GB2436514A

GB2436514A - A granulated sugar product

Info

Publication number: GB2436514A
Application number: GB0606192A
Authority: GB
Inventors: Martin John James; Philip Andrew Freeman
Original assignee: Tate and Lyle PLC
Current assignee: Tate and Lyle PLC
Priority date: 2006-03-28
Filing date: 2006-03-28
Publication date: 2007-10-03
Also published as: GB0606192D0; WO2007110645A1

Abstract

A granulated sugar product which comprises a core material of a granulated first sugar and a surface material which comprises a second sugar and a binder, where the surface material is less dense than the first sugar material. The product may incorporate a sweetener. The first sugar may be sucrose. Also disclosed is a method of producing a granulated sugar product which may utilise a mixer having two drive shafts provided with blades arranged at an angle and parallel to the shafts.

Description

Granulated Sugar Product The present invention relates to a granulated

sugar product and a process for making such a product and, in particular, to a product intended to be used as a substitute for granulated sugar.

W098/02585 discloses a granulated sugar product comprising a core material substantially of a granulated first sugar and a surface material substantially of a second sugar, wherein the second sugar material is less dense than the first sugar material.

Preferably, the product incorporates a sweetener, more preferably a high intensity sweetener, so that, when dispensed by a variety of measures, e.g. spoons, the product delivers less of the weight for the same sweetness when compared with granulated sugar.

W098/02585 aims to achieve half or less of the weight for the same sweetness when compared with granulated sugar. Although this is achievable by the method disclosed therein, it has been found according to the present invention that the product tends to compact on handling, packaging and storage, so that the weight loss is not preserved. In practice, it has been found that only a 33% weight reduction can consistently be achieved by the method of W098/02585.

The present invention aims to achieve a granulated sugar product that has a greater robustness on handling, packaging and storage than the product of W098/02585. In particular, the invention aims to achieve a granulated sugar product that (i) can withstand mechanical handling by belt conveyors, rotary valves, diverter valves, bucket elevators, and volumetric powder fillers; (ii) that can withstand compression forces exerted by storage in small hoppers and silos, road freight transport in Flexible Intermediate Bulk Containers (FIBC5) and storage of packed product in a palletized format; and (iii) that can be loaded into FIBCs and discharged from FIBCs without destruction of agglomerates due to particle to particle attrition.

It is an aim of the present invention to achieve 60% or less, more preferably 50% or less, of the weight for the same sweetness when compared with granulated sugar.

According to one aspect of the present invention, there is provided a granulated sugar product comprising a core material substantially of a granulated first sugar and a surface material comprising a second sugar and a binder, wherein the surface material is less dense than the first sugar material.

The surface material may cover only some or all of the surface of the first sugar granule.

The product may also incorporate a sweetener, preferably a high intensity sweetener.

The sweetener may be included in the surface material, so that the surface material comprises the second sugar, a binder, and the sweetener (preferably high intensity sweetener). In that case, the surface material preferably substantially consists of the second sugar, the binder, and the sweetener (preferably high intensity sweetener).

Alternatively, the sweetener may be present in the product separate from the surface material. In that case, the surface material preferably substantially consists of the second sugar, and the binder.

In this manner, a granulated sugar product can be provided with an overall bulk density less than the bulk density of the granulated first sugar and, therefore, act as a lighter alternative to the first sugar product whilst maintaining the granulated form and "crunch". Furthermore, by the use of appropriate quantities of sweeteners, a lighter product with the same sweetness as the first sugar may be obtained.

Preferably, the first sugar is sucrose but any granulated sugar product may be used. By granulated is meant such products as would include, for instance, commercial table sugar and caster sugar but not icing sugar. Thus, typically granulated may imply having crystals of at least 0.1 mm or between about 0. 1 mm and 1.0 mm, more preferably 0.2 mm and 0.8 mm and including specifically castor sugar having crystals in the range 0.27 to 0.34 mm and conventional granulated or table sugar having crystals in the range 0.60 to 0.67 mm. Preferably, the crystal sizes are in the range 0.27 mm to 0.67 mm.

It has been found that it is advantageous to have two particle sizes of the first sugar. In particular, it is advantageous to employ a mixture of granulated sugar and extra fine sugar. Extra fine sugar has crystals which are intermediate in size between granulated sugar and castor sugar. The mixture is preferably a 1:1 mixture by weight.

The second sugar may be selected from any sugar product. Preferably, the second sugar is selected from sucrose, glucose (dextrose, anhydrous & mono), fructose, lactose (anhydrous and hydrated), maltose, Ribose, galactose, dextrins, maltodextrin, dried glucose syrups, sorbitol, mannitol, grape sugar, arabinose, raffinose, mannose, starch, cellulose, inulin, glycogen, xylitol, levoglucason, rhaninose, maltol (and ethyl derivative), iso-maltose, gentobiose, trehalose, cellobiose, neohesperidose, maltotriose, parose, neokestose, stachyose.

The sweetener may be any sweetener. Preferably, the sweetener is selected from sucralose, sorbitol (E420), mannitol (E42 1), isomalt (E953), maltitol (E965), lactitol (E966), xylitol (E967), acesulfame k (E950), aspartame (E951), cyclamic acid and sodium and calcium salts (E952), saccharin and its sodium, potassium and calcium salts (E954), thaumatin (E957), neohesperidine DC (E959).

More preferably, the sweetener is sucralose. However, the sweetener may be aspartarne andlor acesulfame K andlor other high intensity sweeteners. The high intensity of the sweetener is defined in terms of its sweetness compared with sugar on a weight basis.

Preferably, the high intensity sweetener is at least 30 times, typically 200/300 times or at least 100 times, as sweet as sugar on a weight basis. The product may comprise two sweeteners, typically both aspartame and acesulfame K. In general aspartarne tastes good but tends not to be heat stable whereas acesulfame K is heat stable but does not taste as good. The product may include a liquid component such as water.

Preferably, the second sugar is in a powder fonm More preferably, the second sugar comprises a foam dried sugar and/or a spray dried sugar. Most preferably, the second sugar comprises both a foam dried sugar and a spray dried sugar, with the former having a lower bulk density than the latter. In this case, the proportion by weight of foam dried sugar to spray dried sugar is preferably in the range of from 1: 10 to 1: 2; more preferably in the range of from 1: 7 to 1 4; most preferably in the range of from 1: 6 to 1: 5. Preferably, a sugar having a lower calorific density compared with sucrose is used. The lower calorific density may be due to the chemical or physical form of the sugar or both.

Preferably, a low density maltodextrin is used. Preferably, the maltodextrin is in powder form. More preferably the maltodextrin comprises foam dried maltodextrin and/or spray dried maliodextrin. Most preferably, the maltodextrin comprises both foam dried maltodextrin and spray dried maltodextrin, with the former having a lower bulk density than the latter. In this case, the proportion by weight of foam dried maltodextrin to spray dried maltodextrin is preferably in the range of from 1: 10 to 1: 2; more preferably in the range of from 1: 7 to 1: 4; most preferably in the range of from 1: 6 to I: 5. Foam drying is a known process comprising pumping gas under pressure into the feed to the spray drier prior to the sugar being spray dried. Foam dried sugar has a honeycomb effect which gives it a significantly reduced bulk density. Thus, preferably a sugar that is fluffy and light is used.

The binder is preferably selected from the group consisting of gum arabic, pectin, starch, agar, carboxymethylcellulose and derivatives (hydroxypropylcelluloses, methylcellulose), carrageenans, alginates, gellan gum, xanthan, guar, locust bean gum, gum tragacanth, gelatin, egg albumen, caseinates, soya protein, whey proteins.

The binder is more preferably gum arabic.

Preferably, the product comprises the first sugar in the range of 60-90% by weight, more preferably, 65-75% by weight. Preferably the second sugar is 10-40% by weight, more preferably, 25-35% by weight. Preferably, the sweetener, typically sucralose, is 0.05-1.0% by weight, more preferably, 0.08-0.15% by weight, most preferably 0.10- 0.13% by weight. Preferably the binder is 0.01-1% by weight, more preferably 0.02 to 0.1% by weight, most preferably 0.03 to 0.075% by weight.

According to a second aspect of the invention there is provided a method of producing a granulated sugar product comprising mixing a core material of a granulated first sugar and a surface material comprising a second sugar and a binder, wherein the surface material is less dense than the first sugar material in such a manner as to result in agglomeration of the mixture. Preferably, the components of the mixture are as described above with respect to the first aspect of the invention. Preferably, the mixing is by means of a low shear mixer or slow speed blender. Alternatively, a batch or continuous agglomerator may be used. The agglomerator is preferably a fluid bed agglomerator with top or bottom spray and manual or automated product loading and discharge. Suitable agglomerators are manufactured by Glatt, NIRO, EURO VENTS US (Calmic, and Phoenix). Preferably, liquid, typically water, is added to the mixture during mixing, and preferably the binder is dissolved in this water. The sweetener, if present, can be included in the mixture of powders to be agglomerated, or it can be dissolved in the liquid together with the binder. The liquid may be added by spraying atomised liquid onto the mixture. Advantageously, the liquid turns the mixture into a slurry, but, preferably, does not dissolve the majority of the granulated first sugar or, preferably, the majority of the second sugar although the liquid will, inevitably, dissolve some of the sugars. Advantageously dissolving a small amount of the sugars, the liquid, once dried, has the effect of encouraging the first and second sugars to agglomerate thus producing larger granules with lower bulk density than the first sugar. Preferably, the liquid is water but any liquid able to solubilise sugars may be used. Preferably, the liquid is nontoxic and is easily evaporated. Preferably, 5-20% of liquid by weight, typically, water, is used, more preferably, 5-15% by weight is used, and most preferably 8 to 12 % by weight is used. The binder is typically included in the liquid in an amount of 0.01-0.1, preferably about 0.05% by weight.

The product according to the present invention is preferably dried to a moisture content of from 2 to 5% by weight, preferably from 2. 5 to 3.5% by weight.

Preferably, the mixture may be added to a batch or continuous agglomerator such as a fluidised bed agglomerator. Such an agglomerator may comprise a vessel having an air distribution grate at a lower end thereof. One or more filters may be positioned at an upper end of the vessel to filter out entrained solids. Nozzles for spraying atomised liquids, typically water, may be positioned in, on or adjacent to the vessel, for example iii the sides or top of the vessel. Preferably, a small amount of sugar is added to the liquid or water in either embodiment before it enters the mixer or agglomerator as it has been found that this gives better results.

Alternatively, the mixture is mixed in a low shear mixer and a small amount of liquid, typically water, is added. As a specific example, 50 ml to 3.0 litres water may be added to an approximately 60 kg mixture. This results in the even and permanent agglomeration of the mixture with all of or some of the aforementioned characteristics.

The low shear mixer may be of any suitable type such as drum types, tote blenders or slow speed blenders. The binder is preferably included in the liquid. Preferably, this method comprises mixing using a mixing machine as described in GB 2026881, which document is incorporated herein by reference. Thus, preferably the method comprises mixing by means of a mixing machine in which the components of the mixture are mixed by means of two counterrotating shafts with blades, where some of the blades have different angles of incidence and different blade areas in order to obtain a good mixing of the components. Preferably, the mixing machine comprises a mixing chamber in which two shafts are arranged in substantially the same horizontal plane, the shafts being provided with blades or paddles disposed at an angle to and parallel with the shafts, the shafts rotating in opposite directions. Although the machine may be operated as described in GB 2026881 with reference to Figure 4 thereof, it is preferred that the machine is operated such that downward movements are on the side where the shafts turn toward one another. Preferably, the mixing machine is operated such that the blades have a peripheral rotational velocity of at least 1.2 rn/sec or between 1.2 and 1.8 rnlsec. Preferably, a plurality of opposing pairs of blades of certain area are mounted on each shaft, positioned 90 transverse of the centreline for the shafts and with the blade wings disposed at a 45 angle in relation to the shaft centreline. The supports for the blade wings of some opposing pairs of blades may be displaced 90 in relation to the supports for other pairs as specifically described in GB 2026881. Other specific features of the machine, such as the disposition and form of the blades at the ends of the shafts, may be as described in GB 2026881. As previously mentioned it is preferred that the machine is operated conversely to the operation described in GB 2026881 in that the shafts are rotated in contra-rotation with downward movement of the shafts being on the side where the shafts turn towards each other. This allows the mixing to take place towards the lower region of the chamber, that is below the level of the shafts. It has been found that such operation gives surprisingly better results.

According to a further aspect of the present invention there is provided a granulated sugar product comprising a mixture of granulated sugar, maltodextrin, gum arabic, and high intensity sweetener. Preferably the product is crystalline. Preferably, the sweetener is as described above. Preferably, the product comprises sucralose. The product may include a liquid component such as water. The amount of added liquid typically determines the consistency of the mixture.

Preferably, a low density maltodextrin is used. Preferably, the maltodextrin is in powder fonn. More preferably the maltodextrin comprises foam dried maltodextrin and/or spray dried maltodextrin. Most preferably, the maltodextrin comprises both foam dried maltodextrin and spray dried maltodextrin, with the former having a lower bulk density than the latter. In this case, the proportion by weight of foam dried maltodextrin to spray dried maltodextrin is preferably in the range of from 1: 10 to 1: 2; more preferably in the range of from 1: 7 to 1: 4; most preferably in the range of from 1: 6 to 1: 5. Foam dried maltodextrin has a spherical structure which gives it a significantly reduced bulk density. Thus, preferably a maltodextrin that is fluffy and light is used.

Preferably, the product comprises the granulated sugar in the range of 60-90% by weight, more preferably, 65-75% by weight. Preferably the product comprises maltodextrin in an amount 10-40% by weight, more preferably, 25-35% by weight.

Preferably, the product comprises the sweetener, typically sucralose, in an amount of 0.05-1.0% by weight, more preferably, 0.08-0.15% by weight, most preferably 0.10- 0.13% by weight. Preferably the product comprises gum arabic in an amount of 0.01- 1% by weight, more preferably 0.02 to 0.1% by weight, most preferably 0.03 to 0.075% by weight.

According to a still further aspect of the present invention there is provided a method of producing a granulated sugar product comprising mixing granulated sugar, maltodextrin, gum arabic and high intensity sweetener in such a manner as to result in agglomeration of the mixture. Preferably the components of the mixture are as described above. Preferably, a batch or continuous agglornerator is used.

Alternatively, the mixing is by means of a low shear mixer or slow speed blender.

Preferably, liquid, typically water, is added to the mixture during mixing, and preferably the gum arabic is included in the liquid. The liquid may be added by spraying atomised liquid onto the mixture. Preferably, the mixture is mixed in a low shear mixer and a small amount of liquid, typically water, is added. As a specific example, 50 ml to 3.0 litres water may be added to an approximately 60 kg mixture. This results in the even and permanent agglomeration of the mixture with all of or some of the aforementioned characteristics. The low shear mixer may be of any suitable type such as drum types, tote blenders or slow speed blenders. The gum arabic is preferably included in the liquid.

Preferably, the mixture may be added to a batch or continuous agglomerator such as a fluidised bed agglomerator. Such an agglomerator may comprise a vessel having an air distribution grate at a lower end thereof. One or more filters may be positioned at an upper end of the vessel to filter out entrained solids. Nozzles for spraying atomised liquids, typically water, may be positioned in, on or adjacent to the vessel, for example in the sides or top of the vessel. The gum arabic is preferably included in the water.

Preferably, a small amount of sugar is added to the liquid or water in either embodiment before it enters the mixer or agglornerator as it has been found that this gives better results.

Alternatively, the mixer or blender is as described above and is operated as described above.

The method of the present invention is coimnonly referred to as a re-wet process in the literature. It involves the addition of water or water containing a binding agent to a dry powder and then use some form of agitation to promote interparticle collisions and formation of agglomerates. The agglomerates are then re-dried and screened and any oversized particles are separated and recycled. It is preferred to use a fluidized bed agglomerator to agitate the dry powder and the binder then acts as a glue / bonding agent by adhering to the particles. The use of a binder is usually used to agglomerate inert materials. This is surprising as, according to the present invention, "inert materials" are not present. The ingredients according to the present invention will dissolve and become sticky or tacky and one would expect them to adhere to each other and form clusters. The preferred binder according to the present invention is gum arabic. Gum arabic is a low viscosity binder and it is also surprising that this should give agglomerates of higher strength. According to the literature, it would be expected that use of liquids of higher viscosity results in higher strength than for low-viscosity liquids. However, that is not found in the present invention.

In theory the overall strength and structure of the agglomerated granules depends on the nature of the cohesive forces that hold the particles together. In most cases the electrostatic forces and liquid bonds hold the particles together during the granule growth. Upon drying these usually result in "solid bridges" e.g. recrystallisation of dissolved material, hardening of the binder liquid or by chemical reaction. In this way the agglomerate comprises of particles connected by solid bridges in which capillary pores are present. Although there is a clear understanding of the contributing forces in particulate strength, there is no predictive theory that can evaluate the granule strength from just the knowledge of the powder and liquid properties. The "open/porous" structures of these agglomerates have areas of air trapped and it this that reduces the bulk density of the powders which makes the agglomerates "light", so that they weigh less than just a blend of these powders.

The method of the present invention can be carried out by the methods disclosed in detail in W098/025 85, with the exception that the binder of the present invention is included in the liquid that is added during the agglomeration. The teachings of W0981025 85 are specifically incorporated into the present specification in their entirety by reference.

Alternatively, according to a preferred method of the present invention, a granulated sugar product according to the present invention can be prepared as follows.

A 1:1 mixture of white granulated sugar and Extra Fine sugar is mixed with maltodextrin. To these mixed powders are sprayed a gum arabic solution. Sucralose is added as a powder form at the pre-mix stage or in the spray solution.

The proportion of the ingredients is as follows: Sugar 67.89 % by weight (equal parts of granulated sugar and extra fine sugar) Maltodextrin 31.98% by weight (5% low bulk density maltodextrin; remainder standard spray dried maltodextrin) Sucralose 0.13% by weight Sprayed with gum arabic solution to give 0.05% by weight of gum arabic in the final product.

A batch or continuous GlattINIRO/ Calmic/ Phoenix or equivalent fluid bed agglornerator with top or bottom spray and manual or automated product loading and discharge is used.

The process conditions are as follows: Typical Batch size (Kg) 150 -250 Air atomising pressure for spraying (Bar) 2-4 Spray rate (litres/mm/kg of blended 0.005 -material) 0.01 Inlet air temperature (C) 50-90 Outlet air temperature (C) 40-45C Product temperature (C) 38-43C Process time (mix/heatlspray/dry); mins/kg of blended material 0.04-0.1 Temperature of gum binder solution sprayed (C) 20-60 The air flow rate is set up to provide a "gentle" fluidisation of the ingredients to initially efficiently mix and heat them up to between 30 and 40 C. The inlet air temperature is usually between 50 to 90 C and the spray solution rates are controlled to ensure that the granulation process occurs.

Once a light and fluffy product is produced the agglomeration process is considered to be completed and the agglomerated mix is discharged and screened to remove any large particulates (greater than 3mm) using a flat bed gyratory screen.

For continuous plant feed rates of 10 to 2500 Kg/hour, the range of suitable conditions is as follows: Typical Batch size (Kg) 1-500 Air atomising pressure for spraying (Bar) 0.5-6 Spray rate (litres/mm/kg of blended 0.0025 -material) 0.02 Inlet air temperature (C) 40-90 Outlet air temperature (C) 25-70C Product temperature (C) 25-70C Process time (mix/heat/spray/dry); mins/kg of blended material 0.02-0.2 Temperature of gum binder solution sprayed (C) 5-70

Claims

CLAIMS: 1. A granulated sugar product comprising a core material

substantially of a granulated first sugar and a surface material comprising a second sugar and a binder, wherein the surface material is less dense than the first sugar material.

2. A granulated sugar product according to claim 1, wherein the surface material covers only some or all of the surface of the first sugar granule.

3. A granulated sugar product according to any preceding claim, wherein the product incorporates a sweetener.

4. A granulated sugar product according to any preceding claim, wherein the product comprises a high intensity sweetener.

5. A granulated sugar product according to any preceding claim, wherein the first sugar is sucrose.

6. A granulated sugar product according to any preceding claim, wherein the second sugar is selected from sucrose, glucose (dextrose, anhydrous & mono), fructose, lactose (anhydrous and hydrated), maltose, Ribose, galactose, dextrins, maltodextrin, dried glucose syrups, sorbitol, mannitol, grape sugar, arabinose, raffinose, mannose, starch, cellulose, inulin, glycogen, xylitol, levoglucason, rhanmose, maltol (and ethyl derivative), iso-maltose, gentobiose, trehalose, cellobiose, neohesperidose, maltotriose, parose, neokestose, stachyose.

7. A granulated sugar product according to any preceding claim, wherein the sweetener is selected from sucralose, sorbitol (E420), mannitol (E421), isomalt (E953), maltitol (E965), lactitol (E966), xylitol (E967), acesulfame k (E950), aspartame (E951), cyclamic acid and sodium and calcium salts (E952), saccharin and its sodium, potassium and calcium salts (E954), thaumatin (E957), neohesperidine DC (E959).

8. A granulated sugar product according to any preceding claim, wherein the second sugar comprises a foam dried sugar.

9. A granulated sugar product according to any preceding claim, wherein the second sugar comprises a low density maltodextrin.

10. A granulated sugar product according to any preceding claim, wherein the binder is selected from the group consisting of gum arabic, pectin, starch, agar, carboxymethylcellulose and derivatives (hydroxypropylcelluloses, methylcellulose), carrageenans, alginates, gellan gum, xanthan, guar, locust bean gum, gum tragacanth, gelatin, egg albumen, caseinates, soya protein, whey proteins.

11. A granulated sugar product according to any preceding claim, wherein the binder is gum arabic.

12. A granulated sugar product according to any preceding claim, wherein the product comprises the first sugar in the range of 60-90% by weight.

13. A granulated sugar product according to any preceding claim, wherein the product comprises the second sugar in the range of 10-40% by weight.

14. A granulated sugar product according to any preceding claim, wherein the product comprises the sweetener in the range of 0.05-1.0% by weight.

15. A granulated sugar product according to any preceding claim, wherein the product comprises the binder in an amount of from 0.01-1% by weight.

16. A method of producing a granulated sugar product comprising mixing a core material of a granulated first sugar and a surface material comprising a second sugar and a binder, wherein the surface material is less dense than the first sugar material in such a manner as to result in agglomeration of the mixture.

17. A method of producing a granulated sugar product according to claim 16, wherein mixing is by means of a batch or continuous fluid bed agglomerator operated with top or bottom spray and manual or automated product loading discharge.

18. A method of producing a granulated sugar product according to claim 16, wherein mixing is by means of a mixing machine comprising a mixing chamber in which two shafts are arranged in substantially the same horizontal plane, the shafts being provided with blades or paddles disposed at an angle to and parallel with the shafts, the shafts rotating in opposite directions.

19. A method of producing a granulated sugar product according to claim 18, wherein the machine is operated such that downward movements are on the side where the shafts turn toward one another.

20. A method of producing a granulated sugar product according to claim 18 or claim 19 wherein a plurality of opposing pairs of blades of certain area are mounted on each shaft, positioned 900 transverse of the centerline for the shafts and with the blade wings disposed at a 450 angle in relation to the shaft centreline.

21. A method of producing a granulated sugar product comprising the steps of: (i) adding a core material substantially of a granulated first sugar, and a surface material comprising a second sugar material and a binder, wherein the surface material is less dense than the first sugar material to a low shear mixer or slow speed blender having at least two driving shafts, the shafts being provided with blades arranged at an angle to and parallel with the shafts; and (ii) operating the mixer or blender such that the shafts rotate in opposite directions.

22. A method according to claim 21, wherein the shafts of the mixer or blender are disposed in substantially the same horizontal plane and the mixer or blender is operated such that downward movement of the shafts is on the side where the shafts turn toward one another.

23. A method of producing a granulated sugar product as claimed in any of claims 1 to 15.

24. A product produced by means of a method as claimed in any of claims 17 to 22.