IMPROVED ROLLING COMPOUND AND METHODS OF MANUFACTURING CHEWING GUM USING SAME

Abstract: An improved rolling compound and methods of manufacturing chewing gum. To this end, spray dried mannitol is utilized as a rolling compound.

Description: S P E C I F I C A T I O N TITLE IMPROVED ROLLING COMPOUND AND METHODS OF MANUFACTURING CHEWING GUM USING SAME BACKGROUND OF THE INVENTION The present invention relates generally to chewing gum. More specifically, the present invention relates to methods for manufacturing chewing gum. During the manufacturing process of chewing gum, the components that comprise the water insoluble gum base and soluble portion are mixed together in mixers and then typically extruded. In the extruder, the gum is formed into sheets, pellets, or ropes. The gum is then processed and packaged. In order to process the chewing gum form that is extruded, processing and packaging (wrapping) machines are utilized. However, when the chewing gum form exits the extruder, the gum is sticky. Accordingly, it is known to use agents - dusting agents or rolling compounds - to prevent the gum from sticking to the machinery. The rolling compound also allows sheets of gum to slide easily into high speed wrapping machines that package individual units of chewing gum. Thus, the rolling compound not only prevents the chewing gum from sticking to the machinery, it also provides for ease of handling of chewing gum. With respect to sugar containing chewing gum, powdered sugar is typically used as the rolling compound. Preferably, with respect to stick chewing gum, the powdered sugar is applied as the gum is extruded and formed into sheets. For sugar-free chewing gum, other materials have been utilized as the rolling compound. These materials include starch, powdered mannitol, sorbitol, xylitol, or lactitol. Typically, however, xylitol and sorbitol are not used in chewing gum production because of their hygroscopic nature and also they have a tendency to make the chewing gum look wet. Although starch has been used in the past, it provides chewing gum with an off taste. Additionally, starch has an unusual mouth feel. Accordingly, today, the most common rolling compound for sugarless gum is crystalline powdered mannitol. To provide the crystalline powdered mannitol rolling compound, mannitol is crystallized from a sorbitol/mannitol mixture. The crystalline mannitol is dried to a powder and then ground. Typically, fine powders of mannitol are reguired. Preferably, the crystalline powdered mannitol has a particle size wherein at least 98% of the particles pass through 100 mesh (smaller than 149 microns) . Generally, the mannitol crystalline powder is such that substantially all of the crystalline powdered mannitol will pass through a 200 mesh (smaller than 74 microns) . It is important that the crystalline powdered mannitol is sufficiently fine to eliminate any grittiness that might occur when the gum is chewed by the consumer. Although there are advantages to using crystalline powdered mannitol, e.g., crystalline powdered mannitol is one of the least hygroscopic polyols, there are some disadvantages with the use of crystalline powdered mannitol as a rolling compound. In this regard, crystalline powdered mannitol is higher in cost compared to some other polyols. Crystalline powdered mannitol also does not readily flow through the process equipment used for applying the rolling compound. This is especially a concern with respect to sugar-free gum because sugar-free gum is generally more tender and difficult to process than sugar gum. Thus, sugar-free gum requires more complicated equipment to apply the rolling compound. An additional problem is that crystalline powdered mannitol is only a fair rolling compound. Therefore, typically, additional flow agents must be added to the mannitol to give the chewing gum sufficient flow - properties through the processing machinery. One such flow agent is talc. Talc is typically used at levels from about 2 to 10% and preferably, at 7% of the total rolling compound. The use of talc can significantly improve the flow properties of crystalline powdered mannitol. However, this still does not overcome all of the disadvantages of using crystalline powdered mannitol. A number of patents disclose or discuss rolling compounds or methods. These include U.S. Patent Nos.: 5,094,858; 5,206,042; 4,997,659; 5,145,606; 4,997,659; and 4,976,972. Additionally, U.S. pending application 08/245,202 discloses a chewing gum with a rolling compound containing erythritol. SUMMARY OF THE INVENTION The present invention provides improved rolling compounds and methods of manufacturing chewing gum. To this end, spray dried mannitol is utilized as a rolling compound. The spray dried mannitol provides a material that is a very free flowing powder and easy to handle. The spray dried mannitol also provides improved chewing gum wrapping efficiency. Because the material appears to have a lower bulk density than crystalline mannitol, it is also believed that the use of spray dried mannitol reduces the amount of rolling compound needed and thereby reduces the cost. Due to the spherical nature of the spray dried mannitol, it provides an improved rolling compound. If desired, the mannitol may be spray dried with other fillers, such as talc or calcium carbonate, or with other polyols to reduce costs. To this end, in an embodiment, the present invention provides a rolling compound for chewing gum comprising spray dried mannitol having spherical particles. In an embodiment, the spray dried mannitol has a bulk density of less than 30 lbs/ft 3 . In an embodiment, the spray dried mannitol has the following particle size distribution: at least 95% of the particles pass through a 100 mesh sleeve; at least 90% of the particles pass through a 200 mesh sleeve; and at least 50% of the particles pass through a 325 mesh sleeve. In another embodiment, a method for manufacturing chewing gum is provided including the step of applying after the chewing gum form exists the mixer, spray dried mannitol to the chewing gum form. In an embodiment, the spray dried mannitol is applied with at least one composition chosen from the group consisting of: talc; calcium carbonate; silica; starch; a polyol; or mixtures thereof. In an embodiment, the spray dried mannitol is applied immediately after the chewing gum exists the extruder. In an embodiment, the spray dried mannitol is applied immediately before the chewing gum enters a wrapping machine.. In still another embodiment, a chewing gum is provided including an insoluble base portion, a water soluble portion, the water soluble portion and insoluble base portion defining a unit of chewing gum composition. A spray dried mannitol is located on portions of the unit of chewing gum. It is an advantage of the present invention to provide an improved rolling compound for chewing gum. Another advantage of the present invention is to provide an improved method for making chewing gum. Still further, an advantage of the present invention is to provide an improved rolling compound that has reduced cost as compared to typical rolling compounds. Furthermore, an advantage of the present invention is to provide a rolling compound that improves the flow of chewing gum through the processing machinery. Additionally, an advantage of the present invention is to provide a rolling compound that reduces the cost of manufacturing chewing gum. Further, an advantage of the present invention is to provide an improved rolling compound for sugar-free gum. Additional features and advantages of the present invention are described in, and will be apparent from, the detailed description of the presently preferred embodiments and the drawings. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 illustrates a scanning electron microscope (SEM) photograph of crystalline powdered mannitol. Figure 2 illustrates a SEM photograph of the spray dried mannitol of the present invention. DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS The present invention provides an improved rolling compound for chewing gum, as well as methods of manufacturing chewing gum. Pursuant to the present invention, spray dried mannitol is used as a rolling compound. Spray dried mannitol is a very free flowing powder that is easily handled. The spray dried mannitol provides improved processing of the chewing gum and reduces the amount of rolling compound necessary, thereby reducing the cost of the manufacturing process. The inventors have found that the spray drying process changes the morphology of mannitol. As illustrated in Figure 1, at 362x magnification, crystalline powdered mannitol has a crystalline agglomerate structure with an uneven surface area. As illustrated in Figure 2, spray dried mannitol has many spherical particles or agglomerated spherical particles. These spherical particles act as ball bearings with one another, have a smooth surface area, and increase the free flowing property of spray dried mannitol. Additionally, the mannitol obtained by spray drying a solution of mannitol is less dense than crystalline powdered mannitol. This will allow less material to be utilized, thus reducing costs. Also, mannitol may be spray dried with other fillers, such as talc, calcium carbonate, silica, or starch or spray dried with other sugars, if used on sugar gum, or sugar alcohols such as sorbitol, lactitol, maltitol, or isomalt, to reduce costs. It has also been found that under some conditions of spray drying, mannitol may have at least as advantageous particle size distribution as ground crystalline mannitol. Additionally, friction tests indicate that with spray dried mannitol applied to the gum, the spray dried mannitol reduced friction and improved processability and wrapping of the chewing gum. In an embodiment, preferably, the spray dried mannitol has a bulk density of less than 30 lbs./ft 3 . Preferably, the spray dried mannitol has a particle distribution such that: at least 95% of the particles pass through a 100 mesh sleeve; at least 90% of the particles pass through a 200 mesh sleeve; and at least 50% of the particles pass through a 325 mesh sleeve. Preferably, the spray dried mannitol rolling compound is used in the manufacture of sugar-free chewing gum. However, the spray dried mannitol can be used in the manufacturing of any chewing gum. In this regard, chewing gum generally consists of a water insoluble gum base, a water soluble portion, and flavors. The insoluble gum base generally comprises elastomers, resins, fats and oils, softeners, and inorganic fillers. The gum base may or may not include wax. The insoluble gum base can constitute approximately 5 to about 95 percent, by weight, of the chewing gum, more commonly, the gum base comprises 10 to about 50 percent of the gum, and in some preferred embodiments, 20 to about 35 percent, by weight, of the chewing gum. In an embodiment, the chewing gum base of the present invention contains about 20 to about 60 weight percent synthetic elastomer, 0 to about 30 weight percent natural elastomer, about 5 to about 55 weight percent elastomer plasticizer, about 4 to about 35 weight percent filler, about 5 to about 35 weight percent softener, and optional minor amounts (about one percent or less) of miscellaneous ingredients such as colorants, antioxidants, etc. Synthetic elastomers may include, but are not limited to, polyisobutylene with a GPC weight average molecular weight of about 10,000 to about 95,000, isobutylene-isoprene copolymer (butyl elastomer) , styrene-butadiene copolymers having styrene-butadiene ratios of about 1:3 to about 3:1, polyvinyl acetate having a GPC weight average molecular weight of about 2,000 to about 90,000, polyisoprene, polyethylene, vinyl acetate-vinyl laurate copolymer having vinyl laurate content of about 5 to about 50 percent by weight of the copolymer, and combinations thereof. Preferred ranges are, for polyisobutylene, 50,000 to 80,000 GPC weight average molecular weight, for styrene-butadiene, 1:1 to 1:3 bound styrene-butadiene, for polyvinyl acetate, 10,000 to 65,000 GPC weight average molecular weight with the higher molecular weight polyvinyl acetates typically used in bubble gum base, and for vinyl acetate-vinyl laurate, vinyl laurate content of 10-45 percent. Natural elastomers may include natural rubber such as smoked or liquid latex and guayule as well as natural gums such as jelutong, lechi caspi, perillo, sorva, massaranduba balata, massaranduba chocolate, nispero, rosindinha, chicle, gutta hang kang, and combinations thereof. The preferred synthetic elastomer and natural elastomer concentrations vary depending on whether the chewing gum in which the base is used is adhesive or conventional, bubble gum or regular gum, as discussed below. Preferred natural elastomers include jelutong, chicle, sorva and massaranduba balata. Elastomer plasticizers may include, but are not limited to, natural rosin esters, often called estergums, such as glycerol esters of partially hydrogenated rosin, glycerol esters polymerized rosin, glycerol esters of partially dimerized rosin, glycerol esters of rosin, pentaerythritol esters of partially hydrogenated rosin, methyl and partially hydrogenated methyl esters of rosin, pentaerythritol esters of rosin; synthetics such as terpene resins derived from alpha-pinene, beta-pinene, and/or d-limonene; and any suitable combinations of the foregoing. The preferred elastomer plasticizers will also vary depending on the specific application, and on the type of elastomer which is used. Fillers/texturizers may include magnesium and calcium carbonate, ground limestone, silicate types such as magnesium and aluminum silicate, clay, alumina, talc, titanium oxide, mono-, di- and tri-calciu phosphate, cellulose polymers, such as wood, and combinations thereof. In an embodiment, pursuant to the present invention, softeners/emulsifiers may include tallow, hydrogenated tallow, hydrogenated and partially hydrogenated vegetable oils, medium chain triglycerides, cocoa butter, glycerol monostearate, glycerol triacetate, lecithin, mono-, di- and triglycerides, acetylated monoglycerides, fatty acids (e.g. stearic, palmitic, oleic and linoleic acids) , and combinations thereof. Colorants and whiteners may include FD&C-type dyes and lakes, fruit and vegetable extracts, titanium dioxide, and combinations thereof. The base may or may not include wax. An example of a wax-free gum base is disclosed in U.S. Patent No. 5,286,500, the disclosure of which is incorporated herein by reference. In addition to a water insoluble gum base portion, a typical chewing gum composition includes a water soluble bulk portion and one or more flavoring agents. The water soluble portion can include bulk sweeteners, high intensity sweeteners, flavoring agents, softeners, emulsifiers, colors, acidulants, fillers, antioxidants, and other components that provide desired attributes. The softeners, which are also known as plasticizers and plasticizing agents, generally constitute between approximately 0.5 to about 15% by weight of the chewing gum. The softeners may include glycerin, lecithin, and combinations thereof. Aqueous sweetener solutions such as those containing sorbitol, hydrogenated starch hydrolysates, corn syrup and combinations thereof, may also be used as softeners and binding agents in chewing gum. Bulk sweeteners include both sugar and sugarless components. Bulk sweeteners typically constitute 5 to about 95% by weight of the chewing gum, more typically, 20 to 80% by weight, and more commonly, 30 to 60% by weight of the gum. Sugar sweeteners generally include saccharide- containing components commonly known in the chewing gum art, including, but not limited to, sucrose, dextrose, maltose, dextrin, dried invert sugar, fructose, levulose, galactose, corn syrup solids, and the like, alone or in combination. Sorbitol can be used as a sugarless sweetener. Additionally, sugarless sweeteners can include, but are not limited to, other sugar alcohols such as mannitol, lactitol, xylitol, hydrogenated starch hydrolysates, maltitol, and the like, alone or in combination. High intensity artificial sweeteners can also be used in combination with the above. Preferred sweeteners include, but are not limited to sucralose, aspartame, salts of acesulfame, alitame, saccharin and its salts, cyclamic acid and its salts, glycyrrhizin, dihydrochalcones, thaumatin, monellin, and the like, alone or in combination. In order to provide longer lasting sweetness and flavor perception, it may be desirable to encapsulate or otherwise control the release of at least a portion of the artificial sweetener. Such techniques as wet granulation, wax granulation, spray drying, spray chilling, fluid bed coating, coacervation, and fiber extrusion may be used to achieve the desired release characteristics. Usage level of the artificial sweetener will vary greatly and will depend on such factors as potency of the sweetener, rate of release, desired sweetness of the product, level and type of flavor used and cost considerations. Thus, the active level of artificial sweetener may vary from 0.02 to about 8%. When carriers used for encapsulation are included, the usage level of the encapsulated sweetener will be proportionately higher. Combinations of sugar and/or sugarless sweeteners may be used in chewing gum. Additionally, the softener may also provide additional sweetness such as with aqueous sugar or alditol solutions. If a low calorie gum is desired, a low caloric bulking agent can be used. Examples of low caloric bulking agents include: polydextrose; Raftilose, Raftilin; Fructooligosaccharides (NutraFlora) ; Palatinose oligosaccharide; Guar Gum Hydrolysate (Sun Fiber) ; or indigestible dextrin (Fibersol) . However, other low calorie bulking agents can be used. A variety of flavoring agents can be used. The flavor can be used in amounts of approximately 0.1 to about 15 weight percent of the gum, and preferably, about 0.2 to about 5%. Flavoring agents may include essential oils, synthetic flavors or mixtures thereof including, but not limited to, oils derived from plants and fruits such as citrus oils, fruit essences, peppermint oil, spearmint oil, other mint oils, clove oil, oil of wintergreen, anise and the like. Artificial flavoring agents and components may also be used. Natural and artificial flavoring agents may be combined in any sensorially acceptable fashion. The present invention, it is believed, can be used with a variety of processes for manufacturing chewing gum. Chewing gum is generally manufactured by sequentially adding the various chewing gum ingredients to commercially available mixers known in the art. After the ingredients have been thoroughly mixed, the chewing 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 gum base may alternatively be melted in the mixer. Color and emulsifiers can be added at this time. A chewing gum softener, such as glycerin, can be added next along with syrup and part of the bulking agent. Further, parts of the bulking portion are added, with flavor being added with the final bulk portion. The entire mixing process typically takes from five to fifteen minutes, although longer mixing times use sometimes required. After exiting the mixer, the spray dried mannitol is applied to the chewing gum during the processing of the chewing gum. It should be noted that after the chewing gum exits the mixer, it may be extruded, sheeted, - or cast. The spray dried mannitol would preferably be applied after one of these steps, though it can be applied at any stage during processing or wrapping. The spray dried mannitol functions as a rolling compound improving processability and wrapping. By way of example, and not limitation, examples of the present invention will now be given: EXAMPLE Sample Preparation A 30% solution of mannitol in water at 180°F was prepared by mixing 1020 grams of mannitol in 2,380 g of 180°F water with the temperature held at 180°F until all the mannitol dissolved. This solution was then spray dried in a pilot scale Niro spray dryer, 54 inches in diameter and equipped with a spray nozzle under the following conditions: Feed Pressure 40 psi Feed Temperature 150° - 180°F Inlet Temperature 155° - 160°C Outlet Temperature 85 - 89°C Feed Rate 30 - 40 ml/min. Automizer Air Pressure 36 - 38 PSI Pump Speed 12 - 15 RPM Examples About 740 grams of spray dried mannitol was recovered. This spray dried material (Example 1) was compared to sifted mannitol powder that was made by crystallization (Comparative Example A) , by particle size distribution, bulk density (average of loose and packed bulk density) , and coefficient of friction. Coefficient of friction was determined by using a Friction/Peel Tester Model 225-1 from Thwing-Albert Instrument Co., Philadelphia, PA. In addition to the above, two additional samples were evaluated for angle of repose and coefficient of friction. These samples included two blends of sifted crystalline mannitol powder and spray dried powder at ratios of 1:2 (Example 2) and 2:1 (Example 3) for sifted crystalline powder: spray dried powder. Table I below gives the results of particle size distribution and bulk density: Table I Comp Example A Example 1 % Retained % Retained On 100 mesh 1.00 0.25 On 170 mesh 15.80 1.54 On 200 mesh 2.24 0.49 On 230 mesh 4.20 0.73 On 325 mesh 35.18 34.21 Through 325 mesh 41.58 62.78 100.00 100.00 Bulk density 37.4 lbs/ft 3 25.1 lbs/ft 3 The differences between crystalline mannitol and spray dried mannitol demonstrate that spray dried mannitol has a smaller particle size and lower bulk density than crystalline mannitol. Additional tests for the comparative example and the 3 examples noted above are discussed below. Angel of Repose The method for the angle of repose analysis is described in U.S. Patent No. 5,206,042 (the disclosure of which is hereby incorporated herein by reference) and in U.S. Application No. 08/254,202. Results of the comparative examples and the other 3 examples are shown in Table II (below) . For angle of repose, the lower the number, the more free flowing is the powder. As demonstrated by the results, 100% spray dried mannitol is more free flowing than crystalline mannitol or even crystalline mannitol with a flow agent. Even the blends of spray dried mannitol have better free flow properties than crystalline mannitol or mannitol with talc. The remaining data shown in Table II is from U.S. Application No. 08/245,202, and items 7 and 8 are replicates done at different times. TABLE II ANGLE OF REPOSE POWDER-COMPOSITION ANGLE 1 Spray Dried Mannitol-100% Example 1 20.8 2 SD Mannitol-67%/Mannitol-33% Example 2 21.8 3 SD Mannitol-33%/Mannitol-67% Example 3 25.7 4 Fine Powder Lactitol-100% 26.3 5 Mannitol-93%/Talc-100% 28.6 6 Milled Sucrose-100% 32.8 7 Mannitol-100% Comp. Example A 36.2 8 Mannitol-100% 38.1 9 Xylitol-100% 44.3 RATINGS ANGLE OF REPOSE Excellent <30 Good 31-35 Fair 36-40 Passable 41-45 Poor 46-55 Very Poor 56-65 Coefficient of Friction To the plate of the friction tester, a 18" x 6" x 1/8" thick slab of sugarless gum was attached. The gum had no rolling compound. Another piece of the same gum was attached to the bottom of the 4" x 2 V sled that slides over the plate of gum. It also had no rolling compound. After the gum was attached to the sled, 0.5 grams of material from Example 1 was spread over the gum on the plate and on the sled. To approximate conditions of stacked gum, a 2000 gram weight was placed on the sled. The sled is placed on top of the gum on the plate and then hooked to the friction tester and started with a speed set at "C", temperature off and time set at 10 seconds. The friction tester measures ST (static energy - the amount of energy needed to initiate movement) and KI (kinetic energy needed to maintain movement) . Thus a lower reading indicates lower friction. Three readings were taken for Examples 1, 2, 3, and Example 6A to obtain ST and KI values. Results are shown below: Table III ST fn=3) KI (n=3) Example 1 0.638 0.479 Example 2 0.791 0.632 Example 3 0.838 0.652 Example A 0.848 0.692 The results show that spray dried mannitol reduces friction between gum pieces much more than crystallized mannitol. Even a blend of crystallized mannitol and spray dried mannitol reduces friction of gum. This could improve processing and speed in high speed wrapping machines. 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 invention and without diminishing its attendant advantages. It is therefore intended that such changes and modifications be covered by the appended claims.

Claims: WE CLAIM: 1. A rolling compound for chewing gum comprising spray dried mannitol. 2. The rolling compound of Claim 1 including talc. 3. The rolling compound of Claim 1 including calcium carbonate. 4. The rolling compound of Claim 1 including a filler. 5. The rolling compound of Claim 1 wherein the spray dried mannitol has a bulk density of less than 30 lbs/ft 3 . 6. The rolling compound of Claim 1 wherein the spray dried mannitol has the following particle size distribution: at least 95% of the particles pass through a 100 mesh sleeve; at least 90% of the particles pass through a 200 mesh sleeve; and at least 50% of the particles pass through a 325 mesh sleeve. 7. The rolling compound of Claim 1 including powdered crystallized mannitol. 8. The rolling compound of Claim 1 wherein at least substantially all of the spray dried mannitol has a spherical shape. 9. A method for manufacturing chewing gum including the step of: after the chewing gum exists a mixer applying spray dried mannitol to the chewing gum. 10. The method of Claim 9 including the step of applying with the spray dried mannitol at least one composition chosen from the group consisting of: talc; calcium carbonate; silica; starch; a polyol; and mixtures thereof. 11. The method of Claim 9 wherein the spray dried mannitol has a bulk density of less than 30 lbs/ft 3 . 12. The method of Claim 9 wherein the spray dried mannitol has the following particle size distribution: at least 95% of the particles pass through a 100 mesh sleeve; at least 90% of the particles pass through a 200 mesh sleeve; and at least 50% of the particles pass through a 325 mesh sleeve. 13. The method of Claim 9 wherein the spray dried mannitol is applied after the chewing gum has exited an extruder. 14. The method of Claim 9 wherein the spray dried mannitol is applied after the chewing gum has been sheeted. 15. The method of Claim 9 wherein the spray dried mannitol is applied before the chewing gum enters a wrapping machine. 16. The method of Claim 9 wherein the spray dried mannitol is applied to sugar-free chewing gum. 17. A chewing gum including: an insoluble base portion; a water soluble portion; the water soluble portion and insoluble base portion defining a unit of chewing gum composition; and a spray dried mannitol located on portions of the unit of chewing gum composition. 18. The chewing gum of Claim 17 wherein the chewing gum is sugar-free. 19. The chewing gum of Claim 17 wherein the unit of chewing gum has a stick shape. 20. The chewing gum of Claim 17 wherein the unit of chewing gum is pellet shaped.

Inventors: DAVE JAYANT C, DUBINA EDWARD S, PATEL MANSUKH M, TYRPIN HENRY T, DAVE, JAYANT, C., DUBINA, EDWARD, S., PATEL, MANSUKH, M., TYRPIN, HENRY, T.
Applicants: WRIGLEY W M JUN CO, WM. WRIGLEY JR. COMPANY
Application year: 1995
Main classification: A23G3
IPC codes: A23G3, A23G4