Note: Descriptions are shown in the official language in which they were submitted.
1
Apparatus for and method of processing a confectionery product
Field
The present invention relates to an apparatus for, and a method of,
processing, at least in part,
a confectionery product.
Background to the invention
Generally, the textural properties, for example smoothness, of confectionery
products such as
chocolate contribute, at least in part, to a quality thereof, Hence, for
example, a goal of refining
of chocolate paste, a precursor of the chocolate, is to achieve a target
particle size distribution
of the refined chocolate paste so as to achieve a desired smoothness. However,
natural
variability of the ingredients of chocolate paste may result in batch-to-batch
variability of the
refined chocolate paste, such that some batches fail to meet quality criteria
and/or further
refining is required, thereby increasing wastage and/or process inefficiency
such that
throughput is decreased.
Hence, there is a need to improve processing of confectionery products, for
example so as to
improve batch-to-batch variability while increasing throughput.
Summary of the Invention
It is one aim of the present invention, amongst others, to provide an
apparatus for, and a
method of, processing, at least in part, a confectionery product which at
least partially obviates
or mitigates at least some of the disadvantages of the prior art, whether
identified herein or
elsewhere. For instance, it is an aim of embodiments of the invention to
provide such an
apparatus and/or such a method that decreases batch-to-batch variability while
increasing
throughput. For instance, it is an aim of embodiments of the invention to
provide such an
apparatus and/or such a method that improves a quality of the confectionery
product.
A first aspect provides an apparatus for processing, at least in part, a
confectionery product,
comprising:
a set of mixers, including a first mixer, for mixing one or more ingredients
to provide a
composition, wherein the composition is a precursor for the confectionery
product; and
a set of refiners, including a first refiner and optionally a second refiner,
for refining, at least in
part, the composition to provide a refined composition;
wherein the apparatus further comprises:
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a set of sensors, including a first sensor configured to determine a first
process output of the
set of mixers, of the mixing and/or of the composition; and
a controller configured to control a first process input of the set of
refiners based, at least in
part, on the determined first process output using a control model, wherein
the control model
relates the determined first process output, a first target property of the
set of refiners, of the
refining and/or of the refined composition and the first process input of the
set of refiners.
A second aspect provides a method of controlling, at least in part, processing
of a
confectionery product, comprising:
mixing one or more ingredients to provide a composition, wherein the
composition is a
precursor for the confectionery product; and
refining, at least in part, the composition to provide a refined composition;
wherein the method further comprises:
determining a first process output associated with the mixing and/or of the
composition; and
controlling a first process input for the refining based, at least in part, on
the determined first
process output using a control model, wherein the control model relates the
determined first
process output, a first target property associated with the refining and/or of
the composition
and the first process input for the refining.
A third aspect provides a tangible non-transient computer-readable storage
medium having
recorded thereon instructions which when implemented by a computer device
including a
processor and a memory, cause the computer device to perform a method
according to the
second aspect,
Detailed Description of the Invention
Apparatus
The first aspect provides an apparatus for processing, at least in part, a
confectionery product,
the apparatus comprising:
a set of mixers, including a first mixer, for mixing one or more ingredients
to provide a
composition, wherein the composition is a precursor for the confectionery
product; and
a set of refiners, including a first refiner and optionally a second refiner,
for refining, at least in
part, the composition to provide a refined composition;
wherein the apparatus further comprises:
a set of sensors, including a first sensor configured to determine a first
process output of the
set of mixers, of the mixing and/or of the composition; and
a controller configured to control a first process input of the set of
refiners based, at least in
part, on the determined first process output using a control model, wherein
the control model
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relates the determined first process output, a first target property of the
set of refiners, of the
refining and/or of the refined composition and the first process input of the
set of refiners.
In this way, the first process output of the set of mixers is fed forward to
the set of refiners,
which is downstream of the set of mixers, thereby enabling dynamic, proactive
control of the
set of refiners to thereby increase a throughput of the refined composition
and/or improve the
refining, for example improve a particle size distribution of particles
included in the composition
that are refined by the refining. In other words, responsive to monitoring of
the upstream
mixing, the refining is controlled, for example adjusted, accordingly, thereby
accounting for
variability in the ingredients, for example. In this way, batch-to-batch
variability is improved
because the first target property for each batch is achieved individually,
thereby accounting for
natural variability of the mixed ingredients. Furthermore, by improving the
batch-to-batch
variability to meet desired quality criteria, wastage and/or further refining
is reduced and/or
avoided, such that throughput is increased,
Conventional control of the refining is only reactive to assessment of the
refined composition,
which is thus only after the refining has been completed and hence such
conventional control
cannot influence and/or benefit the already refined composition. Furthermore,
such
conventional control is typically only manually implemented. While this
conventional control
may benefit a subsequent batch, for example, batch-to-batch variability of the
ingredients, for
example, may nullify such retrospective conventional control, which may be
even contrary to
the required control for the subsequent batch. Typically, to account for batch-
to-batch
variability of the ingredients, a predetermined excess degree of refining may
be performed so
as to ensure that all batches meet a desired particle size distribution, for
example. In other
words, the predetermined excess degree of refining accounts for expected batch-
to-batch
variability of ingredients, for example, and thus represents over-refining for
a proportion of the
batches.
In contrast, the inventors have identified that parameters of the mixing of
the composition are
indicators of the required refining for that particular composition, for
example batch thereof,
Hence, by determining such parameters (i.e. the first process output) of the
mixing of that
particular composition, the refining may be controlled specifically for that
particular
composition. In this way, refining of the particular composition to the
desired particle size
distribution, for example, may be performed more efficiently since the
refining may be
controlled appropriately for that particular composition, for example to start
the refining with a
larger particles and/or with smaller particles. In this way, a throughput of
the refining may be
increased since each composition may be refined individually to the desired
particle size
distribution, for example, rather than refining each composition (i.e. batch)
by the
predetermined degree of refining.
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In one example, the apparatus is for processing, at least in part, a batch of
the confectionery
product (i.e. patch processing c.f. continuous processing).
Confectionery product
In one example, the confectionery product comprises and/or is chocolate.
Generally, a process of making chocolate comprises mixing of ingredients of
the chocolate in a
mixer (also known as a paster), to provide a paste (i.e. the composition) and
refining (i.e,
reducing) of a particle size of the paste.
The particle size of the as-mixed composition is typically in a range from
about 700 to about
3000 pm and the consistency of the as-mixed composition is typically described
as coarse or,
as far as a semi-liquid is concerned, as having low viscosity.
Refining is typically a two-stage process including:
1. Pre-refining, in which the particle size distribution of the composition is
reduced by passing
the composition through a gap (also known as a nip) between rollers in a two-
rolls refiner (also
known as a pre-refiner). The gap is typically adjustable, for example in a
range from about 100
pm to about 300 pm, The pre-refiner serves to adjust the composition's (for
example the
paste's) rheological properties and reduce particle size; and
2, Refining, in which the particle size distribution of the composition is
then further reduced to
required specification by passing the composition similarly through one or
more sets of five-
rolls refiners (i.e. one or more steps of refining). For example, the pre-
refined composition (for
example paste) is supplied to one or more five-rolls refiners, which include
five pressed rolls
stack having different rolls temperatures, which serve to achieve the required
product fineness
(i.e. particle size distribution of the refined composition) and which
typically delimits a
throughput of the process. In other words, this second stage of the refining
is typically the rate
determining step and may be thus parallelized to increase throughput.
Refining is typically the final particle size control step, before the refined
composition is
supplied to one or more conching units.
After (i.e. as a result of) pre-refining, the particle size distribution of
the composition is typically
about 250 pm or less and the pre-refined composition may be described as a
semi-liquid, a
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paste or dough-like. After refining, the particle size is typically 30 pm or
less and the refined
composition (also known as flake) may be described as a powder having a fluffy
structure.
Particle size distribution
It should be understood that the composition comprises particles, having a
first (i.e. an initial)
particle size distribution (PSD) which is modified by the refining to a second
(i.e. refined)
particle size distribution of the refined composition. Generally, the refining
reduces a mean, a
median (i.e. D50), a mode and/or another characteristic such as D90 of the
first particle size
distribution and/or reduces a standard deviation (SD), a variance (var) and/or
a span (D90 ¨
D10) / D50 of the first particle size distribution. In one example, the
composition comprises
particles having the first (i.e. initial) particle size distribution and the
refined composition
comprises particles having a second (i.e. refined) particle size distribution,
wherein a 050, a
D90, a SD, a var and/or a span of the second PSD is less than of the first
PSD.
Typically, there is a target particle size for the composition after each
stage of pre-refining and
refining, including the one or more steps of refining. It is, moreover,
desirable to achieve a low
variability in the particle size and optionally, a low variability in
rheological properties of the
pre-refined composition. Particularly, a high variability in the particle size
and optionally, the
rheological properties causes variability In a quality of the final product
(i.e. the confectionery)
and/or reduces a yield of downstream refiners. In more detail, the particles
take up fat
depending on their size, physical properties and/or chemical properties. Thus,
the particle size
has an influence on the rheological properties of the composition. In
particular, for a small
particle size, a total surface area is increased such that more fat can be
taken up, whereby the
composition becomes "more solid" and a viscosity thereof is increased.
Consequently,
variations in the particle size affect the rheological properties of the
composition. Thus, a low
variability in particle size is desirable to attenuate variations in the
rheological properties of the
composition. However, even for a given particle size, the rheological
properties of the
composition may still vary due to differences in physical and/or chemical
properties of the raw
materials (i.e. the ingredients), for example from batch-to-batch due to
different natural sources
of the raw materials.
Particle size distributions of the composition and of the refined composition
may be measured
using a Mastersizer 3000 (RTM) with Hydro MV dispersion unit (Malvern
Panalytical Ltd, UK),
according to the manufacturer's instructions, following ultrasonic pre-
dispersion of samples
thereof in an organic solvent.
Paste
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In one example, the composition comprises and/or is a paste.
Generally, a paste may be defined as a mixture of a solid phase and a liquid
phase or
alternatively, as a dense suspension, exhibiting properties between liquid and
solid. Many
pastes retain their shapes against gravity, like solids. However, at high
shear stresses, pastes
begin to flow, thereby implying a yield stress i.e. a critical stress for
transition from solid-like to
fluid-like behaviour. Furthermore, most of these pastes exhibit thixotropic
behaviour, such that
their viscosities decreases with time, suggesting structure breakup,
Quality of chocolate
Generally, textural properties of chocolate include:
1. hardness in the mouth: the strength required to break off chocolate with
the teeth and
tongue;
2. meltability: the way in which chocolate melts completely in the mouth;
3. smoothness: the degree of roughness or grittiness experienced when
chocolate melts
in the mouth;
4. stickiness: the degree to which the mixture of melted chocolate and saliva
sticks to the
tongue and palate.
These textural properties contribute, at least in part, to a quality of the
chocolate. Hence, by
improving one or more of these textural properties, the quality of the
chocolate may be, in turn,
improved. For example, the smoothness and hence quality of the chocolate may
be improved
by refining the particle size distribution to a desired, refined particle size
distribution.
Rheology of chocolate
These textural properties of chocolate are determined, at least in part, by
the rheological
properties and/or particle size distribution of chocolate. Hence, controlling
the rheological
properties and/or particle size distribution of chocolate is important in
order to control, for
example consistently maintain or improve, the textural properties of the
chocolate. However,
the rheology of chocolate is complex, as detailed below, with significant
interplay between
variables. Furthermore, since the raw ingredients for chocolate are sourced
naturally, further
variability is introduced into the process of chocolate making, for example
from batch-to-batch.
Chocolate is rheologically complex both above and below its broad melting
range. Chocolate
shows semi-solid behaviour at room temperature (20 to 25 C). Chocolate melts
into liquid
form (strictly, a dense suspension of non-colloidal particles) at temperatures
very close to oral
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temperature that is about 30 to 32 C. At room temperature, chocolate
typically comprises
about 10% liquid cocoa butter but this increases to 100% when the chocolate is
fully molten
above 35 C. Generally, chocolate contains about 70% of solid sugar, some
cocoa solids and
crystalline cocoa butter, which are dispersed in a continuous fat-phase cocoa
butter. Different
commercial chocolates can be found and are categorized into three primary
groups that differ
in content of cocoa solids, milk, and cocoa butter: dark chocolate, milk
chocolate, and white
chocolate, Cocoa butter is extracted from cocoa mass (ground cocoa beans) by
pressing,
Cocoa butter triglyceride is mainly formed from Palmitic (P), Stearic (S), and
Oleic (0) fatty
acids. Due to the presence of these triglycerides, cocoa butter is forms six
different crystal
structures with different melting behaviours. Chocolate crystallinity is
greatly influenced by
temperature treatment during processing, fat content, and triglycerides type.
Usually,
chocolates are made by pouring or extruding melt chocolate into a mould at
temperature
around 30 C and cool down to retain the desired shape.
Rheologically, 'liquid' chocolates demonstrate non-Newtonian behaviour with a
yield stress
and plastic viscosity (stress to keep fluid in motion) with mild shear-
thinning characteristics.
Plastic viscosity may also be known as plasticity. The rheological behaviour
of chocolate is
influenced by fat content, emulsifier for example lecithin and/or polyglycerol
polyricinoleate
(PGPR) content, water or moisture content, conching time, crystallization,
particle size
distribution and temperature. Generally, a lower amount of fat results in
higher yield stress
values and/or higher viscosities. Surfactants further influence chocolate
rheology. Addition of
lecithin at low concentrations (below 3 wt.%) reduces both yield stress and
viscosity. At 0.1-0.3
wt.%, lecithin and optionally PGPR, has a viscosity decreasing effect similar
to that achieved
by adding 1-3 wt.% cocoa butter. After around 5 wt.%, addition of more
lecithin increases the
yield stress while the plastic viscosity of the melt continues to drop. The
addition of only a
(very) small quantity of water is sufficient for the plastic viscosity and
yield stress to increase
significantly. Particle size distribution is another important parameter,
which plays a role in
chocolate rheological behaviour. Particularly, the size distribution of the
solid particles greatly
influences the rheological properties of chocolate: the larger the particles,
the lower the yield
value, and also the lower the viscosity, but to a lesser extent. Cocoa
particle size varies from
15 to 30 pm. A bimodal particle size distribution with a small amount of fine
and large amount
of coarse particles may reduce the apparent viscosity. An increase in
temperature above the
melting point of fat will cause the plastic viscosity to decrease but the
yield stress to rise.
Conching mainly affects the yield stress, which decreases considerably
particularly during the
first hours of conching.
Chocolate having a relatively low plastic viscosity is easier to pump while
chocolate having a
relatively low yield stress pours more easily into moulds.
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Liquid chocolate for producing solid moulded bars typically has a plastic
viscosity in a range
from about 1 to about 20 Pa.s and a yield stress in a range from about 10 to
about 200 Pa.
Liquid chocolate for enrobings typically has a plastic viscosity in a range
from about 0,5 to
about 2.5 Pa.s and a yield stress in a range from about 0 to about 20 Pa.
Particle sizes of chocolate and chocolate products strongly influence the
mouth feel of the
chocolate product ¨ a very small particle size produces a "smooth" sensation
in the mouth. To
achieve the desired quality, not only the careful testing of final products,
but also the
monitoring of the production process is desirable. Particularly, the presence
of particles larger
30 pm is a critical quality parameter for chocolate.
Semi-solid food fats, such as chocolate mass, typically include discrete
crystalline particles in a
liquid fat chocolate mass. There is some loose adhesion between the
crystalline particles,
which breaks down rapidly when the fat a shear stress is applied. This is
referred herein as
plasticity. Important factors in the context of measuring plasticity include
(i) content of solids;
(ii) size and shape of crystalline particles; (iii) persistence of crystalline
particles nuclei when
changing temperature; and (iv) mechanical working of the fats. Further, a
texture of the
chocolate mass is governed by the measured plasticity. The quality, which is
in chocolate
production also referred as "tenderness" is essentially dependent upon the
measured
plasticity. The maximum attainable degree of tenderness is often an important
attribute for the
best chocolate quality. Loss of moisture decreases plasticity. Thus,
quantitative measurements
of plasticity can be used for control of quality, in particular in large scale
chocolate production
lines. Plasticity can be measured in different ways. For example, the hardness
of the fat at
different temperatures can be measured, e.g. using a penetrometer, such as a
,Humboldt
penetrometer. Plasticity measurement can also be used for controlling the
effectiveness of
tempering in solid chocolate mass based upon measurements with a sensitive
penetrometer.
Other measurements can also be used to measure surface hardness.
Characteristics and
quality of liquid chocolate mass critically depend upon viscosity, while the
texture of the
solidified chocolate mass is also governed by plasticity. However, the two
properties are
related, Specifications for different grades of the chocolate mass during the
controlling of the
production cycle can include the viscosity of the liquid chocolate mass
determined at
temperatures somewhat above its melting point, e.g. by a viscometer.
Measurement of theological properties
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Measurement of the rheological properties of cocoa and chocolate products may
be according
to IOCCC (International Office of Cocoa, Chocolate, and Sugar Confectionery),
"Viscosity of
Cocoa and Chocolate Products (Analytical Method: 46)," CABISCO, Brussels,
2000.
Chocolate masses are melted in a water bath at 50 C and thermostated for 20
min at 40 C
prior to the measurement in a rotational viscometer Model DV-III+ Digital
Rheometer,
Brookfield Engineering Laboratories (USA) with Spindle SC4-14, at 40 C and
within the 1-50
rpm range, according to the manufacturer's instructions. The viscometer is
operated by using
the Rheocalc V3.2 software which is also used for data analysis.
Rheological parameters: Casson plastic viscosity and Casson yield stress are
calculated using
NCA/CMA Casson model:
(1 + = 2,FT-o- (1+a),F4D
where;
a is spindle outer radius/measurement cup inner radius ratio;
T is shear stress (Pa);
To is yield stress (Pa);
is plastic viscosity (Pas); and
D is shear rate (s-1).
Statistical analysis is performed using software Statistica 7Ø
Different important rheological models have been used to characterize the
rheological
behaviour of chocolate melts including the Herschel¨Bulkley, Casson, Bingham,
and Carreau
models. Although the Casson is the recommended model by IOCCC (International
Office of
Cocoa, Chocolate, and Confectionery), it has been reported that it is not able
to accurately
characterize chocolate melt behaviour at low shear rates and other known
models may be
used.
Apparatus
The apparatus is for processing, at least in part, the confectionery product,
for example
chocolate.
It should be understood that the apparatus may be suitable, more generally,
for processing
other products, such as paints and/or pharmaceuticals, that are similarly
processed by mixing
ingredients and subsequent refining. Hence, more generally, in one example,
the apparatus is
for processing, at least in part, a product, for example a confectionery
product, a paint or a
pharmaceutical product.
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Precursor
The composition is a precursor for the confectionery product. That is, the
confectionery
product is derived, at least in part, from the composition. For example, the
confectionery
product may be produced directly from the refined composition, for example
without further
processing thereof. For example, the confectionery product may be produced
indirectly from
the refined composition, for example following further processing thereof. For
example, the
refined composition may be an ingredient of the confectionery product.
Set of mixers
The apparatus comprises the set of mixers, including the first mixer, for
mixing one or more
ingredients to provide the composition.
Generally, the ingredients are mixed for a period of time, so as to improve a
homogeneity of
the composition, for example by dispersing particles relatively more uniformly
therein. A
rheology of the mixture (i.e. the composition, for example a paste) may vary
with process
figures such as characteristics of the ingredients, temperature of services
(for example,
temperature of water for controlling mixing temperature) and/or residence time
(i.e. the period
of time of mixing).
In one example, the first mixer comprises and/or is a jacket mixer (also known
as a jacketed
mixer). Generally, jacket mixers are heated, for example by a water jacket, to
a temperature in
a range from 40 C to 45 C Other mixers are known.
In one example, the set of mixers includes a second mixer, similar to and/or
the same as the
first mixer. In one example, the first mixer and the second mixer are arranged
mutually in
series, such that the composition is mixed successively by the first mixer and
the second
mixer. In one example, the first mixer and the second mixer are arranged
mutually in parallel,
such that a first portion of the composition is mixed in the first mixer and a
second portion, for
example a remaining portion, of the composition is mixed in the second mixer.
In one example,
the set of mixers includes M mixers, including the first mixer, wherein M is a
natural number
greater than or equal to 1, for example 1,2, 3, 4, 5, 6, 7, 8, 9 or more. In
one example, the M
mixers are arranged mutually in series and/or mutually in parallel.
Ingredients
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In one example, the one or more ingredients include one or more of cocoa
and/or a derivative
thereof for example cocoa liquor, chocolate crumb and/or cocoa butter, milk
powder, fat, sugar
and/or an emulsifier and any combinations of these.
Set of refiners
The set of refiners includes the first refiner and optionally the second
refiner, for refining, at
least in part, the composition to provide a refined composition.
In one example, the first refiner comprises and/or is a pre-refiner, for
example a two-rolls
refiner, having a controllable and/or an adjustable gap, for example in a
range from about 100
pm to about 200 pm, a controllable and/or an adjustable pressure and/or a
controllable and/or
an adjustable speed, so as to control and/or adjust a particle size
distribution of the pre-refined
composition. For example, a particular gap may be provided and/or maintained
by controlling a
corresponding pressure, such as sufficient pressure to maintain a gap defined
by a stop. For
example, by increasing the speed, for example the differential speed, of the
rolls, a particle
size distribution of the pre-refined composition may be refined. Particularly,
increasing a speed
of one of the rolls, while maintaining a speed of the other rolls, will
increase throughput and
hence particle size. If a differential speed between rolls remains the same,
the particle size will
not change significantly. Differential speed control is typically used for
roll stack refiners (for
example 5-roll refiners). For example, the speed ratio between roll 5 and roll
2 of the 5-roll
refiners is equal to the factor of particle size reduction from pre-refined
paste to refiner flake,
The composition after pre-refining may be known as a pre-refined composition.
In one example, the second refiner comprises and/or is a refiner, for example
a three-rolls
refiner or a five-rolls refiner, having 2 and 4 gaps respectively, including
an adjustable gap as
described with respect to the first refiner, an adjustable pressure and/or an
adjustable speed.
In one example, the first gap of the second refiner is an adjustable gap. In
one example, one
or more of the gaps of the second refiner are adjustable gaps, for example the
gap between
the first roller and the second roller thereof while gaps between other
rollers may be fixed. In
one example, the second refiner comprises a plurality N of such refiners,
where N is a natural
number of at least 2, for example 2, 3, 4, 5, 6, 7, 8, 9 or more. In one
example, the plurality N
of such refiners Is arranged mutually in series and/or in parallel, such that
the composition is
refined successively and/or in parallel by the plurality N of such refiners.
In one example, the
second refiner comprises 4 five-roll refiners. It should be understood that
the refined
composition is thus that composition refined by the last gap of the last such
refiner.
Set of sensors
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The apparatus comprises the set of sensors, including the first sensor
configured to determine
the first process output of the set of mixers, of the mixing and/or of the
composition.
That is, the first sensor determines the first process output of the set of
mixers, of the mixing
and/or of the composition.
In one example, the first sensor is communicatively coupled to the set of
mixers. It should be
understood that the first sensor is communicatively coupled to the controller.
In one example, the first process output of the set of mixers, of the mixing
and/or of the
composition comprises and/or is a current, a voltage, a power, a torque, a
speed and/or a
pressure (i.e. sensed measurements) of the set of mixers, for example the
first mixer. In one
example, the set of mixers, for example the first mixer, comprises an electric
motor and the
current, the power, the torque, the speed and/or the pressure is of, for
example drawn by or
applied by, the electric motor.
Particularly, the inventors have identified that the peak paster current is an
inference of a
physical property, or a combination of physical properties, of the paste. For
example, the
physical properties may include a rheological property such as a plastic
viscosity or a yield
stress and/or a particle size distribution of the paste, In turn and without
wishing to be bound
by any theory, it is thought that differences in the physical property, or the
combination of
physical properties, of the paste are due, at least in part, to the particular
ingredients included
in a particular batch. Since the mixing is performed under controlled and
relatively constant
conditions from batch to batch, such as using the same mixer, the same speed
of mixing
and/or at the same temperature, even relatively small variations in the peak
paster current
from batch to batch may be attributable to the respective pastes being mixed.
Hence, by
monitoring the peak paster current for a particular batch, downstream refining
of that particular
batch may be specifically controlled accordingly so as to refine the batch to
thereby provide
the targeted property of the refined paste for that particular batch. It
should be understood that
while this description relates to peak paster current, a voltage, a power, a
torque, a speed
and/or a pressure of the mixing may be equivalent thereto.
More generally, the inventors have identified that the first process output of
the set of mixers,
of the mixing and/or of the composition is an inference of a physical
property, or a combination
of physical properties, of the composition. For example, the physical
properties may include a
rheological property such as a plastic viscosity or a yield stress and/or a
particle size
distribution of the composition. In turn and without wishing to be bound by
any theory, it is
thought that differences in the physical property, or the combination of
physical properties, of
the paste are due, at least in part, to the particular ingredients included in
a particular batch.
Date Regue/Date Received 2022-09-15
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Since the mixing is performed under controlled and relatively constant
conditions from batch to
batch, even relatively small variations in the first process output from batch
to batch may be
attributable to the respective compositions being mixed. Hence, by monitoring
the first process
output for a particular batch, downstream refining of that particular batch
may be specifically
controlled accordingly so as to refine the batch to thereby provide the
targeted property of the
refined composition for that particular batch.
In one example, the first process output comprises and/or is a peak (i.e.
maximum) current, a
peak voltage, a peak power, a peak torque, a peak speed and/or a peak pressure
(i.e. sensed
measurements) of the set of mixers, for example the first mixer.
In one example, the first process output comprises and/or is a moving average
(i.e. maximum)
current, a moving average voltage, a moving average power, a moving average
torque, a
moving average speed and/or a moving average pressure (i.e. sensed
measurements) of the
set of mixers, for example the first mixer.
In one example, the first process output comprises and/or is a peak moving
average (i.e.
maximum) current, a peak moving average voltage, a peak moving average power,
a peak
moving average torque, a peak moving average speed and/or a peak moving
average
pressure (i.e. sensed measurements) of the set of mixers, for example the
first mixer.
In one example, the first sensor is configured to obtain, acquire, receive
and/or sense a first
sensed measurement (also known as an operational figure) of a set of sensed
measurements
for and/or of the set of mixers, of the mixing and/or of the composition and
to determine the
first process output therefrom.
In one example, the first sensor comprises and/or is a soft-sensor (also known
as a software
sensor). Generally, soft-sensors are tools used for measuring one or more
process or quality
attributes that are calculated by software from a variety of inputs variables
using statistical
treatment such Partial Least Squares (PLS) or Recursive Least Squares (RLS).
In one example, the set of sensors, including the first sensor, comprises
and/or is a set of soft-
sensors, including the first sensor wherein the first sensor comprises and/or
is a soft-sensor.
It should be understood that the set of sensors transmits (i.e. sends) the
first set of process
outputs of the set of mixers to the controller,
Controller
Date Regue/Date Received 2022-09-15
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The apparatus comprises the controller configured to control the first process
input of the set
of refiners based, at least in part, on the determined first process output
using the control
model.
That is, the controller controls the refining of the composition based, at
least in part, on the
prior mixing of the composition, for example by controlling a gap and/or a
temperature of the
first refiner according to a current, such as a peak moving average current,
of the first mixer, In
this way, refining of a particular batch of the composition may be specific
(i.e. customised,
tailored) for that particular batch.
In one example, the controller comprises and/or is a computer, including at
least a processor
and a memory, configured to control the first process input of the set of
refiners. In one
example, the controller comprises and/or is a programmable logic controller
(PLC), configured
to control the first process input of the set of refiners. Other controllers
are known.
Process inputs
In one example, the first process input of the set of refiners comprises
and/or is a refining
aperture, for example a nip such as an adjustable nip of refining rollers, a
speed, a pressure
and/or a temperature of the set of refiners, for example tele first refiner.
In this way, a degree
of refining of the composition may be controlled by controlling the set of
refiners, for example
the first refiner and/or the second refiner, thereby controlling a particle
size distribution of the
composition.
In one example, the controller is configured to control the first process
input of the set of
refiners by increasing or decreasing the first process input of the set of
refiners, for example
within a predetermined range.
In one example, the controller is configured to control the first process
input of the set of
refiners continuously, intermittently, periodically and/or responsively, for
example in response
to the first process output transitioning outside a predetermined range.
Control model
The control model relates the determined first process output, the first
target property of the
set of refiners, of the refining and/or of the refined composition and the
first process Input of
the set of refiners. For example, the control model may relate a motor
current, such as a peak
moving average current, of the first mixer (i.e. the first process output of
first set process
outputs of the set of mixers, of the mixing and/or of the composition), a
target physical
Date Regue/Date Received 2022-09-15
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property, or a combination of physical properties, of the composition (i.e.
the first target
property of the set of refiners, of the refining and/or of the refined
composition) and a nip of the
first refiner (i.e. the first process input of the set of refiners).
Particularly, the inventors have
identified that a physical property, or a combination of physical properties,
of the composition
may be inferred from the motor current of the set of mixers, for example the
first mixer, and this
can be used to define a degree of refining required so as to achieve the
target particle size
distribution.
In one example, the first target property of the set of refiners, of the
refining and/or of the
refined composition comprises and/or is a rheological property for example a
plastic viscosity
or a yield stress and/or a particle size distribution of the composition (i.e.
combinations
thereof).
For example, real-time measurement of controlled variables of the set of
mixers may be
passed to a Model Predictive Controller (MPC) to control the process and
achieve a low
variability in the chocolate mass particle size and optionally, maximize
refining throughput.
Generally, MPC is an advanced method of process control, where a set of
constraints is
satisfied and finite time-horizon optimization is achieved by predicting
future events and takes
control actions accordingly. Hence, at least one operational figure (i.e.
first input output) of at
least one two-rolls refiner (i.e. first refiner), such gap (distance between
feeding rolls), and
optionally, one or more operational figures of at least one five-rolls
refiners (i.e. one or more
second refiners), such gap and rolls temperatures, may be adjusted to
predicted MPC optimal
set-points to keep the process, particularly a particle size distribution of
the composition within
specification (i.e. target), while throughput is maximized.
In one example, the control model is developed using first process outputs
previously-
determined from previous compositions and first process inputs of the set of
refiners
previously-required for the respective previous compositions to achieve the
first target property
for the set of refiners, of the refining and/or of the refined composition,
for example using
algorithms, mathematical modelling, numerical regression such as linear and
non-linear
regression and/or machine learning such as using a generalized linear model
(GLM), a
random forest, logistic regression, a support vector machine, K-nearest
neighbours, a decision
tree, AdaBoost, XGBoost, a neural network for example a convolutional neural
network, time-
series classification, a recurrence plot, a linear mixed model, and/or an
ensemble of two or
more thereof.
Second sensor
Date Regue/Date Received 2022-09-15
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In one example, the set of sensors includes a second sensor configured to
determine a
second process output of the set of refiners, of the refining and/or of the
refined composition;
and
the controller is configured to control a second process input of the set of
refiners based, at
least in part, on the determined second process output using the control
model, wherein the
control model relates the determined second process output, a second target
property of the
set of refiners, of the refining and/or of the refined composition and the
first process input of
the set of refiners.
In this way, the second process output of the set of refiners, for example, is
fed back into
refiners, along with the first process output of the set mixers, for example,
which is fed forward
to the set refiners, thereby further enabling dynamic, proactive control of
the set of refiners to
thereby increase a throughput of the refined composition and/or improve the
refining, for
example improve a particle size distribution of particles included in the
composition that are
refined by the refining. In other words, responsive to monitoring of the
upstream mixing and
the refining, the refining is controlled, for example adjusted, accordingly,
thereby accounting
for variability in the ingredients, for example. For example, a gap of the
first refiner may be
controlled based, at least in part, on a motor current of the first mixer and
a motor current of
the first refiner so as to achieve a target particle size distribution of the
composition.
The second sensor may be generally as described with respect to the first
sensor.
In one example, the second process output of the set of refiners, of the
refining and/or of the
refined composition comprises and/or is a physical property, or a combination
of physical
properties, such as a rheological property for example a plastic viscosity or
a yield stress
and/or a particle size distribution of the refined composition, preferably a
particle size
distribution of the refined composition.
In one example, the second process input of the set of refiners comprises
and/or is a refining
aperture, for example a nip such as an adjustable nip of refining rollers, a
speed and/or a
pressure of the set of refiners, for example the first refiner.
In one example, the second target property of the set of refiners, of the
refining and/or of the
refined composition comprises and/or is a physical property, or a combination
of physical
properties, such as a rheological property for example a plastic viscosity or
a yield stress
and/or a particle size distribution of the refined composition.
Third sensor
Date Regue/Date Received 2022-09-15
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In one example, the set of sensors includes a third sensor configured to
determine a third
process output of the set of refiners, of the refining and/or of the refined
composition; and
the controller is configured to control a third process input of the set of
refiners based, at least
in part, on the determined third process output using the control model,
wherein the control
model relates the determined third process output, a third target property of
the set of refiners,
of the refining and/or of the refined composition and the third process input
of the set of
refiners.
In this way, the third process output of the set of refiners, for example, is
fed back into refiners,
along with the first process output of the set mixers, for example, which is
fed forward to the
set refiners, thereby further enabling dynamic, proactive control of the set
of refiners to thereby
increase a throughput of the refined composition and/or improve the refining,
for example
improve a particle size distribution of particles included in the composition
that are refined by
the refining. In other words, responsive to monitoring of the upstream mixing
and the refining,
the refining is controlled, for example adjusted, accordingly, thereby
accounting for variability
in the ingredients, for example. For example, a gap and/or a temperature of
the first refiner
may be controlled based, at least in part, on a motor current of the first
mixer, a motor current
of the first refiner and a throughput so as to achieve a target particle size
distribution of the
composition and a target throughput of the refined composition.
The third sensor may be generally as described with respect to the first
sensor.
In one example, the third process output of the set of refiners, of the
refining and/or of the
refined composition comprises and/or is a current, a voltage, a power, a
torque, a speed
and/or a pressure of the set of refiners, for example the first refiner.
In one example, the third process input of the set of refiners comprises
and/or is a
temperature, for example a roll temperature of refining rollers, of the set of
refiners, for
example the first refiner.
In one example, the first target property of the third set of target
properties of the set of
refiners, of the refining and/or of the refined composition comprises and/or
is a throughput of
the refined composition.
Preferred apparatus
Date Regue/Date Received 2022-09-15
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In one preferred example, the apparatus is for processing, at least in part, a
batch of the
confectionery product wherein the confectionery product comprises and/or is
chocolate, the
apparatus comprising:
the set of mixers, including the first mixer, for mixing the one or more
ingredients to provide the
composition, wherein the composition is a precursor for the confectionery
product and wherein
the composition comprises and/or is a paste; and
the set of refiners, including the fjrst refiner and the second refiner, for
refining, at least in part,
the composition to provide the refined composition, wherein the first refiner
comprises and/or is
a two-rolls refiner and wherein the second refiner comprises a five-roll
refiner;
wherein the apparatus further comprises;
the set of sensors, including the first sensor configured to determine the
first process output of
the set of mixers, wherein first sensor comprises and/or is a first soft-
sensor and wherein the
first process output of the set of mixers is a current, preferably a peak
moving average current
of an electric motor of the first mixer;
the controller configured to control the first process input of the set of
refiners based, at least in
part, on the determined first process output using the control model, wherein
the control model
relates the first process output of the set of mixers, the first target
property of the set of
refiners, of the refining and/or of the refined composition of the composition
and the first
process input of the set of refiners, wherein the first process input of the
refiners comprises
and/or is a gap of the first refiner and wherein the first target property of
the set of refiners, of
the refining and/or of the refined composition of the composition comprises
and/or is a physical
property, or a combination of physical properties, of the composition.
Optionally, the preferred apparatus may comprise a second sensor and/or a
third sensor, as
described above.
Method
The second aspect provides a method of controlling, at least in part,
processing of a
confectionery product, comprising:
mixing one or more ingredients to provide a composition, wherein the
composition is a
precursor for the confectionery product; and
refining, at least in part, the composition to provide a refined composition;
wherein the method further comprises:
determining a first process output associated with the mixing and/or of the
composition; and
controlling a first process input for the refining based, at least in part, on
the determined first
process output using a control model, wherein the control model relates the
determined first
process output, a first target property associated with the refining and/or of
the composition
and the first process input for the refining.
Date Regue/Date Received 2022-09-15
19
The controlling, the processing, the confectionery product, the mixing, the
one or more
ingredients, the composition, precursor, refining, refined composition,
determining, first
process output, first set of process outputs, the first process input, the set
of process inputs,
the control model, the first target property and/or the first set of target
properties may be as
described with respect to the first aspect.
In one example, the method is of controlling, at least in part, processing of
a batch of the
confectionery product (i.e. patch processing c.f. continuous processing).
In one example, the determined first process output comprises and/or is a
current, a voltage, a
power, a torque, a speed and/or a pressure of the mixing.
In one example, the first process input for the refining comprises and/or is a
refining aperture,
for example a nip such as an adjustable nip of refining rollers.
In one example, the first target property of the set of refiners, of the
refining and/or of the
refined composition comprises and/or is a physical property, or a combination
of physical
properties such as a rheological property for example a plastic viscosity or a
yield stress and/or
a particle size distribution of the composition.
In one example, the method comprises:
determining a second process output associated with the refining and/or of the
refined
composition; and
controlling a second process input for the refining based, at least in part,
on the determined
second process output using the control model, wherein the control model
relates the second
process output associated with the refining and/or of the refined composition,
a second target
property associated with the refining and/or of the refined composition and
the second process
input associated with the refining,
In one example, the second process output associated with the refining and/or
of the refined
composition comprises and/or is a current, a voltage, a power, a torque, a
speed and/or a
pressure associated with the refining.
In one example, =the first process input associated with the refining
comprises and/or is a
refining aperture, for example a nip such as an adjustable nip of refining
rollers, a speed
and/or a pressure of the refining.
Date Regue/Date Received 2022-09-15
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In one example, the second target property associated with the refining and/or
of the refined
composition comprises and/or is a physical property, or a combination of
physical properties,
such as a rheological property for example plastic viscosity or a yield stress
and/or a particle
size distribution of the refined composition.
In one example, the method comprises:
determining a third process output associated with the refining and/or of the
refined
composition; and
controlling a third process input of the refining based, at least in part, on
the determined
second process output using the control model, wherein the control model
relates the third
process output associated with the refining and/or of the refined composition,
a third target
property of the set of refiners, of the refining and/or of the refined
composition and the third
process input of the set of refiners.
In one example, the third process output associated with the refining and/or
of the refined
composition comprises and/or is a current, a voltage, a power, a torque, a
speed and/or a
pressure of the refining,
In one example, the second process input of the refining comprises and/or is a
temperature,
for example a roll temperature of refining rollers.
In one example, the first target property of the third set of target
properties associated with the
refining and/or of the refined composition comprises and/or is a throughput of
the refined
composition.
Preferred method
In one preferred example, the method is of controlling, at least in part,
processing of a batch of
the confectionery product wherein the confectionery product comprises and/or
is chocolate,
comprising:
mixing one or more ingredients to provide a composition, wherein the
composition is a
precursor for the confectionery product and wherein the composition comprises
and/or is a
paste; and
refining, at least in part, the composition to provide a refined composition,
wherein the refining
comprises refining using a first refiner and a second refiner, wherein the
first refiner comprises
and/or is a two-rolls refiner and wherein the second refiner comprises a five-
roll refiner;
wherein the method further comprises:
determining the first process output of a first set of process outputs
associated with the mixing,
wherein the determining is by a first soft-sensor and wherein the first
process output of the set
Date Regue/Date Received 2022-09-15
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of mixers is a current, preferably a peak moving average current of an
electric motor of the first
mixer; and
controlling the first process input for the refining based, at least in part,
on the determined first
process output using the control model, wherein the control model relates the
first process
output associated with the mixing, the first target property of the set of
refiners, of the refining
and/or of the refined composition associated with the composition and the
first process input
for the refining, wherein the first process input of the refiners comprises
and/or is a gap of the
first refiner and wherein the first target property of the set of refiners, of
the refining and/or of
the refined composition of the composition comprises and/or is a physical
property, or a
combination of physical properties, of the composition.
CRM
The third aspect provides a tangible non-transient computer-readable storage
medium having
recorded thereon instructions which when implemented by a computer device
including a
processor and a memory, cause the computer device to perform a method
according to the
second aspect.
Definitions
Throughout this specification, the term "comprising" or "comprises' means
including the
component(s) specified but not to the exclusion of the presence of other
components. The
term "consisting essentially of' or "consists essentially of means including
the components
specified but excluding other components except for materials present as
impurities,
unavoidable materials present as a result of processes used to provide the
components, and
components added for a purpose other than achieving the technical effect of
the invention,
such as colourants, and the like.
The term "consisting of' or "consists of' means including the components
specified but
excluding other components.
Whenever appropriate, depending upon the context, the use of the term
"comprises" or
"comprising" may also be taken to include the meaning "consists essentially
of' or "consisting
essentially of", and also may also be taken to include the meaning "consists
of or "consisting
of'.
The optional features set out herein may be used either individually or in
combination with
each other where appropriate and particularly =in the combinations as set out
in the
accompanying claims. The optional features for each aspect or exemplary
embodiment of the
Date Regue/Date Received 2022-09-15
22
invention, as set out herein are also applicable to all other aspects or
exemplary embodiments
of the invention, where appropriate. In other words, the skilled person
reading this specification
should consider the optional features for each aspect or exemplary embodiment
of the
invention as interchangeable and combinable between different aspects and
exemplary
embodiments.
Brief description of the drawings
For a better understanding of the invention, and to show how exemplary
embodiments of the
same may be brought into effect, reference will be made, by way of example
only, to the
accompanying diagrammatic Figures, in which:
Figure 1 schematically depicts an apparatus according to an exemplary
embodiment;
Figure 2 schematically depicts a method according to an exemplary embodiment;
Figure 3 schematically depicts an apparatus according to an exemplary
embodiment;
Figure 4 shows graphs of process outputs for the apparatus of Figure 3;
Figure 5 shows graphs of a process output of Figure 4, in more detail;
Figure 6 shows graphs of the process outputs of Figure 4, in more detail;
Figure 7 shows graphs of process outputs for the apparatus of Figure 3;
Figure 8 shows a graph of correlation of process outputs for the apparatus of
Figure 3; and
Figure 9 shows a graph of correlation of process outputs for the apparatus of
Figure 3.
Detailed Description of the Drawings
Figure 1 schematically depicts an apparatus 10 according to an exemplary
embodiment.
Particularly, the apparatus 10 is for processing, at least in part, a
confectionery product.
The apparatus 10 comprises a set of mixers 100, including a first mixer 100A,
for mixing one or
more ingredients Ito provide a composition C, wherein the composition C is a
precursor for the
confectionery product. The apparatus 10 comprises a set of refiners 200,
including a first
refiner 200A and optionally a second refiner 200B (not shown), for refining,
at least in part, the
Date Regue/Date Received 2022-09-15
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composition C to provide a refined composition RC, The apparatus 10 comprises
a set of
sensors 300, including a first sensor 300A configured to determine a first
process output 120A
of the set of mixers 100, of the mixing and/or of the composition C. The
apparatus 10
comprises a controller 400 configured to control a first process input 210A of
the set of refiners
200 based, at least in part, on the determined first process output 120A using
a control model
500, wherein the control model 500 relates the determined first process output
120A, a first
target property 210A* of the set of refiners 200, of the refining and/or of
the composition C and
the first process input 210A of the set of refiners 200.
The apparatus 10 may be optionally as described herein, for example with
respect to the first
aspect and/or adapted to implement the method as described herein, for example
with respect
to the second aspect.
Figure 2 schematically depicts a method according to an exemplary embodiment,
Particularly, the method is of controlling, at least in part, processing of a
confectionery product.
At S21, one or more ingredients are mixed to provide a composition, wherein
the composition
is a precursor for the confectionery product.
At S22, a first process output associated with the mixing and/or of the
composition is
determined.
At 323, a first process input for the refining is controlled based, at least
in part, on the
determined first process output using a control model, wherein the control
model relates the
determined first process output, a first target property associated with the
refining and/or of the
composition and the first process input for the refining.
At S24, the composition is refined, at least in part, to provide a refined
composition.
The method may include any of the steps described herein, for example with
respect to the
second or the first aspect.
Figure 3 schematically depicts an apparatus 30 according to an exemplary
embodiment.
Generally, the apparatus 30 is as described with respect to the apparatus 10
and like
reference signs denote like features, description of which is not repeated.
Date Regue/Date Received 2022-09-15
24
Briefly, the apparatus 30 comprises the first mixer 100A and a set of refiners
200, with a first
refiner 200A (particularly, a two-roll refiner i.e. a pre-refiner). The
apparatus 30 further
comprises the second refiner 200B, comprising N five-roll refiners: R1 to RN,
The apparatus
30 comprises the first sensor 300A (particularly a soft-sensor), a second
sensor 300B and a
third sensor 300C communicatively coupled to the first mixer 100A, the first
refiner 200A, the
first second refiner 200B.R1 and the Nth second refiner 200B.RN, and to the
controller 400.
The first sensor 300A determines the physical property, or a combination of
physical
properties, of the composition C. using a measured current of the first mixer
100A (i.e. the first
process output 120A of the set of mixers 100), The second sensor 300B
determines the
particle size distribution of the composition C, using the physical property,
or a combination of
physical properties, determined by the sensor 300A by using the first process
output 120A of
the first set of mixers 100 (sensor 300A) and a set of process inputs 210 of
the set of refiners
200 (i,e, pre-refiner gap, refiner R1 and refiner RN gaps). The third sensor
300C determines
the throughput of the refined composition RC, using the current of the first
to Nth second
refiners 200B.R1 to 200B.RN (i.e. the second process output 220B of the set of
refiners 200).
Using the model 500, the controller 400 controls the gap of the first refiner
200A (i.e. the first
process input 210A of the set of refiners 200), as described previously. In
addition, using the
model 500, the controller 400 controls the respective gaps and roll
temperatures of the first to
Nth second refiners 200B.R1 to 200B.RN respectively, as described previously
with respect to
the gap of the first refiner 200A, mutatis mutandis. In this way, quality of
the refined
composition RC may be better maintained and/or improved, since the particle
size distribution
of the refined composition RC is better controlled, while the throughput
increases, as
described previously.
In other words, the particle size of a material (i.e. the composition) is
reduced by the process to
meet a quality specification and the efficiency of the process is increased,
for example
maximized
Particularly, the apparatus 30 includes three soft-sensors:
1, Paster soft-sensor 300A, which receives the mixer current 120A from the
mixer 100A
and provides the predicted paste physical property, or a combination of
physical
properties, to the particle size distribution (d90) soft-sensor 300B;
2. Particle size distribution (d90) soft-sensor 3006, which receives the
predicted paste
physical property, or a combination of physical properties, 120B from the
paster soft-
sensor 300A and the respective gaps of the first refiner 200A and of the first
to Nth
second refiners 200B.R1 to 200B.RN and provides a predicted particle size
distribution
to the controller 400; and
Date Regue/Date Received 2022-09-15
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3. Refiner throughput soft-sensor 300C, which receives the refiner current
120C from the
first to Nth second refiners 200B.R1 to 200B.RN and provides a predicted
throughput
to the controller 400.
in this context, being particle size distribution and throughput highly
influenced by the physical
property, or a combination of physical properties, of the processed paste, in
the method of
controlling, at least one operational figure of a motor associated with the
paster (i.e. the first
mixer 100A) is used as input in the paster soft-sensor 300A to predict the
physical property, or
a combination of physical properties, of paste to be refined. For example, the
paster's motor
current is continuously measured and the process is adjusted based on paste's
predicted
physical property. or a combination of physical properties.
The predicted physical property, or a combination of physical properties, is
used in addition to
process inputs such the first refiner 200A gap and first and Nth second
refiners, 200B,R1 and
200B.RN, gaps to predict particle size distribution (Particle size soft-
sensor). Similarly, at least
one operational figure, such as the motor current, of at least one motor
associated with at least
one roller of one or more five-rolls refiners (i.e, first and Nth second
refiners 200B.R1 and
20013,RN) is continuously measured and used to infer throughput (Throughout
soft-sensor),
Following real-time measurement of controlled variables, as explained above,
Model Predictive
Controller (MPC) (i.e. the controller 400 including the model 500) is used to
control the process
and achieve a low variability in the confectionary mass particle size and
maximize refining
throughput. MPC is an advanced process control method, where a set of
constraints is
satisfied and optimization is achieved by predicting future events and takes
respective control
actions,
In this context, at least one operational figure of at least one refiner, such
as gap (distance
between feeding rolls), pressure, speed and/or temperature, one or more
operational figures of
at least one five-rolls refiners, such gap, pressure, speed and/or
temperature, are adjusted to
predicted MPC optimal set-points to keep process (in this case, particle size)
within
specification (target), while throughput is maximized.
In more detail, the apparatus 30 is for processing, at least in part, the
confectionery product,
wherein the confectionery product is chocolate. The composition C is a
precursor for the
confectionery product, particularly a paste. In this example, the one or more
ingredients I are
crumb, fats and an emulsifier. The refined composition RC is flake,
Date Regue/Date Received 2022-09-15
26
The apparatus 30 comprises the set of mixers 100, including the first mixer
100A, for mixing
one or more ingredients Ito provide the composition a In this example, the
first mixer 100A is
a jacket mixer,
The set of refiners 200 includes the first refiner 200A and the second refiner
200B, for refining,
at least in part, the composition C to provide a refined composition RC. In
this example, the
first refiner 200A is a pre-refiner, having an adjustable gap in a range from
about 100 pm to
about 300 pm. In this example, the second refiner 200B (R1, RN) comprises a
plurality N of
such refiners 200. In this example, the plurality N of such refiners 2006 is
arranged mutually in
parallel, such that the composition C is refined in parallel by the plurality
N of such refiners
200, so as to increase throughput. In this example, the second refiner 2008
comprises N five-
roll refiners 200,
The apparatus 30 comprises the set of sensors 300, including the first sensor
300A configured
to determine the first process output 120A of the first set of process outputs
120 of the set of
mixers 100, of the mixing and/or of the composition C.
In this example, the first process output 120A of the set of mixers 100 is a
current of the first
mixer 100A, In this example, the first mixer 100A, comprises an electric motor
and the current
is drawn by the electric motor. In this example, the first process output 120A
is a peak moving
average (i.e. maximum) current of the first mixer 100A.
In this example, the first sensor 300A is a soft-sensor, labelled mixer soft
sensor.
The apparatus 30 comprises the controller 400 configured to control the first
process input
210A of the set of refiners 200 based, at least in part, on the determined
first process output
120A of the first set of process outputs 120 using the Control model 500. In
this example, the
controller 400 is a computer, including at least a processor and a memory,
configured to
control the first process input 210A of the set of refiners 200.
In this example, the first process input 210A of the set of refiners 200 is a
refining aperture,
particularly a nip, of the first refiner 200A.
In this example, the controller 400 is configured to control the first process
input 210A of the
set of refiners 200 by increasing or decreasing the first process input 210A
of the set of
refiners 200. In this example, the controller 400 is configured to control the
first process input
210A of the set of refiners 200 continuously,
Date Regue/Date Received 2022-09-15
27
The control model 500 relates the first process output 120A of the first set
of process outputs
120 of the set of mixers 100, the first target property 210A* of the first set
of target properties
210* of the refined composition RC and the first process input 210A of the
first set of process
inputs 210 of the set of refiners 200. In this example, the control model 500
relates peak
moving average current of the first mixer 100A (i.e. the first process output
120A of first set
process outputs of the set of mixers 100), a target physical property, or a
combination of
physical properties, of the composition C (i.e, the first target property
210A* of the first set of
target properties 210" of the composition C) and a nip of the first refiner
200A (i.e. the first
process input 210A of the first set of process inputs 210 of the set of
refiners 200).
In this example, the set of sensors 300 includes a second sensor 300B
configured to
determine a second process output 1206 of the set of refiners 200, of the
refining and/or of the
refined composition RC; and
the controller 400 is configured to control a second process input 210B of the
set of refiners
200 based, at least in part, on the determined second process output 1206
using the control
model 500, wherein the control model 500 relates the determined second process
output
120B, a second target property 2106* of the set of refiners 200, of the
refining and/or of the
refined composition RC and the second process input 210B of the set of
refiners 200,
In this example, the second process output 1208 of the set of refiners 200 is
a gap of the
second refiner 200B, a gap of the second refiner 200B.R1 and a gap of the Nth
second refiner
200B.R2. In addition, the second process output 120B of the set of refiners
200 includes the
predicted physical property, or a combination of physical properties, provided
by the first
sensor 300A. In this example, the second process input of the set of refiners
200 is the gap
and a temperature of the second refiner 200B, the gap and a temperature of the
second refiner
2006.R1 and the gap and a temperature of the Nth second refiner 200B,R2. In
this example,
the second target property 210B* of the set of refiners 200 is a particle size
distribution,
particularly D90, of the refined composition RC.
ao In this example, the set of sensors 300 includes a third sensor 300C
configured to determine a
third process output 120C of the set of refiners 200, of the refining and/or
of the refined
composition RC; and
the controller 400 is configured to control a third process input of the set
of refiners 200 based,
at least in part, on the determined third process output 120C using the
control model 500,
wherein the control model 500 relates the determined first process output
120C, a third target
property 210C* of the set of refiners 200, of the refining and/or of the
refined composition RC
and the third process input of the set of refiners 200.
Date Regue/Date Received 2022-09-15
28
In this example, the third process output 120C of the set of refiners 200 is
the refiner current
120C from the first to Nth second refiners 2006.R1 to 200B.RN. In this
example, the third
process input of the set of refiners 200 is the second process input of the
set of refiners 200 is
the gap and a temperature of the second refiner 2006, the gap and a
temperature of the
second refiner 200B.R1 and the gap and a temperature of the Nth second refiner
200B.R2. In
this example, the third target property 210A* of the set of refiners 200 Is a
target throughput of
the refined composition RC.
Figure 4 shows graphs of process outputs for the apparatus of Figure 3.
Particularly, Figure 4 shows graphs, as a function of time during about 1.5
hours of processing
of 5 batch cycles, of:
A, throughput of the refined composition (kg/h) (referred to as Line 8A flake
flow and Line
8B flake flow);
B. refiner R1 current (A) (referred to as R3 current (A)) and refiner RN
current (A)
(referred to as R4 current (A));
C. pre-refiner current (A) (referred to as PR current); and
D. paster current (A).
The refiner R1 and the refiner RN were operational throughout the processing.
The gaps for
the pre-refiner, the refiner R1 and the refiner RN are maintained constant
throughout the
processing. The batch cycles appear consistent.
Figure 5 shows graphs of a process output of Figure 4, in more detail;
Particularly, Figure 5 shows graphs, as a function of time during about 1.5
hours of processing,
of:
A. paster current (A);
B. paster current (A) (40 s moving average); and
C. paster current (A) (peak value of 40 s moving average).
Figure 6 shows graphs of the process outputs of Figure 4, in more detail;
Particularly, Figure 6 shows graphs, as a function of time during about 11.5
hours of
processing, of:
A. throughput of the refined composition (kg/h) (referred to as
Line 8B flake flow);
Date Regue/Date Received 2022-09-15
29
B. refiner R1 current (A) (referred to R3 current (A)) and refiner RN current
(A) (referred
to as R4 current (A));
C. peak paster current (A) and paster current (A);
D. pre-refiner current (A) (referred to as PR current); and
E. paster current (A).
The refiner R1 and the refiner RN were operational throughout the processing.
The gaps for
the pre-refiner, the refiner R1 and the refiner RN are maintained constant
throughout the
processing. The peak paster current is the peak value of 40 s moving average
paster current.
Correlation between the peak paster current, the refiner R1 current, the
refiner RN current and
the throughput of the refined composition is apparent from visual inspection.
Particularly, local
maxima and local minima in the peak paster current, the refiner R1 current,
the refiner RN
current and the throughput of the refined composition are temporally aligned.
Particularly, there is a clear correlation between the peak paster current and
flake flow (i.e. the
throughput of the refined composition):
1. peak paster current is an inference of a paste physical property, or a
combination of
physical properties; and
2. for a given set of running conditions (i.e. refiners on/off and gap sizes
in pre-refiner,
refiner R1, and refiner RN), there is a clear correlation of peak paster
current with flake
flow,
Figure 7 shows graphs of process outputs for the apparatus of Figure 3.
Particularly, Figure 7 shows graphs, as a function of time during 72 hours of
processing, of:
A. throughput of the refined composition (kg/h) (referred to as
Line 8B flake flow);
B. refiner R1 current (A) (referred to as R3 current (A)) and refiner RN
current (A)
(referred to as R4 current (A));
C. peak paster current (A) and paster current (A); and
D. pre-refiner current (A) (referred to as PR current).
The refiner R1 and the refiner RN were operational throughout the processing.
The gaps for
the pre-refiner, the refiner R1 and the refiner RN are maintained constant
throughout the
processing. The peak paster current is the peak value of 40 s moving average
paster current.
Date Regue/Date Received 2022-09-15
30
Correlation between the peak paster current, the refiner R1 current, the
refiner RN current and
the throughput of the refined composition is apparent from visual inspection.
Particularly, local
maxima and local minima in the peak paster current, the refiner R1 current,
the refiner RN
current and the throughput of the refined composition are temporally aligned.
Figure 8 shows a graph of correlation of process outputs for the apparatus of
Figure 3.
Particularly, Figure 8 shows a scatter chart of refiner RN current (referred
to as VT_R4 R4:
Current) of the composition as a function of peak paster current (A) (referred
to as max filtered
paster current), during 72 hours of processing. The throughput of the refined
composition
varied between about 2500 kg/h and about 4200 kg/h. The peak paster current
varied between
about 590 A and about 675 A.
The linear line of best fit has a product moment correlation coefficient of
0,71, which is good,
thereby demonstrating the relationship between the refiner RN current and the
peak paster
current.
Figure 9 shows a graph of correlation of process outputs for the apparatus of
Figure 3.
Particularly, Figure 9 shows a scatter chart of throughput (kg/h) (also known
as continuous
flake flow measurement) of the refined composition as a function of peak
paster current (A)
(referred to as max filtered paster current), during 72 hours of processing.
The throughput of
the refined composition varied between about 2500 kg/h and about 4200 kg/h.
The peak
paster current varied between about 590 A and about 675 A.
The linear line of best fit has a product moment correlation coefficient of
0.40, thereby on the
threshold of indicating a relationship. However, given the batch-to-batch
nature of the
throughput of the refined composition versus the peak paster current, it is
expected that the
mathematical correlation will be less strong.
Although a preferred embodiment has been shown and described, it will be
appreciated by
those skilled in the art that various changes and modifications might be made
without
departing from the scope of the invention, as defined in the appended claims
and as described
above.
In summary, the invention provides an apparatus for, and a method of,
processing, at least in
part, a confectionery product that increases a throughput of the process while
improving a
quality of the confectionery product.
Date Regue/Date Received 2022-09-15
31
Attention is directed to all papers and documents which are filed concurrently
with or previous
to this specification in connection with this application and which are open
to public inspection
with this specification.
All of the features disclosed in this specification (including any
accompanying claims and
drawings), and/or all of the steps of any method or process so disclosed, may
be combined in
any combination, except combinations where at most some of such features
and/or steps are
mutually exclusive.
Each feature disclosed in this specification (including any accompanying
claims, and drawings)
may be replaced by alternative features serving the same, equivalent or
similar purpose,
unless expressly stated otherwise. Thus, unless expressly stated otherwise,
each feature
disclosed is one example only of a generic series of equivalent or similar
features.
The invention is not restricted to the details of the foregoing embodiment(s).
The invention
extends to any novel one, or any novel combination, of the features disclosed
in this
specification (including any accompanying claims and drawings), or to any
novel one, or any
novel combination, of the steps of any method or process so disclosed.
Date Regue/Date Received 2022-09-15
