Patent Publication Number: US-2010129500-A1

Title: Method of preparing a coated confectionary product

Description:
FIELD OF THE INVENTION 
     This invention relates to methods of preparing a food product, and in particular to methods of preparing a coated confectionary product. 
     BACKGROUND 
     Numerous coated confectionaries are available. Many confectionaries, such as M&amp;M&#39;s or chewing gum balls, have a hard shell sugar coating. Some products, such as M&amp;M&#39;s CRISPIES, have a hard center, with a chocolate covering followed by a hard shell coating. Other products include a chewy center with a hard candy shell. Thus confectionary products with multiple layers and coatings are known. 
     However, producing a product with a chewy center and a hard shell can cause processing difficulties, especially with controlling the crystallinity and moisture levels in the product. It is difficult to coat a soft center with a hard coating. Also, hard shells can be brittle and difficult to package without damaging the product or causing the hard shell to chip off or break. 
     BRIEF SUMMARY 
     In one aspect, a method of producing a confectionary product includes providing a chewy material including a first sweetener and a fat. The chewy material is mixed in a mixing device and metered through a pumping device. A candy material including a second sweetener is disposed around the chewy material to form a jacketed confectionary material. The jacketed confectionary material is formed into a confectionary product. 
     In another aspect, a method of producing a confectionary product includes providing a first candy material and mixing the first candy material in an extrusion mixing device. The first candy material is cooled after exiting the extrusion mixing device. The first candy material is metered through an extruder. A second candy material is disposed around the first candy material in a batch roller to form a jacketed confectionary material. The jacketed confectionary material is formed into a confectionary product. 
     In another aspect, a method of preparing a confectionary product includes providing a chewy material including a sweetener and providing a candy material including an amorphous sweetener. Nucleating sites are created in the candy material. The chewy material is mixed in an extrusion mixing device. The chewy material is metered through a pumping device. The chewy material is coated with the candy material to form a jacketed material. The jacketed material is coated with a hard shell coating. The amorphous sweetener is allowed to at least partially crystallize. 
     The foregoing and other features and advantages of the present invention will become apparent from the following detailed description of the presently preferred embodiments, when read in conjunction with the accompanying examples. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  shows an embodiment of a pack of confectionary products. 
         FIG. 2  shows one embodiment of a confectionary product. 
         FIG. 3  shows a cross section along  3 - 3  of the confectionary product of  FIG. 2 . 
         FIG. 4  shows one embodiment of a process for producing the confectionary product of  FIG. 2 . 
     
    
    
     DETAILED DESCRIPTION OF THE DRAWINGS AND PREFERRED EMBODIMENTS 
     The present invention will now be further described. In the following passages, different aspects of the invention are defined in more detail. Each aspect so defined may be combined with any other aspect or aspects unless clearly indicated to the contrary. In particular, any feature indicated as being preferred or advantageous may be combined with any other feature or features indicated as being preferred or advantageous. 
     One embodiment of a pack  10  of confectionary products  12  is shown in  FIG. 1 . While products of the present invention may be made in a wide variety of shapes, one embodiment of the confectionary product  12  is shown in  FIG. 2 . The confectionary product  12  has a cylindrical shape and is about 16-22 mm in diameter and about 8-12 mm high. However, other shapes and dimensions of the confectionary product are possible. 
     As best seen in  FIG. 3 , the confectionary product has a center  20 , an intermediate layer  24 , and an outer layer  22 . The center  20  is chewy and includes a sweetener, water, and flavor. The intermediate layer  24  includes a sweetener and flavor, and is at least partially crystalline. In one embodiment, the intermediate layer  24  includes a crystalline portion  18  and an amorphous portion  16 . The outer layer  22  may be a crunchy hard shell and includes a sweetener and flavor. 
     The chewy center  20  may be crystallized, partially crystallized, uncrystallized, long chew, short chew, or grained. In one embodiment, the chewy center includes a texturizer. The texturizer is added to control the consistency and texture of the chewy center. The texturizer may be a fiber material, such as a dextrin. Other texturizers, such as proteins (such as albumin and gelatin), polyols (such as hydrogenated starch hydrolysates), hydrocolloids, gums, and similar materials, may also be used. The texturizer may be a branched maltodextrin such as Nutriose®. The expression “branched maltodextrin” includes maltodextrins as described in European patent publication EP 1 006 128. These branched maltodextrins exhibit an indigestibility character which has the consequence of reducing their calorific value. 
     The confectionary product may include sugar or sugarless materials. As a general matter, sweeteners used in the confectionary product may include, but are not limited to, sugars, corn syrups, polyols, hydrogenated starch hydrolysate syrup and combinations thereof In one embodiment, the sweetener in the chewy center, the intermediate layer, and the outer layer includes sucrose and corn syrup. Different sweeteners may be used in the different layers of the confectionary product. 
     A conventional hard candy formulation may be used for the intermediate layer  24  and the outer layer  22 . In one embodiment, the hard candy is made with sucrose and corn syrup blends. A blend of about 65/35 is a typical sucrose/syrup blend made for hard candy. Other sugars such as dextrose or lactose, along with corn syrups, may also be used for making a hard candy. The intermediate layer  24  may be glass or amorphous. The outer layer  22  may be a shell coating and may be hard panned, soft panned, or sugar shelled. 
     For a sugarless product, polyols are generally used, such as hydrogenated isomaltulose (which is also called isomalt), xylitol, maltitol and hydrogenated starch hydrolysates (HSH). In addition, isomalt/xylitol blends, isomalt/maltitol blends, isomalt/hydrogenated starch hydrolysate blends or maltitol/HSH blends may be used. Thus, in one embodiment, the sweetener is a non-sugar sweetener such as a polyol (such as isomalt) and a maltitol syrup (such as Lycasin®). 
     In one embodiment, the chewy candy center also includes acacia gum and a fat such as HPKO (hydrogenated palm kernel oil). Other possible fats include, but are not limited to, vegetable oil, partially hydrogenated vegetable oil, palm oil, butter, and lard. In one embodiment, the chewy center also includes lecithin, glyceride, and/or other emulsifiers. The chewy center also includes flavor. The flavor may be any suitable flavor, such as menthol. In one embodiment, the chewy center does not include starch. In another embodiment, the chewy center does not include gelatin. 
     The flavors used in the various layers of the confectionary product may include cooling agents such as menthol as well as essential oils, synthetic flavors, or mixtures including but not limited to oils derived from plants and fruits such as citrus oils, fruit essences, peppermint oil, spearmint oil, clove oil, oil of wintergreen, anise and the like. Artificial flavoring components are also contemplated for use in the confectionary product. Those skilled in the art will recognize that natural and artificial flavoring agents may be combined in any sensorially acceptable blend. All such flavors and flavor blends are contemplated by the present invention. 
     Colors and other additives are also contemplated for use in the confectionary product. Colors commonly used are FD&amp;C lakes and dyes and some natural colors. Preferably, FD&amp;C dyes are used. Other natural colors include colors such as chlorophyll, curcumin, caramel, carmine, annatto, and other similar types of colors. While the chewy center, intermediate layer, and outer layer may comprise a color, one, two, or all three layers can be uncolored, and if a color is used, it may be the same or different in each of the three layers. 
     In one embodiment, a method of producing the confectionary product includes providing a chewy material and a candy material. While not intending to be bound by any particular theory, the relative chewiness and crunchiness of the layers of the confectionary product are determined in part by the crystallinity and moisture content of the respective layers. The candy material includes a sweetener. The sweetener is at least in part amorphous. The water activity of the chewy material may be greater than the water activity of the candy material in this stage of the process. Water activity is the relative availability of water in a substance. Water activity is defined as the vapor pressure of water in a material divided by the vapor pressure of pure water at a given temperature. Water tends to migrate from a material with a high water activity to a material with a lower water activity. 
     Nucleating sites may be created in the candy material to promote crystallization. Nucleating sites may also be created in the chewy center, which will then allow crystallization to begin at the interface between the chewy center and the candy material. Water is allowed to migrate from the chewy material to the candy material. The amorphous candy material is allowed to crystallize at least in part. Thus, the crystallinity of the candy material increases, making it less crunchy and more chewy. 
     In one embodiment, the step of creating nucleating sites in the candy material includes disposing a seeding agent adjacent the candy material. The seeding agent may be a crystalline material such as powdered sugar. In another embodiment, crystallinity is induced in the chewy material and the crystals in the chewy material adjacent the candy material act as nucleating sites. Nucleation sites may also be creating by shearing the candy material and/or the chewy material. 
     Another embodiment of a candy product includes two layers, a chewy center and a hard outer shell. The hard outer shell may be a glass candy material. The outer shell may be transparent or translucent. The candy product may include different flavors in the chewy center and the hard outer shell. Unlike the previously described embodiment, the water activities of the chewy center and the hard outer shell will generally be similar, because it is desired that the outer shell retain its crunchiness. 
     The confectionary product may be produced by any suitable method. One embodiment of a method of preparing the confectionary product is shown in  FIG. 4 . As a brief overview, a sweetener and a texturizer are provided in pre-blend tank  30 . This mixture goes to cooker  40 , and then to mixer and inline aerator  50  (such as a Turbomat), to provide a chewy material. Various other ingredients are also added to mixer  50 . Ingredients for the candy material are provided to cooker  60 . The chewy material and candy material are cooled on belt  70 . The chewy material is placed in an extrusion mixing device  80 , and then transferred to a pumping device  90 . The chewy material and candy material are disposed together in a batch roller  100 , and then formed into individual pieces at forming step  110 . The pieces are pre-coated in an inline coater  120 . The pieces may then be graded at grader  130 . A final coating is then applied at Driam coater  140 . A second grader  150  may also be used, followed by packaging  160 . 
     There are several ways to control the crystallinity and grain size in the layers of the confectionary product. These control methods include adjusting the sweeteners in the chewy material, controlling the shear in the extruders, and the use of seed crystals. Specifically, increasing the amount of corn syrup relative to the amount of sugar in the chewy material will decrease crystallization. Increasing the amount of shear in the extruder will increase crystallization and increase the number of nucleation sites in the material. Seed crystals, such as powdered sugar, may be added at various stages in the process (such as in the Turbomat and in the extruder) to provide nucleation sites to promote crystallization. 
     One embodiment of the process for producing the confectionary product will now be discussed in more detail. A chewy material including a sweetener is provided. In one embodiment, the sweetener includes corn syrup and sucrose. In another embodiment, the sweetener is a non-sugar sweetener. The sweetener, water, and a texturizer are mixed in a pre-blend tank  30 . In one embodiment, the texturizer includes a branched maltodextrin such as Nutriose®. The mixture is heated and pumped to a cooker  40 . The slurry is cooked to the desired moisture level. In one embodiment, the desired moisture level in the slurry coming out of the cooker  40  is in the range of about 6% to about 8%, preferably in the range of about 7.2% to about 7.8%. 
     The slurry is then added to a mixing device  50 . In one embodiment, the mixing device  50  includes aeration. In one embodiment, the mixing device  50  is a Turbomat, which aerates and provides in-line mixing. Alternatively, the chewy material could be pulled (like taffy) to provide aeration. A variety of other materials may be added during of after this mixing step, such as binders, texturing agents, and seeding agents. In one embodiment, an acacia gum solution is added. In one embodiment, a fat, acid, powered sugar and lecithin mixture is metered in to the product stream directly after the aeration step. If a seeding agent is added, the chewy stream may begin to crystallize. In the Turbomat, the resulting slurry is mixed and aerated to form a chewy center stream. The process may include an additional inline mixer  52  after the Turbomat. 
     A candy material stream is formed from a sweetener and water to make a slurry of about 75% solids. In one embodiment, the sweetener is sucrose. In another embodiment, the sweetener is isomalt. The candy material stream may also include starch, water, colorings such as titania, and flavor. The candy material stream is heated and cooked in cooker  60  to reach a desired moisture level of approximately 4% (96% solids). The candy material includes an amorphous sweetener. 
     The chewy center stream and the candy material stream are then pumped to a cooling or tempering belt  70 . Additional materials, such as flavors or acids, may be added to the chewy center and/or the candy material at this stage. In one embodiment, the chewy stream is cooled to about 40-45° C., and the candy material to about 75-80° C. The relative flow rates of the chewy material and the candy material are determined in part by the desired composition of the confectionary product. In one embodiment, the ratio of the flow of the chewy stream to the flow of the candy material is between about 3:7 and 7:3. In another embodiment, the ratio is between 3:7 and 5:5. At this stage, the candy stream is about 96% solids and the chewy center stream is about 92% solids. A nucleating agent such as powdered sugar may be added to the chewy stream. The powdered sugar or other additive may also help provide traction to the chewy material during subsequent processing. 
     The chewy stream is then introduced into a mixing device  80 . The temperature of the chewy stream when entering the mixing device  80  is typically about 40-45° C. The mixing device  80  may be an extruder, such as a conditioning extruder. A suitable conditioning extruder is a Proform Extruder (such as Proform ME140, a co-rotating intermeshed twin screw extruder with no mixing elements and a 750 kg/hr maximum capacity). The conditioning extruder mixes the components of the chewy stream together, and in particular mixes the nucleating agent (which may be powdered sugar) throughout the chewy material. The mixing device  80  may operate at a low shear rate to avoid over-crystallizing the chewy material. After exiting the conditioning extruder, the chewy stream may then be introduced onto a tempering/relaxation belt to cool the stream. The residence time on the tempering belt may be about 4 minutes and preferably cools the chewy stream to under about 51° C. 
     The chewy stream is then introduced into a pumping or metering device  90  in order to provide a constant flow rate. The pumping device  90  may be an extruder, such as a filling extruder. The extruder may be a screw pump which does not provide mixing. A suitable extruder is a Bosch Rope X 1020, a counter-rotating twin screw extruder with a 800 kg/hr maximum capacity. Upon exiting the extruder, the chewy stream is fed to a batch rolling device in order to dispose the candy material around the chewy material. 
     The chewy material is coated with the candy material to form a jacketed material. The candy material may be what is known as a hard candy material. In one embodiment, the chewy stream and the candy material stream are combined in a batch roller  100 , with the candy material stream surrounding the chewy stream. The batch roller  100  may be a center filled batch roller. A suitable center-filled batch roller is a modified Bosch BAK 0165 BB, with a 1000 kg/h maximum capacity. The center-filled batch roller includes a fixed Teflon center tube around which the candy material is deposited. The chewy material flows through the plastic center tube and the candy material is deposited upon the chewy material at the end of the center tube. The angle of the batch roller, direction of the rotation, and product temperature are controlled to provide proper coating. 
     On entering the batch roller  100 , the water activity of the chewy material may be about 0.40-0.60 and the water activity of the candy material may be about 0.15-0.35. After the jacketed material is formed, water migrates from the chewy material to the candy material. As the water migrates from the chewy material to the candy material, it promotes crystallization of the candy material. 
     The temperatures of the chewy material and the candy material are controlled to provide proper coating in the batch roller  100 . The temperature of the hard candy material entering the batch roller may be between about 70° C. and 80° C., and should be between about 72° C. and 76° C. The temperature of the chewy material entering the batch roller should be between about 50° C. and 55° C. If the candy material is too hot, it may slump in the batch roller  100 . The candy material may also wrap around the cone rollers, causing sticking or jamming of the machine. Too hot candy material may also excessively heat the chewy candy portion, causing sticking in the forming dies and causing poor coating of the chewy material. If the hard candy material is too cold, it may have inadequate flow through the batch roller, may set within the machine (forcing machine stoppage), or may cause stretching and cracking during sizing, thus causing chewy candy to be exposed and stick to the sizing rollers during sizing. 
     Particulate material may be added at various stages of the process, such as before the mixing device  80 , or on the tempering belt  70 . 
     The candy stream (consisting of hard and chewy candy) is sent from the batch roller  100  through a rope sizer to reduce the diameter of the rope stream. The stream is then formed into individual candy pieces. In one embodiment, the individual candy pieces are about 2 g each. The resulting candy pieces are cooled in a cooling tunnel  110  and are loaded into a set of rotating cylindrical drums and pre-coated with a sweetener solution in a multi-step precoat addition  120  that consists of adding a pre-coat solution prior to additions of dry sugar and a mixture of dry sugar and dry gum arabic. In one embodiment, the sweetener solution includes sugar. The pre-coat solution may include gum arabic. In one embodiment, the pre-coat solution includes about 60% water, 12% gum arabic, and 28% powdered sugar. In another embodiment, the pre-coat solution includes 30-35% water, 22-27% sugar and gum Arabic solution, and 40-43% 42DE corn syrup. Alternatively, the pre-coating step may be skipped. 
     The individual pieces may then be graded at  130  and transferred to individual plastic storage containers and stored in a refrigerated room, preferably at about 18° C. for about 12 hours. The pieces are then coated with a hard shell coating. The step of coating the pieces with a hard shell coating can occur before or after the candy material reaches crystallization equilibrium. In one embodiment, the pre-coated centers are coated in a Driam coater 140 with a sugar syrup to create a candy product. The use of a Driam coater to coat a confectionary product is described in U.S. Pat. No. 6,444,240, the contents of which are hereby incorporated by reference. 
     The process produces a confectionary product with three layers: a chewy center, an amorphous intermediate layer, and a hard candy outer shell. The amorphous sweetener in the intermediate layer is allowed to at least partially crystallize, which makes the intermediate layer chewier. Preferably, the candy material intermediate layer crystallizes over the course of 1-3 weeks, so that by the time the confectionary product reaches the consumer it has the desired texture. Thus, the process is able to coat the individual candy pieces while hard (as they come out of the batch roller), while during the normal distribution time a portion of the candy layer became soft. The candy pieces may be packaged before the hard candy outer shell becomes brittle. 
     Examples  
     Example 1 
     A confectionary product was prepared from the process depicted in  FIG. 4 . Corn syrup (74.5 kg/hr), granulated sucrose (74.5 kg/hr), water (as needed), and Nutriose (13.7 kg/hr) were mixed in a pre-blend tank. The mixture was heated and pumped to a cooker. The slurry was cooked to 128° C. to the desired moisture level of 6-7%. The slurry was then added to the Turbomat. Also added to the Turbomat are: an acacia gum and water solution at a 1:1 acacia gum to water ratio and a fat mixture including about 72% hydrogenated fat, 25% powdered sugar, 1.7% glyceride and 1.7% lecithin. In the Turbomat, the resulting slurry was mixed and aerated to form a chewy center stream. The Turbomat operated at 8 bar. Individual feed pumps metered the appropriate amount of chewy candy cooked slurry (192 L/h), gum solution (12.5 L/h), and fat solution (40 L/h). 
     A hard candy material stream was formed from corn syrup and sugar to make a slurry. The candy material stream was stored in a water jacketed tank and cooked to 145° C. 
     The chewy center stream and the candy material stream were each pumped to a cooling belt. The chewy stream was cooled to about 40-45° C. and the candy material was cooled to about 70° C.-80° C. on a tempering belt. The ratio of the flow of the chewy stream to the flow of the hard candy material was 3:2. Powdered sugar (0.12 kg/min) was added into the chewy stream. The chewy stream was mixed in a conditioning extruder and then deposited on a tempering/relaxation belt to cool the material. The cooled chewy stream, at a temperature of about 50-52° C., was then fed to a filling extruder to control the flow rate and act as a pump for the batch roller. The chewy stream and the candy material stream were combined in a center-filled batch roller, with the candy material stream surrounding the chewy stream. At the center-filled batch roller, the chewy stream was at about 55° C. and the hard candy material was at about 72° C.-76° C. The jacketed stream was sent through a rope sizer to reduce the diameter of the stream. The stream was then formed into individual candy pieces of about 2 g each. 
     The resulting candy pieces were loaded into a set of two rotating cylindrical drums and pre-coated with a sugar, water, and gum acacia solution at about 10% by weight of the candy pieces. They were then transferred to individual plastic storage containers and stored in a refrigerated room at 18° C. for 12 hours. The pre-coated centers were then coated in a Driam coater with sugar solution to create a candy product of about 2.6 g. 
     Example 2 
     A variety of confectionary products were made according to the general process as shown in  FIG. 4 . The composition of the chewy center material is shown in Table 1. The composition of the candy material is shown in Table 2. The jacketed material included 60% of the chewy center, and 40% of the hard candy material. The jacketed products were then coated with an outer sugar shell with the formulation shown in Table 3. The outer shell provided about 30% by weight of the final candy product. 
     The formulations in Example 2 produced confectionary products with acceptable properties. 
     
       
         
           
               
               
               
               
             
               
                   
                 TABLE 1 
               
               
                   
                   
               
               
                   
                   
                   
                 Example 2 
               
               
                   
                 Ingredient 
                 Solids % 
                 Weight % 
               
               
                   
                   
               
             
            
               
                   
               
            
           
           
               
               
               
               
            
               
                   
                 Corn Syrup 
                 80% 
                 33%  
               
               
                   
                 Sugar 
                 100% 
                 33%  
               
               
                   
                 Water 
                 0% 
                 11%  
               
               
                   
                 Nutriose 
                 100% 
                 6% 
               
               
                   
                 Water 
                 0% 
                 2% 
               
               
                   
                 Gum Arabic 
                 100% 
                 2% 
               
               
                   
                 Hydrogenated Fat 
                 100% 
                 8% 
               
               
                   
                 Glyceride 
                 100% 
                 0.2%   
               
               
                   
                 Lecithin 
                 100% 
                 0.2%   
               
               
                   
                 Powdered Sugar 
                 100% 
                 5% 
               
               
                   
                 Flavor 
                 100% 
                 0.7%   
               
               
                   
                   
               
            
           
         
       
     
     
       
         
           
               
               
               
               
             
               
                   
                 TABLE 2 
               
               
                   
                   
               
               
                   
                 Ingredient 
                 Solids % 
                 Weight % 
               
               
                   
                   
               
             
            
               
                   
               
            
           
           
               
               
               
               
            
               
                   
                 Sugar 
                 100% 
                 57% 
               
               
                   
                 Corn Syrup 
                 80% 
                 30% 
               
               
                   
                 Water 
                 0% 
                 12% 
               
               
                   
                   
               
            
           
         
       
     
     
       
         
           
               
               
               
               
             
               
                   
                 TABLE 3 
               
               
                   
                   
               
               
                   
                 Ingredient 
                 Solids % 
                 Weight % 
               
               
                   
                   
               
             
            
               
                   
               
            
           
           
               
               
               
               
            
               
                   
                 Sugar 
                 100% 
                 66% 
               
               
                   
                 Water 
                 0% 
                 28% 
               
               
                   
                 Starch 
                 100% 
                  5% 
               
               
                   
                 Titanium Dioxide 
                 100% 
                 0.6%  
               
               
                   
                   
               
            
           
         
       
     
     The amount of crystallinity was controlled to obtain the desired amount of chewy and hard material. The process had the benefit of being able to coat the individual candy pieces while hard (as they came out of the batch roller), while during the normal distribution time a portion of the candy layer became soft. 
     It should be appreciated that the methods and compositions of the present invention are capable of being incorporated in the form of a variety of embodiments, only a few of which have been illustrated and described above. The invention may be embodied in other forms without departing from its spirit or essential characteristics. It will be appreciated that the addition of some other ingredients, process steps, materials or components not specifically included will have an adverse impact on the present invention. The best mode of the invention may therefore exclude ingredients, process steps, materials or components other than those listed above for inclusion or use in the invention. However, the described embodiments are to be considered in all respects only as illustrative and not restrictive, and the scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.