Note: Descriptions are shown in the official language in which they were submitted.
CA 02269411 1999-04-20
CASE 21433
TRANSLATION:
Kraft Jacobs Suchard R&D, Inc., 81705 Munich
SOLID CANDY AND A PROCESS AND A DEVICE FOR THE PRODUCTION
OF THIS TYPE OF CANDY
Technical Area
The invention pertains to solid, one-piece, bar-shaped or slab-shaped
candy) especially of chocolate, with a number of sections of essentially equal
strength defined by portioning aids and to a process and a device for produc-
ing candy of this type.
State of the Art
One-piece, bar-shaped or slab-shaped candy of this type, especially of
chocolate, and processes and devices for producing this candy are basically
known. "Solid candy", in contrast to, for example, shell constructions, is to
be understood in the following as candy which has a homogeneous composition
over its entire cross section. This solid candy of the general type in ques-
tion is known, for example, as chocolate bars or slabs, from which individual
volume sections can be removed by making use of the grooves provided in the
bar or slab. In this way, it is possible to separate individual) predeter-
mined pieces from the one-piece bar or slab and thus to divide the candy into
portions. This conventional type of candy is designed to be homogeneous with
respect to taste; that is, the chocolate slab or bar has the same flavor at
every point, and every piece separated from the whole is similar in this
respect to every adjacent piece.
Within the scope of this basic concept, furthermore, it is also possible
for several different types of chocolate to be present in the form of layers,
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one on top of the other, so that each separab'Le volume section of the candy
consists of several components. Thus, although it is possible to combine sev-
eral types of chocolate with different flavors or colors in a single chocolate
bar) nevertheless the pieces which can be separated from the whole will always
have the same composition as all the other pieces, with the result that, when
the chocolate bar is eaten) it is found that all the pieces taste the same.
A method and a known device are used to produce candy of this type; the
process comprises basically four stages. In the first stage, the components
of the product to be produced, such as cocoa liquid, sugar, and cocoa butter)
are mixed and rolled to obtain a smooth, uniform mixture. The rolled choco-
late mixture is then subjected to a heat treatment in a conching step, during
which the mixture acquires a pasty consistency. This procedure is used for
fine chocolate to obtain better smoothness and a melting, delicate character.
In this stage, it is also possible to mix in other components such as flavor-
ings. Then, for further refinement, a third stage is carried out in which the
mixture is tempered in a tempering device to initiate crystallization. In the
fourth stage) a filling device loads the mixture into slab or bar-shaped
molds, for example, after which the candy is cooled in a cooling device,
removed from the molds, and packaged.
Description of the Lnvention
The task of the invention is to develop a solid candy and a process and a
device for producing it of the general type described above in such a way that
the candy can be easily and effectively divided into individual portions with
different flavors, different colors, and/or different shapes.
This task is accomplished in accordance with a first aspect of the inven-
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tion by a product with the features of Claim 1.
Accordingly, a solid) one-piece candy) which is produced in particular
out of chocolate, has a number of sections, of essentially equal strength,
defined by portioning aids, where the at least two adjacent sections differ in
their composition. The candy is made up preferably out of several different
types of chocolate, which are present, separately from each other) in the pre-
defined sections. At least two adjacent sections of the candy differ from
each other with respect to the type and/or color of the chocolate.
According to the invention, the candy is designed in the form of bars or
plates to make chocolate bars or chocolate slabs. The slab-shaped configura-
tion can comprise rectangular, but also circular, oval, or polygonal shapes.
It is preferable to provide grooves, perforations, recesses, etc., in the
candy as portioning aids to facilitate the separation, breaking, or cracking
of the individual sections in predetermined portions from the whole piece of
candy. Thus it is possible, in an easy and simple manner, to obtain portions
of a size suitable for the consumption of the candy. In addition, it is pos-
Bible to break off a certain section with a composition different from that of
an adjacent section of the slab. It is advantageous in this case to design
the course of the boundaries in the grooves between the different types of
chocolate as straight lines, because an edge suitable for breaking defined in
this way can be obtained without the need to introduce an additional mixture
of lesser strength as a portioning aid between the individual pieces intended
for consumption.
Thanks to the way in which the product according to the invention is
designed, it is possible to combine several different types of chocolate into
the same product while at the same time always ensuring that the individual
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types of chocolate can be consumed and enjoyed separately. Thus, even though
a consumer buys only a single product, he or she can choose between several
different types in the one product, depending on his or her preferences at the
time. It is therefore no longer necessary to keep many individual products on
hand) each with a different composition and each packaged separately from the
other. Accordingly, the solutions according to the invention are also advan-
tageous from the standpoints of packaging technology and ecology, because
unnecessary packaging material is eliminated.
Advantageous embodiments of the product according to the invention are
described in the remaining claims.
It is preferred that the sections with different compositions have dif-
ferent flavors. Thus the considerable advantage is obtained that, even though
several flavors are combined in one candy, it is nevertheless possible to
enjoy one flavor separately from all th2.others. The various compositions are
produced by mixing different components and/or by varying the proportions of
the components of the chocolate. Thus, a composition can consist) for
example, of a milk chocolate, a cream chocolate, a bittersweet chocolate) or a
white chocolate, depending on how the components of the chocolate are varied.
In addition, it has also been found to be advantageous for the sections
with different compositions to differ in their external appearance as well.
The selection of the amounts and types of the components of the chocolate will
have the effect primarily of varying the color and/or shade of the sections.
In addition, the different colors of the sections thus obtained can be
arranged in, for example, checkerboard-like fashion or divided into horizontal
or diagonal strips or arranged in variable sequences in the candy, which means
that the range of design possibilities for the external appearance of the
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candy is greatly expanded.
To ensure that the chocolate is divided efficiently into portions, it has
been found advantageous for the candy to be designed in the form of a slab and
that the sections be designed as bars. Thus relatively large pieces with the
same composition can be easily separated from the chocolate.
As a way of optimizing the division of the candy into portions, it is
preferred that the sections consist of individual pieces . small pieces
instead of large ones. In contrast to a design in which the candy
is divided into bars, a greater range of possibilities is thus obtained with
respect to combining different compositions into a single candy.
For varying the shape of the portionable sections) it is advantageous for
the pieces to be designed as circles and/or segments of circles. Here the
candy can have a circular or oval outline) so that the individual sections
which can be separated from the candy are ~in the form of segments of the
circle.
It has also been found to be especially advantageous with respect to the
design of the sections for the pieces to be essentially rectangular. As a
result) a well-defined breaking edge can be obtained along which the pieces
can be separated from each other.
In accordance with another advantageous embodiment of the invention, the
sections are built up of several layers. As a result, the additional possi-
bility is obtained of combining different types of chocolate and/or flavors
with each other in a single section.
In accordance with a further embodiment of the invention, solids) which
are surrounded by the candy, are contained in the sections. Advantageously
these solids consist of nuts or nut pieces such as almonds or hazelnuts, dried
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fruits or fruit pieces, so-called "Poprocks~", and/or extrudates such as
"Crispies" and/or other cereal products such as cereal flakes or ballast mate-
rials (products that contain an increased hull component of the cereal grain).
Poprocks~ is to be understood as an example of a product which reacts when
brought into contact with saliva. As a result, the variety of flavor direc-
tions available for the individual sections can be further increased.
The solution of the task on which the invention is based occurs in accor-
dance with a second aspect of the invention by means of a process, according
to Claim 11, for the production of a solid, one-piece, bar-shaped or slab-
shaped candy) especially of chocolate, which has a number of sections of
essentially the same strength, defined by portioning aids.
Accordingly) different castable mixtures are prepared first. These cast-
able mixtures differ from each other in their composition, in their flavor,
and/or in their color. Thus, various liquid candy substances such as dark
chocolate) milk chocolate) white chocolate, and chocolate-containing compo-
nents and fillings are provided as castable mixtures. The form of the mixture
varies depending on its liquid or viscous aggregate state and can conform to
the shape of the vessel which encloses it. The viscosity of the mixture gives
it a certain strength, which has the effect of improving the castability of
the mixture.
In the next step of the process, casting devices for casting the various
mixtures simultaneously into adjacent molds are actuated, the molds being con-
nected so that the mixture can flow from one mold to the other. To ensure
that the mixtures are fed and metered accurately into the molds) it is prefer-
able to use funnel-shaped casting, spray-, or injection-molding devices such
as nozzles. It is advantageous for a separate device of this type to be
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assigned to each section or each piece of candy to be produced. Thus it is
guaranteed that a different mixture with a different taste and/or color can be
supplied to the individual sections of the candy by the correspond casting
device. In addition, as a result of the simultaneous casting of the different
mixtures, it is ensured that the mixtures arrive in the molds simultaneously
and spread out uniformly in them. Thus, if all the mixtures flow at the same
rate, a sharp separation line can be achieved between adjacent molds and thus
between adjacent cast sections. This is especially advantageous, because it
is thus possible to prevent effectively the different mixtures from mixing
with each other during the casting process.
Because the adjacent molds are connected to each other so that the mix-
tures can flow from one mold to the other) the individual sections can bond
themselves to each other at their flow. edges in the molds during the casting
process to form a (sharp) boundary line. Ridges, elevations, screens) etc.,
are provided between the adjacent molds to produce portioning aids such as
grooves or perforations between the sections of the candy during casting.
Thus it is guaranteed that, first, a (sharp) separation line is produced
between the individual sections of the one-piece candy and) second that, as a
result of the portioning aids, the sections can be separated from each other
exactly at this separation line.
After casting, the cast mixtures are hardened to form the one-piece
candy. This can be done advantageously by cooling the cast mixtures to a tem-
perature below their respective melting points.
Advantageous embodiments of the process according to the invention are
described in the additional claims.
It is preferred that the preparation of the castable mixtures be carried
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out in the known manner by a process which comprises the mixing) couching, and
tempering of at least a cocoa mixture, sugar) and cocoa butter. By means of
couching, a process in which the chocolate composition consisting of cocoa
liquor) sugar) and coca butter is subjected to a temperature treatment and
mechanical processing) it is possible to obtain a chocolate with improved
structure and a full and delicate flavor. During tempering, stable crystals
(~-crystals) are produced) which achieve;a rapid crystallization, which
crystallize rapidly and affect the storage life and structure of
the chocolate.
To improve the external appearance, the gloss) the fracture behavior, and
the melting behavior of the chocolate even more) it is has been found advanta-
genus, during the preparation of the castable mixtures, to subject these mix-
tures to ultrasonic vibrations, usually in a continuous manner (as in conven-
tional tempering systems). As a result-of~this treatment step, furthermore,
it is also possible to obtain a chocolate mixture which shrinks in an optimum
manner during hardening and cooling) so that the mixture can be removed from
the mold more easily after casting.
It is also advantageous to treat the cooled, untempered mixtures in the
casting molds to ultrasonic waves. In this case the ultrasonic waves are
applied during the cooling process.
In this regard, it has turned out to be favorable for the ultrasonic
waves to have a frequency in the range of 20-100 kHz and for them to be
applied to the mixtures before they have been loaded or cast into the molds.
It is also advantageous to expose the castable mixtures to pulses of
ultrasonic waves before the molds are filled. It is easier in this way to
meter the ultrasonic waves, and undesirable heating of the normally precooled
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mixtures beyond their respective melting points can be effectively avoided.
If ultrasonic waves are applied to cast, untempered product) the heat thus
produced must be dissipated by a cooling process.
In this regard) is it also possible to obtain certain advantages by
adjusting the duration of the pulses in accordance with the composition of the
mixture in question to a value in the range o:f 0.1-10 seconds. By means of
the pulse duration, it is possible to control in optimum fashion the amount of
energy supplied to the chocolate, so that the flow properties of the individ-
ual mixtures can be influenced and adjusted. It is advantageous, for example,
for the flow rates of the various types of chocolate to be the same, because
in this way) the different mixtures will reach the boundaries between adjacent
molds simultaneously) and thus the desired straight course of the separation
line between the adjacent types of chocolate in the molds can be obtained.
According to a preferred embodiment.of the process according to the
invention, certain advantages can be obtained if the process step of actuating
the casting devices comprises the control of certain casting parameters. In
this case, the casting parameters which are controlled are the pressure and
the temperature of the castable mixtures as they emerge from the casting
devices. This can be done, for example, by appropriate tempering of the cast-
ing devices. But the precrystallization of the mixtures by means of ultra-
sonic vibrations, as already mentioned, is also a suitable way of controlling
the casting parameters.
It is advantageous for the casting parameters of the casting devices for
the various mixtures to be set to values which are appropriate for the indi-
vidual mixtures. The casting parameters will thus differ as a function of the
flow behavior and flow properties of the different viscous mixtures and will
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be set in such a way that the flow rate of all the different mixtures will be
the same. In this way, all molds will be filled with the same amount; simul-
taneously, the desired sharp-edged, straight separation line between adjacent
sections will be able to form, because, when the molds are filled simulta-
neously with mixtures which are all flowing at the same rate) the mixtures
will contact each other simultaneously at the separation lines.
Thus special advantages are obtained when the casting parameters are con-
trolled in such a way that the castable mixtures have the same flow rate in
the molds.
The step in which the cast mixtures harden occurs advantageously in a
cooling device. The molds filled with chocolate are preferably conducted
through a cooling channel so that the chocolate slabs or bars can solidify and
harden under carefully selected cooling conditions.
It has been found to be especially-favorable for the hardening of the
cast mixtures in the molds to be carried out by cooling the mixtures in three
stages, namely, at an air temperature of 12°C for at least S minutes,
at an
air temperature of 5°C for at least 4-6 minutes, and at an air
temperature of
18°C for at least 3-4 minutes. The indicated temperatures should be
kept
steady to ~ 1°C. The hold times of the cast mixtures during the cooling
pro-
cess depend on the recipe. The cooling temperature in the last cooling stage
depends on the ambient temperature and the relative atmospheric humidity and
is suitably chosen to avoid condensation on the surface of the product. Con-
ducting the cooling process in this manner guarantees that the hardened mix-
tunes will be easy to remove from the molds.
In a preferred embodiment, furthermore, the process according to the
invention comprises the placing of solids into at least one of the molds
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before the casting devices are actuated. As a result, it is possible to
introduce, for example, nuts, fruits) extrudates, or Poprocks~ into the candy
to be produced.
In accordance with a third aspect of the invention, the task on which the
invention is based is also accomplished by a device according to Claim 24.
According to this claim, an appropriate device is provided to implement the
process according to the invention for producing the product according to the
invention as well as to realize the preferred embodiments of the invention.
According to the invention) the device has several containers for differ-
ent castable mixtures. As a result) it is ensured that the different mixtures
will not mix with each other during preparation and that it will thus be pos-
Bible to supply them separately to a number o:E different casting devices. The
different mixtures can thus be effectively prevented from becoming homogenized
with each other to form a uniform mixture. In addition) at least one of the
casting devices is connected to each container by means of a suitable feed
device such as, for example, a feed line, a pipe, or a funnel. In addition,
several adjacent molds are provided, which are connected to each other in such
a way as to allow the mixture to flow between them. As a result, as described
above, a bond can be produced between adjacent castings, so that a one-piece
candy is obtained.
Advantageous embodiments of the device according to the invention for
producing one-piece, bar-shaped or slab-shaped candy are described in the
remaining subclaims.
Thus, in accordance with a preferred embodiment, the containers include
at least one device for controlling the container temperature. As mentioned
above, it is possible in this way to adjust the flowability and flow proper-
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ties of the viscous mixture in question in the container.
In this context) it is preferred that a device for treating the mixtures
with ultrasonic vibrations also be provided. As discussed within the scope of
the process according to the invention, energy in the form of ultrasonic
vibrations is supplied to the mixtures to affect their temperature) viscosity)
and external appearance.
To control the casting parameters, providing the casting deices with
appropriate control devices offers certain advantages. The control devices
preferably control the pressure and temperature of the castable mixtures as
they emerge from the casting devices. As a result, the consistency of the
chocolate can be adjusted in such a way that the flow edge of one mixture
joins to the flow edge of the adjacent mixture but does not mix with it.
1n correspondence with the process. according to the invention) a casting
device is preferably provided for each.mold. As a result) it is possible to
achieve an especially high production output.
Providing at least one casting device for each different mixture also
offers advantages. When the type of chocolate is changed) it is therefore no
longer necessary to clean the casting device in question. This represents an
especially low-cost design variant of the device according to the invention.
For the hardening of the mixture, it is preferred that a cooling device
be provided. As mentioned above, this cooling device is preferably a cooling
channel, through which the molds are filled with cast mixture.
It has been found that it is advantageous for the cooling device to be
designed in such a way that the mixtures are cooled in three stages, namely,
at an air temperature of 12°C for at least 5 minutes, at an air
temperature of
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5°C for at least 4-6 minutes, and at an air temperature of 18°C
for at least
3-4 minutes. In this way it is guaranteed that the mixtures can be easily
removed from the molds and packaged in a sufficiently hardened state. The
hold times of the cast mixtures in the cooling process depend on the recipe.
The cooling temperature in the last stage of the cooling process depends on
the ambient temperature and the relative humidity and is suitably selected to
avoid condensation on the surface of the product.
Short Description of the Drawings
The invention is explained in greater detail below on the basis of actual
embodiments, illustrated by way of example in the drawings:
- Figure 1 shows a top view of a piece of candy according to the inven-
tion as produced in accordance with a first embodiment;
- Figure 2 shows a top view of a second embodiment of the candy according
to the invention;
- Figure 3 shows a schematic diagram, in cross section, of the candy
according to the invention along line I-I of Figure 1 and along line II-II of
Figure 2;
- Figure 4 shows a top view of a third embodiment of the candy according
to the invention;
- Figure 5 shows a schematic diagram of a device for producing the candy
according to the invention; and
- Figure 6 shows a schematic diagram of a detail of Figure 5 of a device
for producing candy according to the invention.
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Description of Embodiments of the Invention
The candy 1 shown in Figure 1 is designed as a single piece with a rec-
tangular outline and is divided into several individual sections 2 for a total
of 16. Sections 2 are essentially rectangular and arranged in rows next to
and above each other in checkerboard fashion. As indicated in Figure 1 by the
different colors) at least two adjacent sections 2 differ from each other in
their composition. In the present case, slab-shaped candy 1 has sections 2
with white chocolate 4, milk or dark chocolate 6, and white chocolate with a
caramel flavor 8, so that a chocolate slab with local differences in flavor is
obtained. Sections 2 form individual pieces 3 of the chocolate slab and are
connected to each other by grooves 10, which extend in straight lines parallel
to each other in both the lengthwise and crosswise directions of the chocolate
slab.
In grooves 10, the thickness of the chocolate slab (not shown) is
reduced, so that individual pieces 3 of the slab with their different flavors
and colors can be easily separated from the whole.
In the embodiment of candy 1 according to the invention shown in Figure
2, sections 2 of the chocolate slab defined by grooves 10 have different out-
lines. As can be seen from Figure 2, the slab consists of a total of three
parallel strips of chocolate) each strip extending over the entire width of
the slab. Two edge strips 12 constitute bars 5 of dark chocolate 6, whereas
center strip 14 consists of white chocolate 4.. In addition, center strip 14
is built up out of four individual rectangular pieces 3, which have grooves 10
along their outer edges. In this embodiment of the invention, it is possible
to separate chocolate pieces 3 and bars 5, which are of different sizes, fla-
vors, and shapes) into portions by breaking them off at grooves 10.
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Figure 3 shows the structure of the candy according to the invention in
the form of a schematic, cross-sectional diagram along line I-I of Figure 1
and along line II-II of Figure 2. On one surface 16 of the chocolate slab,
depressions are provided to serve as grooves 10. The grooves reduce the
thickness A of candy 1. From surface 16, vertical separating planes 20 extend
in the grooves 10 to bottom surface IS of candy 1. At these separating planes
20, sections 2 with their different compositions are in contact with each
other in such a way that a straight, sharp boundary is formed between them.
Sections 2 adhere to each other at separating plane 20, so that candy 1 con-
stitutes a single piece overall.
The embodiment of the candy according to the invention shown in a top
view in Figure 4 has an essentially circular outline. Here) round candy 1
consists of several chocolate-containing sections 2, which are designed in the
form of segments 22 of a circle and in the form of a circle 24. Segments 22
and circle 24 contain different types of chocolate. In addition, in analogy
to the first and second exemplary embodiments of the invention, grooves 10 are
provided, by which sections 2 are connected to each other and which make it
possible for the sections to be separated from each other.
Figure 5 shows a part of a system 26 for producing one-piece, bar-shaped
or slab-shaped candy) especially of chocolate, according to the invention. In
this system, the components for the production of bar-shaped or slab-shaped
chocolate candy 1 are combined in a mixer (not shown) in the conventional man-
ner and sent to a preparation device (not shown). The prepared chocolate is
then sent to a conching machine 28. The resulting liquid chocolate is then
transferred to a tank 30 and then sent to a precooling device 32, in which the
chocolate is cooled to a temperature below its melting point. From the pre-
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cooling device) the supercooled chocolate flows by way of a tempering and/or
ultrasonic device 34, in which it is treated with ultrasound, to tanks 50,
only one of which is shown in the drawing for the sake of clarity. In tanks
50, the various types of chocolate are stored temporarily) separately from
each other. Any excess is sent back through a repeating device 38 to tank 30.
From containers 50, the chocolate mixtures are transferred to casting devices
36, as will be explained in more detail below. Then the chocolate is poured
by casting devices 36 into molds 40. Filled molds 40 pass through a cooling
channel 42, in which the chocolate mixtures are hardened. Then the molds con-
taming the cooled chocolate are transferred to an unmolding unit 44. The
finished chocolate slabs or bars are packaged in a packaging unit 46, stacked
on pallets, and stored in a warehouse 48.
The injection-molding of candy 1 is shown in Figure 6 in the form of a
schematic diagram of a detail within the overall system. The device shown in
this drawing for producing the one-piece) bar-shaped or slab-shaped chocolate
candy according to the invention has several containers 50, in which castable
mixtures 52 of different types of chocolate are held. Thus, a different type
of chocolate is provided in each container 50. Each of containers 50 is con-
nected by a feed line 54 to a casting device 36, which in the present case is
designed as a nozzle. The number of casting devices 36 therefore corresponds
to the number of different types of chocolate in containers 50. A number of
molds 40, furthermore, are arranged in a row in the flow direction. These
molds are connected to each other by ridges 56. One mold 40 is assigned to
each casting device 36. At least one device (not shown) for controlling the
temperature of the container is provided on each container. Similarly) cast-
ing devices 36 have control devices (not shown), by means of which the pres-
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sure and temperature of castable mixtures 52 as they emerge from the casting
devices 16 are controlled.
Castable mixtures 52, in the present case different types of chocolate,
are treated with ultrasound in tempering device 34 shown in Figure 5 and then
loaded into containers 50 shown in Figure 6. Each container 50 contains a
different type of chocolate or candy. Then castable mixtures 52 are sent
indirectly via feed lines 54 separately from each other to casting devices 36.
It is also possible, however, for castable mixtures 52 to flow directly from
containers 50 to casting devices 36. From the nozzles of casting devices 36,
castable mixtures 52 are injected as jets 58 simultaneously into molds 40. In
this way, molds 40 can be filled uniformly with the various types of chocolate
coming from the nozzles, so that a piece of chocolate is formed in each mold
40. Because all of the mixtures flow at the same rate, their edges come into
contact with each other at ridges 56 of-molds 40, where they join together to
form a one-piece chocolate slab but do not mix with each other. Thus, a dif-
ferent piece of chocolate 3 is formed in each mold 40, which ultimately forms
a part of the overall chocolate slab.
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