Patent Application
20130101707
The present invention relates to novel consumable products and also to a method of production thereof. In particular, the invention relates to confectionery products comprising at least one tubule.
It is desirable to produce consumable products (i.e. edible items such as foodstuffs, toothpaste, etc) formed of different components, so as to increase sensory pleasure. A number of consumable products exist, which have a flavoured liquid or syrup centre which is released upon chewing. For example, WO 2007/056685 discloses an apparatus and method for the continuous production of centre-filled confectionery products in the format of a continuous extrudate having a plurality of centre-filled confectionery ropes. Whilst a product formed from such an apparatus does increase sensory pleasure, the period of pleasure is often short lived as the centre is released too quickly and/or degraded. It is therefore an object of the present invention to provide a consumable product which can release a centre-fill over an extended period of time.
There is also a demand for providing consumable products having a reduced fat or sugar content. It is thus an object of the present invention to provide a consumable product which can be produced having a lowered fat or sugar content, whilst still maintaining an excellent sensory pleasure.
Further, there is demand for consumable products having improved visual appearance whilst maintaining flavour. It is thus a further object of the present invention to provide a consumable product which is eye-catching whilst still providing a desirable flavour.
Yet further there is demand for consumable products having improved convenience whilst maintaining or improving flavour. It is thus a further object of the invention to provide a consumable product which increases convenience whilst still maintaining, or even improving, flavour.
It would be beneficial to be able to include two or more components into a consumable product which are generally immiscible or incompatible with one another.
It is another object of the invention to provide a consumable product having an improved or novel sensory experience.
According to an embodiment, there is provided a confectionery product comprising an extruded body portion and at least an extruded tubule, wherein the tubule comprises a tube of a first material and a bore of a second material, and the tubule is formed of a different material than that of the body portion and/or the bore.
The confectionery product of the present invention has an extended release of any material inserted into the tubules, and/or may include a large voidage so as to reduce the amount of material used in the product, whilst maintaining the overall size of the product. Further, the consumable product has a more diverse cross section such that it is more eye-catching, and with the convenience of any material inserted into the tubules being integral with the consumable product and leakage from the ends of the product minimised.
Furthermore, the confectionery product of the present invention also advantageously allows for immiscible or incompatible components to be included into the product. For example, volatile components can be included within the tubules and then kept away from reactive components in the body portion.
It should be understood that the term “tubule” generally refers to a conduit or space created by an extrusion or other forming process within the body of the product. The tubule typically contains matter, and that matter can be in the form of a gas, a liquid, a solid, or a mixture thereof.
It should be understood that the term “voidage” generally refers to the volume percent of the tubule volume relative to the sum of the tubule volume and the extruded body portion volume. That is voidage (%)=100×tubule volume/(tubule volume+extruded body portion volume). In some embodiments, the extruded body portion volume does not include any central region volume created by certain dies, such as an annular die.
In some embodiments, the body portion is a confectionery, for example chocolate. Suitable chocolate includes dark, milk, white and compound chocolate. In some embodiments, the confectionery is chewing gum, bubble gum or gum base. In other embodiments, the confectionery is candy. Suitable candy includes hard candy, chewy candy, gummy candy, jelly candy, toffee, fudge, nougat and the like.
The tubule(s) may be located within the body portion, for example running along a longitudinal axis (that is to say, running in the direction of extrusion) of the body portion. In this instance the tubule(s) are typically extruded during extrusion of the extruded body portion. In another option the tubule(s) can be present on the exterior of the body portion, for example running along the longitudinal axis of the body portion or in any other orientation e.g. random, perpendicular or at an inclined angle to the longitudinal axis. Gaps can exist between tubules present on the exterior of the body portion, or the tubules can be touching one another.
In a yet further option, the body portion is comprised of two or more sections, for example two solid slabs, where the tubules are sandwiched between the two slabs.
In another further option, multiple tubules are held together by a body portion located within the gaps formed between adjacent tubules.
The tubules may extend along substantially the entire length of the body portion, but may in some embodiments extend no less than 75%, 80%, 90%, 95% or 99% along the length of the body portion. If the tubules extend along the entire length of body portion, typically the ends of the tubules are visible at one or more ends of the body portion. The cross-section of the tubule may be circular or polygonal or if a plurality of tubules are provided—a mixture of both circular and polygonal shapes.
It should be understood that the term “plurality” is intended to mean two or more. In some embodiments, a plurality is 3 or more, or 4 or more, or 5 or more, or 6 or more, or 7 or more. There is no particular upper limit on the number associated with “plurality”. In the context of the phrase “plurality of tubules”, numbers up to 50 and higher are contemplated.
The tubule is formed of a first material, wherein this first substance may comprise a number of materials commonly used in the production of confectionery (e.g. candy, gum and chocolate, caramel, cocoa butter, fondant, syrups, peanut butter, jam, jelly, gels, emulsions, truffles, custard cream, etc).
Suitable chocolate includes dark, milk, white and compound chocolate. In some embodiments, the confectionery is chewing gum, bubble gum or gum base or constituents thereof. In other embodiments, the confectionery is candy. Suitable candy includes hard candy, chewy candy, gummy candy, jelly candy, toffee, fudge, nougat and the like.
The bore part of the tubule may be formed of a second substance, wherein this second substance may comprise a number of materials commonly used in the production of consumable products—for example foodstuffs such as confectionery (e.g. candy, gum and chocolate, caramel, cocoa butter, fondant, syrups, peanut butter, jam, jelly, gels, truffle, custard cream, etc). The first and second substances may be different to one another in some way, for example in composition, viscosity, concentration, etc.
The tube is formed of a different material than that of the body portion and/or the bore. It should be understood that the term “different” is intended to mean differs in some way, or by some characteristic of the material, i.e. not-identical. This can be any characteristic of the material, such as composition, viscosity, concentration, colour, texture, physical form, etc. For example, a material being a yellow coloured candy is considered as different to a material being a green coloured candy, etc. Similarly, a material being a candy is different to a material being a gum, chocolate, caramel, cocoa butter, etc.
Advantageously, materials which would have otherwise been immiscible or incompatible with the material of the body portion, can be safely incorporated into the bore and the tubule acts as a “barrier” in order to prevent mixing or migration of the two materials. For example, it may be desired to separate a volatile compound (such as a cooling agent commonly used in confectionery) in the bore material and the tubule acts as a barrier so that migration of the cooling agent into the body portion does not occur. Migration of moisture from liquid centres is often a problem in confectionery products, but again the use of tubules to separate a liquid material from that of the body portion, ensures that no migration of moisture takes place and both components of the confectionery product are only mixed when a consumer chews the product.
The provision of tubules in a confectionery product also provides a novel sensory experience. For example, the body portion may be formed of a relatively soft material, whereas the material used for the tubule may be relatively hard and contains a liquid bore, so that when the product is consumed, the soft body portion has little resistance to chewing, whereas the tubules will be relatively “crispy” and once broken, the liquid bore will be released.
The bore of one or more of the tubule(s) may be filled with a material which is different from that of the material used to form the body portion, i.e. the second substance (comprised within the tubule bore) may be different to the substance used to make the body portion. Alternatively the bore may comprise the same substance as the body portion. Different tubules may incorporate different materials if desired, and/or any one tube or bore can be filled with different substances along its length. The tube(s) and/or bore(s) may comprise a fluid material. Such a fluid may comprise a liquid. The tube(s) and/or bore(s) may be filled with a material which is solid at a room temperature and fluid at a temperature greater than room temperature. For example, a molten chocolate may be incorporated into the tube(s) and/or bore(s) and allowed to set when cooled to room temperature. It will be apparent to the skilled addressee that room temperature is commonly regarded as around 20° C. Alternatively, the tube(s) and/or bore(s) may be filled with a material which is deposited as a liquid and which subsequently solidifies. In such embodiments, the solidification may be dependent or independent of heat. It will be apparent that solidification of a liquid tube and/or bore may be achieved in a number of ways. For example solidification may take place due to one or more of the following:
The bore need not be filled with a fill material and may simply form a void filled with air or inert gas. Thus a consumable product may be formed having a large exterior dimensions, but a substantially reduced density which provides good sensory properties.
If desired, the product may further comprise a coating portion to envelop or enrobe the body portion. The skilled addressee will appreciate that a number of coatings could be employed for example chocolate, gum, candy and sugar etc.
In some embodiments, multiple tubules are distributed substantially uniformly throughout the body portion, and may be spaced evenly apart from adjacent tubules. In other embodiments, tubules may be distributed in pre-defined configurations within the body portion, such as around the periphery of the body portion, or in groups at one or more locations within the body. In some embodiments the body portion has a circular, elliptical, regular polygonal or semi-circular cross-section. The body portion may be shaped in the form of a cylinder, a rope, a filament, a strip, a ribbon or the like, or may be shaped in the form of a standard consumable product such a chocolate bar, or chewing gum slab, pellet, ball, stick or ribbon, for example. The exterior of the body portion may be irregular or regular in shape. Furthermore, the body portion may be formed in potentially any shape, for example in the shape of an object, cartoon character or an animal to name a few.
In some embodiments, the tubules have a diameter or width of no more than about 2 mm, 1 mm, 0.5 mm, 0.25 mm, or even less. It is possible to have tubules having a diameter or width of no more than about 100 μm, 50 μm or 10 μm.
According to a further embodiment, there is provided a method of manufacturing a confectionery product, the process comprising the steps of:
The at least one tubule may be extruded within the body portion. Alternatively, the at least one tubule may be extruded alongside the body portion and the tubule then urged against the body portion so as to form a single confectionery product having two discrete components.
It will be apparent to the skilled addressee that a number of additional processing steps may be employed after the confectionery product has been extruded. For example, the method may further comprise cutting and optionally coating the product. Such a coating may be a chocolate or sugar coating.
The method may also be used in order to produce a confectionery product as hereinabove described.
These steps can be concurrent or sequential (in any order), and can be performed on the same or different machines.
In some embodiments, the process may include an extra step selected from:
Any of the above processes may further comprise the step of depositing a filling in the bore of the tubule. The deposition of the filling may be during the step of extrusion—but could also take place after extrusion. In an embodiment, the filling comprises a fluid. The fluid may comprises a liquid, or a material which is liquid at a temperature greater than room temperature. The fluid may solidify after deposition if desired.
Any of the processes may further comprise the step of quench cooling the body portion and/or tubule after extrusion. The quench cooling may utilise a fluid, such as air, an oil or liquid nitrogen—but other methods of quench cooling will also be apparent to the skilled addressee.
Any of the processes may further comprise the step of, immediately after extrusion, stretching or rotating the body portion and/or the tubule. Stretching or rotating may be undertaken by a number of means, for example passing the body portion over, or through conveyor belts or rollers operating at different speeds, so as to cause stretching.
Any of the processes may further comprise the step of enveloping the consumable product in a coating. Such a coating will be apparent to the skilled addressee and was discussed previously hereinabove.
The extrudable consumable material will at least partially or substantially solidify after extrusion.
As mentioned above, the invention also provides apparatus which is adapted for producing a consumable product according to the processes as herein above described. WO 2005/056272 discloses an apparatus for producing an extrudated product including a plurality of capillary channels. WO 2008/044122 discloses a related apparatus, which additionally includes means for quench cooling an extrudate as it exits the die. Both of these apparatus may be employed/adapted for use in producing the consumable product in accordance with the present invention.
Specific examples of the present invention will now be described, by way of illustration only, with reference to the accompanying drawings, in which:
Experiments were conducted to produce a variety of consumable products incorporating tubules. Two phases of extrusion work were undertaken. The first phase concerned the extrusion of hard candy using a capillary die attached to a small-scale extruder in a non-food grade environment for creating candy extrudates containing chocolate tubes with air filled bores in both low- and high-voidage foams.
The second phase of the experimental work built upon the first phase to produce low and high voidage extrudates containing an array of tubules having chocolate tubes and cocoa butter bores. The first and second phases are described in the below Example.
Phase one concerned the extrusion of candy using a capillary die attached to a small-scale extruder, in order to confirm that candy having chocolate tubes could be formed in accordance with the present invention.
The materials that were trialled during this investigation are shown in Table 1.
Materials 1 and 2 were supplied as large solid blocks. All materials were crushed prior to extrusion to yield a fine granular powder, with grain sizes ranging between 1 mm and 5 mm. Material 3 was supplied as a tub of solidified cocoa butter; the required quantity was broken up into a fine powder containing only small lumps before being fed into the heated cocoa butter reservoir.
The extrusion equipment consisted of a Betol single screw extruder, with a screw diameter of approximately 12 mm, and a screw L/D ratio of roughly 22.5:1. The extruder had four different temperature zones (denoted T1-T4 in
With reference to
In use, the hopper 16 is filled with material 30 (such as candy in solution) which can be heated so as to render it (or maintain it as) a liquid (not solid or solid particulate form). Before the material passes into the screw 14, it can be cooled by means of the cool feed 26, so as to ensure that the material is at the correct temperature for entering the screw extruder. As the screw is rotated, the liquid material is drawn along the screw 14, inside the barrel 28 and the temperature of the zones T1-T3 adjusted accordingly. The material then passes through the feed conduit 29 and the temperature is adjusted again (if required) by temperature control T4 before entering the die 18. The die 18 has a number of hollow needles with further hollow needles located concentrically inside them (not shown) located within an entrainment body so that the candy material passes over and around the outermost needles. Chocolate is extruded by a parallel similar extrusion process (not shown), and the chocolate passes though the void between the two concentric needles. At the same time that the candy and chocolate is being extruded, compressed air 24 is forced through the centre of the central hollow needles so that the chocolate contains hollow capillaries. The air can be pulsed on and off to make capillaries which actually comprise a line of discrete bubbles, or the air pressure can simply be altered to give rise to continuous capillaries having a varying cross-sectional area along their length, from having a relatively wide diameter (for example, almost as wide as the body portion of the product itself) to extremely narrow (for example, on the micrometer scale). Similar effects can be achieved by rotating the die(s) and/or the extrudate to ‘nip’ the capillaries and thus produce ‘bubbles’, and by adjusting the rate of flow of the extrudate. The extrudate 23 is cooled by means of the quench jets 22 as it is released from the die 18. A valve 32 controls the flow of compressed air to the apparatus and pressure devices P1 and P2 control the pressure of the compressed air 24 before and after the valve. The compressed air line also has a temperature control T6 so as to control the temperature of the air before entering the die.
With reference to
With reference to
The apparatus described hereinabove can be adapted so as to produce an extruded body portion having tubules filled with a bore. A die head and process will be described later.
Examples of products made according to the present invention are shown in
In detail,
Referring now to
Although the body portion and tubules may be depicted as uniform in shape and pattern in some embodiments described herein, it should be understood that the body portion and/or the tubules may be non-uniform in some embodiments. There may be variations in the overall dimensions of the product, such as, for instance, the dimensions of the body portion, the capillaries, the wall thicknesses between each tubule and the outer wall thickness of the product. For example, in some embodiments, the mechanical process of extrusion and optional further manipulation of the extrudate, such as stretching, may create non-uniformities in the dimensions of the product. Such processes also may create random variations in the positioning of the tubules. The tubules accordingly may be irregularly positioned in some embodiments. In addition, the tubules may be symmetrically disposed in the body portion or asymmetrically disposed in the body portion. In some embodiments, one group of tubules may be symmetrically disposed and another group of tubules may be asymmetrically disposed in the body portion.
The foregoing embodiments are presented by way of example only, and it will be apparent to the skilled addressee that possible modifications and variations will readily present themselves to those skilled in the art.
| Number | Date | Country | Kind |
|---|---|---|---|
| 1004897.3 | Mar 2010 | GB | national |
| 61316464 | Mar 2010 | US | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/GB11/50590 | 3/23/2011 | WO | 00 | 11/15/2012 |
