CN1111358C - The Process Control System and the method that are used for the automatic continuous production chewing gum - Google Patents

Abstract

A system (301) and method for automated continuous production of chewing gum and/or chewing gum base. A system controller (316) accepts input parameters required for production. Components are automatically and continuously fed in and mixed to form a predetermined final product. During the production of chewing gum, the gum is automatically and continuously discharged from a mixer (324) and can be automatically powdered, rolled, scored, and packaged. The system is continuously monitored using suitable sensors (344, 352, 358, 362, 342, 331, 335). Signals indicating detected conditions are sent to the controller (316), and the system (301) automatically adjusts to produce a consistent final product. An alarm (336) is activated once a predetermined condition is detected.

Description

Process control system and method for automated continuous production of chewing gum

field of invention

The invention relates to a process control system and method for automatic and continuous production of chewing gum.

Background technique

Typically, gum base and gum products are produced in separate mixers, with different mixing techniques, and often in different factories. One of the reasons for this is that the optimum conditions for producing gum base and the optimum conditions for producing chewing gum from gum base and other components, such as sugar, flavors, are so different that bringing the two jobs together is Very impractical. On the one hand, chewing gum base production involves the dispersion (often high shear) of poorly miscible components such as elastomers, fillers, elastic pliers, gum base softeners/emulsifiers and sometimes waxes Mixing, often requires long mixing times. Chewing gum product manufacturing, on the other hand, involves blending gum base and other components, such as product softeners, bulk sweeteners, bulk sweeteners, and flavorants, using distributive (usually low shear) mixing , takes less time.

In order to increase the efficiency of producing gum base and chewing gum products, continuous production of chewing gum bases and products is preferred. US Patent No. 3,995,064 to Ehrgott et al. discloses the continuous production of chewing gum using either a series of mixers or a single variable mixer. US Patent No. 4,459,311 to DeTora et al. also discloses the continuous production of chewing gum using a series of mixers. Other continuous gum base production processes are disclosed in European Publication No. 0,273,809 (General Foods France) and French Publication No. 2,635,441 (General Foods France).

US Patent No. 5,045,325 to Lesko et al. and US Patent No. 4,555,407 to Kramer et al. disclose continuous processes for the production of chewing gum products. In each of the above cases, however, the gum base is initially prepared independently and the prepared gum base is then simply added to the process. US Patent No. 4,968,511 to D'Amelia et al. discloses a chewing gum product containing certain vinyl polymers produced by a straightforward one-step process without the need for separate production of the gum base. However, D'Amelia et al. are only concerned with a one-time volume mixing process, which, however, is inefficient and lacks the consistency of the product obtained with continuous mixing. Also, the single-step process is limited to chewing gums that contain unconventional gum bases that lack elastomers and other key components.

In order to simplify the production of chewing gum and reduce the cost of production, the chewing gum industry needs or desires an integrated continuous production process which can combine the gum base component and other chewing gum components in a single mixer and can produce a wide range of chewing gums. Still further, there is a need to not only produce chewing gum and/or gum base in a continuous manner but also to automate it, requiring little or no human intervention.

Summary of the invention

The present invention is a process control system and method for the automated continuous production of a wide range of chewing gum products. The present invention allows the use of a single high efficiency mixer, eliminating the need for separate production of the chewing gum base.

To this end, in one embodiment, a system for automated continuous production of chewing gum is provided. The system has: means for inputting operating parameters; means for automatically supplying components required for continuous production of chewing gum; means for controlling the automatic feeding means; and means for automatically continuous mixing by inputting operating parameters to the control means.

In one embodiment, a monitoring device is provided for monitoring the component temperature and providing an indicative signal to the control device.

In one embodiment, a monitoring means is provided for monitoring the feed rate of the components supplied by the automatic feed means and providing an indicative signal to the control means.

In one embodiment, an automatic forming device is provided for automatically forming the mixed components collected and discharged from the automatic continuous mixing device into a predetermined shape.

In one embodiment, an automatic powdering device is provided for powdering a predetermined shape formed in the automatic forming device.

In one embodiment, an apparatus for automatically scribing a predetermined shape is provided.

In one embodiment, an apparatus for automatic packaging after dividing a predetermined shape into a number of specified units is provided.

In another embodiment, a system for automated continuous production of chewing gum base is provided. The system comprises: means for inputting operating parameters; means for automatically and continuously feeding the components required for the continuous production of chewing gum base; means for collecting and automatically and continuously mixing the components; means for controlling the automatic and continuously feeding means; and A device that automatically and continuously mixes by inputting operating parameters to the control device.

In another embodiment, a method for automated continuous production of chewing gum is provided. The method comprises the following steps: inputting working parameters; automatically and continuously supplying components required for continuous production of chewing gum to a mixer; automatically and continuously mixing components in the mixer; controlling automatic and continuously feeding and mixing according to working parameters.

In one embodiment, the method further comprises the steps of: monitoring the performance of the components; and providing a signal indicative of performance.

In an embodiment, the method further comprises the step of: providing an alarm to warn of an error condition during the production of the chewing gum.

In one embodiment, the method further comprises the steps of: monitoring the feed rate of the components in the production process; and providing a signal indicative of the feed rate.

In one embodiment, the method further includes the step of continuously displaying the working parameters in real time during the production process.

In one embodiment, the method further comprises the steps of: continuously discharging the mixed components; and automatically forming the mixed components into a predetermined shape.

In one embodiment, the method further includes the step of: dividing the predetermined shape into several specified units and then automatically packaging.

In yet another embodiment of the present invention, a system for automated continuous production of chewing gum is provided. The system has: a device for automatically and continuously supplying the components required for the continuous production of chewing gum; a device for continuously mixing the components to form a mixture; a device for automatically and continuously discharging the mixture from the mixing device; a device for automatically forming the mixture into a predetermined shape; Shaped device; a device that divides a predetermined shape into several specified units and then automatically packs it.

In one embodiment, the system further includes: means for inputting operating parameters; and means for receiving the operating parameters and controlling the system according to the operating parameters.

In an embodiment, the system further comprises: means for monitoring the components and mixture during feeding and mixing.

In an embodiment, the system further comprises: means for monitoring the mixture during forming, scoring and packaging.

In an embodiment, the system further comprises alarm means for providing an indication of a condition detected in production.

In yet another embodiment of the present invention, a method for automated continuous production of chewing gum is provided. The method has the steps of: feeding the components into a continuous mixer; mixing the components in the continuous mixer to form a mixture; discharging the mixture from the container; automatically forming the mixture into a predetermined shape; scoring the predetermined shape to form units; After being divided into several specified units, the predetermined shape is automatically and continuously packaged.

In one embodiment, the method further comprises the step of powdering said predetermined shape with a substance.

In one embodiment, the method further includes the step of: inputting the working parameters required for producing the chewing gum.

In one embodiment, the method further comprises the step of testing the properties of the components and mixture during production.

In one embodiment, the method further comprises the step of controlling the product based on the detected properties.

In one embodiment, the method further comprises the step of monitoring the properties of the components and mixture during production and comparing the detected properties to operating parameters.

In one embodiment, the method further includes the following step: controlling the production of chewing gum according to the comparison result.

In an embodiment, the method further comprises the step of providing an alert indicative of a predetermined condition detected in production.

In one embodiment, the method further includes the step of continuously displaying the real-time status and other working parameters in production.

A feature and advantage of the present invention is to provide an automated continuous system and method for producing chewing gum.

The features and advantages of the present invention are also to provide an automated continuous production system and method for producing chewing gum that requires less manpower than the prior art methods for producing chewing gum.

The characteristics and advantages of the present invention are also to provide a production chewing gum with improved product consistency, less heat loss, shorter thermal process and less pollution than chewing gum produced by the mixing method of one batch of production in the prior art Automated continuous systems and methods.

Yet another feature and advantage of the present invention is to provide an automated continuous system and method for producing chewing gum that substantially reduces waste.

Yet another feature and advantage of the present invention is to provide an automated continuous system and method that substantially reduces error and variability in production.

The above and other features and advantages of the present invention will become more apparent from the following description of preferred embodiments with reference to the accompanying drawings. However, the detailed description and examples are only for illustrating the invention, not for limiting the invention. The scope of the invention is defined by the appended claims and their equivalents.

Additional features and advantages of the present invention will be described and become more apparent through the following description of preferred embodiments with reference to the accompanying drawings.

Description of drawings

Fig. 1 is the partial exploded perspective view of the preferred Buss high-efficiency mixer that implements the inventive method, shows mixing cylinder and mixing spiral structure;

Figure 2A is a perspective view of the screw used on the upstream side of the confinement ring assembly in the preferred high efficiency mixer configuration of the present invention;

Figure 2B is a perspective view of the screw used on the downstream side of the confinement ring assembly in the preferred high efficiency mixer configuration of the present invention;

Figure 2C is a perspective view of a confinement ring assembly for use in the preferred high efficiency mixer configuration of the present invention;

Fig. 3 is the positioning of the components in Fig. 2A, 2B, 2C in the preferred high-efficiency mixer structure of the present invention;

Figure 4 is a perspective view of a low shear mixing screw for use in the preferred high efficiency mixer configuration of the present invention;

Figure 5 is a perspective view of a high shear mixing screw for use in the preferred high efficiency mixer configuration of the present invention;

Figure 6 is a perspective view of a cartridge pin used in the preferred high efficiency mixer configuration of the present invention;

Figure 7 is a schematic diagram of a mixing cylinder pin and a component supply port for implementing the method of the present invention;

Figure 8 is a schematic diagram of a preferred mixed helical structure of the invention for carrying out the method of the invention;

Fig. 9 is a block diagram of the system components used to complete the automatic continuous production of chewing gum according to the present invention;

Figure 10 is a block diagram of the system components used to complete the automated continuous production of chewing gum according to the present invention and the components required for automated downstream production of chewing gum after mixing.

preferred embodiment

The present invention provides a process for the automatic control of a continuous extruder which can be used to process the mixing of gum base, gum or a compound of gum base and gum in an extruder. Further, control of downstream operations after extrusion, such as tableting, powdering, scoring, and packaging, is also disclosed.

The present invention is a method for the overall production of chewing gum using a single continuous high efficiency mixer without the need for separate production of the chewing gum base. The method is preferably carried out with a continuous mixer whose mixing screw essentially consists of precisely arranged mixing elements with only a very small fraction of simple conveying elements. A preferred mixer of the present invention is the knife-pin mixer 100 shown in FIG. 1 . Knife-pin mixers employ structurally selectively rotatable mixing knives and fixed barrel pins to ensure effective mixing over relatively short distances. A commercially available knife-pin mixer is the Buss Kneader manufactured by the Buss Company of Switzerland and available from Buss America, Inc., Bloomingdale, Illinois.

Referring to Figure 1, the preferred knife-pin mixer 100 of the present invention comprises a single mixing screw 120 rotating inside a barrel 140 which, in use, is substantially closed and completely surrounds the mixing screw 120. The mixing screw 120 includes a cylindrical shaft 122 and three rows of mixing blades 124 (only two rows are seen in FIG. 1 ) evenly spaced around the screw shaft 122 . Protruding radially outwardly from the shaft 122 are mixing blades 122, each blade 122 resembling the blade of an axe.

The mixing cartridge 140 includes an inner cartridge housing 142 that is generally cylindrical in shape when the cartridge 140 is closed about the screw 120 during operation of the mixer 100 . Three rows of stationary pins 144 are evenly spaced around the screw shaft 142 and project radially inwardly from the cartridge housing 142 . The pin 144 is generally cylindrical and may have a rounded or flattened end 146 .

A mixing screw 120 with blades 124 rotates inside a barrel 140 and is driven by a variable speed motor (not shown). During rotation, the mixing screw 120 also moves axially back and forth, resulting in a highly efficient combination of rotational and axial mixing. During mixing, the mixing blade 124 passes continuously between the stationary pins, however, the blades and pins never touch each other. Also, the radial edge 126 of the blade 124 never contacts the inner surface 142 of the barrel, and the end 146 of the pin 144 never contacts the mixing screw shaft 122 .

Figures 2-6 illustrate various spiral elements that can be used to construct mixing spiral 120 for optimum use. Figures 2A and 2B show screws 20 and 21 used in conjunction with a confinement ring assembly. Screw members 20 and 21 each include a cylindrical outer surface 22, a plurality of blades 24 projecting outwardly from surface 22, and an inner bore 26 with a keyway 28 for receiving and engaging a mixing screw shaft (not shown). The second screw 21 is approximately twice as long as the first screw 20 .

FIG. 2C shows a confinement ring assembly 30 used to establish back pressure at selected locations along the mixing helix 120 . The confinement ring assembly 30 comprises two halves 37 and 39 mounted to the cartridge housing 142 which, in use, join to form a closed ring. The confinement ring assembly 30 includes a circular outer rim 32, an angled inner ring 34 as shown, and holes 36 in the inner ring for receiving but not contacting a screw mounted on the screw shaft. Screw parts 20 and 21. The faces of the two halves of the confinement ring assembly have mounting holes 35 for mounting the halves to the cartridge housing 142 .

Figure 3 shows the relationship of the confinement ring assembly 30 and the screws 20, 21 during operation. As the mixing screw 120 rotates and axially reciprocates inside the barrel 140, the gap between the screws 20, 21 and the inner ring 34 provides the primary passage of material from one side of the confinement ring to the other. The screw 20 on the upstream side of the confinement ring assembly includes a modified blade 27 to allow clearance for the inner ring 34 . Another screw 21 is disposed generally downstream of the confinement ring assembly 30, the screw 21 having an end blade (not visible) which moves towards and wipes the opposing surface of the inner ring 34.

The gap between the outer surfaces 22 of the screws 20, 21 and the inner ring 34 of the confinement ring assembly 30 largely determines how much pressure increase will occur in the upstream region of the confinement ring assembly 30 during operation of the mixer 100, The gap is preferably in the range of 1-5mm. It should be noted that the length-to-diameter ratio (L/D) of the upstream screw 20 is about 1/3, and the length-to-diameter ratio (L/D) of the downstream screw 21 is about 2/3, so the screw The overall length to diameter ratio (L/D) is approximately 1.0.

Figures 4 and 5 show the mixing or "kneading" element which does most of the mixing work. The main difference between the low shear mixing element 40 of Figure 4 and the high shear mixing element 50 of Figure 5 is the size of the mixing blades protruding outwardly from the mixing element. In FIG. 5 , the high shear mixing blades 54 projecting outward from surface 52 are larger and thicker than the low shear mixing blades 44 projecting outward from surface 42 shown in FIG. 4 . For each mixing element 40 and 50, the mixing blades are arranged in three circumferentially spaced rows as described above with reference to FIG. 1 . Using thicker mixing blades 54 in FIG. 5 means that when the screw 120 rotates and axially reciprocates (as shown in FIG. 1 ), the axial distance between the blades is shorter, and the gap between the blades 54 and the stationary pin 144 smaller. The reduction in the gap causes a higher inherent shear near the mixing element 50 .

FIG. 6 shows the single stationary pin 144 removed from the barrel 140. As shown in FIG. The pin 144 includes a threaded seat 145 for attachment at selected locations along the inner barrel shaft 142 . It is also possible to use some of the pins 144 as liquid injection ports by having hollow holes.

FIG. 7 shows a schematic view of the preferred barrel structure of the present invention, including the arrangement of the preferred barrel pins 144 of the present invention. Figure 8 is a corresponding schematic diagram showing a preferred mixed helical structure of the present invention. Its preferred configuration shows that the overall effective mixing L/D of mixer 200 in FIGS. 7 and 8 is about 19.

The mixer 200 includes an initial feed zone 210 and five mixing zones 220 , 230 , 240 , 250 and 260 . Zones 210, 230, 240, 250 and 260 include five feed ports 212, 232, 242, 252 and 262, respectively, as large as possible, which can be used to add the main (solid) components to mixer 200 . Zones 240, 260 also have five smaller liquid injection ports 241, 243, 261, 263 and 264 for adding liquid components. The liquid injection ports 241, 243, 261, 263, and 264 include special barrel pins, and the barrel pin 144 is formed with a hollow center as described above.

Referring to FIG. 7, barrel pins 144 are preferably located in most or all possible locations, as shown in three rows.

Referring to Fig. 8, for most chewing gum products, the preferred structural shape of the mixer of the present invention is generally described as follows. The configuration of the initial feed zone 210 has a low shear element of approximately 1-1/3 L/D, such as element 40 shown in FIG. 4 . As discussed above, since the purpose of the initial feed zone 210 is only to deliver the components to the mixing zone, the L/D of the initial feed zone is not calculated as part of the total effective mixing L/D of 19.

The first mixing zone 220 is structured from left to right (Figure 8) with two low shear mixing elements 40 (Figure 4) followed by two high shear elements 50 (Figure 5). Two low shear elements contribute approximately 1-1/3 L/D of mixing. Zone 220 has an overall mixing L/D of approximately 3.0, including the ends covered by a 57mm confinement ring assembly 30 with mating screws 20 and 21 (not separately indicated in Figure 8).

A confinement ring assembly 30 with mating screws 20 and 21 spanning between the end of the first mixing zone 220 and the beginning of the second mixing zone 230 has a compound L/D of about 1.0 and is partially in the second mixing zone Within 230. Zone 230 is configured to have three rows of low shear mixing elements 40 and 1.5 rows of high shear mixing elements 50 from left to right. Three rows of low shear mixing elements contribute about 2.0 mixing L/D and 1.5 high shear mixing elements contribute about 1.0 mixing L/D. The overall mixed L/D of zone 230 is approximately 4.0.

Bridging the end of the second mixing zone 230 and the beginning of the third mixing zone 240 is a 60 mm confinement ring assembly 30 with mating screws 20 and 21 having an L/D of approximately 1.0. Zone 240 is configured from left to right with 4.5 high shear mixing elements 50 contributing a mixing L/D of approximately 3.0. Zone 240 has an overall mixed L/D of approximately 4.0.

Bridging the end of the third mixing zone 240 and the beginning of the fourth mixing zone 250 is another 60mm confinement ring assembly 30 with cooperating screws having an L/D of approximately 1.0. The remainder of the fourth mixing zone 250 and the fifth mixing zone 260 are structured with eleven low shear mixing elements 40 contributing approximately Mixed L/D. The overall mixing L/D of zone 250 is about 4.0, and the overall mixing L/D of zone 260 is about 4.0.

Before explaining where the various chewing gum components are added to the continuous mixer 200 and how they are mixed, it is helpful to discuss the components of a typical chewing gum made using the process of the present invention. Chewing gum typically includes a water-soluble bulk portion, a water-insoluble chewing gum base portion, and one or more flavorants. The water soluble portion is consumed over a period of time during chewing. The gum base portion remains in the mouth throughout the chewing process.

The water-insoluble gum base basically includes elastomers, elastic tougheners (resins), fats, oils, waxes, softeners and inorganic fillers. Elastomers may include polyisobutylene, isobutylene rubber, styrene-butadiene copolymers, and natural latexes such as chicle. Resins may include polyvinyl acetate and terpene resins. Low molecular weight polyvinyl acetate is the preferred resin. Fats and oils may include animal fats such as lard and tallow, vegetable oils such as soybean oil and cottonseed oil, hydrogenated and partially hydrogenated vegetable oils, and cocoa butter. Commonly used waxes include petroleum waxes such as paraffin wax and microcrystalline wax, natural waxes such as beeswax, candelilla wax, carnauba wax, and polyethylene wax.

Gum bases also typically include filler components, such as calcium carbonate, magnesium carbonate, talc, dicalcium phosphate, and the like; softeners, including glyceryl monostearate and triacetin; and some optional ingredients Such as antioxidants, colorants and emulsifiers. The gum base constitutes 5-95% by weight of the chewing gum components, more often 10-50% by weight of the chewing gum, most commonly 20-30% by weight of the chewing gum.

The water soluble portion of the chewing gum may include softeners, bulk sweeteners, bulk sweeteners, flavorants, and combinations thereof. Softeners are added to chewing gum for optimum chewing and mouthfeel. Softeners, also known as tougheners or plasticizers, generally constitute 0.5-15% by weight of the chewing gum. Emollients may include glycerin, lecithin, and combinations thereof. Aqueous solutions of sweeteners, such as sorbitol, hydrogenated starch hydrolysates, corn syrup, and combinations thereof, can be used in chewing gum as softeners and binders.

Bulk sweeteners constitute 5-95% by weight of the chewing gum, more often 20-80% by weight of the chewing gum, most commonly 30-60% by weight of the chewing gum. Bulk sweeteners may include components of sugar and sugarless sweeteners. Sugar sweeteners may include saccharide-containing components including, but not limited to, one or more combinations of sucrose, glucose, maltose, dextrin, dry invert sugar, fructose, levulose, galactose, corn syrup . Sugar-free sweeteners include ingredients that have sweetening properties but do not contain known sugars. Sugar-free sweeteners include, but are not limited to, sugar alcohols, such as one or more combinations of sorbitol, mannitol, xylitol, hydrogenated starch hydrolyzate, maltitol and the like.

High-intensity sweeteners can also be present and used with sugar-free sweeteners. When used, high density sweeteners generally constitute 0.001-5% by weight of the chewing gum, preferably 0.01-1% by weight of the chewing gum. Typically, dense sweeteners are at least 20 times sweeter than sucrose. These include, but are not limited to, sucralose, aspartame, salts of acesulfame, alitame, saccharin and its salts, cyclamate and its salts, licorice, dihydrochalcone, thaumatin, monellin, and One or more combinations of analogs.

A combination of sugar and/or sugar-free sweeteners can be used in chewing gum. Sweeteners can function in whole or in part as water-soluble bulking agents in chewing gum. Additionally, softeners can provide additional sweetness, such as water-soluble sugar or alditol solutions.

Flavorants are typically present in the chewing gum in an amount of about 0.1-15% by weight of the chewing gum, preferably between about 0.2-5%, most preferably between 0.5-3%. Flavorants may include essential oils, synthetic flavors, or mixtures thereof, including but not limited to oils extracted from plants and fruits such as citrus oils, fruit essences, peppermint oils, spearmint oils, other peppermint oils, diced Sesame oil, oil of wintergreen, oil of anise, and the like. Artificial flavorants and components may also be used in the flavorant formulations of the present invention. Natural and artificial flavorants can be combined in a perceptually acceptable manner.

Optional ingredients such as colors, emulsifiers, medicaments and other flavoring agents may also be used in the chewing gum.

According to one embodiment of the present invention, the gum base and the final chewing gum product are manufactured continuously in the same mixer. Typically gum bases are made with a combined L/D of about 25 or less, preferably 20 or less, most preferably about 15 or less. Subsequently, the other components of the chewing gum are combined with the gum base to produce a chewing gum product using a mixed L/D of about 15 or less, preferably about 10 or less, most preferably about 5 or less. The mixing of gum base components and other chewing gum components can occur in different parts of the same mixer, or overlap, as long as the total mixing achieves using about 40 or less L/D, preferably about 30 or less, most preferably About 20 or less.

When using the preferred knife pin mixer, with the preferred configuration described above, a mixing L/D of about 19 can be used for the overall chewing gum manufacture. The gum base can be manufactured using a mixed L/D of about 15 or less, and the remaining chewing gum components combined with the gum base can use an L/D of about 5 or less.

In order to complete the entire chewing gum preparation using the preferred knife pin mixer 200, it is advantageous to keep the rpm of the mixing auger 120 less than about 150, preferably less than 100. And the temperature of the mixer is preferably optimized so that when the gum base initially encounters the other components of the chewing gum, it is at about 130°F or lower; when the chewing gum product exits the mixer, its temperature is at about 130°F or lower (preferably 125°F or lower). Temperature optimization can be achieved in part by selectively heating or water cooling the portion of the barrel surrounding the mixing zones 220 , 230 , 240 , 250 and 260 .

To prepare the gum base, the following preferred procedure can be followed. Elastomers, fillers, and at least some elastomer solvents are added to the first large feed port 212 of the feed zone 210 of the mixer 200, which is conveyed in the direction of the arrow while proceeding in the first mixing zone 220 Highly dispersive mixing. The remainder of the elastomer solvent (if any) and polyvinyl acetate are added to the second largest feed port 232 of the second mixing zone 230 and the ingredients are more dispersedly mixed in the remainder of the mixing zone 230 .

Fat, oil, wax (if used), emulsifier, and optional colorant and antioxidant are added to the liquid injection ports 241, 243 of the third mixing zone 240, and the components are dispersed and mixed in the mixing zone 240 while is conveyed in the direction of arrow 122 . At this point, the preparation of the gum base is complete, and the gum base should exit the third mixing zone 240 as a substantially monochromatic, uniform, clot-free mixture.

The fourth mixing zone 250 is primarily used to cool the gum base, but can also accomplish the addition of small ingredients. Subsequently, to prepare the final chewing gum product, glycerin, corn syrup, other bulk sugar sweeteners, high density sweeteners, and flavorants may be added to fifth mixing zone 260 where the components are distributively mixed. If the gum product is sugar-free, hydrogenated starch hydrolyzate, or sorbitol solution can replace corn syrup, and powdered alditols can replace sugar.

Preferably, glycerin is added to the first liquid injection port 261 of the fifth mixer 260 . Solid components (bulk sweetener, sealed high density sweetener, etc.) are added to large feed port 262 . Syrup (corn syrup, hydrogenated starch hydrolyzate, sorbitol solution, etc.) is added to the next liquid injection port 263, and flavoring agent is added to the last liquid injection port 264. Flavoring agents are also alternatively added to ports 261 and 263 to plasticize the gum base, thereby reducing the temperature and torque on the screw. This also allows the mixer to run at higher rpm with higher throughput.

The chewing gum components are blended into a homogeneous mass that exits the mixer in a continuous stream or "rope". The continuous stream or "rope" is placed on a moving conveyor belt and carried to a forming station where the chewing gum is formed into a predetermined shape, eg, it is pressed into sheets, scored, and cut into strips. Because the entire chewing gum preparation process is consolidated in a single continuous mixer, there is little variation in the product, which is cleaner and more stable due to simplified mechanical and thermal profiles.

Wide range of changes or modifications to the preferred embodiments of this invention will be apparent to those skilled in the art. The above-mentioned preferred embodiments and the examples to be described below are only used to illustrate the present invention, not to limit the present invention. For example, different continuous mixing devices and different mixer configurations may be used without departing from the invention as long as the chewing gum base and chewing gum product are produced in a single continuous mixer using a mixing L/D of no greater than 40. Example 1: Testing the suitability of a continuous mixer

The preliminary tests described below can be used to determine whether a particular continuous mixer with a particular configuration meets the requirements for an efficient mixer for use in practicing the process of the invention.

35.7% butyl rubber (copolymer of 98.5% isobutylene-1.5% isoprene, molecular weight 120,000-150,000, POLYSAR butyl 101-3 produced by Polysar Corporation located in SARNIA, Ontario, Canada), 35.7% Calcium carbonate (VICRON15-15 produced by New York Pfizer Company), 14.3% polyterpene resin (ZONAREZ 90 produced by Arizona Chemical Company in Panama City, Florida), and 14.3% of the second polyterpene resin (produced by Arizona Chemical Company ZONAREZ 7125) dry blend was fed into the continuous mixer in question having the mixer profile to be tested. Choose a temperature profile suitable for optimal mixing, limiting the outlet temperature of the mixture to no more than 170°C to prevent heat drop. To qualify as a suitable high efficiency mixer, the mixer should produce a homogeneous clot-free mixture of uniform milky white color with an L/D of no greater than 10, preferably no greater than 7, most preferably no greater than 5.

In order to thoroughly check for clots, the final rubber compound can be stretched visually, or compressed under hydraulic pressure, or melted on a hot plate, or made into the final gum base, and then reapplied by methods known in the art. Detect clots.

Also, the mixer must be of sufficient length to complete the manufacture of gum base and chewing gum products in a single mixer, with a total mixing L/D not exceeding 40. Any mixer meeting these requirements falls within the definition of a high efficiency mixer suitable for carrying out the method of the present invention. Example 2-6: Continuous production of chewing gum

The following example was carried out in the preferred manner above (unless indicated to the contrary) using a Buss kneader with a mixing screw diameter of 100 mm, having five mixing zones, a total mixing L/D of 19, and an initial conveying L/D of 1-1/3. No dies were used at the end of the mixer unless indicated to the contrary; the product mixture was discharged as a continuous rope. Each example was designed with a feed rate to obtain an output rate of 300 lbs/hr of chewing gum product.

The liquid components are fed by a volumetric pump into a large feed port and/or a smaller liquid injection port, generally located as described above, unless indicated to the contrary. The pump is properly sized and adjusted to achieve the desired feed rate.

Add dry ingredients with a gravity screw feeder into the large additional port as described above. The feeder is properly sized and adjusted to achieve the desired feed rate.

Temperature control is achieved by circulating fluid in a jacket around each mixing cartridge zone and inside the mixing helix. Use water cooling at temperatures up to 200°F and oil cooling at higher temperatures. Where water cooling is required, tap water (usually around 57°F) will suffice and no further cooling is required.

Both fluid and component mixing temperatures are recorded. Fluid temperatures were set to the temperature of each barrel mixing zone (corresponding to 220, 230, 240, 250 and 20 in Figures 7 and 8), recorded as Zl, Z2, Z3, Z4 and Z5, respectively. The fluid temperature is also set to the temperature of the mixing screw 120 and is recorded as S1.

The actual temperatures at the downstream ends of the mixing zones 220, 230, 240, 250, near the middle of the mixing zone 260, and near the end of the mixing zone 260 were recorded. These temperatures are recorded as T1, T2, T3, T4, T5, and T6, respectively. The actual mixing temperature is affected by the temperature of the circulating fluid, the heat exchange performance of the mixture and the surrounding cylinder, and the mechanical heating during the mixing process, so it is often different from the set temperature due to the influence of additional factors.

All ingredients were added to the continuous mixer at room temperature (approximately 77°F), unless noted otherwise. Example 2:

This example illustrates the preparation of sugar chunk bubble gum. For this example, the shape of the mixer was slightly different from the preferred shape described above and was used in Examples 2-6. Specifically, a die with a circular hole of 30mm was installed at the outlet end of the mixer.

A blend of 68.9% high molecular weight polyvinyl acetate and 31.1% ground talc was added at a rate of 35.4 lb/h (pounds per hour) to the first large feed port 212 (see Figure 7). Polyisobutylene (preheated to 100°C) was also fed into port 212 at a rate of 3.95 lb/h. Downstream of the first mixing zone 220, acetylated monoglycerides were injected at a rate of 2.6 lb/h using a liquid injection (hollow barrel pin) port (not shown in Figure 7).

Additional polyisobutylene (100° C.) was added to the second large port 232 at a rate of 3.95 lb/h, glycerides of partially hydrogenated wood rosin at a rate of 13.4 lb/h. 43.6% glyceryl monostearate, A mixture of 55.9% triacetin and 0.5% BHT was added to the liquid injection port 241 at a rate of 6.7 lb/h.

Glycerin was injected into liquid injection port 261 at a rate of 2.1 lb/h. A mixture of 98.4% squeezed sugar and 1.6% citric acid was added to large port 262 at a rate of 170.4 lb/h. Corn syrup (40° C.) was injected into liquid injection port 263 at a rate of 58.5 lb/h, and a mixture of 60% lime flavor and 40% soy lecithin was injected into liquid injection port 264 at a rate of 3.0 lb/h .

Zone temperatures (Z1-Z5, °F) were finally set at 440, 440, 160, 61, and 61, respectively. The spiral temperature (S1) was finally set at 80°F. Mixing temperatures (T1-T6, °F) were finally set at 189, 176, 161, 97, 108, and 112, respectively. The helix rotates at 55 rpm.

First, the product came out of the extruder at 140°F and showed signs of thermal stress. Then, zone temperatures Z1 and Z2 were each decreased by 10°F and the spiral temperature S1 was increased by 20°F to the values shown above. This allowed the gum outlet temperature to drop to 122°F and the product quality improved significantly.

When chewed, the product exhibited good texture, taste, and bubble blowing properties. No rubber clots were visible either. Example 3:

This example illustrates the preparation of mint flavored sugar-free chewing gum. 42.1% ground fine calcium carbonate, 16.7% glycerides of partially hydrogenated wood rosin, 17.0% ground butyl rubber, and 5.3% ground styrene-butadiene rubber (25:75) 75% rubber, 25% calcium carbonate), a mixture of 38.4 lb/h was added to port 212 (see Figure 7).

Low molecular weight polyvinyl acetate was fed to port 232 at a rate of 12.7 lb/h and polyisobutylene (preheated to 100°C) at a rate of 7.6 lb/h.

The fat mix (82°C) was injected 50/50 into injection ports 241 and 243 at an overall rate of 20.9 lb/h. The fat blend included 35.7% hydrogenated cottonseed oil, 30.7% soybean oil, 20.6% partially hydrogenated soybean oil, 12.8% glyceryl monostearate, and 0.2% BHT.

Unlike the previous example, glycerin was injected into the fourth mixing zone 250 (FIG. 7) at a rate of 25.5 lb/h through a liquid injection port (not shown). A dehydrated mixture of hydrogenated starch hydrolyzate and glycerin (at 40° C.) is injected downstream of the fourth mixing zone 250 through another liquid injection port (not shown). The dehydration mixture consisted of 67.5% hydrogenated starch hydrolyzate solids, 25% glycerol, and 7.5% water.

A mixture of 84.8% sorbitol, 14.8% mannitol, and 0.4% sealed aspartame is added to port 262 in the fifth mixing zone 260 at a rate of 162.3 lb/h. 94.1% mint flavor and 5.9% The mixture of lecithin is injected into port 264 located further downstream at a rate of 5.1 lb/h.

Zone temperatures (Z1-Z5, °F) were set at 400, 400, 150, 62, and 62, respectively. The spiral temperature (SI) was set at 66°F. Mixing temperatures (T1-T6, °F) were determined to be 307, 271, 202, 118, 103 and 116. The mixing screw rotates at 69 rpm.

The chewing gum product exits the mixer at 117°F. The gum has a good profile with no sorbitol spots or rubber clots. The gum was slightly wet to the touch, sticky, and bulky (low density), but acceptable. During the chewing process, it starts out soft and becomes firmer with more chewing. Example 4:

This example describes sugar-free peppermint gum for use in coated pellets. 28.6% ground butyl rubber (75% rubber, 25% calcium carbonate), 27.4% high molecular weight terpene resin, 26.9% low molecular weight terpene resin and 17.1% calcium carbonate, the mixture is 41.9lb/ The velocity of h is added to port 212 (FIG. 7).

Low molecular weight polyvinyl acetate was fed to port 232 at a rate of 24.7 lb/h and polyisobutylene (preheated to 100°C) at a rate of 1.7 lb/h.

Fat complex (82°C) was injected 50/50 into injection ports 241 and 243 at an overall velocity of 21.7 lb/h. The fat complex included 22.6% hydrogenated cottonseed oil, 21.0% hydrogenated soybean oil, 21.0% partially hydrogenated soybean oil, 19.9% glyceryl monostearate, 15.4% glycerol and 0.2% BHT.

A 70% sorbitol solution was injected into the fourth mixing zone 250 (FIG. 7) at a rate of 17.4 lb/h using a hollow barrel pin liquid injection port (not shown).

A mixture of 65.8% sorbitol, 17.9% precipitated calcium carbonate, and 16.3% mannitol, was fed into the final large port 262 at a rate of 184.2 lb/h. A mixture of 71.4% mint flavor and 28.6% soy lecithin is injected into the final liquid injection port 264 at a rate of 8.4 lb/h.

Zone temperatures (Z1-Z5, °F) were set at 400, 400, 150, 61 and 61, respectively. The spiral temperature (SI) was set at 65°F. Mixing temperatures (T1-T6 in °F) were determined to be 315, 280, 183, 104, 109 and 116. The mixing screw rotates at 61 rpm.

The chewing gum product exits the mixer at 127°F. The gum has a good profile with no sorbitol spots or rubber clots. However the initial gum was coarse and grainy. Example 5:

This example illustrates the preparation of mint flavored sugar-sweetened chewing gum. 27.4% ground butyl rubber (75% butyl rubber powder, 25% calcium carbonate), 14.1% low softening terpene resin (softening point = 85°C), 14.4% high softening terpene resin (softening point = 125°C), and a mixture of 44.1% calcium carbonate was fed at 24.6 lb/h into the first large feed port (port 212 in Figures 7 and 8).

A mixture of 73.5% low molecular weight polyvinyl acetate, 9.2% high molecular weight polyvinyl acetate, 8.6% low softening terpene resin, and 8.7% high softening terpene resin at a rate of 17.4 lb/h Send into the second largest feed port 232. Polyisobutylene was also fed into this port at a rate of 3.5 lb/h.

The fat mixture (preheated to 83°C) was injected into the liquid injection ports (ports 241 and 243 shown in Figure 7) of the third mixing zone at an overall rate of 14.5 lb/h, and the mixture fed to each port was separately is 50%. The fat blend included 0.2% BHT, 2.5% cocoa powder, 31.9% hydrogenated cottonseed oil, 19.8% glyceryl monostearate, 18.7% hydrogenated soybean oil, 13.7% lecithin, and 13.2% partially hydrogenated of cottonseed oil.

A mixture of 84.6% sugar and 15.4% glucose monohydrate was injected into the large feed port 262 of the fifth mixing zone at a rate of 203.1 lb/h. Glycerin was fed into the first liquid injection port 261 of the fifth mixing zone at a rate of 3.9 lb/h. Corn syrup preheated to 44°C is added to the second liquid injection port 263 of the fifth mixing zone at a rate of 30.0 lb/h. The mixture of 90.0% mint flavor and 10.0% lecithin is injected at a rate of 3.0 lb/h Inject into the third liquid injection port 264 of the fifth mixing zone.

Zone temperatures Z1-Z5 were set at 350, 350, 110, 25 and 25 (unit: °F), respectively. The mixing spiral temperature (SI) was set at 101°F. Mixing temperatures T1-T6 were determined to be constant and were 320, 280, 164, 122, 105 and 103 (in °F), respectively. The helix rotated at 63 rpm and the product exited the mixer at 52-53°C.

Peppermint sugary chewing gum products are relatively soft and of acceptable quality. Example 6:

This example describes the preparation of sugar-free bubble gum tablets. For this example, the helical structure shown in Figure 8 used in the previous example was changed as follows. The delivery section 210 and mixing sections 220, 250 and 260 are generally constructed as previously described. In the second mixing zone 230, the three low shear elements 40 are also unchanged.

The 1-1/2 high shear element 50 in region 230, the confinement element 30 bridging regions 230 and 240, all of region 240, and the confinement element 30 bridging regions 240 and 250 are removed. Three high shear elements 50 (composite L/D=2.0) are positioned in zone 230 and extend into zone 240 . Two semi-low shear elements 40 (composite L/D = 1-2/3) follow in zone 240 . Subsequently, three half-height shear elements 50 (composite L/D=2-1/3) follow in zone 240 and extend into zone 250 . Eleven low shear elements 40 in zones 250 and 260 were unchanged.

In order to manufacture the product, 53.1% of high molecular weight polyvinyl acetate, 31.0% of talc, 12.2% of glycerides of wood rosin, and 3.5% of styrene-butadiene rubber (75% rubber) ground into powder (25:75) , 25% calcium carbonate), a mixture of 54.9lb/h is added to the large mouth 212 (Figure 7). Polyisobutylene (preheated to 100°C) was also pumped into the same port at a rate of 9.0 lb/h.

Glycerides of partially hydrogenated wood rosin were added to the large port 232 of the second mixing zone 230 at a rate of 15.3 lb/h and triacetin at a rate of 4.4 lb/h.

The fat/wax mixture (at 82°C) was fed 50/50 into the liquid injection ports 241 and 243 of the third mixing zone 240 at a total rate of 13.9 lb/h. The mixture included 50.3% glyceryl monostearate, 49.4% paraffin (m.p. = 135°F), and 0.3% BHT.

Diluted glycerin was injected into the fourth mixing zone 250 at a rate of 28.2 lb/h using a liquid injection port (not shown). The dilution is 87% glycerin and 13% water.

A mixture of 84.0% sorbitol, 12.7% mannitol, 1.1% fumaric acid, 0.2% aspartame, 0.4% sealed aspartame, 0.7% adipic acid, and 0.9% citric acid, with 165.0lb /h into the port 262 of the fifth mixing zone 260. A mixture of 51.6% bubble gum flavor and 48.4% soy lecithin was injected into port 264 of zone 260 at a rate of 9.3 lb/h.

Zone temperatures (Z1-Z5, °F) were set at 350, 350, 100, 64 and 64, respectively. The spiral temperature (SI) was set at 100°F. Mixing temperatures (T1-T6 in °F) were recorded as 286, 260, 163, 107, 104 and 112, respectively. The mixing screw rotates at 75 rpm.

The chewing gum product exits the mixer at 118°F. The final product obtained was of good shape and free from clots. Both taste and texture are very good in the chew, and the bubble blowing characteristics are also good.

Referring now to Figures 9 and 10, the system 301 of the present invention is described in the form of an automated process control system 301 . The process control system 301 includes several components, including an operator interface computer 310 that can be controlled by, for example, an operator 312 or memory storage 314 . To this end, operator interface computer 310 accepts process control parameters from operator 312 and/or memory storage 314 . Process control parameters are sent to programmable controller 316 . As an example of a process control parameter, a percentage of a component can be entered into operator interface computer 310 and converted to, for example, a feed rate setpoint. Alternatively, feed rate setpoints can be entered directly into computer 310 . The operator interface computer 310 also receives real-time operating data from the programmable controller 316 and provides the data to the operator 312 via a graphical interface (not shown). Operator interface computer 310 may also store data and process parameters in memory storage 314 . Printed or online reports of current or archived operating information to the operator may also be displayed on the display 315 and/or sent to a printer. These can be performed by those skilled in the art.

Programmable controller 316 accepts calculations and process parameters from operator interface computer 310 as described above. The programmable controller 316 can perform control operations and logic operations, and deliver real-time instructions to device controllers to be described later. The programmable controller 316 can accept real-time data from the device controller and communicate the real-time data to the operator interface computer 310 . Alternatively, the device is controlled directly by the programmable controller 316 . Such devices include, but are not limited to, component feed agitators, heaters, funnel injection devices, and the like. In one embodiment, the control functions performed by a dedicated controller, such as component feed rate control, may also be performed by the programmable controller 316 . Further, programmable controller 316 may provide inventory and instruction data to maintain optimal levels of supply composition.

One such device controller mentioned above includes an extruder heating and cooling controller 318 . Extruder heating/cooling controller 318 accepts start and stop commands and extruder zone temperature parameters from programmable controller 316 . Further, the sensor 321 is used to receive real-time temperature data from the extruder heating and cooling device 320 . The extruder heating/cooling controller 318 activates and deactivates the extruder heating/cooling devices 320, and/or regulates them to maintain the actual temperature within the range specified and entered through the process control parameters. Further, extruder heating/cooling controller 318 communicates actual temperature data to programmable controller 316 .

Another device controller used in the system of the present invention is an extruder controller 322 . The extruder controller 322 accepts start and stop commands and parameters, such as revolutions per minute, from the programmable controller 316 . Further, extruder controller 322 also accepts at least real-time material temperature, rpm, torque, and power data from extruder 324 . The extruder motor (not shown) of the extruder 324 is controlled by the extruder controller 322 to maintain the speed at the rpm dictated by the process parameters. The extruder controller 322 may also include communication of operational data, including temperature, from the extruder 324 to the programmable controller 316 .

Another device controller used in the system of the present invention is a component feed controller 326 . Component feed controller 326 accepts start and stop commands and component feed rates from programmable controller 316 . The component feed controller 326 also accepts real-time weight and rpm data from the component feeder 328 . As a result, the component feed controller 326 calculates the actual feed rate and controls the feed rate within the specified range. Correction for abnormal weight changes during hopper filling can be controlled by component feed controller 326 . Component feed controller 326 allows data to be communicated from feeders to programmable controller 316 . The types of ingredients that may be added include those required to prepare the final chewing gum, final gum base, gum alone and/or gum base components.

The process control system 301 of the present invention also includes several controlled devices. A first such device is memory storage 314 for non-volatile storage of digitized information, for example on optical discs or magnetic tape.

Other controlled devices include an extruder heating/cooling device 320 which is used to heat or cool a number of zones on the extruder 324 . Typically, cooling may be accomplished by circulating fluid through a jacket surrounding the extruder 324 barrel. Alternatively, heating may be accomplished by electric heaters disposed on the walls of the extruder 324 . Preferably, however, heating of the extruder 324 is effected by circulating a heating fluid through a jacket surrounding the extruder 324 barrel.

Extruder 324 also includes one or more rotatable screw shafts. Alternatively, extruder 324 may undergo reciprocating axial movement and rotation, as described with reference to FIGS. 1-8 . The shaft can be rotated by the motor and the drive train connected to it. Temperature sensors may be positioned to project inwardly from the barrel wall to measure the temperature of the product at selected points along the length of the extruder 324 .

Component feeders 328 of the system of the present invention may include feeding liquid materials and dry materials via gravimetric feeders which in turn deliver the components to extruder 324 . Feed is accomplished by a variable speed motor driving a pump or auger. However, other component feeders are contemplated and known in the art, such as vibrating plates or racks, rotary valves, mass analyzers or variable orifice discharge valves. Such feeders can be implemented by those skilled in the art. A scoring system or sensor 340 may be used to gauge the component feeder and its contents; this information is then used by the component feed controller 326 to maintain a predetermined feed rate. The hopper level monitor can be used to communicate information to the programmable controller 316 to indicate refilling of the hopper. Preferably, however, hopper refilling is signaled by a weight sensor connected to the gravity feeder. Once it is detected that the total weight has dropped below a predetermined value, indicating a low hopper level, the refilling device is automatically activated to refill the specific hopper.

Other controls include feed temperature control 330 , component feed agitation 332 , and component hopper refill system 334 . Component feed temperature control unit 330 may include various types of heaters and chillers to maintain the temperature of hoppers, feed lines, troughs, and other feeder components within acceptable limits and to communicate the actual temperature to the programmable controller 316. These variables can be sensed by suitable sensors 331 which communicate with the feed temperature control means 330 and the programmable controller 316 . Component feed agitator 332 may include stirring and vibrating elements to prevent feeder bridging or jamming. Such a condition may be detected by a suitable sensor 335 operatively connected to the agitator 334 and providing a signal to the programmable controller 316 . Preferably, agitation and vibration are performed at regular intervals or at predetermined hopper levels, or alternatively, agitation is initiated based on other detected conditions other than direct detection of clogging. Finally, component hopper refill system 334 includes the ability to refill component supply hoppers under the direction of programmable controller 316 . Accordingly, confirmation of the refill and current inventory or component usage status is communicated to the programmable controller 316 .

Preferably, multi-level alarms are provided in the system of the present invention. Alarms 336 include first level alarms that can provide failure information and information outside of the specification reading range for non-critical performance. For example, the failure of a product temperature sensor could be indicated by an informational alert. This information can be displayed on the monitor without further action being taken by the programmable controller 316 . In addition to messages, audible alerts are also available.

The second level of alarms 336 are warnings of failures that will affect the continued operation of the system 301 or critical conditions outside of technically specified performance. The warning alert may display a blocking critical alert if the problem is not resolved within the specified time interval. The size of this time interval depends on the impact on the particular system and/or the degree of deviation from specified tolerances. Warning messages can be displayed on a monitor, and/or can be audible.

The third level of alarm of alarm 336 is a critical alarm state, indicating that there is a failure to shut down the system 301 immediately. A warning condition that is not corrected within a specified predetermined time interval may also trigger a critical alarm. Initially, the extruder 324 may be automatically shut down, accompanied by a message displayed on a monitor and/or an audible alarm. This regulation can also be overridden to allow the operator 312 to prevent automatic cut-off if his behavior is appropriate.

The above describes the process control system 301 in its basic form. However, two or more device controllers may be combined into a single unit. For example, a single controller can be used to handle extruder motor control and extruder heating/cooling control functions. Similarly, the agitator and feeder temperature control functions could be handled by a separate controller rather than directly controlled by the programmable controller 316 described above.

In addition, operator interface computer 310 may serve as programmable controller 316 and one or more device controllers, such as extruder heating/cooling controller 318, extruder controller 322, and/or component feed controller 326 , the interface between.

Some or all of the operating data, such as actual temperature, actual feed rate, and the like, may be stored on a permanent medium for later viewing. This is beneficial in cases where the resulting product is found to be defective, and looking at the operational data can help clarify why the defect occurred. Such data storage may be provided in memory storage controlled by operator interface computer 310 or programmable controller 316 .

Additionally, alarm conditions may be monitored by the device controller and communicated to the programmable controller 316 . Alternatively, the device controller may simply communicate the data to the programmable controller 316, which then determines whether an alarm condition exists. Similarly, separate distinct subsystems may be used in each configuration.

It has been described above that refilling of the funnel is preferably done by automatic means. However, in some instances, the hopper refill is desirably done manually by instructing the operator via the operator interface computer 310 of the hopper refill request. An associated monitor and/or audible signal can be used to alert the operator of the need for hopper refill.

Component feed controller 326 may also control volumetric devices in addition to or instead of the gravimetric feeders described above. Further, in addition to data required for control purposes, data not required for control purposes may be sent to programmable controller 316 via one or more device controllers, or directly to programmable controller 316 . An example is component temperature measurement.

After mixing, other automated processes are completed, including tabletting and packaging of chewing gum products. More specifically, the extruder has a die to form the chewing gum into slabs, sheets, ropes or other desired starting shapes. Alternatively, the unshaped output from the mixing extruder is conveyed to the second forming extruder 348 where it is formed into a starting shape. Automated operations can utilize input data such as gum output pressure and dimensions to control extruder temperature and speed, and take away eg conveyor output speed to control the size of the formed chewing gum wick. Appropriate sensors 344 may be used to monitor specific parameters to control the forming extruder 348 .

After exiting the forming extruder 348, the chewing gum may be moved to or fed into the rollers by transport means such as conveyors. Before entering the rollers, the chewing gum is preferably dusted with a suitable winding compound such as sugar or mannitol by a spreader. An automated control system may also include optical detection or gravimetric output using a suitable sensor 352 to control the application of the winding compound and/or the speed at which the chewing gum passes through the applicator.

If the chewing gum is formed into eg sticks or sheets, the shaped and dusted product is fed to one or more sets of rollers 354 which reduce the thickness of the chewing gum to the desired final value. Subsequently, the product can be scored to the final sheet size simultaneously or separately. The automated process control system 301 may monitor values such as product dimensions and temperature with suitable sensors 358 and use these measurements to control roller speed, spacing, etc., roller separation and temperature.

Finally, once the chewing gum has been formed and scored into its final shape, it is followed by packaging operations by packaging machines to cover and combine the product into units suitable for consumer use, consumer purchase, retailer sale and shipment. Prior to packaging, the scored product is divided into units as desired. Therefore, as shown in Figure 10, the cutting or breaking of the product after scoring is carried out in the packaging process. Packaging operations can be automated and continuously controlled in a number of ways. For example, feed and pack speeds are controlled to vary most effectively with changes in product speed and packs. The temperature of the chewing gum tablets obtained can be optimized by controlling the upstream operations. Various operations of packaging machine 360 may allow for changes in the gum product and packaging material detected by various sensors 362 .

As a result of the automated control process described above, labor costs are saved and manufacturing variability and errors are significantly reduced. In addition, the adaptability of manufacturing is also enhanced, reducing material waste. Moreover, a final product with more stable quality is effectively obtained.

It should be understood that various changes and modifications of the embodiments of the present invention will be obvious to those skilled in the art. Such changes and modifications do not depart from the spirit and scope of the invention, and do not diminish the advantages brought by the invention. All such modifications and changes are therefore intended to be covered by the appended claims hereof.

Claims (43)

1. system that is used for the automatic continuous production chewing gum, this system comprises:

The device that is used for input working parameter;

Be used for supplying with continuously automatically the device of producing the required component of chewing gum continuously;

Be used to collect device with the continuous blending ingredients of automation;

Control device is by controlling automatically continuously feedway and automatically continuous mixing arrangement to the control device input working parameter.

2. the system as claimed in claim 1 is characterized in that, described parameter comprises component percentage or feeding rate.

3. the system as claimed in claim 1 is characterized in that, also comprises:

A monitoring device is used to monitor component temperature and its index signal is offered control device.

4. the system as claimed in claim 1 is characterized in that, also comprises:

One device is used to monitor automatically continuously feedway and supplies with the feeding speed of component and the signal of indicating is offered control device.

5. the system as claimed in claim 1 is characterized in that, also comprises:

An automatic forming device, the blending ingredients that is used for discharging from the device of collecting and mixing continuously automatically forms a reservation shape automatically continuously.

6. the system as claimed in claim 1 is characterized in that, also comprises: the device of described collection and automatically continuous blending ingredients is configured as reservation shape with component in discharge process.

7. system as claimed in claim 5 is characterized in that, also comprises:

An automatic dusting device is used to the reservation shape dusting that forms in automatic forming device.

8. system as claimed in claim 6 is characterized in that, also comprises:

One is used for being automatically the device of reservation shape dusting.

9. system as claimed in claim 5 is characterized in that, also comprises:

A device that is used for the reservation shape that automatic roll comes out from automatic progressive forming device.

10. system as claimed in claim 6 is characterized in that, also comprises: the device that is used for the automatic roll reservation shape.

11. system as claimed in claim 5 is characterized in that, also comprises: be used for drawing automatically the device of carving reservation shape.

12. system as claimed in claim 11 is characterized in that, also comprises: the reservation shape after will drawing quarter is divided into after some designating unit the device of packing reservation shape automatically.

13. system as claimed in claim 6 is characterized in that, also comprises: be used for drawing automatically the device of carving reservation shape.

14. system as claimed in claim 13 is characterized in that, also comprises: the reservation shape after will drawing quarter is divided into after some designating unit the device of packing reservation shape automatically.

15. the system as claimed in claim 1 is characterized in that, described component is to make needed those batchings of final matrix.

16. the system of an automatic continuous production chewing gum base, this system comprises:

The device that is used for input working parameter;

Automatically supply with the device of producing the required component of chewing gum base continuously continuously;

Be used to collect and the automatic device of blending ingredients continuously;

Control device is by controlling automatically continuously feedway and automatically continuous mixing arrangement to the control device input working parameter.

17. system as claimed in claim 16 is characterized in that, also comprises: a device is used to monitor automatically continuously feedway and supplies with the feeding speed of component and the signal of indicating is offered control device.

18. the method for an automatic continuous production chewing gum, this method comprises the following steps:

Input working parameter;

In a blender, supply with continuously automatically and produce the required component of chewing gum continuously;

Automatically continuous blending ingredients in blender;

According to running parameter control continuous supply and mixing automatically.

19. method as claimed in claim 18 is characterized in that, also comprises the steps: to monitor the performance of component; And the signal that the indication performance is provided.

20. method as claimed in claim 18 is characterized in that, also comprises the steps: to provide alarm, occurs error condition with warning in producing the chewing gum process.

21. method as claimed in claim 18 is characterized in that, also comprises the steps: to monitor the feeding speed of component in the production process; And the signal that the indication feeding speed is provided.

22. method as claimed in claim 18 is characterized in that, also comprises the steps: to show in real time continuously in process of production running parameter.

23. method as claimed in claim 18 is characterized in that, also comprises the steps: to discharge continuously mixed component; And with the automatic reservation shape that forms of mixed component.

24. method as claimed in claim 18 is characterized in that, also comprises the steps: mixed component is formed a reservation shape automatically; And be the reservation shape dusting automatically.

25. method as claimed in claim 18 is characterized in that, also comprises the steps: mixed component is formed a reservation shape automatically; And in forming process, be the reservation shape dusting automatically.

26. method as claimed in claim 18 is characterized in that, also comprises the steps: mixed component is formed a reservation shape automatically; And dusting, draw the qualification unit that quarter, roll-in, cut-out, packing reservation shape or the reservation shape after being shaped are divided into.

27. method as claimed in claim 23 is characterized in that, also comprises the steps: the automatic roll reservation shape.

28. method as claimed in claim 23 is characterized in that, also comprises the steps: to draw automatically to carve reservation shape.

29. method as claimed in claim 23 is characterized in that, also comprises the steps: to pack automatically after reservation shape being divided into some qualifications unit.

30. a system that is used for the automatic continuous production chewing gum, this system comprises:

Automatically supply with the device of producing the required component of chewing gum continuously continuously;

Blending ingredients is to form the device of mixture continuously;

Automatically discharge the device of mixture continuously from mixing arrangement;

Mixture is formed automatically the device of reservation shape;

Automatically draw the device of carving reservation shape;

Reservation shape is divided into the device of packing automatically after some designating unit.

31. system as claimed in claim 30 is characterized in that, also comprises: the device that is used for input working parameter; And accept running parameter and according to the device of running parameter control system.

32. system as claimed in claim 30 is characterized in that, also comprises: the device that is used between supply and mixing period, monitoring component and mixture.

33. system as claimed in claim 30 is characterized in that, also comprises: be used at the device that is shaped, draws monitoring mixture during carving and packing.

34. system as claimed in claim 30 is characterized in that, also comprises: the alarm device that is used to provide the detected condition index signal of production period.

35. a method that is used for the automatic continuous production chewing gum, this method comprises the following steps:

Component is infeeded in the continuous mixing device;

Blending ingredients is to form mixture in continuous mixing device;

From continuous mixing device, discharge mixture;

Mixture is formed reservation shape automatically;

Draw and carve reservation shape to form some unit;

Automatically pack reservation shape continuously after being divided into some designating unit.

36. method as claimed in claim 35 is characterized in that, also comprises the steps: to spray described reservation shape with a material.

37. method as claimed in claim 35 is characterized in that, also comprises the steps: the needed running parameter of input production chewing gum.

38. method as claimed in claim 35 is characterized in that, also comprises the steps: the performance of detected components and mixture aborning.

39. method as claimed in claim 38 is characterized in that, also comprises the steps: according to detected Properties Control product.

40. method as claimed in claim 37 is characterized in that, also comprises the steps: the performance of detected components and mixture aborning; And detected performance and running parameter compared.

41. method as claimed in claim 40 is characterized in that, also comprises the steps: the production according to comparing result control chewing gum.

42. method as claimed in claim 35 is characterized in that, also comprises the steps: to provide the alarm of detected predetermined condition in the expression production.

43. method as claimed in claim 35 is characterized in that, also comprises the steps: to show in real time continuously production status and running parameter.

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