WO2011024197A1

WO2011024197A1 - Process for producing a reduced bulk density sucralose containing sweetener system and products thereof

Info

Publication number: WO2011024197A1
Application number: PCT/IN2010/000556
Authority: WO
Inventors: Joseph Michael Zannoni; Malladi Maruthiram
Original assignee: VB Medicare Pvt Ltd
Current assignee: VB Medicare Pvt Ltd
Priority date: 2009-08-25
Filing date: 2010-08-24
Publication date: 2011-03-03
Anticipated expiration: 2012-02-25
Also published as: WO2011024197A4

Abstract

The invention discloses an extruded agglomerated free flowing solid sweetener composition containing at least one caloric carbohydrate sweetener and at least one high intensity sweetener, the said free flowing solid sweetener having caloric density expressed as calories/cubic centimeter (calories/cc) that is half or less than half of the typical caloric density of the crystalline granulated sucrose. Also disclosed is a process for preparing the same comprising a process of extrusion of a blend of the said carbohydrate sweetener and the high intensity sweetener through a low shear, low speed, high pressure cooker extruder wherein temperature required for extrusion is applied externally and extrusion is done through a die of about 6 to 18 centimeter with a residence time of about 50 seconds wherein the said extruder is set for process parameters that result in an extrudate having a calorie density in a range of half the caloric density of the crystalline sucrose plus or minus up to about a quarter of the caloric density of crystalline sucrose, and selecting or mixing fractions that result in a composition of half the caloric density of the crystalline sucrose.

Description

TITLE

PROCESS FOR PRODUCING A REDUCED BULK DENSITY SUCRALOSE CONTAINING SWEETENER SYSTEM AND PRODUCTS THEREOF. TECHNICAL FIELD

The invention relates to a process for the production of reduced calorie sweeteners and sweetener blends. Particularly, the invention relates to production of low and reduced calorie sweeteners and sweetener blends as compared to bulk density / calorie density of sucrose. This invention also relates to production of a specific targeted bulk density product form of a low or reduced calorie sweetener blend that shall have same relative sweetness or a defined multiple of sweetness as sucrose of same volume but for delivery of same sweetness, shall deliver a reduced number of calories from dietetic point of view. BACKGROUND OF INVENTION

High intensity sweeteners of natural origin as well as synthetic route have provided an opportunity to produce sweetener compositions that provide the sweetness provided by sucrose but they result in release of lesser calories in the body than sucrose of same bulk density. Most of the high intensity sweeteners, however, have their own variation in the organoleptic properties as compared to sucrose; such as they may have a metallic after taste or a lingering sweetness effect etc. Further, diluents, such as maltodextrin, carbohydrate sweetener having less sweetness etc. that are necessary to be added to the composition also introduce their own variations in the organoleptic properties. Further, since it is habitual to add a certain volume of sucrose to get a desired amount of sweetness, one of the best preferred methods of reducing calorie consumption with same sweetness available from volume of sweetener would be to prepare a sweetener supplemented by high intensity sweetener, which very closely resembles sucrose in appearance and taste properties and has half the bulk density of sucrose.

There has been a continuing endeavor to produce sweetener composition that incorporates high intensity sweeteners that, for the same volume on spoon-to-spoon basis, have same delivery of sweetness or delivery of a known multiple of sweetness of sucrose but deliver less calories. There has also been a continuing endeavor to use sucrose itself as bulking agent in a sweetener containing high intensity sweetener so that the typical sucrose taste and organoleptic properties of sucrose are augmented during preparation of food products including such sweeteners and during cooking.

Thus, Goodacre et al (US 5061320) disclosed a sweetener comprising hollow spheroids or part spheroids of microcrystalline sucrose, generally bound to crystals of sucrose, and containing sucralose. The sweetener composition is prepared by spray drying sucrose syrup with simultaneous injection of an inert pressurized gas and contacting the sprayed syrup during the spray drying step and/or after completion of said step, with crystals of sucrose, and by incorporating a high intensity sweetener in the syrup or in the agglomeration step. Bulk density varies between 0.15 to 0.77 and high intensity sweetener is added so as to have bulk sweetness similar to that of crystalline sucrose. US20070264403 discloses a sweetener composition comprising a) large sucrose crystals, and b) agglomerated particles each comprising a high intensity sweetener and a plurality of small sucrose crystals; wherein the large sucrose crystals are larger than 400 microns in size and constitute from 5 wt % to 50 wt % of the composition, and wherein the small sucrose crystals are smaller than 300 microns in size and constitute at least 25 wt % of the composition. This sweetener composition is made by a method comprising the steps of agglomerating a mixture comprising small sucrose crystals and a high intensity sweetener by treating the mixture with an agglomeration fluid, and mixing large sucrose crystals with the small sucrose crystals; wherein the large sucrose crystals are larger than 400 microns in size and constitute from 5 wt % to 50 wt % of the composition, and wherein the small sucrose crystals are smaller than 300 microns in size and constitute at least 25 wt % of the composition. US20070059419 disclosed a free-flowing powdered or granular sweetener composition comprising a high intensity sweetener, a food-grade gum, and a food-grade material selected from the group consisting of carbohydrate polymers, glucose, fructose, sucrose, tagatose, and combinations thereof, wherein (a) the composition provides less than about 0.5 calories per gram sucrose equivalent sweetness and (b) the total amount of the food- grade material in the composition, is between about 0.0001% to about 98.5% by weight, based on the total weight of the composition. The patent application also discloses a method for making a free-flowing powdered or granular sweetener composition comprised combining a high intensity sweetener with a food-grade gum and a food grade material that includes a carbohydrate polymer, glucose, fructose, sucrose, and combinations thereof. It is clear, however, that for getting a composition less than to get 0.5 calories per gram sucrose equivalent sweetness this composition will contain far less sucrose and ingredients other then sucrose shall also be as major bulking agents. US20050214425 disclosed granules of sucrose crystals coated with sucralose. This sweetener composition was made by a method comprising the steps of: (a) providing a plurality of granular cores each comprising sucrose; and (b) forming on the granular cores a layer comprising sucralose and sucrose by coating the granular cores with an aqueous mixture comprising the sucrose and the sucralose and drying the coated cores to form the sweetener composition.

Denhartog et al (US5747091 ) have disclosed a sweetened cooked extruded food product having a bulk density and a total sweetness, the food product comprising: a starch-containing vegetable material; and a sweetener, substantially all of the sweetener being incorporated before extrusion, the sweetener comprising sucralose in an amount which provides at least 50% of the total sweetness, wherein the total sweetness is equivalent to that provided by at least 12% sucrose, and the bulk density of the food product is less than that of the food product having the total sweetness provided by sucrose. This is a food product and not a sweetener composition.

Transforming powdered sucrose to a granular free flowing consistency has been a goal for the sugar industry for a number of years. Domino

Sugar produces "Brownulated" Brown sugar of a bulk density 40 Ig/cu ft i.e. 0.64 g/cc bulk (Chen-Chou cane sugar handbook: a manual for cane sugar manufacturers By James C. P. Chen, Chung-Chi Chou page 545 (http://books.google.co.in/books?id=bDlwg2UZ8sYC&pg=PA545&lpg=PA 545&dq=brownulated+sugar+bulk+density&source=bl&ots=ynJJR0imr5&s ig=mdQuFCq9asi98b8jTbLebQ5XvCk&hl=en&ei=gLhsTKr7AoaXcZ2bgWI &sa=X&oi=book_result&ct=result&resnum= 1 &ved=0CAYQ6AEwAA#v=on epage&q=brownulated%20sugar%20bulk%20density&f=false). Bulk density of the fondant sugar prepared by patented technology and marketed by Domino Foods Inc, Domino Specialty Ingredients, 1100 Key Highway East, Baltimore, MD 21230-5180, USA, is 38 Ibs/cu ft (http://www.21food.com/showroom/56804/product/Amerfond-Fondant-

Suqar.html ) The extrusion process patented by Morano [Morano 1996

(US 5549757), 1998 (US 5,779,805) and 2000 (US 6074489)] was designed specifically to provide an alternative process of agglomeration resulting in a "free flowing" brown sugar thereby addressing the industry problem of compaction and lumping typically seen in brown sugar. Bulk densities (g/cc) of sucrose, granulated and otherwise as available from various information sources are substantially around following: Sucrose

0.83, Dextrose 0.62, granulated sucrose 0.70, powdered sucrose 0.56 and

Sugar Ind. 0.74 (http://www.powderandbulk.com/resources/bulk_ density/material_bulk_density_chart_s.htm ; http://www.mpd-inc.com

/material.htm:

http://www.powderandbulk.com/resources/bulk density/material bulk den sitv chart s.htm:

http://www.asiinstr.com/technical/Material_Bulk_Density_Chart_S.htm; http://en.wikipedia.org/wiki/Suqar). Specifically, extruded sucrose marketed by Domino Foods Inc. with product name Amerfond is 0.608 (38 Ib/cuft) and for product name Di-Pac is 0.64 (40 Ib/cu ft).

None of the above compositions of sugar are useful as free flowing half calorie density products as compared to sucrose but with same sweetness of sucrose for same volume.

The present invention had a number of specific objectives:

1. A specific targeted bulk density of 50% of the bulk density of standard granulated refined sucrose

2. A process whereby a range of high intensity sweeteners could be added to create a uniformly dispersed sweetener matrix in addition to the sucralose.

3. A free flowing not clumping finished product

4. A system allowing for a customized particle size profile for specific applications requiring alternative particle distribution profiles To produce a Low Calorie Sweetener System that matches standard sucrose in sweetness intensity on a volumetric basis.

SUMMARY OF INVENTION

The invention comprises an extruded agglomerated free flowing solid sweetener composition containing at least one caloric carbohydrate sweetener and at least one high intensity sweetener, the said free flowing solid sweetener having caloric density expressed as calories/cubic centimeter (calories/cc) that is half or less than half of the caloric density of the crystalline sucrose. the invention also comprises a process of preparation of the said extruded sweetener comprising a process of extrusion of a blend of the said carbohydrate sweetener and the high intensity sweetener, with or without adjuvants and with or without additives, with or without binders, through a low shear, low speed, high pressure cooker extruder wherein temperature required for extrusion is applied externally and extrusion is done through a die of about 6 to 18 centimeter with a residence time of about 50 seconds wherein the said extruder is set for process parameters that result in an extrudate having a calorie density in a range of half the caloric density of the crystalline sucrose plus or minus up to about a quarter of the caloric density of crystalline sucrose, and selecting or mixing fractions that result in a composition of half the caloric density of the crystalline sucrose

The said process comprises the steps of: (a) mixing the said caloric carbohydrate sweetener and the said high intensity sweetener to make a blend, extruding, with or without further addition of one or more of an adjuvant, with or without further addition of one or more of an additive, with or without further addition of one or more of a binder, through a cooker extruder to get an agglomerated extrudate, (b) milling and sizing the extrudate in several fractions, (c) selecting a fraction or a mixture of fractions that has half or less than half of the caloric density of the crystalline said sucrose, and recycling rest of the fraction/s, if any, for extrusion.

In the said process, the preferred setting of various parameters of a cooker extruder comprises steps of: (a) setting extruder shaft RPM (revolutions per minute) from about 100 to 600, (b) setting water or steam addition to 0 to about 4.5 kg/hour, (c) setting feed rate to about 50 to 150 kg/hour, (d) setting throttle valve temp in a range of about 240⁰C to 275°C, (e) setting feed screw speed to 1 to 53 RPM, (f) setting cone head pressure to vary between 50 psi to 400 psi, (g) setting temperature of first Head to 60 to 90⁰C, (h) setting temperature of second Head to a range of 75 to 105°C, (i) setting temperature of third Head to very between about 120 to 140⁰C, (j) setting temperature fourth Head to about 120140°C, (k) setting temperature fifth Head to about 120140⁰C, and (I) a residence time of the charge in extruding zone for about 50 seconds.

The preferred caloric carbohydrate sweetener of this invention is selected from simple mono and di saccharides, sugar alcohols or a combination thereof. Simple mono and di saccharides may be selected from a group comprising sucrose, sucrose, glucose, dextrose, maltose, lactose, fructose, wherein the illustrated saccharide is sucrose and the said sugar alcohols may b selected from a group of erythritol, Isolmaltol, mannitol, maltitol, lactitol.

Additives, adjuvants, binders for compositions of this invention may be selected from dextrins, maltodextrins, molasses, corn syrup, invert sugar, fiber, flavors, colors, starches, proteins, probiotics, non-caloric sweeteners, caloric carbohydrates, botanical extracts, vitamins, minerals, and pharmaceutical actives or a combination thereof.

An extruded agglomerated free flowing solid sweetener composition of this invention may further comprise at least one sweetness potentiator or/and a sweetness modifier. The said sweetness potentiator or/and a modifier may be selected from a group comprising MAG - Mono-Ammonium Glycyrrhizinate, 2,4-Dihydroxybenzoic acid (2,4-DHB), monosodium glutamate (MSG), disodium 5'-inosinate (IMP), and disodium 5'-guanylate (GMP) flavor potentiator selected from the group consisting of sodium chloride, monosodium glutamate, quercetin, adenosine monophosphate, inosine monophosphate, guanylate monophosphate, edible salts of the foregoing, and combinations of at least two of the foregoing, monoammonium glycyrrhizinate, a licorice glycyrrhizinate, citrus aurantium, alapyridaine, alapyridaine (N-(1-carboxyethyl)-6- (hydroxymethyl)pyridinium-3-ol) inner salt, miraculin, curculin, strogin, mabinlin, gymnemic acid, cynarin, glupyridaine, a pyridinium-betain compound, sugar beet extract, neotame, thaumatin, neohesperidin dihydrochalcone, a hydroxybenzoic acid, 2-hydroxybenzoicacid, 3- hydroxybenzoic acid, 4-hydroxybenzoic acid, 2,3-dihydroxybenzoic acid, 2,4-dihydroxybenzoic acid, 2,5-dihydroxybenzoic acid, 2,6- dihydroxybenzoic acid, 3,4-dihydroxybenzoic acid, 3,5-dihydroxybenzoic acid, 2,3,4-trihydroxybenzoic acid, 2,4,6-trihydroxybenzoic acid, 3,4,5- trihydroxybenzoic acid,4-hydroxyphenylacetic acid, 2-hydroxyisocaproic acid, 3-hydroxycinnamic acid,3-aminobenzoicacid,4-aminobenzoic acid, 4-methoxysalicylic acid, 2-(4-hydroxy-3-methoxyphenyl)-1-(2,4,6- trihydroxyphenyl)ethanone, 1-(2,4-dihydroxyphenyl)-2-(4-hydroxy-3- methoxyphenyl)ethanone, 1-(2-hydroxy-4-methoxyphenyl)-2-(4-hydroxy-3- methoxyphenyl)ethanone, 2,4-dihydroxy-N-[(4-hydroxy-3- methoxyphenyl)methyl]benzamide, 2,4,6-trihydroxy-N-[(4-hydroxy-3- methoxyphenyl)methyl]benzamide,2-hydroxy-N-[(4-hydroxy-3- methoxyphenyl)methyl]benzamide,4-hydroxy-N-[(4-hydroxy-3- methoxyphenyl)methyl]benzamide,2,4-dihydroxy-N-[(4-hydroxy-3- methoxyphenyl)methyl]benzamide,2,4-dihydroxy-N-[2-(4-hydroxy-3- methoxyphenyl)ethyl]benzamide,N-[(3-ethoxy-4-hydroxyphenyl)methyl]- 2,4-dihydroxy-benzamide,N-[(3,4-dihydroxyphenyl)methyl]-2,4-dihydroxy- benzamide, tagatose, trehalose, maltol, ethyl maltol, vanilla extract, vanilla oleoresin, vanillin, sugar beet extract, sugarcane leaf essence, a compound that respond to a G-protein coupled receptor, an edible salt of the foregoing, or a combination of at least two of the foregoing sweetness potentiators.

The said high intensity sweetener of the extruded agglomerated free flowing solid sweetener composition of this invention may be selected from the group Sucralose, fructose, polyols, acesulphame K, monellin, steviosides, glycyrrhizin, dihydroflavenol, sorbitol, mannitol, maltitol, monatin, an L-aminodicarboxylic acid aminoalkenoic acid ester amide, a water-soluble saccharin salt, a cyclamate salt, an acesulfame salt, the calcium salt of 3,4-dihydro-6-methyl- 1 ,2,3- oxathiazine-4-one-2,2-dioxide, the potassium salt of 3,4-dihydro-6-methyl- 1 ,2,3-oxathiazine- 4-one-2,2- dioxide, the free acid form of saccharin, L-aspartyl-1 -phenylalanine methyl ester, L-alpha-aspartyl-N-(2,2,4,4-tetramethyl-3-thietanyl)-D-alaninamide hydrate, the methyl ester of L-aspartyl-1 -phenylglycerine, L-aspartyl-1 -2,5- dihydrophenyl-glycine, L- aspartyl-2,5- dihydro-1 -phenylalanine, L- aspartyl-1-(1-cyclohexen)-alanine, neotame, steviosides, chloro-1¹- deoxysucrose, 4-chloro-4-deoxygalactosucrose, 4, 1 '-dichloro-4, 1 '- dideoxygalactosucrose, 1',6'-dichloro 1 ',6'-dideoxysucrose, 4,1 ',6'- trichloro-4,1 ',6'- trideoxygalactosucrose, 4,6,6'-trichloro-4,6,6^l- trideoxygalactosucrose, e.i'.e'-trichloro-e.i'.β'-trideoxysucrose, 4,6,1 ',6'- tetrachloro4,6,1 '.δ'-tetradeoxygalacto-sucrose, 4,6,1 ',6'- tetradeoxysucrose, thaumaoccous danielli, talin, or a combination of at least two of the foregoing high intensity sweeteners.

The sweetener composition of this invention may be in the form of a tablet or a solid dosage form as a bar provided with break lines to choose portions of desired sweetness or as a stick.

The sweetener composition of this invention is made on a cooker extruder. Preferred cooker extruder model for making sweetener composition of this invention comprises Wenger^® extruder model X 85 Optima II.

DETAILED DESCRIPTION OF INVENTON

The invention disclosed here comprises a free flowing sweetener for use as a sweetening ingredient, the said sweetener being an agglomerate of at least a caloric carbohydrate sweetener and a high intensity sweetener and has, on equal volume basis, a sweetness that is same as or more than that of sucrose but a calorie density expressed as calories/CC that is half or less than half as that of sucrose. The product of this invention does not comprise hollow spheroids or part spheroids of microcrystalline sucrose of Goodacre et al (US 5061320).

This invention also comprises a process of preparing a free flowing sweetener for use as a sweetening ingredient, the said sweetener being an agglomerate of at least a caloric carbohydrate sweetener and a high intensity sweetener and has, on equal volume basis same as or more than the same sweetness delivery profile but a calorie density expressed as calories/CC that is half or less than half as that of sucrose wherein the said high intensity sweetener is stable under conditions of a process by which the said free flowing sweetener is prepared comprising steps of 1. compressing a blend of crystalline or powdered forms of caloric carbohydrate sweetener and a high intensity sweetener, with or without further addition of water or steam, with or without addition of additional ingredients, through a cooker extruder accompanied with heating at various sectors in the extruder while the charge is passing through the barrel of the extruder resulting into extrusion of agglomerated extrudate that has a bulk density of less or more than about half of the bulk density of standard sucrose (that has a bulk density of around 0.82 g/cc) used in the blend, 2. milling the extrudates, if required, mixing the grades in appropriate proportions to get the desired sweetener composition that has half or lesser than half calories per CC as compared to sucrose but same or more sweetness as sucrose on equal volume basis.

3. The product is free flowing and granular. The product also dissolves rapidly when added to aqueous solution.

Several novel methods have been developed, as elaborated above, to achieve a reduced bulk density or a reduced caloric density sucrose, however, the granulation and particle distribution profile of the sweetener and bulk density achieved by the current processes used in the sugar industry do not achieve the desired bulk density target of the current invention. Further, no extrusion process so far achieved feasibility of making half calorie sweetener that has sweetness intensity as much as or more than same volume of standard sucrose but calorie density half or less than that of corresponding standard sucrose. Standard granulated sucrose has a bulk density of around 0.8 - 0.9 The present invention has been demonstrated by using sucrose as a caloric carbohydrate sweetener and sucralose as the high intensity sweetener.

It was found in this invention that when sucralose is blended with sucrose that is either in crystalline, or in a paste or powdered form, with or without the pre-blending or pre-addition of water and passed through a low shear, low speed, high pressure cooker extruder, by controlling and varying the temperature applied to the charge from an external source such as a steam jacket, pressure applied, moisture content, speed of the extruder, raw material feed rate and the design of the die, an agglomerated sweetener composition is formed as an extrudate with various bulk densities that has sweetness either same or higher than sucrose when the sweetness is compared with crystalline sucrose as the caloric control as well as sweetness control, but a calorie density of the extrudate is less than sucrose. A bulk density of a sweetener is understood here as gram/CC and for convenience the "bulk" or volume may also be expressed in this specification in conventional units such as a teaspoonful or a cupful and an equal volume basis may also be expressed by a phrase "spoon to spoon basis". A "calorie density" of a sweetener is understood here as calories/CC (volume).

In a preferred embodiment of this invention, the sucrose:sucralose extruded and granulated sweetener of this invention, on spoon to spoon basis i.e. on equal volume basis has, as compared to sucrose, about half the bulk density of the sucrose but is equal to sucrose in sweetness intensity. In effect, caloric content of the sweetener of this invention is about half that of sucrose on an equal volume basis although it has sweetness equal to sucrose on spoon to spoon basis. In other embodiments of this invention, it is possible to envisage a sweetener, on spoon to spoon basis, to have a bulk density less than about half the density of sucrose but sweetness being equal to or more than sucrose. Final product (sucrose-sucralose extruded) is a free flowing, non dusting granular product having a particle size profile similar to standard granulated sugar. Thus, in one preferred embodiment of this invention, the final product is a sucrose:sucralose extruded sweetener, with or without other ingredients, that has Cup for Cup sweetness of sucrose associated with only 50% of the calories of sucrose required for same sweetness,

50% of the sweetness contributed by sucrose and 50% of the sweetness contributed by sucralose and has 50% bulk density of sucrose. In another preferred embodiment, the extruded and granulated sucrose:sucralose sweetener may have same bulk density but one spoonful may provide sweetness equivalent to 2 teaspoonful of sucrose, where 25% of sweetness may come from sucrose and 75% sweetness may come from sucralose.

In a further embodiment of this invention, the granules can be transformed into bars that have known delivery of sweetness expressed in terms of teaspoon or cup equivalent to sucrose. The said bars may have break lines along which it is possible to break the bar into discrete units that have known delivery of sweetness in terms of equivalence to spoons or cups of sucrose.

Optionally, additional ingredients can be added, while blending before extrusion or to the extruded product by spraying, dusting etc., that deliver functionality depending on their properties. Such additional ingredients comprise, without limitation, flavors, colors, fibers, starches, proteins, probiotics, non-caloric sweeteners, caloric carbohydrates, sugar alcohols, botanical extracts, vitamins, minerals, and pharmaceutical actives.

These compositions would on one hand be very convenient to the users of high intensity sweeteners to understand easily how much of the same needs to be used for the desired degree of sweetness and on the other hand, since sucrose is the main bulk sweetener, sucrose will make maximum possible contribution in organoleptic properties of the sweetener composition of a certain bulk density to take it as close as sucrose as possible.

The bulk density of the sweetener composition of this invention illustrated here have been seen to vary between 0.319g/CC and 0.617 g/CC. The preferred bulk density varies between 0.35g/CC and 0.47g/CC. more preferably between 0.38 g/CC. and 0.42g/CC if the target bulk density of the sucrose:sucralose extruded sweetener is 50% that of its sucrose ingredient. The preferred bulk density of the extrudate shall vary appropriately as per the target bulk density of the extrudate sweetener to be used at the end. Additional water may or may not be added to the blend before extrusion or during the course of passing of the charge through the extruder, and when additional water is added, it may amount to up to 5% of the blend, preferably to 3% of the blend, preferably to 2% of the blend.

These sweetener compositions may also optionally contain ingredients other than sucrose and high intensity sweetener depending on added functionality desired. Such additional ingredients comprise, without limitation, flavors, colors, fibers, starches, proteins, probiotics, non-caloric sweeteners, caloric carbohydrates, sugar alcohols, botanical extracts, vitamins, minerals, and pharmaceutical actives.

High intensity sweetener of preference is sucralose. However, any high intensity sweetener can be used in this invention due to the limited time that the material is exposed to the processing conditions of extrusion at the pressure and temperature described in process of making the sweeteners of this invention is also included within the scope of this invention. High Intensity sweeteners include but are not limited to Stevia and all its forms, saccharin and all of its salts, acesulfame K, cyclamate and all of its salts, aspartame and all other natural and synthetic materials providing a sweetness intensity greater than sucrose on a weight basis Including without limitation all high intensity sweeteners which can potentially replace sucralose in the process of this invention as long as they can withstand the pressure and temperature encountered in the process of extrusion. Such other sweeteners, include monellin, steviosides, glycyrrhizin, dihydroflavenol, sorbitol, mannitol, maltitol, monatin, an L-aminodicarboxylic acid aminoalkenoic acid esteramide, a water-soluble saccharin salt, a cyclamate salt, an acesulfame salt, the calcium salt of 3,4-dihydro-6-methyl- 1 ,2,3- oxathiazine-4-one-2,2-dioxide, the potassium salt of 3,4-dihydro-6-methyl- 1 ,2,3-oxathiazine- 4-one-2,2- dioxide, the free acid form of saccharin, L-aspartyl-1 -phenylalanine methyl ester, L-alpha-aspartyl-N-(2,2,4,4-tetramethyl-3-thietanyl)-D-alaninamide hydrate, the methyl ester of L-aspartyl-1 -phenylglycerine, L-aspartyl-1 -2,5- dihydrophenyl-glycine, L- aspartyl-2,5- dihydro-1 -phenylalanine, L- aspartyl-1-(1-cyclohexen)-alanine, neotame, steviosides, chloro-1'- deoxysucrose, 4-chloro-4-deoxygalactosucrose, 4,1'-dichloro-4,1'- dideoxygalactosucrose, 1 ',6'-dichloro 1',6'-dideoxysucrose, 4,1 ',6'- trichloro-4,1',6¹- trideoxygalactosucrose, 4,6,6'-trichloro-4,6,6'- trideoxygalactosucrose, 6,1 ',6'-trichloro-6,1 '.β'-trideoxysucrose, 4,6,1 ',6'- tetrachloro4,6,1',6'-tetradeoxygalacto-sucrose, 4,6,1 ',6'- tetradeoxysucrose, thaumaoccous danielli, talin, or a combination of at least two of the foregoing high intensity sweeteners. To the best of understanding of the inventors, the time and temperature conditions used in the process of this invention will not adversely impact the stability or quality of the ingredients listed as potential additives to a caloric carbohydrate sweetener and hence, all of them could potentially replace sucralose fully or partly to prepare compositions of this invention.

The caloric sweetener of preference is sucrose. However, any other caloric carbohydrate sweetener can be used as a primary ingredient or secondary ingredient in this invention including but not limited to, glucose, dextrose, maltose, lactose, fructose, and all other simple mono and di saccharides. In addition, all commercially available sugar alcohols including erythritol, Isolmaltol, mannitol, maltitol, lactitol as well as all other commercially available carbohydrates including dextrins, maltodextrins, saccharides and fractions thereof in liquid, powdered or other forms with and without the addition to water are also included in the scope of this invention.

The sweetener compositions of this invention may also optionally contain in addition to a caloric sweetener and a high intensity sweetener, one or more of a sweetness potentiator or/and a modifier comprising, without limitation, MAG - Mono-Ammonium Glycyrrhizinate, 2,4-Dihydroxybenzoic acid (2,4-DHB), monosodium glutamate (MSG), disodium 5'-inosinate (IMP), and disodium 5'-guanylate (GMP) flavor potentiator selected from the group consisting of sodium chloride, monosodium glutamate, quercetin, adenosine monophosphate, inosine monophosphate, guanylate monophosphate, edible salts of the foregoing, and combinations of at least two of the foregoing, monoammonium glycyrrhizinate, a licorice glycyrrhizinate, citrus aurantium, alapyridaine, alapyridaine (N-(1- carboxyethyl)-6-(hydroxymethyl)pyridinium-3-ol) inner salt, miraculin, curculin, strogin, mabinlin, gymnemic acid, cynarin, glupyridaine, a pyridinium-betain compound, sugar beet extract, neotame, thaumatin, neohesperidin dihydrochalcone, a hydroxybenzoic acid, 2- hydroxybenzoicacid, 3-hydroxybenzoic acid, 4-hydroxybenzoic acid, 2,3- dihydroxybenzoic acid, 2,4-dihydroxybenzoic acid, 2,5-dihydroxybenzoic acid, 2,6-dihydroxybenzoic acid, 3,4-dihydroxybenzoic acid, 3,5- dihydroxybenzoic acid, 2,3,4-trihydroxybenzoic acid, 2,4,6- trihydroxybenzoic acid, 3,4,5-trihydroxybenzoic acid,4- hydroxyphenylacetic acid, 2-hydroxyisocaproic acid, 3-hydroxycinnamic acid,3-aminobenzoicacid,4-aminobenzoic acid, 4-methoxysalicylic acid, 2- (4-hydroxy-3-methoxyphenyl)-1-(2,4,6-trihydroxyphenyl)ethanone, 1-(2,4- dihydroxyphenyl)-2-(4-hydroxy-3-methoxyphenyl)ethanone, 1 -(2-hydroxy-

4-methoxyphenyl)-2-(4-hydroxy-3-methoxyphenyl)ethanone, 2,4- dihydroxy-N-[(4-hydroxy-3-methoxyphenyl)methyl]benzamide, 2,4,6- trihydroxy-N-[(4-hydroxy-3-methoxyphenyl)methyl]benzamide,2-hydroxy- N-[(4-hydroxy-3-methoxyphenyl)methyl]benzamide,4-hydroxy-N-[(4- hydroxy-3-methoxyphenyl)methyl]benzamide,2,4-dihydroxy-N-[(4-hydroxy-

3-methoxyphenyl)methyl]benzamide,2,4-dihydroxy-N-[2-(4-hydroxy-3- methoxyphenyl)ethyl]benzamide,N-[(3-ethoxy-4-hydroxyphenyl)methyl]- 2,4-dihydroxy-benzamide,N-[(3,4-dihydroxyphenyl)methyl]-2_I4-dihydroxy- benzamide, tagatose, trehalose, maltol, ethyl maltol, vanilla extract, vanilla oleoresin, vanillin, sugar beet extract, sugarcane leaf essence, a compound that respond to a G-protein coupled receptor, an edible salt of the foregoing, or a combination of at least two of the foregoing sweetness potentiators.

In another aspect, this invention discloses a process for producing a sweetener composition containing at least a high intensity sweetener that is stable under conditions of a process by which the said free flowing sweetener is prepared comprising steps of: (a) adding a high intensity sweetener to sucrose in such an amount that sweetness contribution from the said high intensity sweetener and sucrose is about 1 :1 or more, (b) optionally adding a binder, (c) optionally adding water, (d) optionally adding non-sweet ingredients, (e) passing the mixture under low shear mixing under a high pressure and an elevated temperature that is applied externally, (f) pressing through a die under pressure selected to get an extruded product, (i) milling the extruded product to make them in the form of agglomerated granules that has bulk density lesser than that of sucrose.

In another aspect, this invention discloses a process for producing a sweetener composition containing at least a high intensity sweetener that is stable under conditions of a process by which the said free flowing sweetener is prepared, the said sweetener composition having same sweetness as for same volume of sucrose at less than 65%, more preferably at about half the calorific value, incorporation of non-sweet ingredients being optional, comprising steps of: (a) adding a high intensity sweetener to sucrose in such an amount that sweetness contribution from the said high intensity sweetener and sucrose is about 1 :1 or more, (b) optionally adding a binder, (c) optionally adding water to the same, (d) optionally adding non-sweet ingredients, (e) passing the mixture under low shear mixing under a high pressure and an elevated temperature applied externally, (f) finally pressing through a die under pressure selected to get an extruded product of around half bulk density of sucrose or less, (i) milling the extruded product to make them in the form of agglomerated granules, sizing them and recycling oversized granules for milling..

In yet another aspect, this invention discloses a process for producing a sweetener composition comprising steps of: (a) adding a high intensity sweetener that is stable under conditions of a process by which the said free flowing sweetener is prepared, and optionally other non-sweet ingredients, to sucrose in such an amount that sweetness contribution from the said high intensity sweetener and sucrose is more than about 1 :1 , (b) optionally adding a binder, (c) optionally adding water to the same, (d) optionally adding non-sweet ingredients, (e) passing the mixture under low shear mixing under a high pressure and an elevated temperature applied externally, (f) finally pressing through a die under pressure selected to get an extruded product that has bulk density around half the bulk density of sucrose, (i) milling the extruded product to make them in the form of agglomerated granules, sizing them and recycling oversized granules for milling. In yet another aspect, this invention discloses a process for producing a sweetener composition comprising steps of: (a) adding a high intensity sweetener that is stable under conditions of a process by which the said free flowing sweetener is prepared, and optionally other non-sweet ingredients, to sucrose in such an amount that sweetness contribution from the said high intensity sweetener and sucrose is equal to or more than about 1 :1 , (b) optionally adding a binder, (c) optionally adding water to the same, (d) optionally adding non-sweet ingredients, (e) passing the mixture through low shear zone under a pressure and elevated temperature that is applied externally and finally pressing through a die under high pressure selected to get an extruded product in form of agglomerated granules, (f) transforming the granules into a tablet or an individual portion, or a bar of sweetener composition of known sweetness delivery as compared to sweetness of a certain commonly used measure of sucrose comprising a table spoon or a cup, (g) optionally providing break lines on the said bar that can result into pieces when manually broken along its break-lines, each piece having same or a known multiple of delivery of sweetness as that of a certain commonly used measure of sucrose comprising a table spoon or a cup.

The binders used in the compositions of the invention mentioned above may be one or a mixture of molasses, high fructose corn syrup and the like maltodextrin, dietary sugars and fibers.

Sucralose or high intensity sweetener mentioned in the compositions disclosed in this invention may be replaced totally or in part or mixed with other sweeteners or other high intensity sweeteners commonly used by a person of an ordinary skill in the art including Fructose, Polyols, Acesulphame K, monellin, steviosides, glycyrrhizin, dihydroflavenol, sorbitol, mannitol, maltitol, monatin, an L-aminodicarboxylic acid aminoalkenoic acid ester amide, a water-soluble saccharin salt, a cyclamate salt, an acesulfame salt, the calcium salt of 3,4-dihydro-6- methyl- 1 ,2,3- oxathiazine-4-one-2,2-dioxide, the potassium salt of 3,4- dihydro-6-methyl- 1 ,2,3-oxathiazine- 4-one-2,2-dioxide, the free acid form of saccharin, L-aspartyl-1 -phenylalanine methyl ester, L-alpha-aspartyl-N-

(2,2,4,4-tetramethyl-3-thietanyl)-D-alaninamide hydrate, the methyl ester of L-aspartyl-1 -phenylglycerine, L-aspartyl-1 -2,5-dihydrophenyl-glycine, L- aspartyl-2,5- dihydro-1 -phenylalanine, L-aspartyl-1 -(1 -cyclohexen)- alanine, neotame, steviosides, chloro-i'-deoxysucrose, 4-chloro-4- deoxygalactosucrose, 4,1'-dichloro-4,1'-dideoxygalactosucrose_J 1',6'- dichloro 1',6'-dideoxysucrose, 4,1\6'-trichloro-4,1',6'- trideoxygalactosucrose, 4,6,6^I-trichloro-4_I6,6^I-trideoxygalactosucrose, e.i'.e'-trichloro-θ.r.e'-trideoxysucrose, 4,6,1 ',6'- tetrachloro4,6,1',6¹- tetradeoxygalacto-sucrose, 4,6, 1 ',6'-tetradeoxysucrose, thaumaoccous danielli, talin, or a combination of at least two of the foregoing high intensity sweeteners.

Variants of above objective shall also include a tablet, optionally of other non-sweet ingredients, which has same delivery of sweetness as that of sucrose for a certain commonly used measure of sucrose comprising a table spoon, a cup; and deliver less calories than the said measure of sucrose.

Non sweet additives that can be added in the sweetener compositions disclosed by this invention includes ingredients such as colour, flavor, fiber, vitamins, prebiotics etc. Morano 1996 (US 5549757), 1998 (US 5,779,805) and 2000 (US 6074489) has disclosed a process for preparing recrystallized sucrose product. The process comprises blending powdered sucrose and an adjuvant up to about 15% by means of extrusion. Morano has proposed addition of several adjuvants to form a blend that can be extruded to give granules to add a taste, a color, a medicinal activity, or a functional food value. Examples of adjuvants / additives given by him include: sucrose, invert syrup, honey, maple syrup, malt extracts, sweet sorghum syrup, sugarcane juice concentrate, sugar beet juice concentrate, fruit juice concentrate, refiners syrup, molasses, maltodextrines, regular corn syrups, dextrose, fructose, glycerin xylitol, mannose, sorbitol, mannitol, natural and artificial flavors, a botanical flavor extractive, a high-intensity sweetener, a pharmaceutical, a gum, a hydrocolloid and mixtures of these. Examples of high-intensity natural and artificial sweeteners cited include aspartame, glycyrrhizin, stevioside, saccharin, acesulfame K.

Morano has not provided any example in which high intensity sweeteners have been included beyond just mentioning a feasibility of using the same, nor has he mentioned sucralose in above list of high intensity sweeteners. Problem he aimed at solving was recrystallization of sucrose in a free flowing granular form.

In the co-crystalization process of Morano, except a mention of optional incorporation of adjuvants, nowhere did he contemplate producing sweeteners having same sweetness as sucrose but having half the calories for same bulk although such a requirement existed since a long time. For that matter, extruded sugar products, prepared by a sugar industry Domino Sugar, have been in existence, but as fondants and no sweetener came into existence to fulfill delivery of same sweetness as sugar for only for half its calorific delivery. Obviously, the reduction in the bulk density achieved by them was not enough and not notable that can suggest use of Morano's process for developing "Half Calorie" (for same volume as that of sucrose, providing at least same sweetness intensity as that of sucrose but carrying half the calories of sucrose for same volume) or appreciably lower calorie sweeteners.

Wenger^® extruders, in the meanwhile made rapid improvements in extruders and their extrusion capability. They are now in use for production of aquatic feed or pet feed and specialty animal feeds and hundreds of different foods and feeds in several countries including ready- to-eat cereals, pastas, snack foods, breadings, industrial starch products and meat extenders. However, Wenger^® extruders were never contemplated for producing extruded sweetener form sucrose. In fact Z.BIGNIEW BOREJSZO and KHALIL KHAN (Reduction of Flatulence-

Causing Sugars by High Temperature Extrusion of Pinto Bean High Starch Fractions, Journal of Food Science, Volume 57, Issue 3, pages 771-777, May 1992.) disclosed in the abstract that "Pinto bean high starch fractions were extruded using a Wenger TX-52 twin screw extruder. The effect of process temperature and moisture in the barrel on flatulence- causing sugars was investigated. Levels of flatulence causing sugar were lower in extruded compared to non-extruded samples with higher reduction at higher process temperature. Sugar content decreased from 5.29% in nonextruded samples to 3.69% in samples extruded at 163°C. Moisture content in the extruder barrel did not significantly affect sugars in the samples. Raffinose and stachyose contents were reduced 47 to 60% by extrusion.". This report of 1992 was a clear disincentive to consider Wenger^® extruders for producing low calorie sweeteners.

It was surprisingly found in this invention that an extruder machine from Wenger^® could be used with excellent reproducibility to get extrudates of sucrose having a range of bulk densities above and below half the bulk density of sucrose. This embodiment of this invention provides a basis for further embodiments that compise producing sucrose-sucralsoe extrudats that have bulk density below and above 50% of bulk density of sucrose so that with a judicious combination of fractions of different bulk densities, a mix of the size reduced extruded product is formed that has very close to

50% bulk density (g/CC) and has sweetness in desired multiples of sucrose. The desired multiples can be equal to sweetness of sucrose or double as that, triple as that and so on for same volume as sucrose; the most desired being 50% bulk density of sucrose with same sweetness delivery as that of sucrose for same bulk / volume.

This invention also discloses a process of producing low calorie sweetener wherein a blend of sucrose and a high intensity sweetener that is stable under conditions of a process by which the said low calorie sweetener is prepared is passed through an extruder and conditions of extrusion, such as, moisture content, temperature and pressure in various sections of the extruder, configuration of the die, screw barrel configurations, feed screw speed, feed rate and temperatures maintained at the various zones of the extruder , classification, milling and sifting are adjusted to control the bulk density to a desired value. Morano's objective as well as finding was limited to produce a finished sweetener product having a free flowing form. The objective was never to produce a reduced bulk density material using this process. The primary objective of our invention is to use extrusion process to produce a specific targeted lower bulk density. Our invention is an improvement over Morano in that by creating a specific bulk density one can customize a caloric density in order to make a specific nutritional claim and application to get a specific health benefit of 50% or less calorie consumption for same degree of sweetness when compared to sucrose. This feature is not part of the Morano claims nor the objective of his patents nor is it possible by process of Morano.

By critical control of the primary process variables one is able to produce an extruded material that upon further processing (size reduction and classification) one is able to produce the targeted particle size and distribution profile required to deliver the target bulk density.

In this process, the critical material variables are ingredient blend composition (from one or more of the above listed ingredients), , total blend moisture content (either already in the material, added in a preblending stage or added during the extrusion via the extruder), uniformity in the blending of the high intensity sweetener, particle size of the dry ingredients which should not exceed 100 mesh, the sugar used must be milled having a particle size of 6X and 12 X containing no added starch, flow-ability of the blend, melting point of the individual ingredients, water solubility of the individual ingredients, heat stability of the individual ingredients, ingredient interactions and compatibility. The critical process variables further include relative humidity of the blending environment, rate of feed of the blend to the extruder, extruder speed, extruder barrel stage temperatures and temperature controls, steam and or water injection into the extruder barrel, residence time of the charge, die configuration on the extruder, screw barrel configuration

(single or double), screw flight design, die head cutter design and configuration, product takeaway design and configuration, conveying and cooling stages, grinding and crushing design and configuration and particle classification processes.

The bulk density of sucrose crystals collected from markets of Saudi

Arabia, India and U.S. ranged between 0.74 to 0.94 g/cc. Thus, for these sucrose preparations, the target for preparing the sweetener composition of this invention that delivers half the calories in same volume or on spoon to spoon basis, shall be to get a bulk density of 0.37 to 0.47 g/CC in the granulated extruded product.

EXAMPLE 1

In the initial trials that were conducted on a lab scale model, the objective was to make a lite sweetener of a bulk density 0.35 to 0.45 g/cc with a particle size distribution : 450 - 600 microns, white to off-white color, moisture content was more than 1%, containing sucrose, Sucralose and any other soluble excipient. The lab scale model had an output of 1 kg/1 hr had twin Screw, counter rotating, a stainless steel jacketed barrel which is electric heated wherein the temperature is maintained between 100 - 17O⁰C, having a die hole 2.8 mm, L/D ratio of screw 9.5, RPM of the screw 200, 250, 350 RPM and pressure at the outlet was 11-12 bar (160-174 psi). This equipment did not have extrusion die cutter to cut extruded product.

In above trials on lab scale model, the residence time was between 40 to 65 seconds. The process comprises the steps of mixing, extrusion, cooling on steel trays, pulverizing using domestic mixer, sieving and packing.

Powder mixing was done using high speed blender for 7 minutes, liquid part was manually added & again whole mix was blended for another 5 minutes. To sucrose and Sucralose mixture (1.67 gm Sucralose/kg of sucrose) was added water at 3% level (dry mix weight basis). Sucralose mass, made wet by adding above mentioned water was added to high speed mixer containing the other ingredients and mixed for 5 minutes to enable uniform mixing of ingredients. The premix was extruded in the extruder containing the above parameters. Product extruded was either in the form a puffed noodle or a foam. The extruded product was collected manually on steel trays and left to cool at room temperature for 5 - 10 minutes. The cooled extrudate was packed in plastic covers. The extrudate was milled in a domestic mixer. Milled product was collected every 60 seconds and sieved through series of sieves with mesh no. 25, 60, 80 and 200, kept one above the other. The powder fraction that passed through 25# mesh screen and retained on 60# mesh was analyzed for appearance, odour, moisture, loose and tapped bulk density. Each batch was 2 kg. Invert sugar contained 20% moisture. The results obtained are given in Table 1.

Formulation 1 did not foam in the extruder. The extrudate had a slightly puffed noodle form. Formulation 2 foamed the best out of all the trials. The cooling of the foam was faster than all formulations tried. Formulation 3 did not foam in the extruder. The extrudate had a slightly puffed noodle form. Formulation 4 was better than Formulation 3, however, did not foam like Formulation 2 in the extruder. The extrudate had a slightly puffed noodle form. Formulation 5 foamed in the extruder, however the foam formed was not as large as Formulation 2. The cooling time was slightly more than Formulation 2 (by 2 - 3 minutes). Formulation 6 did not foam in the extruder. The extrudate has a puffed noodle form.

From the above trials, it was concluded that Formulation 2 (10% maltodextrin + 90% sucrose + 3% water with required amount of sucralose) works best. Maximum amount of air was trapped in the foam formed by this formulation which helps in reduction of bulk density of the product mix. Photograph of the foam formed using Formulation 2 is given in figure 1. From initial work described above the feasibility of the use of extrusion for preparing half calorie sweetener composition capable of delivering same sweetness as sucrose on spoon to spoon basis and as close a sweetness delivery profile and organoleptic properties to sucrose as possible was established and it appeared that molasses or maltodextrin addition was essential for getting low density sweetener by extrusion.

However, in further trials that were carried out in a larger capacity extrusion machine showed that extrudates could be obtained even without any additional carrier such as maltodextrin or molasses.

EXPERIMENT 2

Further work carried out was on a machine of larger capacity and better controls (Wenger^® extruder model X 85 Optima II, (address: Wenger Plant and Corporate Offices, 714 Main Street, Sabetha, Kansa 66534-0130 USA) and the process used and observations are given below. The large scale process involves pre-blending sucralose with a small amount of powdered crystalline sucrose. The pre-blend is then mixed with the rest of the powdered crystalline sucrose and adjuvant as the case maybe with or without moisture and mixed in mixer / blender to attain uniform mixing of the ingredients. The mixer/blender used in this work was a Hobart mixer / blender, although any other mixer/blender can be used.

Liquids used or syrups used were directly added through another pipeline to the extruder along with the premix. The premix is then passed through screw feeder into the extruder. The extruder is heated by a heating system to control temperature at various zones of the extruder. The extrudate obtained is then collected in a cooling belt and sized and classified to obtain the desired product. The matter that is over sized, is collected and sent back to the sizing mill and the fines are collected and sent back to the mixer.

The processing conditions play an important role in the bulk density of the product. Experiments were carried to make low bulk density agglomerated sweeteners to replace brown sugar as well as white sugar.

The brown agglomerated sweetener was produced by using a blend of sucrose: sucralose: blackstrap molasses, sucrose:sucralose:maltodextrin and sucrose:sucralose:corn syrup. The white agglomerated sweetener was produced by sucroserSucralose combination.

The details of the trials are given in Table 2. For trial nos. 1 to 6, the extrudates obtained were milled through Fritz mill, fractions separated using sieves mesh # 12, 16, 20, 25, 30, 35 and 40, and a range of bulk densities obtained from the fractions obtained has been given in column M of Table 2. For trial nos. 7 to 17, the milled composition was not separated in fractions by sieving and the figures of their bulk densities are of the composite milled sample. For trials 18 to 30, the extrudate obtained was not milled and the bulk density of the whole extrudate is given in Table 2.

Results of trials with sucrose:sucralose: Blackstrap molasses combination are give in trial nos. 1 to 7 wherein trial nos. 1 to 3 are repeated in trials nos. 4 to 6 and have given reproducible results. In these trials, extruder shaft speed varied between 205 rpm to 405 rpm, feed rate was 50 kg per hour with feed screw speed of 9 rpm, and in one treatment steam at 3.2 kg per hour was introduced. With increase in extruder shaft speed, the bulk density ranged from 0.399 - 0.437 for extruder shaft rpm of 205, 0.374 - 0.456 for 286 rpm (with 3.2 kg / hr. additional steam), to 0.338 - 0. 564 for 404 rpm. Trial no. 7 is practical replica of trial no 6 and 3, gave bulk density of 0.370 on ground composite sample.. The bulk densities achieved here are enough for getting half calorie sweetener composition of this invention by either selecting the fraction that has half the caloric density as that of sucrose or by judiciously mixing two or more fractions. However, further reduction in bulk density would be required for getting one third reduction in calorie density if sweetness contribution from sucrose and sucralose in the sweetener composition is same. However, it may be easier to increase sweetness contribution from sucralose to the sweetener to 75% to get a calorie density that is 25% of sucrose for same degree of sweetness. In trials with Blackstrap molasses, the molasses contained about 19.5 % moisture, which at 10% level in the blend accounted for 2% moisture. Results of trials with sucrose:Sucralose:maltodextrin are given in trial nos.

10, 11 and 12, which are repeated with same results in trial ncvs. 18, 19 and 20. Trail 10 resulted in -extrudate with lowest bulk density of 0.439 under conditions of extruder shaft rpm 400, additional of water at 0.15 kg per hour, feed rate of 50 kg per hr and feed screw speed of 9 rpm. Increase in water addition to 0.74 kg per hour in trial 12 resulted in extrudate of higher bulk density.

Results of trials with sucrose:Sucralsoe:corn syrup are given in trial nos. 13 and 14 which are repeated in trial nos. 21 and 22 with same results. Feed rate and feed screw speed respectively were 50 kg/hr and 9 rpm respectively in both the trials. Lower bulk density of 0.476 was given when the extruder shaft speed was higher i.e. 505 rpm, than the bulk density of 0.514 that was obtained when the extruder shaft rpm was 404 in trial no. 14.

Results of sucrose: sucralose trials have been conducted in four phases.

In the first phase in the trials 8 and 9, water was added at 3% to the blend, the feed rate was 50kg / hr and feed screw speed of 9 rpm. In trial no. 8 the extruder shaft rpm was 500 that resulted in an ground extrudate having bulk density of 0.560 g/CC and the same in trail 9 was 403 rpm with decrease of about 10 degrees in the temperature of second to fifth head and the ground extrudate from the same had bulk density of 0.500. Both the trials had density close to desired for a "half calorie" sweetener where there may be no need or minimal need to mix them with extrudates with other densities to achieve a mix that is "Half calorie" sweetener.

In the second phase, in trial 15 (repeated as trial 23 with same results) no water was added to the blend, extruder shaft rpm was increased to 541, water was added at 1.1 kg peer hour with feed rate of 50 kg per hour to get an extrudate density of 0.617. This performance was seen to significantly improve in trial 16 (repeated with same results in trial 24) where extrudate with bulk density of 0.355 was obtained when water addition rate was increased to 1.53 kg per hour, feed rate was improved to 100 kg per hour and feed screw was improved to 31 rpm, which also corresponded to a residence time of about 50 seconds in the extrusion zone.

The time the product actually is retained in the extruder was estimated at

50 seconds when calculating the feed flow rate and screw speed in RPM's as well as the diameter of the screw and holding volume of the screw chamber. Residence time can be varied by adjusting any or all of these variables with the critical variable being the compositional profile of the ingredient mix related to the temperature of the mix and the moisture content. If the temperature is too high the mix will melt and not expand. If the temperature is too low it will not expand to achieve the desired bulk density. If the total moisture content in the feed mixture is too high it is not possible to achieve the desired mix expansion and desired finished product bulk density. If the total moisture content in the feed mixture is too low it is not possible achieve the desired expansion and low bulk density. If the residence time is too short it is not possible to achieve proper temperature for expansion relative to the moisture content required to achieve the desired bulk density. If the residence time is too long or the temperature too high it results in browning and impact the quality of the product in addition to improper expansion. In the third phase, further variations in the conditions adopted in trial no.

16 that is replicated in trial no. 24 were examined where extruder shaft rpm was increased to 582, water addition rate was kept at 1.7 kg/hr, feed rate of 100 kg/hr and feed screw speed of 31 rpm. It was surprising to get an extrudate bulk density of 0.319 g/hr in trial no. 30 when trial no. 29 which gave extrudate bulk density of 0.557 with the only difference that it was that trial no. 29 was done with two holes in final die, When the trial no. 29 was interrupted, die was changed to a smaller slot die and then run resumed for completion, it resulted in extrudate of bulk density 0.319. This observation has dramatically brought in focus the importance of size of the slot of the die as the next most important parameter that governs the bulk density of the extrudate. Morano has not mentioned bulk densities of his products by process claimed by him. However, it is obvious that in view of residence time of only 0.5 to 12 seconds and extruder shaft rpm of less than 550, the degree of extrusion obtained would be far less than is required for achieving substantial reduction in calorie density in this invention. For that matter the objective of Morano was not to achieve a low calorie sweetener that has same sweetness as sucrose on spoon to spoon basis but, to obtain an improved process for manufacturing sugar products containing aggregates of fondant-size sucrose crystals by recrystallization. Further, Morano's process requires a high speed, high shear extrusion process which results in high temperature and short residence time in the mass that is being extruded. Between Moarno's process and the process of this invention, although both are extrusion processes, important differences are that the process of this invention is a low speed, low shear and higher pressure process with longer residence time and passage through a smaller die. All these differences makes it possible to get far lower bulk densities in the process of this invention enabling production of half calorie density and further lower calorie density extruded sugar products.

During extended runs it was observed that the system experiences some instability or large swings in motor load without change in system inputs. A

Twin Screw Extruder provides a much more positive pressure and would lead to a more stable and consistent process / product. Densities of both products (10X & 6X) were around 0.460 g/CC on a single screw extruder.

It was also confirmed that with use of a small slot die it was possible to achieve a density of 0.319 g/CC. The indicator is that it may be possible to achieve lighter product bulk density by reducing the final die to several small holes instead of one large hole. A product of less surface area will cool more rapidly and maintain light density structure. Comparing results of milling through a Fitz mill and a roller mill, it was observed that the Fitz mill actually gave us a lighter product bulk density by 0.1 g/CC. Additionally it was noted that the roller mill had slight build up on the corrugated rolls. Therefore, it appears that the roller mill would not be the most suitable mill for this application.

An extrudate of sucrose:sucralose, with optional excipient upto 15 %, having a bulk density range that is on the lighter side as well as to a heavier side of the half or one third the bulk density of sucrose was prepared. Such extrudate can be milled, sized and a fraction having bulk density lighter than the target bulk density is mixed with appropriate portion of a fraction of a bulk density higher than the target density so that the mixture contains the desired target bulk density with desired precision. In this invention, sucrose may be replaced by any other carbohydrate sweetener, and by routine experimentation it would be possible to work out conditions appropriate for getting desired bulk densities of the extruded sweetener. Sucralose may also be replaced by any other high intensity sweetener mentioned in the list of high intensity sweeteners given earlier.

Thus, in summary, in one aspect this invention comprises a process of preparation of a free flowing sweetener composition having a bulk density lesser than sucrose. The said sweetener composition may have sweetness, on spoon to spoon basis, same as that of sucrose or in known multiples of sweetness of sucrose. The said known multiples of sweetness may, for example, be twice, thrice, four times etc. and may be useful for making or manufacturing sweet food products by adding them for known sucrose equivalence.

The process also comprises using carbohydrate sweetener as a base, adding sucralose to the same, the quantity of said sucralose being computed to achieve the desired sweetness intensity in the final product, optionally adding water or excipients to the blend and passing the blend through an extruder using conditions that result into a sweetener extrudate of bulk density that is 50% or lesser compared to sucrose, the said extrudate is further ground, sized, fractions of appropriate size selected and blended together to result into a blend of target bulk density. The oversized and undersized fractions are recycled. .

Preferably the bulk density of the extruded product to be used may be half of the bulk density of the corresponding sucrose used, so that on spoon to spoon basis this sweetener will provide only half the calories for same volume of sucrose. In such a composition, its sucralose content can be calculated such that the sweetness intensity of one spoon of the sucrose- sucralose extrudate is equal to the sweetness intensity of sucrose. It is also possible to envisage using double that amount of sucralose in the composition and one spoon of the half calorie composition being equal to two spoons of sucrose in sweetness, so that in actual use, instead of two spoons, one can use only one spoonful of the extruded composition and that will result in consumption of calories to one quarter. In this way, several combinations could be worked out for several types of applications. Similarly, in addition to half calorie sweetener, it may also be possible to get about one third calorie sweetener having same or double the sweetness as sucrose but at about one third or one sixth of the calories in one spoonful of the extruded sweetener for same sweetness that could have been received through sucrose.

The extrudates of this invention after sizing and grading provide free flowing compositions.

If the requirement of the sweetener is not a free flowing composition, once the extrudates are milled and sized, it is possible for a person of an ordinary skill in the art to envisage converting such compositions into cubes or into bars carrying dividing lines / break lines along which the bars can be broken by hand and each such defined portion having a known equivalence to the sweetness of sucrose in terms of volume of sucrose expressed in spoonfuls.

Table 2: Extrusion trial details on a Wenger^® machine

Claims

1. An extruded agglomerated free flowing solid sweetener composition containing at least one caloric carbohydrate sweetener and at least one high intensity sweetener, the said free flowing solid sweetener having caloric density expressed as calories/cubic centimeter (calories/cc) that is half or less than half of the typical caloric density of the crystalline granulated sucrose.

2. A process of preparation of an extruded agglomerated free flowing solid sweetener composition containing at least one caloric carbohydrate sweetener and at least one high intensity sweetener, the said free flowing solid sweetener having caloric density expressed as calories/cc that is half or less than half of the caloric density of the crystalline sucrose comprising a process of extrusion of a blend of the said carbohydrate sweetener and the high intensity sweetener, with or without adjuvants and with or without additives, with or without binders, through a low shear low speed, high pressure cooker extruder wherein temperature required for extrusion is applied externally and extrusion is done through a die of about 6 to 18 centimeter with a residence time of about 50 seconds wherein the said extruderis set for process parameters that result in an extrudate having a calorie density in a range of half the caloric density of the crystalline sucrose plus or minus up to about a quarter of the caloric density of crystalline sucrose, and selecting or mixing fractions that result in a composition of half the caloric density of the crystalline sucrose.

3. A process of preparing an extruded agglomerated free flowing solid sweetener composition of claim 2 wherein the said process parameters of extrusion through a cooker extruder comprises steps of: a. mixing the said caloric carbohydrate sweetener and the said high intensity sweetener to make a blend, extruding, with or without further addition of one or more of an adjuvant, with or without further addition of one or more of an additive, with or without further addition of one or more of a binder, through a cooker extruder to get an agglomerated extrudate, b. milling and sizing the extrudate to a range of desired particle distribution profiles several fractions, c. selecting a fraction or a mixture of fractions that has half or about a quarter of calorie density less or more than half of the caloric density of the crystalline sucrose, and recycling rest of the fraction/s, if any, for extrusion and or milling.

4. A process of preparing an extruded agglomerated free flowing solid sweetener composition of claim 2 wherein the said process of extrusion through a cooker extruder further comprises steps of: a. setting extruder shaft RPM (revolutions per minute) from about 100 to 600, b. setting water or steam addition to 0 to about 4.5 kg/hour, c. setting feed rate to about 50 to 150 kg/hour, d. setting throttle valve temp in a range of about 240⁰C to 275°C e. setting feed screw speed to 1 to 53 RPM₁ f. setting cone head pressure to vary between 50 psi to 400 psi, g. setting temperature of first Head to 60 to 90⁰C,

h. setting temperature of second Head to a range of 75 to 105⁰C, i. setting temperature of third Head to very between about 120 to 140⁰C₁ j. setting temperature fourth Head to about 120140⁰C, k. setting temperature fifth Head to about 120140°C, and

I. a residence time of the charge in extruding zone for about 50 seconds.

5. An extruded agglomerated free flowing solid sweetener composition of claim 3 wherein the said caloric carbohydrate sweetener is selected from simple mono and di saccharides, sugar alcohols or a combination thereof.

6. An extruded agglomerated free flowing solid sweetener composition of claim 3 wherein: a. the said simple mono and di saccharide is selected from a group comprising sucrose, glucose, dextrose, maltose, lactose, fructose, and / or b. the said sugar alcohols is selected from a group of erythritol, Isolmaltol, mannitol, maltitol, lactitol.

7. An extruded agglomerated free flowing solid sweetener composition of claim 3 wherein the said additives, adjuvants, binders are selected from dextrins, maltodextrins, molasses, corn syrup, invert sugar, fiber, flavors, colors, starches, proteins, probiotics, non-caloric sweeteners, caloric carbohydrates, botanical extracts, vitamins, minerals, and pharmaceutical actives or a combination thereof.

8. An extruded agglomerated free flowing solid sweetener composition claim 3 further comprising at least one sweetness potentiator or/and a sweetness modifier.

9. An extruded agglomerated free flowing solid sweetener composition of claim 6 wherein the said sweetness potentiator or/and a modifier is selected from a group comprising MAG - Mono-Ammonium Glycyrrhizinate, 2,4-Dihydroxybenzoic acid (2,4-DHB), monosodium glutamate (MSG), disodium 5'-inosinate (IMP), and disodium δ'-guanylate

(GMP) flavor potentiator selected from the group consisting of sodium chloride, monosodium glutamate, quercetin, adenosine monophosphate, inosine monophosphate, guanylate monophosphate, edible salts of the foregoing, and combinations of at least two of the foregoing. monoammonium glycyrrhizinate, a licorice glycyrrhizinate, citrus aurantium, alapyridaine, alapyridaine (N-(1-carboxyethyl)-6- (hydroxymethyl)pyridinium-3-ol) inner salt, miraculin, curculin, strogin, mabinlin, gymnemic acid, cynarin, glupyridaine, a pyridinium-betain compound, sugar beet extract, neotame, thaumatin, neohesperidin dihydrochalcone, a hydroxybenzoic acid, 2-hydroxybenzoicacid, 3- hydroxybenzoic acid, 4-hydroxybenzoic acid, 2,3-dihydroxybenzoic acid, 2,4-dihydroxybenzoic acid, 2,5-dihydroxybenzoic acid, 2,6- dihydroxybenzoic acid, 3,4-dihydroxybenzoic acid, 3,5-dihydroxybenzoic acid, 2,3,4-trihydroxybenzoic acid, 2,4,6-trihydroxybenzoic acid, 3,4,5- trihydroxybenzoic acid,4-hydroxyphenylacetic acid, 2-hydroxyisocaproic acid, 3-hydroxycinnamic acid,3-aminobenzoicacid,4-aminobenzoic acid, 4-methoxysalicylic acid, 2-(4-hydroxy-3-methoxyphenyl)-1 -(2,4,6- trihydroxyphenyl)ethanone, 1-(2,4-dihydroxyphenyl)-2-(4-hydroxy-3- methoxyphenyl)ethanone, 1-(2-hydroxy-4-methoxyphenyl)-2-(4-hydroxy-3- methoxyphenyl)ethanone, 2,4-dihydroxy-N-[(4-hydroxy-3- methoxyphenyl)methyl]benzamide, 2,4,6-trihydroxy-N-[(4-hydroxy-3- methoxyphenyl)methyl]benzamide,2-hydroxy-N-[(4-hydroxy-3- methoxyphenyl)methyl]benzamide,4-hydroxy-N-[(4-hydroxy-3- methoxyphenyl)methyl]benzamide,2,4-dihydroxy-N-[(4-hydroxy-3- methoxyphenyl)methyl]benzamide,2,4-dihydroxy-N-[2-(4-hydroxy-3- methoxyphenyl)ethyl]benzamide,N-[(3-ethoxy-4-hydroxyphenyl)methyl]-

2,4-dihydroxy-benzamide,N-[(3,4-dihydroxyphenyl)methyl]-2,4-dihydroxy- benzamide, tagatose, trehalose, maltol, ethyl maltol, vanilla extract, vanilla oleoresin, vanillin, sugar beet extract, sugarcane leaf essence, a compound that respond to a G-protein coupled receptor, an edible salt of the foregoing, or a combination of at least two of the foregoing sweetness potentiators.

10. An extruded agglomerated free flowing solid sweetener composition of claim 3 wherein the said high intensity sweetener is selected from the group Sucralose, fructose, polyols, acesulphame K, monellin, steviosides, glycyrrhizin, dihydroflavenol, sorbitol, mannitol, maltitol, monatin, an L-aminodicarboxylic acid aminoalkenoic acid ester amide, a water-soluble saccharin salt, a cyclamate salt, an acesulfame salt, the calcium salt of 3,4-dihydro-6-methyl- 1,2,3- oxathiazine-4-one- 2,2-dioxide, the potassium salt of 3,4-dihydro-6-methyl- 1 ,2,3-oxathiazine- 4-one-2,2-dioxide, the free acid form of saccharin, L-aspartyl-1- phenylalanine methyl ester, L-alpha-aspartyl-N-(2,2,4,4-tetramethyl-3- thietanyl)-D-alaninamide hydrate, the methyl ester of L-aspartyl-1- phenylglycerine, L-aspartyl-1-2,5-dihydrophenyl-glycine, L- aspartyl-2,5- dihydro-1 -phenylalanine, L-aspartyl-1-(1-cyclohexen)-alanine, neotame, steviosides, chloro-1 '-deoxysucrose, 4-chloro-4-deoxygalactosucrose, 4,1'-dichloro-4,1^l-dideoxygalactosucrose, 1',6'-dichloro 1',6'- dideoxysucrose, 4,1',6^I-trichloro-4,1^I,6^l- trideoxygalactosucrose, 4,6,6'- trichloro-4,6,6'-trideoxygalactosucrose, 6, 1 '.β'-trichloro-β, 1 ',6'- trideoxysucrose, 4,6,1',6'- tetrachloro4,6,1^l,6'-tetradeoxygalacto-sucrose, 4_I6,1',6'-tetradeoxysucrose, thaumaoccous danielli, talin, or a combination of at least two of the foregoing high intensity sweeteners.

11. An extruded agglomerated free flowing solid sweetener composition of claim 1 or 2 wherein the said extruded agglomerate is made on a cooker extruder.

12. A cooker extruder model of claim 12 which comprises Wenger^® extruder model X 85 Optima II.