Gradual release structures for chewing gum

Abstract: Gradual release structures for the release of active agents in chewing gum and a process for making such structures are provided. The gradual release structures are formed by extrusion techniques and comprise an active agent (13) and a wall material (12).

Description: The invention is related to processes for making delivery systems for the gradual release of active agents and is particularly directed to processes for making delivery systems for use in chewing gum that have an active agent that is gradually released by direct interaction with a solvent and extrusion processes for making such systems. The present invention is an advance in the art of making delivery systems for the gradual release of active agents. A delivery system produced according to the process of this invention enables an active agent to be gradually released through the direct interaction of the agent and a solvent either within channels in the structure enclosing the active agent or through exposure of the active agent to the solvent when the structure enclosing the active agent is deformed. Prior to the present invention, the gradual release of active agents, such as drugs, could be accomplished by the diffusion of the active agent through an encapsulating material. A discussion of such encapsulated structures is found in R. Dunn & D. Lewis, Fibrous Polymers for the Delivery of Contraceptive Steroids to the Female Reproductive Tract , Controlled Release of Pesticides and Pharmaceuticals 125-46 (D. Lewis ed. 1981), which describes fiber-like structures. Alternatively, an encapsulating shell around the active agent could be ruptured causing exposure of the active agent to various solvents. Further, prior to the present invention, the Applicant's devised a method of producing gradual release structures, which method was the subject of Application WO90/12511. These structures were produced by melt spinning extrudate through a die having one or more small diameter holes. A particular feature of this invention is to provide a novel process for making a gradual release structure having an active agent that is gradually released through direct interaction with a solvent. According to one embodiment of the invention there is provided a process for making chewing gum which comprises the steps of: a. preparing a gum base; b. preparing a water soluble bulk portion; c. preparing a gradual release structure which comprises the steps of: i) preparing a mixture of active agent and wall material, having more than zero but less than about 55 percent by weight active agent, said wall material being less soluble than said active agent, said wall material and said active agent being immiscible with each other and being capable of being uniformly dispersed when mixed together; and, ii) extruding the mixture through one or more die having one or more holes into an extrudate having a cross-sectional area of at least 161 square mm (½ square inches) in size; and, iii) grinding the extruded mixture; and, d. combining the gradual release structure, the gum base and the water soluble bulk portion. To aid in understanding the invention one is directed towards the drawings and the detailed description of the present preferred embodiment of the invention. In the drawings: Fig. 1 is an illustration of a gradual release structure. Fig. 1A is an illustration of the gradual release structure of Fig. 1 after it has been subjected to a solvent. Fig. 2 is a Scanning Electron Photomicrograph (SEPM) of a gradual release structure showing the end and side. Fig. 3 is a SEPM of a gradual release structure showing the side. Figs. 4 & 5 are SEPMs of a gradual release structure showing the channels within the encapsulating structure. Fig. 6 is a SEPM showing the side and end of a gradual release structure. Fig. 7 is a SEPM showing the side of a gradual release structure. Fig. 8 is a graph showing the differences in sweetness over time between encapsulation and the gradual release structures of the present invention when used in chewing gums. Fig. 9 is a SEPM of a gradual release structure extruded from a slot die. Fig. 10 is a SEPM of a gradual release structure extruded from a slot die. A gradual release structure produced according to the present invention and used in a chewing gum made in accordance with the present invention has a support matrix. The support matrix is made up of a wall material. An active agent is dispersed throughout the support matrix and may be in contact with itself forming a contiguous phase within the support matrix. The active agent, however, does not necessarily have to be in a contiguous phase. The ends of the support matrix have openings, exposing the active agent. Additionally, the active agent may be exposed along the sides of the support matrix. The amount of active agent in this structure is from 10 percent by weight to 55 percent by weight. It is believed, however, that loading as low as a fraction of a percent will exhibit gradual release characteristics. The loading of the structure is influenced by the characteristics of the active agent and the solubility or extractability from the support matrix. After the gradual release structure is formed by extrusion, it may be stretched by applying a draw or stretching force. The draw can be applied at a winder or by venturi after the structure exits the die. Other methods of stretching known to the art may also be employed. In this structure gradual release of the active agent occurs when the structure is brought in contact with a solvent, or dispersing media, for the active agent. The wall material is less soluble in the solvent than the active agent and preferably the wall material should be substantially insoluble in the solvent under the conditions in which the fiber is being used. It is presently believed that the solvent first dissolves the active agent in the openings at the ends of the support matrix. If the active agent is in a contiguous phase within the support matrix, the active agent in those openings is dissolved and spaces or channels in the support matrix are created. The solvent fills these channels and begins to dissolve the newly exposed active agent, which was in contact with the now dissolved active agent located in the openings at ends of the support matrix. Thus, the length of the channels in the support matrix gradually increases as the active agent directly in contact with the solvent is dissolved. It is presently believed that the support matrix does not prevent the dissolution of the active agent because the active agent is in a contiguous phase. Rather, the support matrix serves to limit the rate of dissolution by restricting the area of active agent in direct contact with the solvent to the ends of the channels within the support matrix. Thus, the solvent can gradually work its way into the structure by following the contiguous phase of active agent. Additionally, it is presently believed that depending on the stiffness of the wall material making up the support matrix, the support matrix can be deformed to expose new surface areas of active agent and thus bring them in direct contact with the solvent. For instance, when gradual release structure is incorporated into chewing gum as the gum is chewed the pressure from chewing will flatten, stretch, and deform said structure exposing new surface areas of active agent to the solvent. This gradual release by deformation should occur even if the active agent is not in a contiguous phase. Higher molecular weight polymers used as wall material will not as readily exhibit this gradual release by deformation. For instance, it is believed that polyvinylacetate having a molecular weight greater than about 100,000 will not exhibit gradual release by deformation during gum chewing. Furthermore, it is theorized that if the active agent is not in a contiguous phase the deformation of the support matrix may create channels, similar to those described above, through which the solvent can be brought in contact with the active agent. Finally, depending on the wall material chosen, the active agent chosen, and the solvent being used an extremely small amount of the active agent may dissolve by diffusion through the wall material. One embodiment of a gradual release structure made in accordance with the present invention is illustrated in Fig. 1. In this embodiment, the structure has a support matrix 12. The support matrix is made up of a wall material. An active agent 13 is dispersed throughout the support matrix and is in contact with itself forming a contiguous phase within the support matrix. The ends 14 and 15 of the support matrix have openings, exposing the active agent. Additionally, the active agent may be exposed along the sides of the structure as can be seen in Figs. 2 and 3. The active agent makes up at least about 25 percent of the structure by weight. Gradual release of the active agent in this embodiment occurs when the structure is brought in contact with a solvent, or dispersing media, for the active agent. The wall material is less soluble in the solvent than the active agent and preferably the wall material should be substantially insoluble in the solvent under the conditions in which the gradual release structure is being used. As illustrated in Fig. 1A, the solvent first dissolves the active agent in the openings at the ends 14 and 15 of the support matrix. As this material is dissolved, spaces or channels 13a in the support matrix are opened. The solvent fills these channels and begins to dissolve the newly exposed active agent, which was in contact with the now dissolved active agent located in the openings at ends of the support matrix. Thus, the length of the channels in the support matrix gradually increase as the active agent directly in contact with the solvent is dissolved. It is presently believed that the support matrix does not prevent the dissolution of the active agent because the active agent is in a contiguous phase. Fig. 1 and 1A. Rather, the support matrix serves to limit the rate of dissolution by restricting the area of active agent in direct contact with the solvent to the end of the channels within the support matrix. Thus, the solvent can gradually work its way into the fiber by following the contiguous phase of active agent. Additionally, depending on the wall material chosen, the active agent chosen, and the solvent being used a small amount of the active agent may dissolve by diffusion through the wall material. Gradual release by deformation may also be exhibited by this structure. Figs. 4 and 5 contain SEPMs of structures made in accordance with the present invention. These structures were subjected to a solvent. The spaces or channels 13a where the active agent was dissolved out are shown in these SEPMs. The active agent can be any material such as artificial sweeteners, powdered flavour oil, or drugs, which the gradual release of may be desired. They must be solid or in the form of powers, including liquids encapsulated by spray drying techniques or liquids adsorbed or absorbed into or onto a supporting matrix, i.e., silica, zeolite, carbon black, or porous matrices. Combinations of different active agents in the same structure may also be employed. For purposes of illustration, possible active agents may be: high intensity sweeteners, such as Aspartame, Alitame, Acesulfam-K and its salts, saccharin and its salts, Thaumatin, Sucralose, Cyclamic acid and its salts, Monellin, and Dihydrochalcones; acidulants, such as malic acid, citric acid, tartaric acid, and fumaric acid; salt, such as sodium chloride and potassium chloride; bases, such as, magnesium hydroxide and urea; flavours, such as spray dried natural or synthetic adsorbed onto silica, and absorbed into maltodextrin; flavour modifiers, such as Thaumatin; breath fresheners, such as zinc chloride, encapsulated menthol, encapsulated anise, zinc glucinate, and encapsulated chlorophyll; glycyrrhizins, including glycyrrhizic acid or salts (food grade) thereof, one such commercially available compound called Magnasweet 135 is manufactured by MacAndrew and Forbes, Camden, New Jersey, these compounds may be combined with a sugar; and medicaments. Of the various types of high intensity sweeteners, glycyrrhizins, such as Magnasweet 135, show surprisingly good results when combined with wall materials such as PVAc. When using Magnasweet 135, the occurrence of "off notes" (a residual taste of licorice) can be avoided by combining the product with a sugar. Furthermore, Magnasweet 135 can be used to form a gradual release structure, by combining it with a wall material such as PVAc and a sugar and heating the mixture in the temperature range of 140°-160°C. The resulting material can then be ground and exhibits gradual release characteristics. Care must be taken to avoid the degradation of the active agent from high temperatures, shear, or other conditions, which may occur during formation. The wall material can be any synthetic or nature polymer such as polyethylene, polyvinylacetate, polyesters, chitosan, and copolymers and polymer blends of these polymers. The active agent and wall material must meet the solubility requirements discussed above. Additionally, they must be immiscible with each other and capable of being uniformly dispersed when mixed together. The process of the present invention can be used to produce gradual release structures used in chewing gum. Chewing gum consists of a gum base to which a water soluble bulk portion may normally be added. Chewing gum bases generally comprise a combination of elastomers and resins together with plasticizers and inorganic fillers. The gum base produced by the process may contain natural gums and/or synthetic elastomers and resins. Natural gums include both elastomers and resins. Suitable natural gums include, but are not limited to chicle, jellutong, sorva, nispero tunu, niger gutta, massaranduba belata and chiquibul. When no natural gums are used, the gum base is referred to as "synthetic" and the natural gums are replaced with synthetic elastomers and resins. Synthetic elastomers may include polyisoprene, polyisobutylene, isobutylene-isoprene copolymer, styrene, butadiene rubber, a copolymer form Exxon Corp. under the designation "butyl rubber," and the like. The amount of elastomer used in the gum base can typically be varied from 10 to 20 percent depending on the specific elastomer selected and on the physical properties desired in the final gum base. For example, the viscosity, softening point, and elasticity can be varied. Resins used in gum bases may include polyvinylacetate, polyethylene, ester gums, (resin esters of glycerol), polyvinylacetate polyethylene copolymers, polyvinylacetate polyvinyl laurate copolymers, and polyterpenes. Additionally, a polyvinylacetate obtained from Monsanto under the designation "Gelva" and a polyterpene obtained from Hercules under the designation "Piccolyte" may be used. As with the elastomer, the amount of resin used in making the gum base can be varied depending on the particular resin selected and on the physical properties desired in the final gum base. Preferably, the gum base produced by the process also includes plasticizers selected from the group consisting of fats, oils, waxes, and mixtures thereof. The fats and oils can include tallow, hydrogenated and partially hydrogenated vegetable oils, and cocoa butter. Commonly employed waxes include paraffin, microcrystalline and natural waxes such as beeswax and carnauba. Additionally, mixtures of the plasticizers may be used such as a mixture of paraffin wax, partially hydrogenated vegetable oil, and glycerol monostearate. Preferably, the gum base produced by the process also includes a filler component. The filler component is preferably selected from the group consisting of calcium carbonate, magnesium carbonate, talc, dicalcium phosphate and the like. The filler may constitute from 5 to 60 percent by weight of the gum base. Preferably, the filler comprises 5 to 50 percent by weight of the gum base. Further, gum bases produced by the process may also contain optional ingredients such as antioxidants, colors, and emulsifiers. These ingredients of the gum base can be combined during the process in a conventional manner. In particular, the elastomer, resins, plasticizers, and the filler are typically softened by heating and then mixed for a time sufficient to insure a homogenous mass. The mass can be formed into slabs, or pellets and allowed to cool before use in making chewing gum. Alternatively, the molten mass can be used directly in a chewing gum making process. Typically, the gum base constitutes from 5 to 95 percent by weight of the gum. More preferably the insoluble gum base comprises from 10 to 50 percent by weight of the gum and most preferably from 20 to 35 percent by weight of the gum. In general, a chewing gum composition typically comprises a water soluble bulk portion added to the water insoluble chewable gum base portion. The flavoring agents are typically water insoluble. The water soluble portion dissipates with a portion of the flavoring agent over a period of time during chewing, while the gum base portion is retained in the mouth throughout the chew. The water soluble portion of the chewing gum produced by the process may further comprise softeners, sweeteners, flavoring agents and combinations thereof. Softeners are added to the chewing gum in order to optimize the chewability and mouth feel of the gum. Softeners, also known in the art as plasticizers or plasticizing agents, generally constitute between about 0.5 to about 15.0 percent by weight of the chewing gum. Softeners contemplated by the present invention include glycerin, lecithin, and combinations thereof. Further, aqueous sweetener solutions such as those containing sorbitol, hydrogenated starch hydrolysates, corn syrup and combinations thereof may be used as softeners and binding agents in the chewing gum. Sugar sweeteners generally include saccharide containing components commonly known in the chewing gum art which comprise but are not limited to sucrose, dextrose, maltose, dextrin, dried invert sugar, fructose, levulose, galactose, corn syrup solids, and the like, alone or in any combination. Non sugar sweeteners can include sorbitol, mannitol, and xylitol. Optional ingredients such as colours, emulsifiers and pharmaceutical agents may be added to the chewing gum. 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 by rolling into sheets and cutting into sticks, extruding into chunks or casting into pellets. 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. Colour 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 bulking agent. Further portions of the bulking agent may then be added to the mixer. The flavouring agent is typically added with the final portion of the bulking agent. The entire mixing procedure typically takes about fifteen minutes, but longer mixing times may sometimes be required. Those skilled in the art will recognise that many variations of the above described procedure may be followed. Gradual release structures are produced according to the present invention by extruding a uniform mixture of active agent and wall material into a fiber. The general principles for extruding polymers are well known in the art. In this process, a mixture of a polymer for the wall material and an active agent is prepared in powder or pellet form. The particles of polymer and active agent are mixed together into a homogeneous phase. The concentration of active agent in this mixture is such that the particles of active agent may be in contact with each other. The mixture is extruded. The extrudate is then gently broken into smaller sizes. Any grinding machine or knife which reduces the length of extrudate without excessively damaging the support matrix is suitable. Extrudate brittleness eases the cutting process and can be achieved by concentrating the solid active agent particles. To avoid the detection of the fibers when chewing the gum, broken extrudate of a size such that they can pass through a 60 mesh screen is used. Processability can be improved by increasing the processing temperature, introducing plasticizers, changing nozzle dimensions, adding dispersing agents, or modifying it by blending with other polymers. Changing nozzle dimensions such as by increasing the nozzle size can result, for example, in greater throughput, lower residence time, and lower pressure and sheer. Additionally, increasing the size of the nozzle results in an extrudate that is easier to handle and easier to cool. By way of illustration, larger fibers can be extruded using a slot die having a 25 mm (1 inch) by 3.2 mm (1/8 inch) opening. Handling and storage of the ground particles can also be facilitated by coating or blending them with a fumed silica, such as Cab-O-Sil. Extrudates of this type have been made having the following compositions (percentages are given by weight): (1) 75% PVAc having a molecular weight of about 50,000 - 80,000 as the wall material and 25% Acesulfam-K as the active agent; (2) 47.26% PVAc having a molecular weight of about 30,000 and 37.81% PVAc having a molecular weight of about 15,000 as the wall material and 37.81% sucrose, 9.45% Magnasweet 135, and 0.50% Magnesium Stearate as the active agent; (3) 75% PVAc having a molecular weight of about 50,000 - 80,000 as the wall material and 25% finely ground salt as the active agent; (4) 75% PVAc having a molecular weight of about 30,000 as the wall material and 25% Acesulfam-K as the active agent; (5) 74.6% PVAc having a molecular weight of about 50,000 - 80,000 as the wall material and 13.8% Magnasweet 135, 11.1% finely ground salt, and 0.5% Magnesium Stearate as the active agent; (6) 75% PVAc having a molecular weight of about 50,000 - 80,000 as the wall material and 15% Magnasweet 135 and 10% sugar as the active agent; (7) 99.5% (a mixture of 74.6% PVAc having a molecular weight of about 50,000 - 80,000 as the wall material and 13.8% Magnasweet 135, 11.1% finely ground salt, and 0.5% Magnesium Stearate as the active agent) and 0.5% fumed silica; and (8) 99.5% (a mixture of 75% PVAc having a molecular weight of about 50,000 - 80,000 as the wall material and 15% Magnasweet 135 and 10% sugar as the active agent) and 0.5% fumed silica. Active agents which may be heat sensitive and thus susceptible to degradation during the extrusion process can be cooled down quickly after extrusion to minimize or eliminate such degradation. As extrudate size increases, the demands upon cooling may also become greater. This quick cooling can be accomplished through the use of chilled rollers or plates. For example, three chromium coated water chilled compression rolls were used for quick cooling. The rolls compressed the extrudate into a thin wide sheet which allowed more surface area to be exposed to the cooling effects of the rolls. To create more surface area for cooling, the extrudate was mechanically compressed due to the relatively high extrudate viscosity. The compression rolls were obtained from Killion Extrudors, Inc., 200 Commerce Rd., Ceda Grove, NJ, 07009. The rolls were mounted 5.08 - 7.12 cm (2 to 3 inches) from the exit end of the extruder and vertically aligned with a 0.04 cm (0.016 inch) space (nip) between them. Each roll was eight inches long and five inches in diameter. City water, approximately 12.8°C (55°F), was pumped into each roll and passed through channels inside the rolls. The chromium coating conducted the heat well and kept the extrudate from sticking to the roll, allowing for easy cleanup. The extrudate was fed into the nip of the first two rolls. The opposing rotation of the first two rolls caused the extrudate to wrap around the second roll which in turn caused the extrudate to be fed into the nip between the second and third rolls. Once the extrudate past the third roll, it met two other rolls that were not chilled but were covered in rubber and plastic and which took the extrudate to a collection bin. These last two rolls were eight inches long and five inches in diameter. They helped keep the extrudate from blocking any of the first three rolls by keeping tension in the sheeted extrudate. They were also vertically aligned and counter-rotating. All of the rolls rotated at a speed of 30 revolutions per minute. By way of example, embodiments of the present invention were carried out on the following types of equipment. Twin Screw Extruder In Example 1, a type LSM 30:34 twin screw extruder from American Leistritz Extruder Corporation was used to produce the fibers. Generally, a homogeneous mixture of wall material and active agent in powdered form were poured into a hopper on the extruder. The hopper feed screws which forced the mixture through heated sections of the extruder, melting the polymer, and then through a die. The die consists of one or more holes having a specific diameter and length. Upon leaving the die the extrudate was stretched by either drawing it with a winder or by blowing air past it with a venturi. The twin screw extruder consisted of two sets of eight element screws. These screws can operate in an intermeshing fashion in either a co-rotational or a counter rotational mode. These screws can function as kneading elements or conveying elements. For the following examples, four kneading elements were used. Other configurations are possible and will depend on the process conditions and the types of materials being melt spun and the degree of mixing required. The twin screw extruder used in the following examples was divided into eight zones. The temperature of each zone was controlled. For example, a mixture of 50 percent by weight PVAc with a molecular weight of about 30,000, 25 percent by weight PVAc with a molecular weight of about 15,000, and 25 percent by weight Aspartame was extruded to produce extrudates. The following temperatures in degrees centigrade were used for each zone: Zone Temp. Feeding or hopper zone 85 2 95 3 95 4 95 5 95 6 95 7 95 Die or last zone 102 Example 1. Using slotted 2.54 cm by 3.18 cm (1 inch by 1-1/4 inch) die instead of a 2 mm die extrudate having 9.5% Magnasweet 135 by weight and 38% sugar by weight as the active agents and having 47.5% PVAc with a molecular weight of about 30,000 and 5% PVAc with a molecular weight of about 50,000 to 80,000 as the wall materials were extruded at about 80-100°C. In the following example 2, a twin screw extruder manufactured by Weisert Loser & Sohn KG (commonly referred to as a WLS extruder) was used. The wall material and active agent were premixed in a ribbon blender manufactured by Aaron Process Equipment until the active agent was well dispersed throughout the wall material. The screws were counter rotated, non-intermixing, and had a single pitch. There were no mixing or kneading elements. A single temperature zone was used having a temperature range of 90-110°C. A pipe having a length to diameter ratio of about 5 to 1 was attached to the extruder exit. A plate having 42 3.175 mm (1/8 inch) holes was placed at the end of the extruder with a 50.8 mm (2 inch) diameter extension pipe of eight inches in length being placed after the plate. Thus, the extrudate exited the extruder, was forced through the holes in the plate, and then recombined into a single extrudate again as it was forced through the extension pipe. Upon exiting the extension pipe an extrudate of about 50.8 mm (2 inches) in diameter was produced which was immediately fed through three chromium coated water chilled compression rolls of the type and configuration described hereinabove. Upon exiting the chill rolls the extrudate was sent through a cooling tunnel. The cooled extrudate was subsequently ground by using a hammer mill under cryogenic conditions. After which the desired particle size of smaller than 0.42 cm (0.165 inches) was obtained by centrifugal sifting through a 40 mesh sieve for incorporation into a chewing gum. Example 2. Extrudate having 9.45% by weight Magnasweet 135 (MacAndrews and Forbes), 37.81% sugar by weight and 0.50% Magnesium Stearate by weight as the active agent and 4.98% by weight PVAc with a molecular weight of about 15,000 and 47.26% by weight PVAc with a molecular weight of about 32,000 as the wall material were extruded at 90-100°C. The ground extrudate was incorporated into chewing gum which exhibited a gradual release of the active agent when chewed. Gradual release fibers having the formulation 24.52 wt percent NaCl and 15.48 wt percent KCl as active agents and Allied Chemical PE 735 as the wall material, were incorporated into gum having the following formulation: Ingredient % by weight Sugar 54.9 Stick Base 19.3 Corn Syrup 16.8 Dextrose Monohydrate 7.3 Glycerin 0.65 Fruit Flavor 0.8 Fibers 0.25 This gum was chewed by a panel of sensory experts who found that the gum was sweeter in the intermediate chew in addition to longer lasting flavor than a control gum of similar formulation which did not contain gradual release fibers. Similarly, gradual release fibers made in accordance with the present invention were incorporated into a gum having the following ingredients: Ingredient % by weight Stick Base 25.5 Sorbitol 44.7 Mannitol 8.0 Syrup 9.1 Ingredient % by weight Glycerin 6.3 Lecithin 0.2 Brown Color 0.05 Mint Flavor 1.4 Water 4.05 Fibers 0.7 The syrup consisted of 67% by weight Lycasin solids, 5.36% by weight water, and 27.14% by weight glycerin. The active agent in the gradual release fibers was Aspartame loaded at 33% by weight. This gum was chewed by a panel of sensory experts and found to have superior sweetness lasting when compared to a control gum of similar formulation that did not contain gradual release fibers. Chewing gums were prepared having the following general formula: Ingredient % by weight Sugar 50.76 Base 20.68 Corn Syrup 16.86 Dextrose 10.15 Glycerin 0.94 Spearmint Flavour 0.56 Brown Colour 0.05 To three gums having the above formula 0.3% by weight Aspartame was added. In the first gum, the Aspartame was contained in gradual release structure having 25% by weight loading of Aspartame and a wall material consisting of PVAc having a molecular weight of about 15,000. In the second gum, the Aspartame was contained in gradual release structure having 25% by weight loading of Aspartame and a wall material consisting of 50% (by weight of the total fiber) PVAc having a molecular weight of about 30,000 and 25% (by weight of the total fiber) PVAc having a molecular weight of about 100,000. In the third gum the Aspartame was encapsulated. A fourth gum of the above formula was prepared to which no Aspartame was added. Ten expert panellists were asked to chew samples of the above four gums and rate the sweetness of each gum over a 20 minute period. Sweetness ratings were taken after the first half minute of chewing, the first full minute of chewing and each full minute thereafter. This data is depicted graphically in Fig. 10. Analysis of this data shows that chewing gums containing gradual release structures exhibited significantly improved sweetness in the final chew when compared to the other two gums. Particularly, the sweetness levels in the gum containing the gradual release structures began to increase after 9 minutes of chewing while the other gums' sweetness was declining. Accordingly, a gum containing both encapsulated sweeteners and gradual release sweeteners could be made to obtain the benefits of both delivery systems in the same gum, the encapsulated sweetener providing sweetness during the initial and intermediate part of the chew and the gradual release structure providing sweetness during the final chew. Additionally, the data in Fig. 10 illustrates the difference in release rate between fibers having different wall material. Gradual release structure having a formulation of 47.26% PVAc having a molecular weight of about 30,000 and 4.98% PVAc having a molecular weight of about 15,000 as the wall materials and 37.81% sugar, 9.45% Magnasweet 135, and 0.5% Magnesium Stearate as the active agents were made. The Magnasweet 135 was first mixed with the Magnesium Stearate. The rest of the components were then added to this mixture. The fibers were extruded using a slot die of 25.4 mm (1 inch) by 1.59 mm (1/16 inch). The fibers were stretched by venturi. The temperature zones during extrusion were between 90° and 100°C. The temperature was 95°C at the die. These fibers were incorporated into a gum having the following formulation: Ingredient % by weight Sugar 53.3 Stick Base 24.0 Corn Syrup 5.1 Dextrose Monohydrate 13.4 Glycerin 2.0 Flavour (Mint) 1.4 10% Salt Solution 0.1 Fibers 0.7 This gum was chewed by about 100 people in a blind taste test. The control gum had the same formulation but had no fibers and no Magnasweet. The test showed that in comparison to the control: the gum having the fibers was preferred overall; that it had better flavour; that it had longer lasting taste, including sweetness; and that it had a sweeter taste.

Claims: A process for making chewing gum which comprises the steps of: a. preparing a gum base; b. preparing a water soluble bulk portion; c. preparing a gradual release structure which comprises the steps of: i) preparing a mixture of active agent and wall material, having more than zero but less than about 55 percent by weight active agent, said wall material being less soluble than said active agent, said wall material and said active agent being immiscible with each other and being capable of being uniformly dispersed when mixed together; and, ii) extruding the mixture through one or more die having one or more holes into an extrudate having a cross-sectional area of at least 161 square mm (½ square inches) in size; and, iii) grinding or breaking the extruded mixture; and, d. combining the gradual release structure, the gum base and the water soluble bulk portion. A process as claimed in claim 1 wherein the extruded mixture forms an extrudate which is cooled by passing it over at least one chill roll prior to grinding; A process as claimed in claim 2 wherein said chill roll is chromium coated. A process as claimed in any one of claims 1 to 3 wherein said extrudate exiting said die is passed through an extrusion pipe such that said extrudate is recombined into a single extrudate. A process as claimed in any one of claims 1 to 4 wherein said hole size is 25 mm x 6.3 mm (1 inch x ¼ inch). A process as claimed in any one of claims 1 to 5 wherein one or more of said holes are in the form of a slot. A process as claimed in any preceding claim in which the wail material comprises at least about 75 weight percent of the gradual release structure. A process as claimed in any preceding claim in which the wall material comprises at least one polyvinyl acetate having a molecular weight of from 15,000 to 80,000. A process as claimed in claim 8 in which said polyvinyl acetate has a molecular weight of about 30,000. A process as claimed in claim 8 in which the wall material comprises a blend of polyvinyl acetates having molecular weights from 15,000 to 80,000. A process as claimed in any preceding claim wherein said ground extrudate is coated or blended with fumed silica. A process as claimed in any preceding claim in which the active agent comprises aspartame. A process as claimed in any one of the preceding claims in which the active agent comprises a high intensity sweetener. A process as claimed in any one of the preceding claims in which the active agent comprises alitame. A process as claimed in any one of the preceding claims in which the active agent comprises Acesulfam-K. A process as claimed in any one of the preceding claims in which the active agent comprises glycyrrhizin. A process as claimed in any one of the preceding claims in which the active agent comprises a sugar and glycyrrhizin. A process as claimed in any one of the preceding claims wherein the gradual release structure prepared according to the process has more than about 10 percent by weight active agent. A process as claimed in one of claims 1 to 17 wherein the gradual release structure prepared according to the process has more than about 15 percent by weight active agent. A process as claimed in any preceding claim wherein the extruded mixture is ground or broken sufficiently small to avoid significant detection when the gum is being chewed. A process as claimed in any preceding claim wherein the extruded mixture is ground or broken such that the particles obtained pass a 60 mesh screen.

Inventors: COPPER CHARLES M, SONG JOO H, SPISIAK DANIEL R JR, COPPER, CHARLES M., SONG, JOO H., SPISIAK, DANIEL R., JR.
Applicants: WRIGLEY W M JUN CO, WM. WRIGLEY JR. COMPANY
Application year: 1992
Main classification: A23G3
IPC codes: A23G4, A23L1