Breakable capsules and methods of forming thereof

1. A method of forming a seamless breakable capsule, the method comprising:

supplying a shell forming solution to an outer nozzle of a coaxial multiple nozzle system, the shell forming solution comprising agar, at least one filler, carboxymethyl cellulose, and water;

supplying a liquid or gel composition of a flavorant and/or non-flavorant to an inner nozzle of the coaxial multiple nozzle system;

simultaneously delivering the shell forming solution from the outer nozzle and the liquid or gel composition from the inner nozzle while vibrating the coaxial nozzles such that the vibration causes droplets of the liquid or gel composition to form as the liquid or gel composition exits the inner nozzle, wherein the shell forming solution surrounds the droplets of the liquid or gel composition and forms wet capsules; and

drying the wet capsules so as to form respective seamless breakable capsules that include an outer shell formed of a cross-linked agar matrix that includes at least one filler and an inner core surrounded by the outer shell that includes the liquid or gel composition;

wherein the shell forming solution includes an effective amount of carboxymethyl cellulose dispersed throughout empty spaces in the cross-linked agar matrix when the shell forming solution is dried and the carboxymethyl cellulose fills a sufficient amount of the empty spaces in the agar matrix to inhibit the liquid or gel composition from passing through the empty spaces of the agar matrix, wherein:

(a) the at least one filler includes about 0.05 to 0.5% locust bean gum, about 3 to 5% pullulan, about 0.1 to 1% glycerin and/or sorbitol, and about 0.1 to 1% sodium chloride;

(b) the at least one filler includes about 0.05 to 0.5% locust bean gum, about 3-5% hydroxypropyl methylcellulose and/or maltodextrin, about 0.1 to 1% glycerin and/or sorbitol, and about 0.1 to 1% sodium chloride; or

(c) the at least one filler consists of about 0.05 to 0.5% locust bean gum, about 4 to 4.5% pullulan, about 1% glycerin, and about 1% sodium chloride.

2. The method of claim 1 , comprising supplying the shell forming solution at a temperature of about 50 to about 65° C., and supplying the liquid or gel composition at ambient temperature.

3. The method of claim 1 , comprising delivering the wet capsules into a cold oil bath maintained at a temperature of about 10° C.

4. The method of claim 3 , further comprising:

removing the wet capsules from the cold oil bath;

washing the wet capsules with ethanol to remove residual oil and/or water; and

sprinkling the wet capsules with a separating agent so as to separate the seamless breakable capsules.

5. The method of claim 1 , further comprising coating the outer shells of respective seamless breakable capsules with an outer coating of ethyl cellulose.

6. The method of claim 1 , wherein:

(a) the flavorant of the liquid or gel composition is selected from the group consisting of licorice, wintergreen, cherry and berry type flavorants, Dramboui, bourbon, scotch, whiskey, spearmint, peppermint, lavender, cinnamon, cardamon, apium graveolents, clove, cascarilla, nutmeg, sandalwood, bergamot, geranium, honey essence, rose oil, vanilla, lemon oil, orange oil, Japanese mint, cassia , caraway, cognac, jasmine, chamomile, menthol, ilangilang, sage, fennel, piment, ginger, anise, coriander, coffee, salts, sweeteners, carbohydrates, mint oils from a species of the genus Mentha, eugenol, cocoa, citrus, fruit flavors, and combinations thereof; and/or

(b) the non-flavorant of the liquid or gel composition is selected from the group consisting of sensates, diluents, aerosol formers, and combinations thereof.

7. The method of claim 1 , wherein:

(a) the shell forming solution includes about 1 to 2% agar, about 0.05 to 0.5% carboxymethyl cellulose, and about 90 to 95.7% water;

(b) the shell forming solution includes up to about 2% agar and up to about 0.5% carboxymethyl cellulose;

(c) the shell forming solution has a viscosity of less than about 400 cP at a temperature of about 60° C.;

(d) the shell forming solution includes about 1% agar, about 0.05% carboxymethyl cellulose and the outer shell has a diameter of about 2 mm;

(e) the shell forming solution includes about 1.4% agar, about 0.05% carboxymethyl cellulose, and the outer shell has a diameter of about 2.5 mm;

(f) the shell forming solution includes about 1.4 to 2% agar, about 0.05 to 0.5% carboxymethyl cellulose, and the outer shell has a diameter of about 2.5 to 4.5 mm;

(g) the shell forming solution consists essentially of about 1 to 2% agar, about 0.05 to 0.5% carboxymethyl cellulose, 0.05 to 0.5% locust bean gum, about 3 to 5% pullulan, about 0.1 to 1% glycerin and/or sorbitol, about 0.1 to 1% sodium chloride, and about 90 to 95.7% water; or

(h) the shell forming solution consists of about 1 to 2% agar, about 0.05 to 0.5% carboxymethyl cellulose, 0.05 to 0.5% locust bean gum, about 3 to 5% pullulan, about 0.1 to 1% glycerin, about 0.1 to 1% sodium chloride, and about 90 to 95.7% water.