Note: Descriptions are shown in the official language in which they were submitted.
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Method and Apparatus for Making a Confectionery Product
The present invention relates to a method and apparatus for making a
confectionery
product. In particular, the invention relates to a method of shaping a
confectionery
product using a gas jet, and apparatus for use in the method.
Popular confectionery products include confectionery shells containing a
filling, for
example, a chocolate shell containing a caramel or other contrasting filling.
Chocolate shells are typically produced either by shell moulding or by cold
stamping.
In shell moulding (also referred to as mould inversion), a mould cavity in a
mould tray
is completely filled with molten chocolate then partially cooled so that the
chocolate
which is in contact with the mould cavity sets. The mould is then inverted and
shaken so that the molten chocolate in the centre of the mould pours out,
leaving
behind a chocolate shell. This process is not efficient since it requires a
large
amount of excess chocolate which must be re-used. The resulting shell may not
be
uniform, and the process is very messy.
Cold stamping is more efficient since it requires only a small amount of
excess
chocolate mass, and the resulting shells are often very uniform. In this
process,
molten chocolate is deposited into a mould and then pressed into shape using a
chilled stamp or die, which also functions to solidify the chocolate. The
stamp is then
removed, leaving a solid or semi-solid chocolate shell. However, this method
relies
on strengthened moulds and dies, thus requiring a high initial investment.
Another
problem is the risk of liquid condensing on the surface of the stamp, which
can be
extremely detrimental to the final product. To avoid this, the process must be
carried
out in a low-humidity atmosphere. Maintaining the stamp at a low temperature
(e.g.
0 C or less) also consumes large amounts of energy.
The present invention seeks to mitigate some of the problems described above.
According to a first aspect of the present invention, there is provided a
method of
forming a confectionery product, the method comprising
depositing molten or semi-solid confectionery into a mould and
shaping the confectionery while at least semi-solid by applying a gas jet
thereto,
wherein the temperature of the gas jet is lower than that of the
confectionery.
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According to a second aspect of the present invention, there is provided the
use of a
gas jet to shape molten or semi-solid confectionery.
By "shaping", it will be understood that the gas jet applies a force to the
confectionery
that is sufficient to displace the confectionery within the mould. In other
words, the
gas jet changes the overall 3-dimensional shape of the confectionery material
within
the mould. Since the temperature of the gas jet is lower than that of the
confectionery, the confectionery is simultaneously cooled.
The gas jet is applied to the confectionery until the confectionery is
solidified to an
extent that is sufficient for it to retain the shape imparted by the gas jet
once the gas
jet is no longer applied. In some embodiments, the gas jet is applied until
the
confectionery is partially solidified (i.e. semi-solid). Alternatively, the
gas jet may be
applied until the confectionery has completely solidified.
By using a gas jet to shape the confectionery, no equipment comes into contact
with
the confectionery other than the mould. The method avoids the need for a large
excess of confectionery material, as is required by shell moulding. It also
overcomes
the problem of providing a low-humidity atmosphere and is more energy-
efficient
since it does not rely on a low-temperature stamp, as required by cold
stamping.
It will be understood that the following statements may apply equally to the
first and
second aspects of the invention as appropriate, unless otherwise stated.
In some embodiments, the method comprises depositing molten confectionery into
the mould. In these embodiments, the gas jet is applied to the confectionery
until the
confectionery is at least partially solidified.
In some embodiments, the method comprises depositing confectionery in a semi-
solid state. As used herein, "semi-solid" will be understood as meaning that
the
confectionery is not entirely molten and that some solid crystals have formed
in the
confectionery mass, but that the confectionery is still flowable (for example,
having
similar flow properties to a tempered chocolate mass at 28 C).
In some embodiments, the method comprises applying at least 2, at least 4, at
least
6, at least 10 or at least 15 gas jets to the confectionery. It will be
appreciated that
the number, strength and direction of the gas jets, and the length of time for
which
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they are applied, will be selected according to factors including the desired
shape of
the confectionery product and the mass of the confectionery deposited. The use
of
two or more gas jets facilitates the shaping of the confectionery by providing
a more
even flow of gas, and by providing multi-directional forces on the
confectionery. It will
also be appreciated that multiple gas jets may be applied to a confectionery
mass
within a single mould cavity, or that each of a plurality of gas jets may be
applied to a
different mould cavity.
The gas jet(s) produces a gas bed, i.e. a 3-dimensional region of increased
pressure
(relative to ambient pressure), the force of which is sufficient to displace
the
confectionery within the mould cavity and cause it to be shaped. The force
imparted
by the gas jet on the confectionery must be sufficient to shape the
confectionery but
not so high that it entirely displaces the confectionery out of the mould or
creates
holes in the confectionery.
In some embodiments, the pressure of the gas jet(s) is at least 1.5 bar
(150000 Pa),
at least 2 bar (200000 Pa), at least 3 bar (300000 Pa) or at least 4 bar
(400000 Pa).
In further embodiments, the pressure is no more than 10 bar (1000000 Pa), no
more
than 8 bar (800000 Pa) or no more than 6 bar (600000 Pa). In preferred
embodiments the pressure is from 2 to 6 bar (200000 to 600000 Pa).
In some embodiments, the velocity of the gas in the gas jet(s) as measured at
the
point of exit of a gas outlet, aperture or nozzle is at least 2, 4, 6, 8, 10,
12, 14, 16, 18
or 20m/s. In further embodiments the flow rate is no more than 25, 20, 15 m/s,
12 or
10 m/s. In some embodiments the velocity is from 8 to 20m/s or from 15 to
20m/s.
It will be appreciated that the gas jet is applied to the confectionery for a
length of
time which is sufficient to form the confectionery into the desired shape
(without de-
tempering the mass in the case of chocolate), and to solidify the
confectionery to an
extent which allows the confectionery to retain that shape. Thus, the length
of time
the gas jet is applied will depend on the type and mass of the confectionery,
the
temperature of deposition of the confectionery (i.e. whether the confectionery
is
molten or semi-solid), the velocity/temperature of the gas jet and the shape
required.
In some embodiments, the gas jet is applied to the confectionery for at least
0.5
seconds, at least 1 s, at least 2 s, at least 3 s, at least 5 s or at least 8
s. In further
embodiments, the gas jet is applied to the confectionery for no more than 15,
10, 7,
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5, 3, 2.5 or 2s. In one embodiment the gas jet is applied to the confectionery
for from
1 to 3s
The gas jet may be applied continuously to the confectionery during the
shaping
process, or it may be pulsed with intervals of from 0.1 to 3 or from 0.5 to 1
seconds.
For example, the gas jet may be applied in bursts of from 0.5 to 5 seconds,
with
intervals of from 0.1 to 1 second.
The force applied to the confectionery during the shaping process may be
constant,
or it may be variable. In some embodiments, the pressure of the gas jet
remains
constant during the shaping process. In other embodiments, the pressure of the
gas
jet is increased or decreased during the shaping process, in order to vary the
force
applied to the confectionery until the desired shape is achieved. For example,
a gas
jet may be applied in 5 second bursts, the gas jet having an initial pressure
of 6 bar
(600000 Pa), which is linearly decreased to a pressure of 4 bar (400000 Pa).
The gas jet(s) may be provided by an apparatus comprising one or more gas
outlets.
It will be appreciated that the position of the gas outlets relative to the
confectionery
may be adjusted according to the type of confectionery, the pressure of the
gas and
the shape required. The force applied to the confectionery by the gas jets may
be
varied by changing (increasing or decreasing) the distance between the
mould/confectionery and the gas outlets, and/or by changing the pressure of
the gas,
as described above. In some embodiments, after the confectionery has been
deposited into the mould, the method comprises increasing the force applied to
the
molten confectionery by the gas jet(s). This may be achieved by reducing the
distance between the gas outlets and the confectionery within the mould, or by
increasing the velocity of the gas. In one embodiment the distance between the
confectionery and the gas outlets is from 5 to 100mm, from 10 to 50mm, from 15
to
30mm or approximately 20mm.
In some embodiments, a predetermined mass of confectionery is deposited into
the
mould. The mass deposited will depend on the size and shape of the desired
product. The mass of confectionery deposited may be equal to the mass required
to
form the product. In some embodiments, an excess mass of confectionery is
deposited into the mould. This takes into account the displacement of a small
amount of confectionery out of the mould during the shaping process.
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It will be appreciated that a "mould" may comprise a single cavity, or it may
comprise
multiple cavities. For example, a typical 620mm x 320 mm mould may comprise 12
cavities for moulding 100 g confectionery tablets.
5 To form
an individual centre-filled product, the mass deposited into the mould (or a
mould cavity of a multi-cavity mould) may be from about 2 to about 10 grams,
or from
about 3 to about 7 grams (e.g. about 6 grams). Alternatively, the mass
deposited
into the mould cavity may be from 15 g to 150 g, from 30 g to 100 g or from 50
g to
75 g (e.g. to form confectionery tablets). It will be appreciated that for
such relatively
large confectionery products, multiple gas jets may be applied to shape the
confectionery mass. These gas jets may be combined in order to form a single
shape (e.g. a single hollow) in the confectionery mass, or the multiple gas
jets may
be applied to form multiple shapes (e.g. a plurality of hollows) in the
confectionery
mass.
The gas may be any gas which is compatible with the confectionery, for example
air,
carbon dioxide or an inert gas such as nitrogen or argon. As used herein
"inert" will
be understood as meaning that the gas is unreactive with the confectionery
under the
conditions used. In particular embodiments, the gas is air.
The temperature of the gas jet is lower than that of the confectionery in
order to cool
and at least partially solidify the confectionery. In some embodiments, the
gas jet is
applied to the confectionery until the confectionery has partially solidified.
In such
embodiments, the method may further comprise cooling the shaped confectionery
until it has completely solidified. The cooling may be carried out at ambient
temperature or under reduced temperature, for example in a cooling tunnel. In
alternative embodiments, the gas jet is applied to the confectionery until the
confectionery has completely solidified. Partial (or complete) solidification
of the
confectionery in the mould allows the confectionery to retain its shape in the
absence
of the gas jet, and also prevents backflow of the confectionery caused by the
force of
the gas jet.
As will be appreciated by the skilled person, the temperature of the gas jet
must be
selected according the type of confectionery, the temperature of the
confectionery at
the moment of deposition, the shape formed and the extent of solidification
required.
For example, in embodiments wherein the gas jet is used to form a
confectionery
shell, the temperature of the gas jet will also depend on the shell thickness.
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However, the temperature of the gas jet should not be so low that the
confectionery
solidifies before it is shaped by the gas jet. In some embodiments, the
temperature
of the gas jet is from 0 C to 25 C, from 2 C to 20 C, from 3 C to 15 C
or from 5
C to 10 C.
In some embodiments the gas jet has a humidity of no more than 80%, no more
than
70% or no more than 60%. In further embodiments, the gas jet has a humidity of
less than 60%. Controlling the humidity of the gas jet helps to prevent the
formation
of condensation on the gas outlet or the mould.
In some embodiments, the gas jet is applied to the confectionery so as to form
a
hollow in the confectionery. This may be achieved by applying one or more gas
jets
towards the centre of the confectionery mass in the mould (or mould cavity)
such that
the confectionery is displaced outwardly and up the sides of the mould. In
this way, a
confectionery shell is formed.
In some embodiments, the method comprises shaping the confectionery by
applying
two or more gas jets in sequence. For example, a first gas jet (or a first
group of gas
jets) may be applied to the confectionery followed by a second gas jet (or
second/further group of gas jets). The second gas jet(s) may have a different
temperature, pressure and/or application time to the first gas jet(s). In some
embodiments, the method comprises applying a series of gas jets to the
confectionery, wherein each subsequent gas jet has a lower temperature, a
higher or
lower pressure, and/or is applied to the confectionery for a greater or lesser
amount
of time.
The method may further comprise depositing a filling into the hollow or shell.
The
filling may be deposited after the confectionery has been completely
solidified.
Alternatively, the filling may be deposited while the confectionery is still
partially solid.
In some embodiments, the filling is deposited less than 10 seconds, less than
5
seconds, less than 3 seconds or less than 2 seconds after the shaping of the
confectionery (i.e. after the gas flow is stopped). The filling may be
deposited by a
depositor which forms part of an apparatus comprising the gas outlets. The use
of
an apparatus which both provides the gas jets and deposits the filling allows
the
filling to be deposited almost immediately after the gas flow stops, thereby
improving
the efficiency of the process.
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The filling may be a solid (e.g. fruit, nuts), a liquid (e.g. liqueur) or a
paste (e.g.
fondant). It may be savoury or sweet. In particular, the filling may be a
sweet
material such as, but not limited to, marshmallow, caramel, toffee, chocolate,
fudge,
praline, mousse, fondant, nougat, Turkish delight, jelly, candy or honeycomb.
Some fillings, such as aerated fillings, form peaks when deposited into
confectionery
shells or hollows. Fillings of moulded confectionery products are
conventionally
flattened using vibration. However, vibration can cause aerated fillings to
lose
aeration. The present inventors have found that a gas jet can also be used to
flatten
fillings. Thus, in further embodiments, the method comprises applying a gas
jet to a
filling deposited in the shaped confectionery hollow so as to even out or
flatten the
filling. This is particularly advantageous for aerated fillings since the use
of a gas jet
avoids a loss of aeration.
In some embodiments, the method further comprises depositing molten or semi-
solid
confectionery onto the filled confectionery hollow or shell to form a back or
lid. The
confectionery which forms the back/lid may be the same as that which forms the
shell, or it may be different. For example, the shell may be formed from white
chocolate and the back/lid may be formed from dark chocolate. In a further
embodiment, a gas jet is applied to the confectionery in order to flatten or
smooth the
back/lid. This avoids the need for depositing an excess amount of
confectionery and
scraping away the excess to provide a smooth surface. The gas jet may also
serve
to at least partially solidify the back/lid.
In some embodiments, the filling and the confectionery which forms the lid of
the
product are deposited simultaneously using one-shot depositing. One-
shot
depositing is a commonly used technique in the art and will be known to a
skilled
person.
In some embodiments, the confectionery is chocolate. As used herein, the term
'chocolate' is intended to refer to chocolate compositions based on cocoa
butter, as
well as to chocolate-like compositions in which some or all of the cocoa
butter is
replaced by cocoa butter equivalent (CBE), cocoa butter substitute (CBS),
cocoa
butter replacer, a non-metabolisable fat, or a non-fat ingredient. Such
compositions
are well known in the art. Typically, the chocolate will be milk, plain or
white
chocolate.
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In some embodiments, the method is carried out using an apparatus in
accordance
with the third aspect of the invention, or a system in accordance with the
fourth
aspect of the invention.
According to a third aspect of the present invention there is provided a
system for
shaping confectionery, the system comprising a shaping apparatus having a body
comprising:
a gas inlet in fluid communication with at least one gas outlet for providing
at least
one gas jet; and
at least one depositor for depositing confectionery and/or filling material.
The shaping apparatus is capable of shaping deposited confectionery through
the
force of one or more jets of gas without any physical contact between the
confectionery and the apparatus. The shaping apparatus may thus be described
as
a "gas stamp". In use, the shaping apparatus may be positioned over a mould
tray
comprising one or more mould cavities containing confectionery so that the gas
jets
produced by the outlets contact the surface of the confectionery. Such a "gas
stamp"
is advantageous in that it reduces the amount of equipment that comes into
contact
with the confectionery, thereby reducing cleaning and reducing the possibility
of
contamination of the confectionery. The gas stamp also operates at ambient
temperatures, and does not require cooling like a conventional stamp for use
in cold
stamping. The energy requirements of the system of the invention are therefore
reduced compared to a conventional cold stamp.
The body may comprise a plurality of gas outlets. In some embodiments, the
body
comprises at least 2, at least 4, at least 6, at least 8, at least 10 or at
least 15 gas
outlets.
The gas outlet(s) may be connected to the gas inlet via one or more conduits
which
pass through the body of the shaping apparatus. In some embodiments, the body
comprises a pressure chamber situated between the gas inlet and the gas
outlet(s).
This helps to homogenize the velocity of the gas across the body of the
shaping
apparatus so that the velocity of the gas jet produced by each gas outlet is
substantially the same. The gas inlet may directly lead into the pressure
chamber.
Each gas outlet may be connected to the pressure chamber by a conduit.
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In some embodiments, the gas outlets are positioned in an exterior surface of
the
body. In some embodiments, the exterior surface of the body has a convex or a
concave shape. A convex or a concave surface may conveniently angle the gas
jets
relative to the confectionery in the mould to aid shaping of the
confectionery. In other
embodiments, the exterior surface of the body in which the gas outlets are
located is
substantially planar.
In some embodiments, the at least one depositor is constituted by a pipe
having at
least one opening through which confectionery and/or filling material is
released.
The body may comprise at least 2, at least 4, at least 6, at least 8, at least
10
depositors. Alternatively, the body may comprise a depositor having at least
2, at
least 4, at least 6, at least 8, at least 10 depositor openings therein.
The depositor opening(s) may be positioned in an exterior surface of the body.
For
example, the gas outlets and the opening(s) of the depositor may be flush
with, or
recessed in, the body of the apparatus.
In alternative embodiments, the gas outlets, and/or the depositor, may
comprise
nozzles which project beyond the exterior surface of the body.
In some embodiments, the exterior surface of the body comprises two or more
zones
or sectors, each of which comprises at least one depositor or depositor
opening, and
at least one gas outlet. The number and arrangement of zones may be arranged
according to the number and arrangement of mould cavities within the mould
tray.
For example, for each mould cavity there may be provided a corresponding zone
in
the exterior surface of the body. Alternatively, a single zone may serve two
or more
mould cavities.
It will be appreciated that the arrangement of the gas outlets in the exterior
surface of
the body will also be selected according to the shape of the confectionery
product
required. For example, where it is desired to produce a confectionery shell,
the gas
outlet(s) may be positioned in the body to align with the centre of the mould
cavity, so
that the gas jet produced is applied to the centre of the confectionery mass.
In some further embodiments, the shaping apparatus comprises at least two
bodies,
at least 4 bodies, at least 6 bodies, or a plurality of bodies (i.e. a
collection of
individual "gas stamps"), each comprising a gas inlet in fluid communication
with at
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least one gas outlet for providing at least one gas jet and at least one
depositor for
depositing confectionery and/or filling material. The number, size and
arrangement
of the bodies may be selected in accordance with the design of the mould tray.
For
example, each body may be configured to shape a mass of confectionery within a
5 single
mould cavity. Alternatively, a single body may be configured to shape the
confectionery deposited in multiple mould cavities. The bodies may be arranged
in
series in order to provide sequential gas jets which may have different
temperatures,
pressures or application times. For example, the apparatus may comprise a
first
body for providing a first gas jet at a first temperature, pressure or for a
first amount
10 of time,
and a second body for providing a second gas jet at a second temperature,
pressure or a second amount of time.
The gas outlets may have a cross section of any shape. For example, the cross
section of the gas outlets may be circular, square, rectangular, triangular,
elongate or
irregular in shape. In some embodiments, the gas outlets are circular. It will
be
appreciated that the diameter of the gas outlets, in addition to the flow rate
of the
gas, will influence the pressure of the gas jets provided by the outlets. In
some
embodiments, the diameter of the gas outlets is from 1 mm to 10 mm, from 2 mm
to
7 mm or from 3 mm to 5 mm.
The angle at which the gas jet is applied to the confectionery will influence
the shape
of the confectionery. In some embodiments, the or each gas outlet is parallel
to, or
aligned with, the exterior surface of the body (i.e. the angle of the outlet
is 0 relative
to the exterior surface of the body). Thus, when in use the body is held
substantially
horizontally and positioned directly above (and parallel to) a mould, the gas
jet will be
applied perpendicularly to the surface of the confectionery. In further
embodiments,
the or each gas jet is angled relative to the exterior surface of the body.
Thus, when
the body is held horizontally and positioned vertically above (and parallel
to) a mould,
the gas jet will be angled relative to the surface of the confectionery. The
angle of
the outlet may be from 0 to 90 relative to the exterior surface of the body.
In some
embodiments, the angle of the outlet is at least 10 , at least 20 , at least
30 or at
least 40 , relative to the exterior surface of the body. In other embodiments,
the
angle of the outlet is 0 . Where at least two gas outlets are provided, the
gas outlets
may be angled differently to each other. For example, one or more gas outlets
may
have an angle of 0 relative to the exterior surface of the body, while one or
more
other gas outlets has an angle of more than 0 relative to the exterior
surface of the
body. The use of multiple outlets with different angles results in the
application of
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gas jets to the confectionery from slightly different directions. This
facilitates shaping
of the confectionery.
In some embodiments, the shaping apparatus and/or the system comprises a
temperature control means for controlling the temperature of the body.
Controlling
the temperature of the body may be useful to prevent a change in the
temperature of
the gas as it passes through the body between the gas inlet and outlets.
In some embodiments, the shaping apparatus and/or the system comprises a
temperature control means for controlling the temperature of the gas. It may
be
desirable to heat the gas (for example, if the gas is very cold at the point
of supply)
so that the gas jet does not solidify the confectionery before it has been
shaped.
Alternatively, it may be desirable to cool the gas to accelerate
solidification of the
confectionery. The temperature control means may thus comprise a heater and/or
a
chiller. The use of a gas jet to both shape and solidify the confectionery is
particularly advantageous since it mitigates the need for an additional
cooler. Thus,
in some embodiments, the gas jet also constitutes a cooler. The temperature
control
means may further comprise a thermometer for measuring the temperature of the
gas, and/or a controller for controlling the heater and/or the cooler. For
example, the
temperature control means may be provided on a line between the source of gas
and
the stamp.
The system may further comprise a source of a confectionery and/or filling
material in
fluid communication with the depositor(s) of the body of the shaping
apparatus, for
example via at least one pipe. For example, the confectionery/filling may be
supplied
to the depositor via one or more lines which connect the depositor to a tank
in which
the confectionery/filling is stored. In embodiments wherein the confectionery
is
chocolate, the chocolate may pass through a temperer prior to being supplied
to the
depositor. The mass of confectionery/filling deposited may be regulated either
by
valves or by a valve/piston combination, as is conventional in the art.
The system may additionally comprise a source of gas in fluid communication
with
the gas inlet of the body of the shaping apparatus, for example via at least
one gas
line. The flow of gas between the source of gas and the body may be controlled
by
at least one valve. The source of gas may be pressurised. The velocity of the
gas in
the gas jet(s) may be controlled by one or more valves.
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The system may further comprise a mould. The mould may be any standard mould
tray used in the industry, comprising at least one mould cavity. The mould
tray may
be made from any suitable material, for example polycarbonate. In
some
embodiments the mould tray comprises a plurality of mould cavities. The mould
tray
may comprise at least 10, at least 20, at least 50 or at least 100 cavities.
The depositor may be arranged to deposit confectionery and/or filling material
into
the mould. For example, the body of the shaping apparatus may be positioned so
that the or each depositor is directly above the mould, or that the opening(s)
of the or
each depositor corresponds to the position of the mould cavities.
Similarly, the gas outlets may also be arranged to direct a gas jet towards
the mould
cavity. In some embodiments, the body of the shaping apparatus is arranged so
that
the gas outlets are positioned directly above the mould, or so that one or
more gas
outlets is positioned directly above each mould cavity. The gas outlets may be
positioned at a distance of from 5 mm to 300 mm, from 10 mm to 200 mm, or from
25
mm to 50 mm from a top surface of the mould. In further embodiments, the body
of
the shaping apparatus is arranged so that the gas outlets are positioned below
a top
surface of the mould (i.e. within the mould cavity).
In some embodiments, the system further comprises a movable support on which
the
shaping apparatus is mounted. This allows vertical and/or horizontal movement
of
the shaping apparatus, so that the distance between the gas outlets and the
mould
can be adjusted. The moveable support allows the shaping apparatus to be moved
(e.g. lowered/raised) towards or away from the mould tray before and/or during
the
application of the gas jets to the confectionery. Lowering of the shaping
apparatus
towards the mould during the shaping process increases the control over the
shaping
process by gradually increasing the force/pressure applied to the
confectionery by
the gas jets. This is particularly advantageous where the confectionery is
being
shaped into a shell since it enables gradual building of the hollow.
The mould itself may also be movable. In some embodiments, the system further
comprises a conveyor on which the mould, or a plurality of moulds, is
positioned. In
use, the conveyor may transport the moulds until they are positioned beneath
the
shaping apparatus and the mould cavities are aligned with the gas outlets.
After the
confectionery has been shaped by the gas jets, the conveyor may transport the
moulds to the next stage of the process, for example filling, further coating
or cooling.
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The system may further comprise a cooler. A cooler may be required to complete
the solidification of the confectionery in embodiments where the gas jets only
partially
solidify the confectionery. In some embodiments the cooler is a cooling
tunnel.
However, as mentioned above, the gas jet(s) may also function to cool and
solidify
the confectionery, in which case an additional cooler may not be required.
Thus, in
some embodiments, the shaping apparatus does not comprise a separate cooler
(other than the gas jets themselves).
Embodiments of the invention will now be described with reference to the
accompanying figures in which:
Figure 1 is a schematic side cross-sectional of a system comprising a shaping
apparatus and a mould tray;
Figure 2 is a schematic underside view of the shaping apparatus of Figure 1;
Figure 3-6 show the system of Figures 1 and 2 in use;
Figure 3 is a schematic side cross-sectional view of the system of Figure 1,
prior to
shaping a chocolate mass deposited in the mould tray;
Figure 4 is a schematic side cross-sectional view of the system of Figure 1,
being
used to form a hollow in the chocolate, thereby providing a shell;
Figure 5 is a schematic side cross-sectional view of the system of Figure 1,
during
deposition of a filling material into the chocolate shell; and
Figure 6 is a schematic side cross-sectional view of the system of Figure 1,
after
deposition of the filling material into the shell.
Figures 1 and 2 show an embodiment of a system in accordance with the present
invention comprising a shaping apparatus 10 and a mould tray 23. The shaping
apparatus 10 has a body 12 comprising a gas inlet 14, two depositors 16 and a
plurality of gas outlets 18. The depositors 16 are constituted by tubes 20
which pass
through the body 12 and which are connected to a source of confectionery and
filling
material (not shown). The depositors 16 have terminal openings 22 from which
confectionery or filling material is deposited into a mould tray 23. Gas
entering the
body 12 through the gas inlet 14 is received into a pressure chamber 24. The
pressure chamber is connected to the gas outlets 18 via a series of conduits
26.
The body 12 has a planar lower surface 28 in which the gas outlets 18 and the
depositor openings 22 are located. As shown in Figure 1, the gas outlets 18
and the
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depositor openings 22 are flush with the lower surface 28 of the body 12,
although it
will be appreciated that it alternative embodiments the openings 22 and/or gas
outlets 18 may protrude from, or be recessed into, the body 12. As can be seen
from
Figure 2, the lower surface 28 of the body 12 comprises two identical zones
30, each
zone 30 containing a central depositor opening 22 and half of the gas outlets
18,
which are arranged in a regular pattern around the depositor opening 22.
In the embodiment shown in Figure 1, molten or semi-solid chocolate 32 is
deposited
through the openings 22 of the depositors 16 and into the empty mould cavity
34 of
the mould tray 23. In alternative embodiments, chocolate (or other
confectionery)
may be deposited into the mould cavity 34 prior to the mould tray 23 being
positioned
beneath the apparatus 10.
A method of forming a confectionery product, using the system described
herein,
may be carried out as follows. Once the chocolate 32 has been deposited into
the
mould cavity 34 and is positioned directly beneath the shaping apparatus 10,
the
shaping apparatus 10 is moved downwardly towards the mould 23 (in the
direction of
the arrow, Al), as shown in Figure 3. At the same time, gas jets 36 are
produced
from the gas outlets 18. In the embodiment shown, the direction of the gas
flow is
perpendicular to the lower surface 28 of the body 12, and perpendicular to an
upper
surface 38 of the mould 23.
The shaping apparatus 10 is moved downwardly until the body 12 is partly is
received within the mould cavity 34 but the lower surface 28 of the body 12 is
not in
contact with the chocolate 32 therein, as shown in Figure 4. This results in
the
formation of a gas bed 38, i.e. a region of increased pressure between the
surface of
the chocolate 32 and the lower surface 28 of the body 12, which displaces the
chocolate outwardly and up the sides of the mould cavity 34. Since the
temperature
of the gas jets 36 is lower than the temperature of the chocolate 32 at the
time of
deposition, the chocolate 32 is cooled by the gas and starts to solidify. The
chocolate is thus shaped into a shell 40 by the shaping apparatus 10, which
acts as a
gas stamp, without physical contact between the chocolate 32 and the surface
28 of
the stamp.
After shaping of the chocolate shell 40, filling material 42 is released into
the
chocolate shell 40 through the depositors 16, as shown in Figure 5. The
shaping
apparatus 10 is moved away from the mould tray 23, in the direction of the
arrow A2.
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The shaping apparatus 10 may be moved before, after, or at the same time as
deposition of the filling material 42. A chocolate shell 40 containing a
filling material
42 is thereby produced, as shown in Figure 6.
5
Example 1: Proof of concept
The use of a gas jet to form a chocolate shell was tested. Molten milk
chocolate was
deposited into one of a plurality of hemispherical mould cavities within a
mould tray,
until the cavity was approximately half filled. An air tube providing a stream
of air (i.e.
10 a gas jet), having a pressure of 6 bar and a temperature of 20 C, was
positioned
directly above the centre of the chocolate mass. The air tube was then lowered
by
hand towards the mould until the pressure of the air was sufficient to cause
displacement of the chocolate within the mould cavity. At this point the
distance
between the tip of the tube and the top surface of the mould was 5 mm. The
stream
15 of air was applied for 3 seconds, until the chocolate was displaced up
the sides of the
mould cavity, forming a hollow, and until the chocolate was partially
solidified. After
the air tube was lifted away from the mould, the chocolate retained the shape
imparted by the gas jet, thereby providing a chocolate shell into which
filling material
could subsequently be deposited.
Example 2
An air rig was employed to provide compressed air (6 bar, 20 C) at controlled
pressure and flow rates. Tempered chocolate was deposited into hemi-spherical
moulds and an air jet was applied from a nozzle having a single central hole
held
2cm from the chocolate. The speed to the air jet was increased to determine
when
the chocolate began to yield.
Comparative example 1 Example 2
Volumetric
flow 0.000385 (=23 litres per 0.000667 (=40 litres per
(m3/s) minute) minute)
Nozzle radius (m) 0.0035 0.0035
Nozzle area (m2) 0.0000385 0.0000385
Distance (m) 0.02 0.02
Mould radius (m) 0.02 0.02
Speed (m/s) 10 17.3
Comment Chocolate does not yield Yielding starts
It can be seen that a speed of 17m/s for 2s allowed the chocolate to yield.
The
chocolate was displaced up the sides of the mould, forming a hollow. The shape
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remained after the jet was removed and thereby formed a chocolate shell into
which
filling material could subsequently be deposited.
It was noted that the single hole nozzle displaced the chocolate in the centre
of the
cavity quickly and pushed the rest of the chocolate up the sides of the mould.
Hence
the resulting shell was thinnest at its midpoint and thicker at the walls.
Example 3
Example 2 was repeated but instead of holding the nozzle at a fixed distance
from
the chocolate, the nozzle was moved upwards (away from the chocolate) during
shaping. In this way the speed impact at the centre was reduced and the air-
flow
spread more to the sides creating a more even thickness of shell.
Example 4
Example 2 was repeated with a different nozzle in place of the single hole
nozzle.
The new nozzle has 8 holes arranged to form the circumference of a circle.
This
nozzle created a more equal pressure on the surface of the chocolate leading
to a
shell of more even thickness.
Example 5
Example 2 was repeated with a mould having a rectangular cross-section instead
of
a circular cross-section. Although a shell was obtained, the shell thickness
was
uneven; the sides nearest to the nozzle were thicker than those further away.
The
inventors propose an elongated slot nozzle to match the shape of the mould.
30
