METHOD FOR PREPARING AN ENCAPSULATE COMPOSITION FOR USE IN AN EDIBLE COMPOSITION

A method for preparing at least a first component of a comestible composition includes providing particles of an encapsulating ingredient having an average longest dimension of less than 1000 microns to a mixer. Particles of an active ingredient having an average longest dimension of less than 1000 microns are also provided to said mixer. A composition of said encapsulating ingredient and said active ingredient is formed.

FIELD

The disclosure relates generally to a system and method for manufacturing comestible compositions, and more particularly, to a system and method for manufacturing a first component used as an ingredient in a comestible composition.

BACKGROUND

Conventional methods for preparing one or more active ingredients for use in a comestible include forming an extrudate having the active ingredients encapsulated therein. The extrudate is then convectively cooled to a temperature such that the extrudate may be broken into plurality of pieces before being ground into a powder. Typically, during the formation of the extrudate, an encapsulating ingredient, provided to an extruder as large pellets, is melted before being mixed with one or more active ingredients, supplied as a powder. This melting and mixing requires both energy and heat generation which can be problematic in applications where the active ingredients are heat sensitive.

Accordingly, a system and method capable of continuously and efficiently preparing an active ingredient for use in a comestible is desirable.

SUMMARY

According to one embodiment of the invention, a method for preparing at least a first component of a comestible composition includes providing particles of an encapsulating ingredient having an average longest dimension of less than 1000 microns to a mixer. Particles of an active ingredient having an average longest dimension of less than 1000 microns are also provided to said mixer. A composition of said encapsulating ingredient and said active ingredient is formed.

According to another embodiment, a method for preparing at least a first component of a comestible composition includes providing particles of an encapsulating ingredient and particles of an active ingredient to a mixer. A composition of said encapsulating ingredient and said active ingredient is formed. A ratio of an average longest dimension of said particles of encapsulating ingredient to an average longest dimension of said particles of active ingredient is less than about 20:1.

DETAILED DESCRIPTION

The following disclosure will detail particular embodiments according to the present invention, which provides methods and systems for manufacturing encapsulate compositions, particularly for use in chewing gum and other such confections.

The comestible included in the comestible extrudate, mass and sheet discussed herein include any type of edible product, such as but not limited to chewing gum (at any stage including elastomer, partially finished base, finished chewing gum base, and finished chewing gum), confection (which may be synonymous with chewing gum and candy), sweet and savory biscuits and cakes, nuts, and grains. For ease of description, the comestible will be referred as chewing gum for the remainder of the description. Certain compositions of chewing gum may have a non-uniform texture and/or a multi-layered composition.

As used herein, a product referred to as “chewing gum” or “gum” includes, but is not limited to, compositions ranging from and inclusive of compounded elastomer to finished gum, which may include compounded elastomer in addition to some compounding aids, master batch gum base, compounded elastomer in addition to some subsequent gum ingredients, gum base, gum base in addition to some subsequent gum ingredients, master batch finished gum, and finished gum.

Before explaining the various systems and methods according to the present invention, it is helpful to discuss the general composition of several typical stages of chewing gum manufacture in which encapsulate may be used, namely finished gum.

A “finished chewing gum” or “finished gum,” as used herein, will refer to chewing gum that is generally ready for preparation to distribute the product to the consumer. As such, a finished gum may still require temperature conditioning, forming, shaping, packaging and coating. However, from a compositional standpoint, the chewing gum itself is generally finished. Not all finished gums have the same ingredients or the same amounts of individual ingredients. By varying the ingredients and amounts of ingredients, textures, flavor and sensations, among other things, can be varied to provide differing characteristics to meet the needs of users.

As is generally well known, a finished gum typically includes a water soluble bulk portion, a water insoluble gum base portion, and one or more flavoring agents. The water soluble portion dissipates over a period of time during chewing. The gum base portion is retained in the mouth throughout the chewing process. A finished gum is to be defined as a chewing gum that is ready for user consumption.

A “finished chewing gum base” or “finished gum base”, as used herein, will refer to chewing gum that includes a sufficient combination of gum base ingredients that need only be combined with subsequent gum ingredients to form a finished gum. A finished gum base is a visco-elastic material that includes at least a viscous component, an elastic component, and a softener component. For example, a typical gum base may include elastomer, at least some of the filler, resin and/or plasticizer, polyvinyl acetate, and a softener (such as an oil, fat or wax). Merely compounded elastomer without the addition of any softener, for example, would not be a finished gum base because it would not be considered useable in a finished gum structure because of its difficulty, if not impossibility, to chew. In one embodiment, the viscosity of the finished gum base or the extrudate output from the extruder described further below is between about 75 pascal-seconds and about 140,000 pascal-seconds.

A “partial chewing gum base” or “partial gum base,” as used herein, will refer to chewing gum that includes a gum base ingredient or combination of gum base ingredients that need be combined with further gum base ingredients and subsequent, non-base gum ingredients to form a finished gum. A partial gum base includes at least an elastic component, and will require addition of at least a viscous and/or softener component to form a finished gum base.

Chewing gum may include a vast number of ingredients in various categories. The systems and methods discussed below may be used to mix any and all known ingredients including, but not limited to, ingredients in the following ingredient categories: elastomers, bulking agents, elastomer plasticizers (which includes resins), elastomer solvents, plasticizers, fats, waxes, fillers, antioxidants, sweeteners (e.g. bulk sweeteners and high intensity sweeteners), syrups/fluids, flavors, sensates, potentiators, acids, emulsifiers, colors, and functional ingredients.

The insoluble gum base in its finished gum base form generally includes ingredients falling under the following categories: elastomers, elastomer plasticizers (resins or solvents), plasticizers, fats, oils, waxes, softeners and fillers. Further discussion of representative ingredients within each category will be provided later on. The gum base may constitute between 5-95% by weight of a finished gum, more typically 10-50% by weight of the finished gum, and most commonly 20-30% by weight of the finished gum.

The water soluble portion of finished gum will be referred to as subsequent ingredients in this disclosure (as they are added subsequent to manufacture of a) finished gum base, and may include subsequent gum ingredients falling under the following categories: softeners, bulk sweeteners, high intensity sweeteners, flavoring agents, acids, additional fillers, functional ingredients and combinations thereof. Softeners are added to the gum in order to optimize the chewability and mouth feel of the gum. The softeners, which are also known as plasticizers, plasticizing agents or emulsifiers, generally constitute between about 0.5-15% by weight of the finished gum. Bulk sweeteners constitute between 5-95% by weight of the finished gum, more typically 20-80% by weight of the finished gum and most commonly 30-60% by weight of the finished gum. High intensity sweeteners may also be present and are commonly used with sugarless sweeteners. When used, high intensity sweeteners typically constitute between 0.001-5% by weight of the finished gum, preferably between 0.01-3% by weight of the finished gum. Typically, high intensity sweeteners are at least 20 times sweeter than sucrose.

Flavor should generally be present in the gum in an amount within the range of about 0.1-15% by weight of the finished gum, preferably between about 0.2-5% by weight of the finished gum, most preferably between about 0.5-3% by weight of the finished gum. Natural and artificial flavoring agents may be used and combined in any sensorially acceptable fashion. When included, acids typically constitute between about 0.001-5% by weight of the finished gum. Optional ingredients such as colors, functional ingredients and additional flavoring agents may also be included in gum.

Referring now to the FIGS., during the formation of a gum or other comestible, a first component may be mixed with one or more other ingredients, such as in a gum manufacturing system for example, to form a finished gum product. The first component may include a composition containing both an “active ingredient” and an “encapsulating ingredient,” the active ingredient being surrounded or encapsulated by the encapsulating ingredient. In some embodiments, the active ingredient may be relatively sensitive to high energy mixing environments (such as heat and shearing forces that can be associated with some types of mixing). Any active ingredients typically used in a comestible, such as but not limited to high intensity sweeteners (including natural sweeteners and synthetic sweeteners), food acids, and miscellaneous ingredients (including texture modifiers, coloring agents, salts, oral care ingredients, and other ingredients), are within the scope of the present disclosure. Any encapsulating ingredients typically used in comestible, such as but not limited to polymer or resin, are also contemplated in the formation of the first component. The encapsulating ingredients may, but need not be insoluble in water.

For example, active ingredients may include, but are not limited to sweeteners and food acids. Sweeteners used may be selected from a wide range of materials including water-soluble sweeteners, water-soluble artificial sweeteners, water-soluble sweeteners derived from naturally occurring water-soluble sweeteners, dipeptide based sweeteners, and protein based sweeteners, including mixtures thereof. Without being limited to particular sweeteners, representative categories and examples include: (a) water-soluble sweetening agents such as dihydrochalcones, monellin, steviosides, glycyrrhizin, saccharin salts, i.e., sodium or calcium saccharin salts, cyclamate salts, acesulfame salts, such as the sodium, ammonium or calcium salt of 3,4-dihydro-6-methyl-1,2,3-oxathiazine-4-one-2,2-dioxide, the potassium salt of 3,4-dihydro-6-methyl-1,2,3-oxathiazine-4-one-2,2-dioxide (Acesulfame-K), the free acid form of saccharin and monatin; (b) dipeptide based sweeteners, such as L-aspartic acid derived sweeteners, such as L-aspartyl-L-phenylalanine methyl ester (Aspartame) and L-alphaaspartyl-N-(2,2,4,4-tetramethyl-3-thietanyl)-D-alaninamide hydrate (Alitame), methyl esters of L-aspartyl-L-phenylglycerine and L-aspartyl-L-2,5-dihydrophenyl-glycine, L-aspartyl-2,5-dihydro-L-phenylalanine; L-aspartyl-L-(1-cyclohexen)-alanine, neotame and advantame; (c) water-soluble sweeteners derived from naturally occurring water-soluble sweeteners, such as Reb-A, chlorinated derivatives of ordinary sugar (sucrose), e.g., chlorodeoxysugar derivatives such as derivatives of chlorodeoxysucrose or chlorodeoxygalactosucrose, known, for example, under the product designation of Sucralose; examples of chlorodeoxy.sucrose and chlorodeoxygalactosucrose derivatives include but are not limited to: 1-chloro-1′-deoxysucrose; 4-chloro-4-deoxy-alpha-D-galactopyranosyl-alpha-D-fructofuranoside, or 4-chloro-4-deoxygalactosucrose; 4-chloro-4-deoxy-alpha-D-galactopyranosyl-1-chloro-1-deoxy-beta-D-fructo-furanoside, or 4,1′-dichloro-4,1′-dideoxygalactosucrose; 1′,6′-dichloro 1′,6′-dideoxysucrose; 4-chloro-4-deoxy-alpha-D-galactopyranosyl-1,6-dichloro-1,6-dideoxy-beta-D-fructofuranoside, or 4,1′,6′-trichloro-4,1′,6′-trideoxygalactosucrose; 4,6-dichloro-4,6-dideoxy-alpha-D-galactopyranosyl-6-chloro-6-deoxy-beta-D-fructofuranoside, or 4,6,6′-trichloro-4,6,6′-trideoxygalactosucrose; 6,1′,6′-trichloro-6,1′,6′-trideoxysucrose; 4,6-dichloro-4,6-dideoxy-alpha-D-galacto-pyranosyl-1,6-dichloro-1,6-dideoxy-beta-D-fructofuranoside, or 4,6,1′,6′-tetrachloro 4,6,1′,6′-tetradeoxygalacto-sucrose; and 4,6,1′,6′-tetradeoxy-sucrose, and mixtures thereof; or (d) Other protein based sweeteners such asthaumaoccous danielli(Thaumatin I and II) and talin. Food acids may include citric acid, malic acid, fumaric acid, tartaric acid, lactic acid and adipic acid.

Encapsulation of an active ingredient will result in the protection of the active ingredient from dissolution as a result of contact with water or saliva, thereby extending the relative life of the active ingredient within a finished gum product. In addition, encapsulation of an active ingredient may also result in the protection of the active ingredient during the remainder of the production process. As components of the comestible to be encapsulated may be sensitive to temperature, mixing, extruding, or other factors, the encapsulation allows for efficient handling and protection of these sensitive components during production. Protection of the active ingredient as referenced above is achieved via a mixing of the active ingredient(s) with an encapsulating ingredient(s). Indeed, a composition of at least one encapsulated active ingredient as defined herein includes an active ingredient(s), such as that discussed above, mixed for production or extrusion with an encapsulating ingredient(s) such as that discussed immediately below.

Examples of encapsulating materials/ingredients include polymers or resins, wherein the characteristics of the polymer or resin ingredient control the release profile and the protection of the active ingredient to be encapsulated. In some embodiments, the encapsulating material may be polyvinyl acetate, polyethylene, crosslinked polyvinyl pyrrolidone, polymethylmethacrylate, polylactidacid, polyhydroxyalkanoates, ethylcellulose, polyvinyl acetatephthalate, polyethylene glycol esters, methacrylicacid-co-methylmethacrylate, polyvinylacetate-viynyl alcohol copolymer or any other ingredient suitable for polymer matrix type encapsulation.

As discussed above, it may be desirable to encapsulate certain ingredients or components used in pharmaceuticals or comestibles, such as chewing gum for example. Such compositions described herein include at least one active ingredient or component to be protected and released in a certain release profile, and at least one additional encapsulating ingredient such as, but not limited to a polymer or resin for example.

Typically, encapsulation of an active ingredient (e.g., the flavor, sweetener, etc.), will result in a delay in the release of the predominant amount of the active ingredient during consumption of a comestible, such as a gum structure, that includes the encapsulated active ingredient. The initial release of the active ingredient from the encapsulating material of the first component, such as when the first component is used as an ingredient in a gum, permits a portion of the active ingredient to be digested. This initial release generally occurs in response to a release trigger, such as by rupturing the encapsulated active ingredient particles due to chewing, or dissolving the encapsulated ingredients via saliva or solvents in the alimentary canal. However, in pharmaceutical applications, a chemical catalyst, such as stomach acid for example, may be configured to break down the encapsulating material and expose the active ingredient contained therein.

In one embodiment, the first component is formed by supplying the encapsulating ingredient and the active ingredient to an extruder. However, other devices suitable for forming an encapsulating composition, such as a batch mixer for example, are also within the scope of the disclosure. With reference now toFIG. 1, an example of an extruder20is illustrated. The extruder20is a twin screw extruder including a substantially hollow barrel22within which a first screw24aand second screw24bare mounted. However, other types of extruders, such as planetary roller extruders and single screw extruders for example, are within the scope of the invention.

As shown, each of the first and second screws24a,24bgenerally extends from an inlet or feed end26to an outlet or extrusion end28of the barrel22and includes a central longitudinal axis A, B, respectively.

Referring now to the screws24a,24bin more detail, in one embodiment, a diameter of each screw24a,24bmay remain constant over the length thereof. However, as different portions of the extruder20may be configured to perform different functions, e.g. mixing and melting, each screw24a,24bmay have different configuration at different positions over the length of the extruder20. For example, a first portion30of the screws24a,24barranged near the feed end26of the extruder20may have a first configuration and a downstream, central portion32of the screws24a,24bmay have a second, configuration. The first portion30may be configured to mix the ingredients within a corresponding portion of the barrel22and the central portion32may be configured primary to melt the ingredients within a central portion of the extruder barrel22. The screws24a,24binclude corresponding or intermeshing grooves or flights34. These flights34assist in efficiently moving and mixing the first ingredient flowing through the extruder20, with space35remaining for the first ingredient to flow between the flights34of the screws24a,24b.The flights34may have any desirable configuration, including but not limited to, a variance in the distance or gaps between adjacent flights, flight shape, and flight length for example.

Each screw24a,24bincludes a shaft having a plurality of elements mounted thereto in a specific configuration to achieve a desired operation of the extruder. The elements may be selected from feeding elements, distributive elements, pumping elements, and dispersive elements. In one embodiment, at least one of the screws24a,24bwithin the extruder20includes one or more dispersive elements configured to provide a more aggressive level of mixing than screws24a,24bcommonly used in the production of a comestible. An example of such a screw is illustrated inFIG. 2. Inclusion of at least one screw having a configuration as described herein more efficiently mixes the ingredients within the extruder20resulting in a more homogenous mixture thereof.

Referring again toFIG. 1, the extruder20includes at least one point of entry36for ingredients entering the extruder20, such as a point of entry located adjacent the feed end26or a point of entry located downstream from the feed end26of the barrel22. The position of each of these points of entry36is selectable depending on the chosen application, the ingredient being added, and the form of the ingredient being added. Various types of feed inlets38may be used at the points of entry36to supply an ingredient to the inner volume of the extruder20. In one embodiment, the feed inlet38is a gravity driven hopper/feeder. Alternatively, the feed inlet38may be a side feed inlet configured to provide a supply of an ingredient laterally to a side of the extruder20.

An extrusion point40arranged at the outlet of extrusion end28of the barrel22, includes an opening through which the composition flowing through the extruder20will ultimately be extruded. It is notable that a downstream end of the screws24a,24bare generally located in proximity to the extrusion point40of the extruder20. Indeed, the downstream end of the screws24a,24bmay terminate such that the ends thereof are flush with the extrusion point40. As is known in the art, the extrusion point40is fluidly coupled to an extruder die42mounted at the extrusion end28of the barrel22. The extruder die42is configured to extrude the first component in one or more desirable shapes, such as a rope or a continuous rectangular sheet for example. In an embodiment, a melt pump or gear pump may be positioned between the extrusion end28of the barrel22and a downstream extrusion die42. In such instances, the melt pump receives an unformed mass of encapsulate composition from the extruder20via extrusion point40and provides the encapsulate composition to the extruder die42where it is extruded into a desired shape.

In addition, the extruder20may include efficient temperature control for the first ingredient mixed therein and extruded therefrom. In one embodiment, the extruder20includes a temperature control system44, such as but not limited to a cooling jacket and/or a heating jacket46positioned circumferentially about a portion of the barrel22. The extruder20illustrated and described herein is intended as an example, and other known extruders20, such as planetary roller extruders for example, are within the scope of the invention.

At least one motor50is operably coupled to the screws24of the extruder20and is configured to rotate the screws24about their respective longitudinal axes A, B. The screws24may be configured to co-rotate, or alternatively, may be configured to counter-rotate. Upon entry of the ingredients into the extruder20, the rotation of the screws24a,24b,creates a directional flow of the ingredients towards the extrusion end28of the extruder20. As the ingredients move away from the feed end26of the extruder20, the rotating screws24a,24bmix the ingredients in the flow via movement of the flow through the spaces35defined between the flights34of the rotating screws24a,24b.As the ingredients are conveyed and mixed, the ingredients form a first component. An extrudate12of the first component is expelled from the extruder20in a desired shape complementary to the extruder die42.

The properties of the encapsulate composition are largely determined by the specific mechanical energy (SME) input to the materials during operation of the extruder20. Interactions between the active and encapsulating ingredients, feeding position, screw design, and other operating variables are captured within the SME parameter and can therefore be used to manage the extrusion process and the properties of the encapsulate composition formed in the extruder20. In one embodiment, the SME is increased by operating the extruder20at a reduced barrel temperature compared to conventional operational temperatures, such as about 20° C. for example. However, it should be understood that the SME may be increased by altering other operational parameters of the extruder20. To improve the dispersion of the active ingredient within the encapsulating ingredient, and therefore slow the release of encapsulated active ingredient over time when exposed to a dissolving agent, the specific mechanical energy input to the material is increased compared to a conventional extrusion process.

With reference toFIG. 3, the extrudate output from the extruder20or other device may be further processed before being added as an ingredient in a comestible. In one embodiment, after being cooled, the extrudate is provided to a milling machine60or other similar device configured to grind the extrudate into a powder comprising particles of a desired size. The residence time of the extrudate within the milling machine60may be any suitable period of time necessary to achieve the desired particle size. From the milling machine60, the ground first component may then be provided to a mixing machine (not shown) of a comestible manufacturing system, where the first component is used as an ingredient of a comestible composition as is known in the art.

During the encapsulation process, one or more active ingredients are provided to the extruder20from an active ingredient source and one or more encapsulating ingredients are added to the extruder20from an encapsulating ingredient source. Alternatively, the active and encapsulating ingredients may enter the extruder20from a common source at an active ingredient feed inlet38and an encapsulating ingredient feed inlet38, respectively. In one embodiment, the active and encapsulating ingredients may be mixed before being supplied to the extruder20via a single inlet38. The active ingredients and the encapsulating ingredients may be disposed at the same entry point36or at different entry points36of the extruder20, thereby allowing for varying durations of mixing of the active and encapsulating ingredients. The active and encapsulating ingredients may be added in pellet or raw ingredient form, such as but not limited to powder or flake materials.

In one embodiment, the encapsulating ingredient is mixed with the active ingredient before any melting of the encapsulating ingredient occurs. Melting of the encapsulating ingredient occurs when the encapsulating ingredient changes from a powdered form to flowable mass having a measurable viscosity. The encapsulating and active ingredients may be mixed within a portion of the extruder20, such as a first barrel located upstream of a portion of the extruder20where the melting occurs for example, or alternatively, may be mixed together before being provided to the extruder20. In addition, both the encapsulating ingredient and the active ingredient may be supplied having a similar raw ingredient form, such as particles. Further, the particles of encapsulating ingredient and the particles of active ingredient used to form the first component may be closer in size than in conventional comestibles. For example, a ratio of the average longest dimension of the particles of encapsulating ingredient to the average longest dimension of the particles of active ingredient is less than or equal to about 20:1. To achieve this reduced sizing ratio, the size of the particles of encapsulating ingredient provided to the extruder20may be decreased. In one embodiment, the particles of encapsulating ingredient have an average longest dimension of less than 1000 microns, such as less than 700 microns for example. The particles of active ingredient similarly have an average longest dimension of less than 1000 microns. This reduction in size of the particles of encapsulating ingredient may occur by milling, grinding, or another suitable form of breaking the particles of encapsulating ingredient prior to providing the encapsulating ingredient to the extruder20.

Reducing the size of the particles of encapsulating ingredient and mixing of the encapsulating and active ingredients before initiating any melting of the encapsulating material occurs provides the unexpected result of improving the encapsulation efficacy of the encapsulating composition. For example, as shown inFIG. 4, an encapsulating composition as described herein with a first active ingredient, such as Ace-K for example, has a release profile such that less than or equal to about 30% of said active ingredient dissolves after 3 minutes. However, an encapsulated first active ingredient having the same composition but being formed via conventional methods of mixing the active ingredient into the melted encapsulating ingredient, has a release profile of greater than 50% after the same length of time. Consequently, when an encapsulating composition formed by mixing the encapsulating and active ingredients before melting the encapsulating material is exposed to a dissolving agent, the amount of dissolution that occurs within a first minute is less than half of the amount of active dissolved from an identical encapsulating composition formed via a conventional method. The initial mixing of the encapsulating and active ingredients results in better dispersion of the active ingredient within the encapsulating ingredient prior to the softening of the encapsulating ingredient.