MASS PRODUCED, ALCOHOL-CONTAINING SPHERICAL BEAD WITH IMPROVED SHELF LIFE AND "POP"

Abstract

A shelf stable, substantially spherical food product measuring about 4-20 mm in average diameter. The food product has a thin, outer gelatinous shell that is edible and makes a pop when bit into along with an alcohol-containing purely liquid center fully encased by the thin outer shell, said liquid center containing from about 2 to 40% alcohol by volume. Following its manufacture by extrusion, this food product is stored in a jar with an aqueous solution containing liquid alcohol additives. Until it is opened, the contents of that jar are suitable for at least one year. Once that jar is opened, this food product has a shelf life of at least about 3 months.

Claims

1. A shelf stable, substantially spherical food product measuring about 8-20 mm in average diameter, said food product having: a thin, outer gelatinous shell that is edible and makes a pop when bit into; and an alcohol-containing purely liquid center fully encased by the thin outer shell, said liquid center containing from about 2 to 40% alcohol by volume, said spherical food product adapted for storing in a jar with an aqueous solution containing liquid alcohol additives for a shelf life of at least about 3 months after opening the jar.

2. The spherical food product of claim 1, which measures about 8-12 mm in average diameter.

3. The spherical food product of claim 1 wherein said liquid center contains about 10-20% alcohol by volume.

4. The spherical food product of claim 1, which is supplied with a natural or artificial flavor additive selected from the group consisting of: strawberry, raspberry, lychee, blueberry and wildflower, autumn apple, peach, maple and cranberry.

5. The spherical food product of claim 1, which is made as a mass-produced extrudate from a combination of a first solution that includes a solvent, a multivalent salt, one or more liquid alcohol additives, a preservative and a thickening agent; with a second solution that includes an alginate bath.

6. A consistently spherical, alcohol-containing food product measuring greater than about 8 mm in average diameter, said food product having a shelf life of at least one year before opening and roughly 3-6 months after opening, said food product being made by combining: (a) a first aqueous solution that includes a multivalent salt, one or more liquid alcohol additives, a preservative and a thickening agent; with (b) a second aqueous solution that includes an alginate bath for extruding to mass produce spherical beads of the one or more liquid alcohol additives encapsulated as a liquid in an edible, gelled outer shell, said encapsulated outer shell being deposited and stored in a third aqueous solution that includes one or more liquid alcohol additives.

7. The food product of claim 6 wherein the monovalent salt of the first aqueous solution is selected from the group consisting of: calcium chloride, calcium lactate, calcium lactate gluconate, magnesium chloride, manganese chloride and combinations thereof.

8. The food product of claim 7 wherein the monovalent salt of the first aqueous solution is selected from the group consisting of: calcium chloride, calcium lactate, calcium lactate gluconate and combinations thereof.

9. The food product of claim 6 wherein the first aqueous solution contains about 0.2 to 10 wt. % of the monovalent salt.

10. The food product of claim 6 wherein the first aqueous solution further contains about 50 to 99 wt. % of an aqueous solvent.

11. The food product of claim 10 wherein the first aqueous solution contains about 60 to 80 wt. % water as the aqueous solvent.

12. The food product of claim 6 wherein the thickening agent includes a polysaccharide selected from the group consisting of: xanthan gum, starch and combinations thereof.

13. The food product of claim 6 wherein the first aqueous solution contains about 2 to 40% alcohol by volume resulting from a liquid alcohol additive selected from the group consisting of: neutral spirits, ethyl alcohol, wine, sherry, brandy, liqueur, port, vodka, gin, whisky, scotch, cognac, tequila, rum, champagne and combinations thereof.

14. The food product of claim 13 wherein the first aqueous solution contains about 10-20% alcohol by volume.

15. The food product of claim 6, which further contains at least one of: an anti-bitterness agent, a pH buffer, a sweetener and a preservative.

16. The food product of claim 6, which further contains one or more natural or artificial flavor extracts selected from the group consisting of: strawberry, raspberry, lychee, blueberry and wildflower, autumn apple, peach, maple and cranberry.

17. The food product of claim 6 wherein the second aqueous solution includes between about 0.3 to 10 wt. % of an alginate selected from the group consisting of sodium alginate, potassium alginate and combinations thereof.

18. The food product of claim 17 wherein the second aqueous solution further contains from 90 to 99.6 wt. % of an aqueous solvent.

19. The food product of claim 6 wherein each spherical bead has a typical diameter between about 9 to 11 mm.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0026] Further features, objectives and advantages of this invention will become clearer with the following description of preferred embodiments made with reference to the accompanying drawings in which:

[0027] FIG. 1 is a schematic view showing a PRIOR ART bead and its relative size;

[0028] FIG. 2 is a schematic view showing a bead made according to the present invention;

[0029] FIG. 3 is a front schematic view showing one representative set up for extruding beads per the present invention;

[0030] FIG. 4 is a front schematic view showing one representative container for storing and transporting these pre-made alcoholic beads to consumers;

[0031] FIG. 5 is a perspective view of one representative equipment set up for mass producing alcoholic beads according to this invention with various component parts duly labeled; and

[0032] FIG. 6 is a top plan view of the equipment from FIG. 5 with various component parts duly labeled.

DESCRIPTION OF PREFERRED EMBODIMENTS

[0033] This disclosure relates to a method for preparing liquid alcohol-containing bead compositions. In one embodiment, a desired end product can be prepared by adding an aqueous composition containing a multivalent salt (hereinafter the first composition) to an aqueous composition containing an alginate alkali metal salt (the second composition). The resultant spheres include an aqueous solution that remains ungelled but encapsulated in a water-insoluble shell or outer coating.

[0034] The first composition generally includes a multivalent salt and solvent (e.g., water). The multivalent salt mentioned herein refers to one or more salts containing a multivalent cation (e.g., Ca.sup.2+, Mg.sup.2+, or Mn.sup.2+). Representative multivalent salts include calcium chloride, calcium lactate, calcium lactate gluconate, magnesium chloride, or manganese chloride. It is believed that when this first composition contacts with the second described below, the multivalent cations of the first will cross-link with polysaccharides in the second thereby forming coordination bonds to make an outermost encapsulating exterior.

[0035] In some embodiments, the first composition can include from about 0.2 to 10 wt % and preferably about 0.5 to 5 wt. % of the multivalent salt. Without wishing to be bound by theory, it is believed that, if the first composition contains less than about 0.2% by weight of the multivalent salt, it would not be effective in forming a water-insoluble encapsulating coating. Further, if the first composition contains more than about 20% by weight of the multivalent salt, it could have a relatively strong bitter taste or have a relatively short shelf life (e.g., by forming a precipitate).

[0036] The first composition also includes a water-based solvent. In some cases, the first composition includes from about 50 to 99 wt. % water, preferably between about 60 to 80 wt. % water.

[0037] In some embodiments, the first composition can further include an anti-bitterness agent. Examples of suitable anti-bitterness agents include sodium benzoate, potassium sorbate, or inverted sugar.

[0038] In embodiments when the first composition contains a relatively large amount of multivalent salt, an anti-bitterness agent (e.g., sodium benzoate, potassium sorbate, or inverted sugar) can be added to cover or eliminate the bitter taste of that composition. In general, the first composition can include from about 0.01% to about 1% by weight and preferably about 0.3 to 0.7% by weight anti-bitterness agent. Certain anti-bitterness agents can also function as a preservative (e.g., sodium benzoate or potassium sorbate) or a sweetener (e.g., an inverted sugar).

[0039] In some embodiments, the first composition can further include a thickening agent. Examples of suitable thickening agents include polysaccharides, such as xanthan gum, guar gum, starch, or agar agar. In general, the first composition can include from about 0.005% to about 3.5% by weight, or preferably about 0.01% to 3.1% thickening agent. It is believed that adding a thickening agent to the first composition results in remarkable improvement to the spherification process (e.g., better sphere integrity and consistency), when mixed with alcohol. Particularly, adding a thickening agent (e.g., xanthan gum or starch) to the first composition allows it to be mixed with a large variety of alcoholic beverages with different viscosities to form spheres consistently with improved integrity.

[0040] In some embodiments, the first composition can further include a pH buffer to maintain and/or adjust its pH. Examples of suitable pH buffers include phosphoric acid and its salts or citric acid and its salts (e.g., sodium or potassium salts). The pH buffer can be formed by adding acid alone to the first composition. That acid, together with the cations in the other first composition ingredients, can form the pH buffer. Alternatively, the pH buffer can be formed by directly adding an acid and its salts into this composition. In general, the first composition can include from about 0.1% to about 2% by weight, preferably about 0.2% to 1% by weight of pH buffer.

[0041] In some embodiments, the first composition can further include a sweetener. Examples of suitable sweeteners include sugars, fructose, corn syrup, and inverted sugars. In general, the first composition can include from about 1.5% to about 30% by weight, preferably about 10% to 20% by weight sweetener. It is believed that in addition to imparting sweetness, the above amount of sweetener additions may improve spherification as the weight of that sweetener prevents a sphere from floating at the surface of the composition thereby negatively impacting mechanical strength and/or sphere integrity. Certain sweeteners can also function as a thickening agent (e.g., fructose or an inverted sugar).

[0042] In some embodiments, the first composition can further include a preservative. Examples of suitable preservatives include sodium benzoate, sodium metabisulfite, or potassium sorbate. In general, the first composition can include from about 0.01% to about 1% by weight, and preferably about 0.3% to 0.7% by weight preservative. It is believed that the above amount of preservative can effectively inhibit growth of bacteria, molds, or yeasts and extend shelf life of this first composition without imparting any undesired changes in taste, odor, viscosity, or color thereto. Certain preservatives can also function as an anti-bitterness agent (e.g., sodium benzoate or potassium sorbate).

[0043] The first composition may be mixed with ethyl alcohol, or any form of liquor/spirit/wine, to prepare an alcoholic food product. For example, the first composition can be mixed with ethyl alcohol (95% to 97.5% alcohol by volume) to form a mixture containing about 2% to about 40% by volume ethyl alcohol. The ethyl alcohol can be pre-mixed with the first composition and stored for an extended period of time. It can be added either in a pure form or as an ingredient in an alcoholic beverage.

[0044] Alternatively, the encapsulations can be produced without alcohol and then soaked in an alcoholic composition wherein the alcohol would permeate the encapsulations by osmosis.

[0045] Without being bound by theory, it is believed that a resulting alcoholic bead containing more than 60% alcohol by volume will have a deteriorating effect on the coating shell, reducing the shelf life of the end product. Further, if the resulting beads have an alcohol content above 40% by weight, the end product could be deemed by regulators to be unfit for public consumption, as the beads could be swallowed like pills, instead of being popped as intended, and could be harmful to the public.

[0046] In some embodiments, the first composition can further include one or more additives, such as natural or artificial flavoring agents, or natural or artificial coloring agents. Examples of flavoring agents include flavor extracts (e.g. peach extract, orange extract, strawberry extract, oakwood extract) for providing such bead flavorings as strawberry, raspberry, lychee, blueberry and wildflower, autumn apple, peach, maple and cranberry. Examples of artificial coloring agents include FD&C, Blue No. 1, Blue No. 2, Green No. 3, Red No. 40, Red No. 3, Yellow No. 5, and Yellow No. 6. Examples of natural coloring agents include caramel E150, annatto E160b, chlorophyll E140, cochineal E120, betanin, turmeric E100, saffron E160a, paprika E160c, elderberry juice, pandan, and butterfly pea.

[0047] The second composition generally consists of an alginate alkali metal salt and a solvent. The alginate alkali metal salt can be formed between alginate anions and alkali metal cations. Examples of suitable alginate alkali metal salts include sodium alginate and potassium alginate. In some embodiments, the second composition includes from about 0.3% to 10% by weight, preferably from about 0.5% to 6% by weight alginate alkali metal salt.

[0048] The solvent in the second composition can also include water. In some embodiments, from about 90% to about 99.6% by weight, preferably 94% to 99.5% by weight water.

[0049] Preferably, the solvent in both compositions includes deionized (or distilled) water. It is believed that it is advantageous to use deionized water as residual ions (e.g., calcium ions) in water could form precipitates with the alginate salt, thereby reducing the shelf life of this second composition.

[0050] In general, the alcohol bead product described herein is prepared by adding the first composition into the second composition via extrusion. See the description of this process above and in FIGS. 5 and 6. One preferred method of manufacture employs a drop-on-demand jetting system that extrudes droplets of first composition into a lower bath of the second composition. That arrangement allows the calcium (first composition) to diffuse into the polysaccharide (second composition) thus forming a polysaccharide outer gel that effectively encapsulates the still liquidous first composition inside.

[0051] As an alternate to the foregoing calcium ion-induced gelation, other polymers can be used. They will form gels by such means as cooling or heating (e.g. gelatin, agar, gellan). A co-extrusion method can also be used. This method takes an emulsion, without calcium or other divalent ions, and co-extrudes the same with a gel-forming component so that latter extrudes as an outer layer surrounding the emulsion. Such extruding forms droplets then either: (a) fall into a calcium or other divalent ion-containing solution (if alginate or pectinase is employed as the gel-forming component); or (b) form by cooling down or heating up one or more of the other gel-forming components, e.g., gelatin or gellan, discussed above. A nozzle, more particularly a vibrating nozzle, is preferably used when co-extruding beads by this alternate approach. Such nozzles result in well-shaped capsules having a narrow size distribution.

[0052] Referring to representative FIG. 4, a collection tank container for one third composition for this invention consists of a liquid similar to that of the first composition. To ensure a long shelf life (one year or longer), the resulting alcohol beads are best preserved when the beads are submerged in this third liquid. Maintaining a sugar content, pH balance, flavor and color profile, and alcohol content similar to that of the bead interiors minimizes (or otherwise slows) transference through the membrane coating.

[0053] The resultant food product is a sphere (or ball) containing an aqueous solution encapsulated by the coating. As the encapsulating coating forms by cross-linking of alginate molecules, the sphere interior thus formed can be free of gelatin and does not require heating and cooling.

[0054] The beadlike food product prepared by the method described above is intentionally alcohol-containing. Examples of alcoholic ingredients include wine, sherry, brandy, liqueurs, port, vodka, gin, whisky, scotch, cognac, tequila, rum, or champagne.

[0055] In other instances, the method described above can be used to prepare a multilayer bead like a food product with an encapsulated aqueous solution surrounded by another encapsulated aqueous solution. In one such example, a relatively small amount (e.g., about 0.5 ml) of first composition is added to a second composition to form a sphere with the first solution surrounded by a first encapsulation coating. After excess second composition is removed (e.g., by filtration or decantation), the resulting beads can be co-extruded so that a different gel-forming component becomes extruded as an outer layer surrounding the initial bead. In one version, the large (first level) droplets are extruded into a calcium- or other divalent ion-containing solution. The food product thus formed is a bilayer sphere, i.e., one having an encapsulated inner aqueous solution surrounded by yet another encapsulated (outer) solution.

[0056] The food-like beads that result from this invention will exhibit a flavor and mouth-feel sensation to the person consuming it because of the still liquid encapsulation described above. Preferably this is a burst effect, or splash, from the sudden release of liquid alcohol in the consumer's mouth.

[0057] The consumer who bites down, squeezes or otherwise causes one or more such beads to break open in his/her mouth will experience alcohol in a new, refreshing manner. By selective blending in the same bead, alternating between beads, or combining different varieties of beads at the same time, consumers will be able to enjoy two or more alcoholic flavors and sensations. The differing tastes can be complimentary or intentionally contrasting. Note, however, that contrasting taste stimuli are not necessarily incongruent. So long as they are well compartmentalized and their release kept sudden, distinct encapsulated flavors can still be experienced together.

[0058] These alcohol beads are primarily intended for serving as additives to a cocktail or non-alcoholic beverage. They will either sink to the bottom of a glass, or float around the beverage when densities are similar, or when these alcohol beads contain air bubbles. Either way, they will provide an aesthetic appeal until bitten and consumed. Alternately, the alcohol beads of this invention can be eaten directly from a bowl, as finger food, or consumed like one would a shot of alcohol.

[0059] When frozen, these same alcohol beads can be used as a replacement for ice in a cocktail and/or non-alcoholic beverage. Unlike ice, however, which can water down a drink as it melts, the frozen beads of this invention will instead thaw back to their standard liquid-y middle forms.

[0060] Suitable edible shell materials that can be used in less preferred embodiments include: (a) polymers, like the polysaccharides pectinase, gellan, or carrageenan; or (b) proteins, notably milk protein and milk-derived proteins like casein (or caseinate) and gelatin. For any such wall alternative, it is preferred that such materials form gels or can otherwise cross-link and/or rapidly harden.

[0061] The resulting food like beads have a rounded, spherical shape (i.e., not flattened or oval) with a typical size diameter ranging from about 1 to 20 mm, preferably between about 9 to 11 mm, and most preferably around 10 mm wide.

[0062] In a cocktail or other beverage, the resulting beads can be used to represent overall drink volumes from about 0.1 to 50%, and more preferably between about 3 to 20% by volume. As a cocktail garnish, usually only about 4 to 8 beads need to be added to a standard size consumable. Though for a more substantial cocktail, 40 to 70 such beads may be added.

Description of Machinery and Mass Production Process

[0063] One key to better understanding the utter novelty of this invention is the production of a spherical alcohol product in a method that is (a) cost efficient, (b) produces spherical alcohol beads that are consistently uniform in size and quality, (c) produces spherical alcohol beads that are shelf stable for a year or more to allow for distribution and use by bars and restaurants, and (d) produces spherical alcohol beads at a large enough scale to allow for commercial sale and wide-scale distribution.

[0064] FIGS. 5 and 6 show the 2 phases of mass production via the present invention, FIG. 5 in perspective view and FIG. 6 is a more detailed, component-labeled top view. The first phase includes the mixing and processing of the materials used.

[0065] First, the ingredients for the liquid to be encapsulated, described below as the first composition, are heated up, mixed, dissolved together, and cooled (per elements 1, 2 and 6 in FIG. 6). These ingredients are described below but in general include water, alcohol, flavor, and multivalent salt.

[0066] Simultaneously, the ingredients for the alginate encapsulating liquid, described below as the second composition, are heated up, mixed, dissolved together, and cooled (elements 3 and 7). These ingredients are described below but in general include water and an alginate alkali metal salt.

[0067] Simultaneously, the calcium enriched first composition is transported into a hopper (element 11). At the bottom of this hopper are piezoelectric extruders (element 13) for extruding out droplets of the first composition in a uniform and continuous manner.

[0068] In Phase 2, the two mixed compositions are combined to create mass produced alcohol encapsulations. During phase 2, the alginate enriched second composition is transported and extruded into trays (element 15).

[0069] The machine continuously moves alginate-enriched trays under these continuously extruded droplets. Once the encapsulation shells have formed to the desired thickness, the trays drop the encapsulations out onto a rubber mesh belt (element 16).

[0070] The machine next moves the formed encapsulations across the rubber mesh belt and under a water sprinkler (see, pump 17) where residue from the second composition is cleaned off. The encapsulations are then stored in a collection tank (element 19) that includes what is described herein as the third composition.

Example

[0071] One representative example according to this invention has a first composition containing: 1 parts by weight calcium lactate, 65 parts by weight water, 12 parts by weight ethyl alcohol, 19 parts by weight fructose, 3 parts by weight starch, 0.01 parts by weight xanthan gum, 0.2 parts by weight of citric acid, 0.03 parts by weight of potassium sorbate, and 0.08 parts by weight of strawberry flavor extract.

[0072] It is to be mixed with a second composition comprising: 5 parts by weight of sodium alginate and 95 parts by weight of deionized water.

[0073] The resulting beads will be stored in a third composition comprising: 67 parts by weight deionized water, 12 parts by weight of ethyl alcohol, 20 parts by weight of fructose, 0.08 parts by weight of strawberry extract.

[0074] Generally, all of the foregoing ingredients can be obtained from commercial sources.

[0075] It is to be understood that the present invention is not limited to the foregoing particulars. Other modifications and variations are possible as appreciated by those skilled in the art in light of the foregoing.