor
34, across glide plate 42, through the calender roll despite the
calender roll reducing the width, and onto transfer conveyor 56. As
such, the cooling load of the top calender roll is increased but
the plane of processing is maintained constant. This configuration
of calender rolls 32 may also be used for cross scoring unit or
rolls 52 and circular scoring unit or rolls 54.
[0050] FIG. 3 illustrates another suitable calender roll
configuration for use in this invention. Alternatively, the chewing
gum 44 is approximately centered between two calender rolls 32. As
such, the cooling load of both the top and bottom calender roll is
evenly distributed but the plane of processing is changed from one
side of the calender rolls 32 to the next. However, the base of the
chewing gum is maintained on a first plane when passed from mesh
conveyor 34 and across a first glide plate 42 but on a second plane
exiting the calender rolls 32, across a second glide plate 42 and
onto a transfer conveyor 56. This configuration of calender rolls
32 may also be used for cross scoring unit 52 and circular scoring
unit 54.
[0051] The configurations as seen in FIGS. 2 and 3 permit adjusting
the width of the chewing gum 44 by adjusting the top calender
rolls. It has been found that adjusting the top calender roll is
easier to control than the bottom calender roll. Although not
illustrated in FIGS. 2 and 3, the rollers of the forming unit 50
may have a similar configuration. The calender rolls may be
configured to permit the chewing gum 44 to move directly to a glide
plate, a moving conveyor or additional rollers. Preferably, the
rolls are configured to avoid contact with stationary parts.
[0052] The transfer conveyor 56 is preferably a solid conveyor
using a food grade polymer belt. The transfer conveyor 56 permits
controlled transfer of the chewing gum from the calender rolls 32
and an internal scoring unit (either cross scoring unit 52 or
circular scoring unit 54 whichever is placed internally). The
transfer conveyor belt should be fabricated for minimal deformation
during stopping and starting of the belt to prevent deformation in
the chewing gum during stopping, starting, and speed
fluctuations.
[0053] The cross scoring unit 52 and the circular scoring unit 54
may be pairs of scoring rollers. Alternatively, the scoring units
52, 54 may be a single roller scoring the chewing gum against a
conveyor. Still alternatively, the forming unit 50 may use a set of
forming rollers or a forming roller against a conveyor which
simultaneously cross and circular scores. The forming unit 50 may
make a slight indentation in the chewing gum slab which would
require additional processing steps to separate the chewing gum
pieces. Alternatively, the forming unit 50 completely separates the
chewing gum into individual pieces.
[0054] The forming unit 50 may include glide plates 42 between an
adjacent calender roll 32, cross scoring unit 52, or circular
scoring unit 54. When using glide plates, the rollers themselves
provide velocity to the chewing gum to move the chewing gum to the
next set of rollers or to another conveyor. Glide plates may be
coated with a non-stick material such as polytetrafluoroethylene or
polished stainless steel. Conventionally, however, coating rollers
or glide plates with a non-stick material such as
polytetrafluoroethylene is not preferred due to manufacturing cost
and a tendency of pieces of a coating to come off during
processing.
[0055] As seen in FIG. 4, conveyors 56 may be between and adjacent
calender roll 32, cross scoring unit 52, or circular scoring unit
54. When using conveyors 56, chewing gum may move directly from the
rollers to the conveyor without use of a glide plate 42.
Alternatively, a glide plate may be included for incidental contact
and support during downtime but not during production. As such, the
chewing gum does not encounter a stationary contact surface during
production.
[0056] To further permit product flow, glide plates 42 may include
indentations or grooves matched to the chewing gum passing through
the scoring system. During circular scoring, the chewing gum may
take on a rounded shape and indentations or grooves may be placed
upon the glide plate to accommodate the rounded shape.
[0057] Scoring rollers preferably are chilled. Alternatively, the
scoring rollers are coated with a non-stick material such as
polytetrafluoroethylene. Still alternatively, the scoring rollers
are chilled and coated with a non-stick material such as
polytetrafluoroethylene. Scoring rollers have not previously been
coated with a non-stick material due to the protrusions upon the
scoring rollers and the likelihood of having the non-stick material
come off of the scoring rollers.
[0058] The scoring rollers may also be in a temperature and
humidity controlled environment such as being enclosed in an
insulated and sealed closure 58. The environmental air around the
scoring rollers may have a dew point just above the temperatures of
the rollers. Under such conditions a thin layer of moisture may
accumulate on the rollers and enhance the non-stick properties of
the scoring rollers.
[0059] Alternatively, a closure 58 may be provided to control the
environment about the scoring system 50 which may be conditioned to
have a dew point of -13 to -12.degree. C. (8 to 10.degree. F.).
Under such conditions, the temperature of the rollers may be cold
and the surface of the rollers dry. Surface temperatures from -12
to -6.degree. C. (10 to 20.degree. F.) permit the chewing gum to
pass through the scoring system 50 without adhering to the
rollers.
[0060] Still alternatively, the environmental air around the
rollers may have a dew point above the temperature of the rollers
and the rollers have a temperature below freezing temperature.
Under such conditions ice may form upon the rollers and create
non-stick surface properties.
[0061] Upon exiting the forming unit 50, in one embodiment, the
chewing gum slab may enter a post-scoring area where the chewing
gum is treated for later packaging and/or processing. In the
embodiment illustrated in FIG. 7, the post-scoring area is a
tempering room 86. In this embodiment, products exiting the forming
unit 50 are transported using a conveyor 68 to trays 80. The
chewing gum may be stacked as sheets into trays 80 which may be on
a rotating conveyor 82. A non-stick agent may be applied in between
each sheet to prevent the sheets from sticking to one another
during storage or while waiting to be fed into a wrapping machine.
The trays 80 may be moved via a conveyor 84 to tempering room
86.
[0062] The tempering room holds the chewing gum slab for a
pre-determined period such that the chewing gum hardens for
packaging, such as for stick and/or tab chewing gum, or further
processed in a pellet coating machine. Alternatively, the
post-scoring area may include a post-scoring cooling unit 60.
[0063] As seen in FIGS. 1, 5 and 6, the post-scoring cooling unit
60 may include a cooling area which supplies cooled air through air
ducts 62. The air ducts 62 may be supplied by air supply 40 which
is also supplying the air ducts 36 in the pre-scoring area 30. The
post-scoring air supply ducts may supply one-way impingement ducts
64 or two-way impingement ducts 66.
[0064] In the embodiment illustrated in FIG. 6, a conveyor 68
receives chewing gum slabs or individual pieces from the forming
unit 50. A single pass conveyor 68 may have a long length sized to
cool the chewing gum entering the post-scoring area at
approximately 43.degree. C. to a temperature between 15-20.degree.
C. With a single pass conveyor, one-sided impingement ducts 64 may
be used.
[0065] In the embodiments illustrated in FIGS. 1 and 5, the
conveyor 68 may be a multi-pass conveyor (i.e. a first conveyor is
stacked upon a second conveyor 68 and third conveyor 68). In this
embodiment products from the first conveyor 68 drops onto a second
conveyor once it has achieved a temperature at which point the
chewing gum does not deform during the transfer or below
approximately 35.degree. C. (95.degree. F.). The second conveyor
conveys products back under the first conveyor through two-way
impingement ducts 66. The two-way impingement ducts 66 may also be
two one-sided impingement ducts facing away from one another. The
impingement ducts 66 blow air both up through the first conveyor 68
and down upon the chewing gum pieces on the second conveyor. The
chewing gum pieces move along the second conveyor to a section of
sheet metal or other connector which moves the chewing gum pieces
to the third conveyor down below. The third conveyor moves back
between an impingement duct 66 and an impingement duct 64. The
final exit temperature from the third conveyor 68 is between
15-20.degree. C. (59-68.degree. C.).
[0066] In an alternative embodiment, the post-extruding cooling
unit 30 and the post-scoring cooling unit 60 may be within the same
cooling unit enclosure. In such an embodiment, the post-extruding
cooling unit includes a conveyor which passes through the enclosure
to a forming unit and then continues through the enclosure for
post-scoring cooling. In still another embodiment, the forming unit
may be outside of the enclosure.
[0067] As seen in FIG. 1, the chewing gum may be separated into
individual pieces and collected in tubs or bulk storage containers
for storage and later use in pellet forming systems such as for
making Wrigley Eclipse.RTM. chewing gum. The chewing gum may also
be sent to a conveyor 70 which may feed a piece separator 72. The
piece separator 72 breaks the chewing gum into pieces for later
feeding into a coating unit 76. A non-stick agent may be applied
during the tumbling to prevent the pieces from sticking to one
another during storage or while waiting to be fed into the piece
coater or even while sitting in a coater 76 waiting to be coated.
The non-stick agent is added in amounts less than 1.0% by weight of
the total chewing gum piece, preferably less than 0.5%, and still
preferably less than 0.2%.
[0068] Exiting the tumbler the chewing gum may be sent to storage
for tempering or may go immediately to the piece coater 76. When
being sent to a coater 76 the pellets may be elevated using a
conveyor 74. Alternatively, as seen in FIG. 5, the chewing gum may
be stacked as sheets into trays 80 which may be on a rotating
conveyor 82. A non-stick agent may be applied in between each sheet
to prevent the sheets from sticking to one another during storage
or while waiting to be fed into a wrapping machine. The trays 80
may be moved via a conveyor 84 to a tempering room 86.
[0069] It should be understood that various changes and
modifications to the presently preferred embodiments described
herein will be apparent to those skilled in the art. Such changes
and modifications can be made without departing from the spirit and
scope of the present subject matter and without diminishing its
intended advantages. It is therefore intended that such changes and
modifications be covered by the appended claims.
* * * * *