Note: Descriptions are shown in the official language in which they were submitted.
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WO 99/4839 PC1YUS99/03812
CALCIUM-BASED CHEWY NOUGAT FORMULATION WITH MAGNESIUM
This is a continuation-in-part of co-pending U.S. application Serial No.
08/881,853 filed June 24, 1997, which is a continuation-in-part of co-pending
U. S.
application Serial No. 08/773,025 filed December 24, 1996, which is a
continuation-in-
part of co-pending U.S. Application Serial No. 08/770,859, f led December 20,
1996,
15 which is a continuation of U.S. Application Serial No. 08/455,936, filed
May 31, 1995,
now U.S. Patent 5,587,198.
Field of the Invention
The present invention relates to the art of unique delivery systems for
comestibles,
20 especially to novel methods of making a functionalized confectionery mass
which do not
require cooking to dehydrate and products therefrom. More particularly, the
invention
relates to comestible delivery systems, uncooked confectioneries and nougats,
and
methods for making same. The invention also provides a chewy confectionery
nougat
formulation containing bioassimilable sources of both calcium and magnesium.
Background of the Invention
It is generally considered a necessity in the art of preparing food or drug
delivery
systems like confectionery masses such as nougats to use water as a mixing
medium and
source of hydration for ingredients. Specifically with respect to nougats, a
typical recipe
3o calls for soaking egg albumen in water over a period of time, such as
overnight, in order
to fully hydrate the protein. Following hydration the egg albumen is stirred
and strained
before being beaten into a stiff foam. Other ingredients such as sugar, honey,
and corn
syrup are separately cooked with water to a relatively high cooking
temperature of from
about 135°C to about 138°C to achieve the necessary interaction
among the ingredients.
The cooked mixture is then poured into the egg and beaten with a nougat mixer.
This
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conventional nougat preparation method requires cooking the ingredients and
using a
significant amount of water to serve as a mixing medium and source of
hydration.
The amount of water used is much larger than that which would permit the
formation of the solid nougat. The water is supplied in more than su~cient
quantity to
ensure that specific ingredients are wetted and functionalized. Consequently,
the
excessive moisture must be driven off as much as possible to achieve the
structural
integrity and consistency necessary for the end product. Unless the water is
forcibly
removed, the process will result in an incoherent product having no
significant structural
integrity.
1 o Removal of excess water is generally undertaken by a combination of mixing
and
boiling to drive off the moisture and bring the mass to proper viscosity and
consistency.
This process, however, can be highly energy-inefficient and very costly as it
requires
heat, excessive handling of nougat masses, flashing off of some critical
fluids, and an
inability to incorporate heat sensitive materials, as well as a less desirable
overall stability
15 of the product. Moreover, it is not effective in completely eliminating a
substantial
amount of the moisture contained in the confectionery mass.
One of the unwanted results of inefficient dehydration is that water remains
as a
separate phase in the end product. This water is not bound to other
ingredients and can be
referred to as free moisture or unbound water. Free moisture can detract from
the end
2o product because it weakens the structural integrity and/or reduces the
quality of
organoleptic perception. Moreover, excessive free moisture results in higher
water
activity, and thereby provides an environment in which microorganisms can
grow.
Microbiological growth in food products has also been used to measure the
existence of
free moisture.
25 Many food preservation processes attempt to eliminate microbial growth and
spoilage by lowering the availability of water to microorganisms. Reducing the
amount
of free moisture or unbound water also minimizes other .undesirable chemical
changes
which can occur in foods during storage. The processes used to reduce the
amount of
unbound water in foods include techniques such as concentration, dehydration,
and
30 freeze-drying. These processes require intensive expenditure of energy and
are not cost
ei~cient.
2
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The present invention overcomes the difficulties set forth above as well as
other
difficulties generally associated with the prior art. In particular, both the
necessity of
cooking the confection and using excessive water to mix and hydrate one or
more
ingredients is eliminated, and the method and product of the invention are
obtained
without any need for dehydration. Consequently, the detrimental heat history
generally
associated with energy-intensive procedures is also eliminated. Separation of
the water
from the resulting product is avoided and the lowered water activity results
in a pmduct
having superior physical, storage, and organoleptic properties with reduced
microbial
growth problems.
1o Finally, the present invention addresses the issue of producing a chewy
nougat
confectionery formulation containing calcium, and preferably also magnesium,
which is
palatable and storage stable, but which avoids the problems normally attendant
in the
production of these nutritional-type supplements.
15 Summary of the Invention
The present invention is a method of making a unique food and drug delivery
system, and especially a novel confectionery delivery system, especially a
nougat, via
hydration, without the need for cooking or subsequent dehydrating, in order to
produce the
confectionery mass. The present invention also includes the product resulting
form the
2o new method of preparation.
In one embodiment, a saccharide-based component is combined with a hydrated
hydrobinding component to form the confectionery of the system.
In a more preferred embodiment, it is also contemplated that active
ingredients
can be included in the confectionery mass which is formed as a result of the
present
25 invention. The active ingredients are typically ones which are intended to
produce a
biological and/or chemical response in the body.
Especially preferred actives as part of the composition of the invention
include
bioassimilable sources of calcium, and particularly combinations of calcium
and
magnesium.
3o The product resulting from the present invention is unique because it
requires no
cooking and no dehydration by traditional heating at high temperatures to
produce, and
has substantially no phase separation of moisture. The only moisture present
is bound
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WO 99/48379 PCTIUS99/03812
therein in an amount sufficient to functionalize the mass. Thus, the product
can be
prepared without cooking.
As herein further described, the product may also be prepared using flash-flow
processing, low or high shear mixing, or any combination thereof. As a result
of one or
more of these methods, many of the attendant processing problems associated
with either
calcium or magnesium additives can be substantially reduced or eliminated.
The final product furthermore exhibits improved content uniformity and
improved
taste perception qualifies. Overall, the formulated confectionery delivery
system herein
described is more palatable (no grit or chalkiness) than many of the current
products
l0 available in the art.
Detailed Description of the Invention
The confectionery-mass delivery systems in accordance with the present
invention
includes a saccharide-based component and a hydrobinding component, the latter
15 component being hydrated sufficiently to provide controlled water delivery
to the
saccharide-based component and/or other ingredients. Controlled water delivery
means
delivery of water in an amount and at a rate which is sufficient to provide
internal
viscosity and cohesivity to the saccharide-based component. The ward hydrated
as used
in the term hydrated hydrobound component herein means containing sufficient
water to
2o provide the requisite controlled water delivery.
Furthermore, the system created by the combination of the present invention is
a
water-starved system, which means that the system has only enough moisture to
bind the
ingredients together and provide internal lubricity. Since the ingredients are
competing
for moisture due to enhanced wettability, there is virtually no free moisture
available to
25 separate from the mass, and thus no attendant problems associated
therewith.
In the present invention, the hydrobinding component is used to provide a
functionalized hydrobound confectionery mass. The hydrobinding component is
thus an
ingredient which imbibes, delivers and maintains water in an amount sufficient
to
functionalize the resulting mass. The water which is hydrobound does not
separate and
3o become a separate phase. A hydrobinding component cooperates with other
ingredients
to deliver and maintain water sufficient to functionalize the mass of
ingredients (including
those ingredients which have been subjected to flash-flow processing - e.g.
the
saccharide-based component, hereinafter described).
4
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Ingredients useful in the present invention which make up the hydrobinding
component include, for example, proteinaceous materials known to those skilled
in the
art, and preferably gelatins of various grades and types. Also preferred are
food grade
gums such as gum arabic, carrageenan, guar gum, and locust bean gum, and
mixtures
thereof. Hydrobinding components constituting a mixture of ingredients are
desirable in
some situations. Highly preferred hydrobinding ingredients include, for
example, a
mixture of gelatin and gum arabic, or a mixture of carrageenan and locust bean
gum with
a crosslinking agent, such as potassium citrate or potassium chloride, which
induces
crosslinking between these materials. These mixed hydrobinding materials are
to advantageous not only for their hydrobinding capacities, but also because
they impart
viscoelasticity to the resulting confectionery. It is possible that
crossiinking in these
materials contributes to their desirable physical properties. The hydrobinding
material
can also benefit from inclusion of a wetting agent or humectant such as a
polyol known in
the art, desirable glycerin, or other functionally similar materials which are
commercially
available.
The hydrobinding component will comprise about 0.5-20% of the confectionery
system of the invention. Preferable, the hydrobinding component will be within
the range
of about S-15%, and even more desirably within the range of about 5-10% of the
final
confectionery composition. Of the foregoing hydrobinding component, water will
2o comprise about 30 - 80% thereof, and preferably about 40 - 70% of the
hydrobinding
component. The proteinaceous material or the gum, or combination thereof, will
make up
about 0.5 to 60% of the hydrobinding component, and more preferably be within
the
range of about 3 to 50%, more desirably about 5 to 20% (unless otherwise set
forth, all
%s herein are percentages by weight, or weight percent).
Another material which may be included as part of the hydrobinding component
is
a wetting or softening agent, such as a polyol, preferably glycerin, which may
be included
in amounts equal to about 0 -1'S%, preferably about 0.1-10% of the composition
of the
invention, even more desirably about 5-10%. The glycerin (or other selected
material)
can also function as a humectant, and thereby keep moisture in the system.
3o The hydrobinding component may also be aerated, preferably in the presence
of
an aerating agent, before or after being combined with the other components
making up
the confectionery composition of the invention. Preferred aerating agents
include egg
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whites and soy protein. Aerating agents are desirably added in amounts within
the range
of about 0 - 5%, more desirably 0. I - 3% of the confectionery mass of the
invention.
It is also within the scope of the invention that ingredients which are used
in the
hydrobinding component may also be added as part of the saccharide-based
component,
hereinbelow described. Thus, in a somewhat less preferred embodiment, gelatins
and
food grade gums such as gum arabic, carrageenan, guar gum, locust bean gum,
etc., can
be used to prepare the saccharide-based component, e.g., by being included in
the
feedstock used to prepare that component.
The invention also employs a saccharide-based material as another major
component (the hydrobinding material being the heretofore set forth first
major
component). The saccharide-based material can include any of a large variety
of
saccharide materials, such as small sugars, e.g., dextrose, sucrose, fructose,
etc., and
larger saccharides such as corn syrup solids and polydextrose, as well as
mixtures of two
or more of these materials.
Corn syrup solids are highly preferred for use as the saccharide-based
material in
the composition of the invention. Com syrup solids are commonly known as
maltodextrins. Maltodextrins are composed of water soluble glucose polymers
obtained
from the reaction of the starch with acid or enzymes in the presence of water.
Polydextrose is a non-sucrose, essentially non-nutritive, carbohydrate
substitute.
2o It can be prepared from polymerization of glucose in the presence of
polycarboxylic acid
catalysts and polyols. Generally, polydextrose is known to be commercially
available in
three forms: Polydextrose A and Polydextrose K, which are powdered solids, and
Polydextrose N supplied as a 70% solution. Each of these products can also
contain some
low molecular weight components, such as glucose, sorbitol, and oligomers.
Sugars can also be used as saccharide-based materials according to the
invention.
Sugars are those substances which are based on simple crystalline mono- and di-
saccharide structures, i.e., based on C5 (pentose) and C6 (hexose) sugar
structures. Sugars
include dextrose, sucrose, fructose, lactose, maltose; etc., and sugar
alcohols such as
sorbitol, mannitol, maltitol, etc.
3o Typically, the foregoing saccharide-based component can comprise about 30 -
99.5% of the confectionery delivery system according to the embodiments herein
set
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WO 99/48379 PCT/US99/03812
forth. Preferably, there will be about 40 - 75% of this component present, and
even more
desirably about 50-70% present. In addition, those skilled in the art may
discover a
higher or lower percentage of the saccharide-based component, or other
ingredients
herein set forth, will produce a suitable final product, depending upon the
final
characteristics, e.g. texture, mouth feel, product consistency, etc., which
are desired. A
highly preferred saccharide-based material will comprise a mixture of corn
syrup solids
and sucrose in a ratio of approximately 50/50 or 40/60.
In addition to the heretofore described hydrobinding- and saccharide-based
components, other materials may also be incorporated into the material of the
invention,
to enhance its appearance, taste, texture, and other perceptions of the
consumer, and can
include, for example, flavors, sweeteners, colorants, surfactants or
emulsifiers, and fats or
oils. Any one or a combination of more than one of the foregoing may comprise
from
about 0 - 20% of the confectionery mass, and more desirably be within the
range of about
-10% or even up to I S% of the comestible mass.
Flavors may be chosen from natural and synthetic flavoring liquids. An
illustrative list of such agents includes volatile oils, synthetic flavor
oils, flavoring
aromatics, oils, liquids, oleoresins or extracts derived from plants, leaves,
flowers, fruits,
stems and combination thereof available to the skilled artisan.
Other flavorings may include whole and partial fruits and nuts, peanut butter,
candy bits, chocolate chips, bran flakes, etc.
Sweeteners may be added to the confectionery system of the invention. These
may be chosen from the following non-limiting list: glucose (corn syrup),
dextrose, invert
sugar, fructose, and mixtures thereof (in addition to those which may be
utilized as part of
the saccharide-based component), saccharin and its various salts such as the
sodium salt;
dipeptide sweeteners such as aspartame; dihydrochalcone compounds,
glycyrrhizin;
Stevia Rebaudiana (Stevioside); chloro derivatives of sucrose such as
sucralose; sugar
alcohols such as sorbitol, mannitol, xylitol, and the like. Also contemplated
are
hydrogenated starch hydrolysates and the synthetic sweetener 3,6-dihydro-
6-methyl-I-1-1,2,3-oxathiazin- 4-one-2,2-dioxide, particularly the potassium
salt
(acesulfame-K), and sodium and calcium salts thereof. Other sweeteners may
also be
used. The sweeteners are added in amounts equal to about 0 -10% of the
composition,
and preferably about 0.1- 5%.
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Surfactants or emulsifiers may also be included in the composition of the
invention. These may be any food grade emulsifying material, for example,
lecithin or
other phospholipid material, monoglycerides and/or diglycerides, and mixtures
thereof in
amounts of from about 0 - 3%, more desirably about 0.1-1%.
Fats may also be included in the composition, and these can include partially
or
entirely unsaturated fats such as palm oil and cocoa butter. Hard fats having
melting
points above body temperature (37 degrees C), and soft fats having a melting
point of
about or below body temperature, can be used alone or in combination. The
texture and
mouth feel of the resulting confection can be influenced by selecting the
types and
1o amounts of fats included in the saccharide-based component. Fats marketed
under such
trade names a Durem and Paramount have been found to be useful. Those skilled
in the
art will find that fats are optional as part of the composition of the
invention, and may be
eliminated altogether if so desired. Thus, fats will comprise about 0 -10% of
the product
herein set forth, preferably less than about 7%, and even more preferably less
than about
15 5%.
Additional materials which can be incorporated into the confectionery
composition include, for example, biologically and chemically active
ingredients such as
medicinal substances, e.g. drugs, pharmaceuticals and antacids. These are
referred to
herein as active ingredients. Active ingredients may make up from about 0-5%
of the
2o product of the invention, and even more depending upon the needs and
abilities of those
skilled in the art. It is preferred, however, to include up to about 40% of
active substance
in the compositions set forth herein.
As active ingredients, the aforecited U.S. Patent No. 5,587,198 contains a non-
exhaustive listing of active substances, the salient portion of which is
incorporated herein
25 by reference.
Calcium supplement products can be prepared by incorporation of a
bioassimilable calcium source as an active ingredient in the comestible
delivery system
confectionery of the invention. Preferably, the calcium source is calcium
carbonate, but
other sources of calcium capable of absorption or bioassimilation can be
employed,
3o including finely divided bone meal, egg shell or oyster shell materials and
the like, as
well as calcium derived from milk solids. The calcium-containing material is
preferably
8
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WO 99/48379 PCT/US99/03812
very fnely divided so as not to impart any unnecessary chalkiness or other
unpalatable
characteristic to the confection. Finely ground calcium materials are
commercially
available, e.g., from Specialty Minerals or Omya, for use either in antacid
products or
calcium supplement products. In one preferred embodiment of the invention, a
calcium
supplement product is prepared which incorporates about 500 mg. of
bioassimable
calcium, along with about 200 LU.'s of vitamin D3 into a single dosage form of
the final
product, which represents 50% of the RDA of those nutrients. Another preferred
embodiment will include about 1200 mg. of bioassimable calcium and about 400
LU.'s of
vitamin D3.
to In an especially preferred embodiment of the invention, a calcium source
may be
combined with a magnesium source to yield a mineral supplement "active"
included in
various embodiments of the chewy nougat formulation. Magnesium has been
recognized
as an essential element which aids in metabolism. Magnesium also aids in the
absorption
of calcium, and is therefore highly desirable as an additional component of a
chewable
15 calcium supplement formulation. Any bioassimilable magnesium source may be
utilized.
Non-limiting examples include those selected from the group consisting of
magnesiums
oxide, hydroxide, phosphate, carbonate and lactate, for example. Of these,
magnesiums
oxide; carbonate and lactate are more preferred. Magnesium lactate is
desirable because
it is highly stable for extended periods, and its inclusion in a chewy
supplement imparts
2o very little or and color, flavor, sweetness or textural off notes thereto.
These attributes
may be particularly important from a commercial point of view.
An especially preferred dietary supplement therefore includes about 500 mg. of
bioassimable calcium, about 40mg. magnesium, and about 200 LU.'s of Vitamin D3
into
a single dosage form. This represents 50% of the RDA for these nutrients. More
or less
25 of the foregoing nutrients may be added, depending upon the particular
needs of the
skilled artisan. For example, a proportional scale-up or down of the foregoing
substituents could be utilized to yield a formulation having, for example,
75%, 100% or
even 25% of the foregoing nutrients.
It is certainly within the scope of the invention to include in a chewy nougat
3o dietary supplement from about 0 - 40% of a calcium source, about 0 - 5% of
Vitamin D3
and about 0 - 50% of a magnesium source. More preferably, about 10 - 40% of a
calcium
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WO 99/48379 PCT/US99/03812
source, about 1 - S% of Vitamin D3, and about 1- 20% of a magnesium source may
be
included in the chewy nougat dietary supplement.
The products according to the various embodiments of the invention are tasty
and
sweet chewy nougat confectioneries, with a smooth texture and consistency,
with no grit
or chalkiness. These products are well hydrated, and yet evidence no phase
separation of
moisture upon extended periods of storage.
One of the advantages of the present invention is that a large proportion of
the
product can be displaced by a bulky material such as calcium and magnesium
sources.
For example, as alluded to above, up to about 25-35% or in some embodiments,
up to
1o about 40% or even up to about 50% or more of the total weight of the
resulting product
can be an added bioassimilable calcium source (or more desirably calcium with
magnesium, etc.) without imparting undesirable taste or texture to the
product. In fact,
the product according to several embodiments of the invention exhibits
improved taste
and texture characteristics as compared with similar commercially-available
products.
"Improved" means that individual consumers rate the product overall to be
superior when
such characteristics as firmness, flavor, bite, sweetness, chewiness, melt
characteristics,
stickiness, juiciness, freedom from grit, and aftertaste are analyzed.
Other bulky materials can also be included as "actives", i.e, active
ingredients, in
the confectionery composition of the invention. These can include such food
material as
2o fiber and other vegetable and fruit materials. Of course, useful comestible
delivery
systems can also be produced wherein as little as only a trace amount of the
total weight
of the product is a deliverable active ingredient.
The products resulting from the present invention are unique, in part because
they
require no dehydration to produce, i.e., the product can be prepared without
cooking.
Moreover, there is substantially no separation of moisture in the resulting
product. The
only moisture present is supplied by the hydrated hydrobinding component an
amount
sufficient to functionalize the mass. No excess water is thus present, and
thus the final
product of the invention is stabilized with regard to nutritional content,
microbial growth,
organoleptic characteristics and other factors.
3o In the present invention water activity is significantly lower than water
activity of
similar products found in the candy bar industry. For example, candy bars
usually have a
water activity of 62% - 68% equilibrium relative humidity (ERH). The
confectionery
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WO 99/48379 PCTlUS99103812
product of the invention, however, has at most only about 60% ERH, and is
preferably
not greater than about SS% ERH.
Another measure of free water in foodstuffs can be provided by the amount of
biological growth within the composition. In the present invention, the
biological activity
is less than about 100 ppm, preferably less than about 25 ppm, and most
preferably less
than 10 ppm.
It is a fiirttler aspect of the invention that at least some of the
confectionery
compositions according to the various embodiments set forth above be
advantageously
provided in the form of a shearform matrix, as that term is defined hereunder,
as
shearform matrix materials can exhibit significantly enhanced wettability
because of a
randomized structure resulting from flash-flow processing or high or low shear
mixing,
hereinafter described.
Shearform matrix refers to the product prepared by the method of flash-flow
processing, a method which mixes and conditions. ingredients for intimate
contacting and
15 enhanced hydration described, for example, in U.S. Patent No. 5,587,198.
The term
flash-flow has become recognized in the art as referring to a process which
uses
conditions of temperature and force to transform a solid feedstock having a
certain
morphological and/or chemical structure into a new solid having a different
morphological and./or chemical structure without subjecting the solids to
excessive heat
20 or other requirements inherent in extrusion processing. The resultant
structure has now
been referred to as a "shearform matrix." The terms flash-flow and shearform
matrix are
further described and set forth in commonly-owned U.S. Patent Nos., 5,236,734,
5,238,696, 5,518,730, 5,387,431, 5,429,836, 5,582,855.
Flash-flow processing can be advantageous in the present invention since it is
25 useful for preparing ingredients to be easily and quickly mixed and
hydrated. Another
very important result of flash-flow processing is intimate mixing of the
ingredients.
Intimate mixing has traditionally been achieved by the use of water as a
mixing medium.
Flash-flow processing, however, intimately contacts ingredients and randomizes
ingredient location and structure of the resulting shearform matrix.
Randomizing the
3o structure can be thought of as opening the physical and/or chemical
structure for
hydration. Thus, flash-flow processing not only ensures intimate mixing of
ingredients
11
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without the use of water as a medium, but also conditions the ingredients for
subsequent
wetting with a minimum of water.
Flash-flow processing can be accomplished either by a flash-heat method or via
the somewhat less preferred flash-shear method, as described further herein.
In the flash-
y heat process, the feedstock is heated sufficiently to create an internal
flow condition,
which permits internal movement of the feedstock at a subparticle level, and
to exit
openings provided in the perimeter of a spinning head. The centrifugal force
created in
the spinning head flings the flowing feedstock material outwardly from the
head so that it
reforms with a changed structure, i.e. a shearform matrix. The force necessary
to separate
to and discharge flowable feedstock is provided by centrifugal force and the
force of the
ambient atmosphere impinging on feedstock exiting the spinning head.
One apparatus for implementing a flash-heat process is a cotton candy
fabricating
type machine, such as the Eocene-floss model 3017 manufactured by Gold Medal
Products company of Cincinnati, Ohio. Other apparatus which provides similar
forces
15 and temperature gradient conditions substantially equivalent to flash-heat
can also be
used.
In particular, a spinning machine developed by Fuisz Technologies Ltd. of
Chantilly, VA and patented under U.S. Patent No. 5,458,823 may be especially
preferred
for the flash-heat process. This patent describes a spinning machine which has
a series of
20 elongated heating elements arranged in between a base and a cover. The
heating
elements, base and cover together define a chamber into which a non-
solubilized
feedstock material is inserted which is capable of intraparticle flow upon
application of
heat and force. Means are provided for individually heating each of the
elongated heating
elements, and restriction means in the form of a cylindrical shell or annular
plate which
25 circumscribes the heating elements permits restrictive flow of the
processed feedstock
which is expelled from the chamber.
In the flash-shear process, a shearform matrix is produced by raising the
temperature of the feedstock, which includes a non-solubilized Garner such as
a
saccharide material, until the carrier undergoes internal flow upon
application of a fluid
3o shear force. The feedstock is advanced and ejected while in internal flow
condition, and
subjected to disruptive fluid shear force to form multiple parts or masses
which have a
morhpology different from that of the original feedstock.
12
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The flash-shear process can be carried out in an apparatus which has means for
increasing the temperature of a non-solubilized feedstock and means for
simultaneously
advancing it for ejection. A multiple heating zone twin screw extruder can be
used for
increasing the temperature of the non-solubilized feedstock. A second element
of the
apparatus is an ejector which reduces the feedstock to a condition for
shearing. The
ejector is in fluid communication with the means for increasing the
temperature and is
arranged at a point to receive the feedstock while it is in internal flow
condition. The
flash-shear process and apparatus are described in U.S. Patent No. 5,380,473,
which is
incorporated herein by reference. Of the flash-heat and flash-shear processes
herein
1 o described, flash-heat appears to be much more readily adaptable to the
process of the
invention. However, those skilled in the art may find that flash-shear
methodology can be
adjusted to their particular needs.
Thus, one or more components of the composition of the invention may be
advantageously processed using flash-flow procedures, e.g. flash-heat or flash-
shear.
Particularly well adapted for flash-flow processing is the saccharide-based
component of
the invention. Maltodextrin, for example, may be utilized as the feedstock to
process
thmugh the flash-flow apparatus: The saccharide-based component can also serve
as a
"carrier" material for piggybacking some of the other constituents which may
also be
flash-flow processed with the saccharide-based component, e.g. one or more of
the
2o emulsifiers, oils, fats, flavorings, and sweeteners etc., as well as one or
more of the active
materials. As a result of being flash-flow processed, the saccharide-based
component and
any optional ingredients are provided in the form of a shearform matrix, as
set forth
above.
One embodiment of the present invention may also include pre-flash-flow
processing of certain ingredients. Pre-flash-flow processing is simply flash-
flow
processing of one or more ingredients before combining these with either the
saccharide-
based component or the hydrobinding component for additional flash-flow
processing or
additional admixing. Flash-flow processing results in creased surface area and
increased
solubility of the ingredients subjected thereto, and contributes to actual
binding of the
3o ingredients to each other, and therefore, preliminary or pre-flash-flow
processing may
particularly advantageous to the skill artisan.
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For example, in one embodiment of the invention, it may be especially
desirable
to pre-flash-flow the magnesium component as part of the calcium/magnesium
active
ingredient of the calcium-based chewy confectionery nougat formulation of the
invention.
Attendant problems associated with using magnesium as an additive are in this
way
largely avoided. Because the magnesium is "bound up" or encapsulated as a
result of pre-
flash-flow, it is far less likely to subsequently interact with any moisture
or humidity,
Light or heat, however small these quantities may be. A preferred pre-flash-
flow
magnesium formulation may comprise from about 0.1 - 50%, more preferably about
15 -
40% of magnesium from whatever source; together with about 5 - 95%, more
preferably
1o about 25 - 75% saccharide material; along with 0 - 15% of one or more
optional materials
such as emulsifiers, fats, oils. Especially desirable is about 20 - 30%
magnesium source,
about 35 - 70% saccharide material, and about 0 -10% optional materials. Once
this
material is pre-flash-flow processed, it will constitute the active ingredient
(together with
the calcium source) and is further mixed with the saccharide-based component
for further
flash-flow processing or shear-mixing (because the encapsulated magnesium
contains
saccharide material, the amount in the actual saccharide-based component of
the final
formulation may be proportionately reduced). Magnesium oxide is well adapted
to pre-
flash-flow processing because it is a strong oxidizing agent, and will react
with a
minimum of water, air or Light, and thereby may alter the organoleptic
properties of the
2o final chewy nougat formulation. Other magnesium sources which may also be
processed
in this manner include magnesiums carbonate, phosphate and lactate. Any other
sources
of magnesium are also contemplated by the foregoing method, depending upon the
needs
of the technician and the attributes one desires in the final product.
Another means for processing the components making up the compositions of the
invention is via low and high shear mixing processes. In some instances, the
added time
and expense associated with flash-flow processing (or pre-flash-flow
processing) may be
avoided. The same qualities associated with the final product (e.g. shear-form
matrix
attributes, intimate mixing, no cooking) can be attained through the use of
the shear
mixing methods as would be attained through the use of flash-flow processing.
3o As that term is used herein, "high shear mixing" refers to relatively
intensive
mixing action concentrated in a localized area. The high speed impact of
mixing
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mechanisms such as blades or choppers results in shearing action. This in turn
creates
localized high shear force and a fluidizing effect at the point of contact,
which causes
particular scale diffusion and disagglomeration and faster mixing in a
relatively small
area of the entire mixing volume, i.e. the formation of a localized shearform
matrix. High
shear mixing may also result in increased temperature at the point of impact
of the
shearing apparatus with the mix, thereby further contributing to the effective
mixing
action.
High shear mixing should be contrasted with low shear mixing in which the main
action of mixing is due to the relative motion of a much larger volume of mix
being
1 o circulated by the spinning or churning action of a lower impact type
mechanism, such as a
paddle-blade typically found in a Sigma or Hobart mixer. Whenever high or low
shear
mixing is utilized to produce the functionalized confectionery mass of the
present
invention, the resultant product can be referred to as both uncooked (in the
sense that
excessive heat is no utilized) and unspun (in the sense that a flash-flow
apparatus is not
i 5 utilized).
Thus, any number of the components comprising the composition of the invention
may be mixed together through the use of high or low shear mixing, as well as
flash-flow
processing, as well as any combination thereof. For example, as heretofore
noted, it may
be particularly preferred to flash-flow process the saccharide-based component
along with
2o certain of the above-cited adjunct ingredients, including any active
material(s). (As also
previously noted, it may also be desirable to pre-flash-flow process one or
more of the
actives before further flash-flow processing with the saccharide material).
The materials
making up the hydrobinding component such as the cited gums, gelatin and
glycerine can
then be combined and hydrated, for example, using high or low shear mixing.
The final
25 composition can then be formed by combining all the aforementioned
components, again
by utilizing either high or low shear mixing, preferably high shear mixing.
Upon
combining the hydrated hydrobinding component, the saccharide-based component,
the
other ingredients, and any actives, moisture is readily imbibed and
disseminated
throughout the non-hydrated components and/or ingredients. Again, unlike prior
art
3o methods and confectionery compositions, additional moisture is not required
to form a
CA 02325941 2000-09-25
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hydrated mixture. Thus, excess water is not present in the resulting mass, and
no cooking
or heating is then required to drive off this excess moisture.
In still another embodiment of the invention, it may be desirable to process
all
materials using high shear mixing. For example, the saccharide-based
component,
optional ingredients, and any actives may be admixed using high shear. The
ingredients
constituting the hydrobinding component may also be processed using high
shear. The
final formulation can be achieved by then submitting all components to high
shear
mixing. Alternative, it is also contemplated to process all components using
low shear
mixing.
1 o An especially preferred high-shear mixer for use with the invention is
known as a
Littleford FKM 1200. This device provides high shear mixing by proximal
shearing
blades which are at right angles to one another. The shearing blades consist
of "plowers"
and choppers, both of which are utilized for high shear mixing action. While
not wishing
to be bound by any particular theory, it is believed that high shear action
provides both
mixing and heating at the localized points of blade contact with the mix
ingredients,
thereby resulting in excellent dispersibility without the undesired effects of
lumping etc.
Other high shear mixers (with one or more mixing blades), currently available
or yet to be
developed, are also contemplated by the method of the invention.
If desired, the high shear mixer can be further equipped with a jacket heater
to
2o provide the benefits of additional warming. A preferred temperature range
is from about
30 degrees C to about 60 degrees C, more desirably within the range of about
30 degrees
to about 45 degrees C.
A preferred procedure for high shear mixing is as follows: The jacket heater
on
the high shear mixer is first activated and allowed to wamn to a temperature
of about 40
degrees C. Next, the saccharide-based component and other dry ingredients,
e.g. calcium
and/or magnesium source, may be fed through the open hopper and allowed to nux
using
the plowers (the magnesium may be provided as a dry encapsulation as a result
of flash-
flow processing). For an 18 pound mixture, for example, the device is first
run for about
2 minutes. Any added fat, along with emulsifiers, and the liquid-based
hydrobinding
3o component (which has been previously prepared using low shear mixing),
together with
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any flavorings, sweeteners and coloring, are then fed into the mixer, and the
choppers or
high shear blades are activated to further complete the mixing. During this
time, the
jacket temperature may be increased to within the range of about 50-60 degrees
C,
preferably about 58-60 degrees to assist in the mixing, especially if fat is
present in the
mixture. The mixer is then run for about 5-10 minutes more, perhaps longer, to
complete
the mixing of the saccharide-based component and the hydrobinding component.
Once
mixing is complete, the entire matrix is then emptied into an
appropriate.container for
slicing, sorting, packaging and shipping etc., e.g. is extruded and cut into
dosage size
pieces.
1o In certain instances, the use of a low shear mixing apparatus can also
provide the
product of the invention. Of these, a Sigma mixer andlor Hobart industrial
paddle mixer
may be suitable. In one preferred embodiment, the dry ingredients (saccharide-
based
component and any additional materials) are mixed in a Sigma mixer until a
good
consistency is obtained. Separately, the liquid ingredients (hydrobinding
components) are
nuxed and allowed to hydrate in a Hobart mixer, and then added to the Sigma
mixer with
the dry ingredients. The whole mixture is then run in the Sigma mixer for
about 3
minutes. Variations of the foregoing process are certainly within the scope of
the
invention, depending upon the characteristics of the individual ingredients,
and the
attributes desired within the final product.
2o Another method of formulating the product of the invention may comprise the
utilization of both high- and low-shear mixing apparatus set forth above,
depending upon
the needs of the skilled artisan.
EXAMPLES-
For a better understanding of the present invention, together with other and
further
objects, the following examples and tables are provided to illustrate the
unique methods
of making confectionery mass and products resulting therefrom. These examples
should
not be construed as limiting the scope of the invention. Unless otherwise
specified,
3o percentages of components in the compositions are given as percentage by
weight (wt%).
Also, unless otherwise indicated, all materials were obtained from commercial
suppliers.
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EXAMPLE 1
A series of confectionery-type masses was prepared according to the invention
for
the delivery of a bioassimilable calcium source, in this case powdered calcium
carbonate.
The hydrobinding material was selected to be a mixture of medium weight
gelatin (250
Bloom) and gum arabic. The saccharide-based material was selected to be
sucrose (6X)
or a mixture of sucrose and corn syrup solids. The components and the
preparation
conditions for these batches are given below in Table 1.
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In this series of batches, the gelatin and gum arabic were premixed with
glycerin
using low shear mixing methods. Then a controlled amount of water was added
thereto,
along with flavoring and color. The calcium carbonate and the saccharide-based
material
(corn syrup solids and sucrose) were added to a Littleford FKM-1200 high shear
mixer.
The mixer was then operated for 2 minutes using the plowers only. The premixed
fat/emulsifier/sorbitan mixture was added to the mixer. The hydrobinding
material above
(gelatin et al.) was also added., and the resulting mass was mixed with the
FKM-1200
high shear mixer for approximately 5-10 minutes.
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TABLE 1
MATERIAL BATCH BATCH BATCH BATCH BATCH
(wt%) lA 1B 1C 1D lE
Gelatin 1-5% _~-> ____> ____> _____->
Gum Arabic 0.1-1% ~__> -_____> ___~> _____>
Flavoring 0.1-1% -----> _----> _____> _____>
Water S-10% ____> __-_> _-___> ______>
Glycerin (99%) 0.1-3% _____> __~_> ~ ___> _____>
COIOr 0.1-0.5%__--__>____> ~___> ___>
Calcium Carbonate 28.57% ~__> __-___> _____> ____>
Sugar 6X 25-40% 25-40 60-70 25-40 25-40
Corn Syrup Solids 25-40% 25-40 --- 25-40 25-40
Fat Solids 3-10% ------>------> ------> ------>
Lecithin 0.1-1% ------>______> -_____> ____->
Sorbitan 0.1-1% __-__> ~__> ~__> _____->
Kettle Temp 43C 40C 40C 350 40C
Dry Powder Temp 39C 36C 40C 32C 40C
Fat System Temp 74C 55C 54C 56C 86C
Binder Temp 45C 44C 44C 45C 48C
Final Product Temp39C 50C 40C 42C 43C
Mixing Time (Min) 5 5 5 5 S
Mixing Speed (%) 40 40 40 60 b0
All of these batches yielded products which were extruded and cut into pieces
calculated to deliver about S00 mg of bioassimilable calcium. The products
varied in the
degree of tackiness to touch, but all were chewy, with more than acceptable
mouthfeel
with at most only a minor amount of chalky texture on chewing. Thus, a nougat
product
quite acceptable to consumers is produced 1 ) without driving off excess
water, and 2)
without cooking the material.
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EXAMPLE 2
A nougat composition was prepared without cooking or removal of water. The
ingredients set forth in Table 2-A were mixed using the aforementioned
Littleford high
shear mixer for 5 min at 40-50 cycles/min.
TABLE 2-A
Ingredient Percent of Composition
Calcium Carbonate 28.75 wt%
Powdered Sugar 30-40 wt%
Corn Syrup Solids, DE 30-40 wt%
36
Fat Solids 3-8 wt%
Emulsifiers 0.1-1 wt%
TOTAL 100 wt%
This mixed composition was then mixed with colors and flavors in a Sigma
mixer,
again for 5 min at 40-50 cycles/min.
1 o In a separate vessel, glycerin and a vegetable gum were mixed and low
shear-
stirred to smoothness. Water was added, and again the mixture was stirred to
smoothness. Gelatin was then added along with flavoring and coloring, and the
mixture
was low shear-stirred again for about 1 minute to thicken. This mixture was
then warmed
to about 50°C for about 15-20 minutes. The warmed mixture was added to
the primary
~ 5 mixture, and stirred with the Sigma mixer for about 5 min at 40-50
cycles/min. The final
product is present in Table 2-B.
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TABLE 2-B
Ingredient Percent of Composition
Primary Mixture 80-90 wt%
Flavoring 0.1-1 wt%
Coloring 0.1-1 wt%
Glycerin 0.5-3 wt%
Vegetable Gum 01.1 wt%
Water 5-10 wt%
Gelatin I-5 wt%
TOTAL 100 wt%
The resulting mass was removed from the mixer, and rolled to the desired
thickness, e.g. about 3 cm. This product was completely homogeneous, and had a
chewy
texture.
EXAMPLE 3
Another chewy nougat product was made using the same materials and
proportions described in Example 1, except that the components described there
as being
1o part of the saccharide-based component were processed together using flash-
flow
processing to provide a shearform matrix. This shearform matrix was then added
to the
coloring and flavoring, and used as described. Again, the resulting product
was
homogenous, chewy in texture, and flavorful.
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EXAMPLE 4
The primary mixture prepared according to the method described in Example 1
was used to make a gelatin-free confection product suitable for use as a
calcium
supplement. The primary mixture, together with flavorant, colorant, and an
artificial
sweetener, was mixed together in a kettle for 5 min. Potassium citrate was
then dissolved
in water with warming to - 85 degrees C. The hot solution was immediately
added to a
mixture of locust bean gum, carrageenan, and glycerin in a beaker and mixed,
to provide
a warm paste. This paste was then added to the pre-mixed primary mixture, and
mixed
t o for about 5 min. The final temperature of the resulting nougat was -50
degrees C. The
amounts of the ingredients in this chewy nougat confection are given in Table
3.
TABLE 3
Percent of Composition
Ingredient
Primary Mixture 85-95 wt%
Flavoring 1-3 wt%
Coloring 0.001 wt%
Aspartame 0.009 wt%
Locust Bean Gum 0.1-1 wt%
Calrageenan 0.1.1 wt%
Glycerin 2-7 wt%
Potassium Citrate 0.1-1 wt%
Potable Water 2-7 wt%
TOTAL 100 wt%
t s This pleasant-tasting and chewy gelatin-free nougat material was cut into
approximately 5.3 g pieces, each of which provided 500 mg of calcium.
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EXAMPLE 5
An additional chewy nougat product was made according to the method set forth
in Example I which delivered 500 mg of calcium and 200 LU.'s of vitamin D3 in
chocolate, mint and cherry flavors in a 5.3 gram piece according toTable 4
below:
TABLE 4
Ingredient Percent of Composition
Calcium Carbonate 23.7%
Corn Syrup Solids 18.1-27.1%
6X Powered Sugar 26.6-35.6%
Additional Corn Syrup Solids2.6-3.0%
Fat Solids (Paramount B) 5.9%
Lecithin 3F UB 0.35%
Emulsifier (DurEm 117) 0.25%
Sorbitan Stearate (Sorbitan 0.25%
60K)
Vitamin D3 * 2%
Glycerin 3.0%
Gum Arabic 0.4%
Gelatin (250 Bloom) 1.5-1.8%
Water 6-7%
Flavoring* * 0.64-1.2%
Coloring 0.01%
Acesulfame K (Hoechst) 0.10%
*Vitamin D3 was dissolved in a small amount of corn syrup and added with the
liquid components.
**Flavorings included the following: Peppermint, Spearmint, Vanilla, Cream,
1o Chocolate, Cocoa Powder and Cherry.
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CONSUMER TASTE PREFERENCES
A mint-flavored chewy nougat formulation according to the foregoing
embodiment was compared with three leading commercially-available (store
bought)
calcium supplement preparations in a random taste test. 100 consumers between
the ages
of 30-70 were chosen to participate and evaluate a total of four products
according to the
following criteria on a scale of 1-9: bite, firmness, flavor, sweetness,
chewiness, melt,
stickiness, juiciness, grit, aftertaste and coolness (the higher the score,
the more positively
the consumer judged each attribute). Each consumer was given an identical bite-
size
serving of each one of the four products in the same order (with crackers and
a sip of
1 o water in between each serving). Consumers were not told the source or
identify of the
products they were evaluating, other than that each was a calcium supplement.
Results
are indicated below:
PRODUCT PRODUCT PRODUCT PRODUCT C INVENTION
A B
BITE 5.95 3.78 4.11 6.49
FIRM 6.11 4.24 4.49 6.43
FLAVOR 5.65 4.43 4.81 6.57
SWEET 5.89 4.65 5.49 6.35
CHEW 6.41 3.78 4.00 5.81
MELT 5.62 4.65 4.43 5.86
STICK 5.22 4.95 4.81 4.81
JUICINESS 5.19 4.57 4.35 5.81
GRIT 6.27 3.59 3.22 5.84
I5
PRODUCT AFTERTASTE COOLNESS
Product A 6.49 6.38
Product B 4.89 4.97
Product C 4.92 5.78
Invention 6.41 6.46
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EXAMPLE 6
An additional chewy nougat product was made according to the method set forth
in Example I which delivered 500 mg of calcium, 40 mg of magnesium and 200
LU's of
vitamin D3 in a cherry flavor in a 5.3 gram piece according to Table 5 below:
TABLE 5
Ingredient Percent of Composition
Calcium Carbonate 23.7%
Magnesium Carbonate 2.9%
Corn Syrup Solids 18.1-27.1
6X Powered Sugar 26.6-35.6%
Additional Corn Syrup Solids2.6-3.0%
Fat Solids (Paramount B) 5.9%
Lecithin 3F UB 0.35%
Emulsifier (DurEm 117) 0.25%
Sorbitan Stearate (Sorbitan0.25%
60K)
Vitamin D3* 2%
Glycerin 3.0%
Gum Arabic 0.4%
Gelatin {250 Bloom) 1.5-1.8%
Water 6-7%
Flavoring** 0.64-1.2%
Coloring 0.01
Acesulfame K {Hoechst) 0.10%
*Vitamin D3 was dissolved in a small amount of corn syrup and added with the
liquid components.
**Flavorings included the following: Vanilla and Cherry Flavors from various
1 o commercial sources.
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EXAMPLE 7
A further chewy nougat confectionery product was made according to the method
set forth in Example 1 which delivered 500 mg of calcium, 40 mg of magnesium
and 200
L.U.'s of vitamin D3 in a cherry flavor in a 5.3 gram piece according to Table
6 below:
TABLE 6
Ingredient Percent of Composition
Calcium Carbonate 24.5%
Magnesium Lactate 9.6%
Corn Syrup Solids 18.1-27.1%
6X Powered Sugar 26.6-35.6%
Additional Corn Syrup Solids2.6-3.0%
Fat Solids (Paramount B) 4.9%
Lecithin 3F UB 0.30%
Emulsifier (DurEm 117) 0.20%
Sorbitan Stearate (Sorbitan 0.20%
60K)
Vitamin D3* 0.05%
Glycerin 3.0%
Gum Arabic 0.4%
Gelatin (250 Bloom) 1.5-1.8%
Water 6-7%
Flavoring* * 0.64-1.2%
Coloring 0.04%
Acesulfame K (Hoechst) 0.10%
*Vitamin D3 was dissolved in a small amount of corn syrup and added with the
liquid components.
**Flavorings included the following: Vanilla and Cherry Flavors from various
1o commercial sources.
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In both Examples 6 and 7, the calcium-magnesium chewy nougat confectioneries
had a smooth consistency, and were very tasty, with a pronounced cherry
flavor.
Thus, while there have been described what are primarily believed to be the
preferred embodiments, those skilled in the art will appreciate that other and
further
changes and modifications can be made without departing from the true spirit
of the
invention, and it is intended to include all such changes and modifications
within the
scope of the claims which are appended hereto.
28
