A method of processing a gel confectionery

Abstract

The application discloses a processing method of gel candies, and belongs to the technical field of gel candies. The method comprises a control unit with multiple independent pouring units, each pouring unit comprising a pouring head and a temperature control module, and the following steps are performed: S1: initial sensing and parameter setting; S2: a staged dynamic pouring step; S201: a starting stage, in which pouring is started at P0 and the F0, and lasts for a predetermined starting time Δt1; S202: a stable stage, in which after Δt1 ends, a control mode based on real-time viscosity feedback is switched to, the heating power is adjusted to maintain the real-time viscosity μ of the material in a target range [μ min , μ max ], and pouring is performed at a basic pump pressure F base . Through the staged dynamic control, the application realizes the precision and high efficiency of the gel candy pouring process.

Description

Technical Field

[0001] This invention belongs to the field of gel candy technology, and specifically relates to a gel candy processing method. Background Technology

[0002] Gel candies (such as jelly and gummies) are widely popular due to their soft, chewy texture and diverse shapes. In their production, the boiled syrup is precisely poured into molds through a pouring head to form products of predetermined shapes and weights. This pouring process is a crucial step in determining the product's appearance quality and consistency with its specifications.

[0003] The inherent high viscosity, low fluidity, and significant viscoelasticity of the boiled syrup make it difficult to flow smoothly from the pouring head during casting, easily resulting in interruptions or discontinuous dripping. This leads to unstable initial injection volumes for each candy, and the dripping syrup contaminates the mold, severely impacting production cleanliness and the quality of the first batch of products. Existing technologies typically address this by simply increasing pump pressure or preheating the material. However, increasing pump pressure, if not properly controlled, can lead to excessively rapid discharge later on, while overall material preheating is difficult to precisely control the fluidity at the start-up moment, resulting in delayed response and high energy consumption.

[0004] There is a need for a processing method for gel candies that can actively sense and adapt to changes in syrup viscosity. Summary of the Invention

[0005] To address the aforementioned problems in the existing technology, this invention provides a method for processing gel candies, which solves the problem that leakage occurs everywhere on the mold surface during the existing gel candy casting process, resulting in low casting quality and efficiency.

[0006] The objective of this invention can be achieved through the following technical solutions:

[0007] A method for processing gel candy employs a control unit with multiple independent pouring units, each pouring unit including a pouring head and an independent temperature control module, and performs the following steps:

[0008] S1: Initial Sensing and Parameter Setting: Before the pouring starts, measure the initial temperature T0 and initial viscosity μ0 of the material in each pouring head; based on T0 and μ0, independently set the initial heating power P0 and initial pump pressure F0 for each pouring head;

[0009] S2: Staged dynamic casting steps:

[0010] S201: Start-up phase, pouring is initiated with P0 and F0, and continues for a predetermined start-up time Δt1;

[0011] S202: In the stabilization phase, after Δt1, switch to the control mode based on real-time viscosity feedback, and adjust the heating power to maintain the real-time viscosity μ of the material within the target range [μ]. min μ max [Inside, and with the base pump pressure F] base Pour the water in.

[0012] S3: Finishing step: When the single pouring volume reaches the target value, turn off the pump pressure and perform mechanical shearing to cut off the material liquid column.

[0013] Preferably, in the initial state sensing and parameter preset step, the initial parameters are set according to the initial temperature T0 and the initial viscosity μ0 as follows: when μ0 is higher than the preset viscosity threshold and T0 is lower than the preset temperature threshold, it is set to a combination of high initial heating power P0 and high initial pump pressure F0; when both μ0 and T0 are in the middle range, it is set to a combination of medium initial heating power P0 and medium initial pump pressure F0; when μ0 is lower than the preset viscosity threshold and T0 is higher than the preset temperature threshold, it is set to a combination of low initial heating power P0 and low initial pump pressure F0.

[0014] Preferably, the stabilization phase further includes a dynamic zoning control step: calculating the average viscosity μ of all working pouring heads in real time. avg The real-time viscosity μ is higher than the average viscosity μ. avg The pouring head is marked as a high-viscosity unit, and the heating power of the high-viscosity unit is increased; the real-time viscosity μ is lower than the average viscosity μ. avg The pouring head is marked as a low-viscosity unit, and the heating power is reduced for the low-viscosity unit.

[0015] Preferably, the temperature control module is provided with a temperature protection point, which is set to be 3°C to 5°C higher than the material gelation temperature.

[0016] Preferably, the mechanical shearing action is performed by a cutter, and the shearing speed of the cutter is set based on the initial viscosity μ0: when μ0 is higher than the preset viscosity threshold, the shearing speed is set to a first speed; when μ0 is lower than the preset viscosity threshold, the shearing speed is set to a second speed, wherein the first speed is higher than the second speed.

[0017] Preferably, in the closing step, there is a predetermined delay time Δt2 between shutting off the pump pressure and performing the mechanical shearing action. The delay time Δt2 is set based on the real-time viscosity μ monitored at the end of the stabilization phase: the higher the real-time viscosity μ, the longer the set delay time Δt2.

[0018] Preferably, it also includes a visual monitoring unit, which is used to acquire images of the syrup feed column and identify two abnormal states of the liquid column by performing edge detection and morphological analysis on the images: the first state is that the diameter of the liquid column continues to become thinner and is accompanied by stringing; the second state is that the liquid column shows discontinuous dripping; when the first state is identified, the temperature control module is controlled to increase the heating power; when the second state is identified, the temperature control module is controlled to decrease the heating power.

[0019] Preferably, the pouring head is provided with a pneumatically driven anti-drip needle valve at its end; after mechanical shearing is completed in each finishing step, the needle valve is closed to seal the nozzle.

[0020] Preferably, the pouring head is composed of a material chamber and a nozzle section connected by a quick-disassembly structure, and a sealing element is provided at the connection.

[0021] The beneficial effects of this invention are as follows:

[0022] This application achieves precision and efficiency in the gel candy casting process through phased dynamic control. The initial soft start ensures smooth material flow, avoiding fluctuations in injection volume and mold contamination caused by start-up inertia. The real-time viscosity closed-loop feedback in the stabilization phase effectively maintains the optimal flow state of the syrup, significantly improving the consistency of product weight and shape while reducing energy consumption. The mechanical shearing in the final stage solves the problems of tailing and dripping of high-viscosity materials, reducing raw material waste. Attached Figure Description

[0023] To facilitate understanding by those skilled in the art, the present invention will be further described below with reference to the accompanying drawings.

[0024] Figure 1 This is a schematic diagram of the processing flow of a gel candy provided in one embodiment of the present invention; Detailed Implementation

[0025] To further illustrate the technical means and effects adopted by the present invention in order to achieve the intended purpose, the following detailed description is provided in conjunction with the accompanying drawings and preferred embodiments, based on the specific implementation methods, structures, features and effects of the present invention.

[0026] like Figure 1 As shown, a method for processing gel candy employs a control unit with multiple independent pouring units, each pouring unit including a pouring head and an independent temperature control module, and performs the following steps:

[0027] S1: Initial sensing and parameter setting: Before the pouring starts, measure the initial temperature T0 and initial viscosity μ0 of the material in each pouring head; based on T0 and μ0, independently set the initial heating power P0 and initial pump pressure F0 for each pouring head.

[0028] S2: Staged dynamic casting steps:

[0029] S201: During the startup phase, the control unit initiates pouring at P0 and F0 set in S1, continuing for a predetermined startup time Δt1. During this period, the temperature control module rapidly heats the syrup to the transition temperature, while the pump pressure is applied in a slow-increase mode to ensure a smooth transition of the syrup from a static state to a flowing state. This phased control solves the startup inertia problem caused by the viscoelasticity of the syrup: In traditional methods, simply increasing the pump pressure can easily cause over-rushing or material splashing in the later stages. However, this step combines initial heating and pump pressure to achieve a "soft start" pouring in a short time, effectively reducing the yield stress of the syrup and making the outflow more continuous. This not only reduces fluctuations in the initial injection volume but also prevents mold contamination, demonstrating the optimization of dynamic response and energy efficiency, and improving the stability and cleanliness of the entire production line.

[0030] The transition temperature is set within the range where the viscoelasticity of the syrup changes. Its specific value range is between the initial temperature T0 and the target pouring temperature. During the transition temperature, the yield stress of the syrup has been significantly weakened, which is sufficient to start the flow, but has not yet reached the final optimal pouring viscosity, thus leaving room for adjustment and response time for the subsequent closed-loop control in the steady stage. In addition, the slow-rise mode means that within the start-up time Δt1, the pump pressure starts from the initial pump pressure F0 and gradually increases to the base pump pressure in the steady stage in a non-linear manner and at a gradually decreasing rate.

[0031] S202: Stabilization Phase. After the startup phase, the control unit switches to real-time viscosity feedback control mode, continuously monitoring the syrup viscosity μ using an online viscosity sensor, and dynamically adjusting the heating power through a PID controller to stabilize μ within the target range [μ]. min μ max Within, at the same time, with a constant base pump pressure F base The process involves pouring the syrup. A closed-loop feedback mechanism is introduced to overcome the problem of inconsistent pouring caused by changes in material properties in traditional open-loop control. Traditional preheating methods are slow to respond and difficult to adapt to disturbances in production. This step, through real-time adjustment, maintains the optimal fluidity of the syrup, ensuring a high degree of consistency in the shape and weight of the pouring, while reducing the risk of overheating and production energy consumption.

[0032] S3: Finishing Step: When the single pouring volume reaches the target value, the pump pressure is turned off, and a mechanical shearing device is triggered to perform a shearing action, quickly cutting off the syrup column; combining mechatronics, it solves the problems of tailing and dripping caused by the high viscosity of syrup: traditional methods rely solely on gravity or simply closing the valve, which easily leads to incomplete cutting and mold contamination. However, this step applies instantaneous force through mechanical shearing, achieving clean and efficient separation, reducing material waste and cleaning costs. This method not only improves production efficiency and product appearance quality, but also enhances the reliability and automation level of the control unit.

[0033] In one embodiment, a viscosity threshold and a temperature threshold are preset as comparison benchmarks; the initial viscosity and initial temperature values ​​of the syrup in the pouring head are measured and obtained by sensors; the system also includes a control module for analyzing data, which compares the initial viscosity value with the viscosity threshold and the initial temperature value with the temperature threshold; if the initial viscosity value is greater than the viscosity threshold and the initial temperature value is less than the temperature threshold, the syrup is determined to be in a first state, and a first preset heating power and a first preset pump pressure are set for the pouring head; if the initial viscosity value is within a preset tolerance range of the viscosity threshold and the initial temperature value is within a preset tolerance range of the temperature threshold, the syrup is determined to be in a second state, and a second preset heating power and a second preset pump pressure are set for the pouring head; if the initial viscosity value is less than the viscosity threshold and the initial temperature value is greater than the temperature threshold, the syrup is determined to be in a third state, and a third preset heating power and a third preset pump pressure are set for the pouring head; wherein, the first preset heating power is greater than the second preset heating power, the second preset heating power is greater than the third preset heating power, the first preset pump pressure is greater than the second preset pump pressure, and the second preset pump pressure is greater than the third preset pump pressure.

[0034] When the control module determines that the syrup is in a difficult-to-flow state of "high viscosity and low temperature" and applies a combination of high power and high pressure, the traditional method of simply increasing the pump pressure is not only inefficient, but also prone to causing uncontrolled material gushing out at the moment of breaking through static friction. This solution synchronously couples high-intensity heating with high-pressure pumping: the heating function reduces the viscosity of the material from the inside, making it "soften" and "relax", while the high pressure is responsible for providing thrust from the outside, which can induce the syrup from a gel-like static state to a continuous flow state in a shorter time and in a smoother manner. This solves the problem of intermittent start-up of high-viscosity fluids and significantly improves the start-up success rate and reliability of the production line.

[0035] The viscosity threshold is set based on the rheological properties of the syrup and is used to distinguish between pumpable and non-pumpable critical viscosity conditions; the temperature threshold is set based on the phase change properties of the syrup and the viscosity-temperature relationship and is used to distinguish between the critical temperature conditions of the syrup in the high viscosity low temperature range and the low viscosity high temperature range.

[0036] The first state corresponds to the start-up condition where the syrup is difficult to flow due to its high viscosity and low temperature; the second state corresponds to the normal operating condition where the syrup viscosity and temperature are moderate; and the third state corresponds to the operating condition where the syrup flows easily due to its low viscosity and high temperature.

[0037] The first preset heating power is the highest value among multiple discrete heating power levels pre-stored in the control unit. In the first state, it provides the maximum rate of heat output, significantly improving the fluidity of the syrup by rapidly increasing its temperature. The first preset pump pressure is the highest value among the pump pressure levels pre-stored in the control unit. In the first state, it provides the maximum horizontal thrust to overcome the high flow resistance of the syrup. The second preset heating power is a level between the highest and lowest levels, providing moderate heat output for smooth start-up in the second state. The second preset pump pressure is also a level between the highest and lowest levels, providing moderate thrust to balance flow requirements and operational stability in the second state. The third preset heating power is the lowest value, providing only the basic heat required to maintain the fluidity of the syrup in the third state. The third preset pump pressure is also the lowest value, providing only the basic thrust required to maintain stable syrup flow in the third state.

[0038] In one embodiment, the stabilization phase further includes a dynamic zoning control step: calculating the average viscosity μ of all working pouring heads in real time. avg The real-time viscosity μ is higher than the average viscosity μ. avg The pouring head is marked as a high-viscosity unit, and the heating power of the high-viscosity unit is increased; the real-time viscosity μ is lower than the average viscosity μ. avg The pouring heads are marked as low-viscosity units, and the heating power is reduced for these units. Specifically, during the stabilization phase, the control unit uses a centralized pump to provide a uniform outlet pressure to all working pouring heads, calculates the average viscosity of all pouring heads in real time, and marks them as "high-viscosity units" or "low-viscosity units" based on the average viscosity. However, since the pump pressure is uniform and cannot be adjusted independently, the control unit can only intervene by adjusting the heating power of each unit: increasing the heating power for high-viscosity units to reduce their viscosity; and reducing the heating power for "low-viscosity units" to prevent them from becoming overly thinned, thereby compensating for the uneven flow rate caused by the uniform pump pressure through temperature control.

[0039] In one embodiment, if the temperature exceeds the gelation temperature by a significant margin, the rheological properties of the syrup will undergo irreversible deterioration. This not only results in loss of viscoelasticity but may also lead to molecular chain breakage or water evaporation, directly affecting the product texture and clogging the pouring head. The temperature control module is equipped with a temperature protection point, set 3°C ​​to 5°C above the material's gelation temperature. For example, if the gelation temperature of the jelly syrup is 60°C, the control unit will set the temperature protection point of its temperature control module to 63°C to 65°C. In actual operation, regardless of whether the pouring head is in the start-up, stabilization, or finishing stage, once the real-time temperature of the temperature control module reaches or exceeds this protection point, the control unit will immediately trigger the protection mechanism, automatically cutting off or significantly reducing the heating power to the unit, stopping the heating process, and ensuring that the material temperature is kept within a safe range.

[0040] High-viscosity materials, like very thick syrup, are tough and flow slowly. When cut by a cutter, they produce noticeable "stringing" or "tailing" phenomena. If the cutter speed is too slow, it is insufficient to apply shearing force quickly enough to cleanly cut the liquid column, resulting in a small tail trailing from one end of the candy, or the material sticking to the cutter, affecting subsequent cuts. Low-viscosity materials, like water, are fluids with good flowability but weak cohesion. If the cutter speed is too fast, the strong impact force may cause the liquid column to break prematurely at an unexpected location, splashing, or resulting in an uneven cut surface, similarly affecting the product's appearance and weight. In one embodiment, the mechanical shearing action is performed by a cutter, and the cutter's shearing speed is set based on the initial viscosity μ0: when μ0 is higher than a preset viscosity threshold, the shearing speed is set to a first speed; when μ0 is lower than the preset viscosity threshold, the shearing speed is set to a second speed, where the first speed is higher than the second speed. When a high initial viscosity μ0 is detected, the control unit anticipates that the material is prone to stringing during cutting. Therefore, setting the cutter speed to a higher initial speed allows for a faster and more immediate shearing force to sever the high-viscosity liquid column, overcoming its cohesive forces and achieving a clean cut. This effectively eliminates tailing and adhesion. When the initial viscosity μ0 is detected to be low, the control unit anticipates good material flowability and warns that excessively forceful cutting may cause splashing. Therefore, setting the cutter speed to a lower second speed provides a gentler shearing force sufficient to break the low-viscosity liquid column, while avoiding product shape damage and splashing caused by excessive impact force, ensuring a smooth cut surface.

[0041] At the instant the pump pressure is shut off, residual stress exists inside the compressed liquid column, especially for high-viscosity materials. If shearing is performed immediately, this stress will force the material at the top of the liquid column to rebound and contract, forming an incomplete "dimpled" defect. In one embodiment, in the final step, there is a predetermined delay time Δt2 between shutting off the pump pressure and performing the mechanical shearing action. The delay time Δt2 is set based on the real-time viscosity μ monitored at the end of the stabilization phase: the higher the real-time viscosity μ, the longer the set delay time Δt2. After the pump pressure is shut off, the compressed liquid column, especially for high-viscosity materials, has significant residual stress inside. If it is cut off immediately, this stress will cause the top of the liquid column to retract and become concave, forming a defective product. By introducing a delay time Δt2 that is positively correlated with the real-time viscosity, a crucial stress release and natural leveling window is provided for the material. The higher the viscosity, the greater the internal stress, and the longer the required release time Δt2. By intervening in the physical behavior of the material, the fullness and regularity of the candy shape are ensured, greatly improving the quality of the final product.

[0042] A single viscosity sensor may fail to fully reflect the overall outflow pattern of the material due to response delay, measurement point limitations, or calibration drift. This can lead to morphological defects in the actual pouring, where the control unit maintains the viscosity reading within the target range, but the actual effective viscosity is either too high or too low. In one embodiment, a visual monitoring unit is also included. The visual monitoring unit acquires an image of the syrup column and identifies two abnormal column patterns by performing edge detection and morphological analysis on the image: the first pattern is a continuously thinning column diameter accompanied by stringing; the second pattern is discontinuous dripping of the column. When the first pattern is identified, the temperature control module is controlled to increase the heating power; when the second pattern is identified, the temperature control module is controlled to decrease the heating power.

[0043] Traditional methods that rely solely on shutting off the pump pressure and external shearing cannot completely remove material adhering to the inner wall and outlet of the nozzle. These residues will slowly drip off under gravity, and the dripping syrup will contaminate the mold cavity below, causing subsequent candy adhesion or surface defects, wasting raw materials, and increasing the equipment cleaning burden. In one embodiment, the pouring head is equipped with a pneumatically driven anti-drip needle valve at the end. After mechanical shearing is completed in each finishing step, the needle valve closes to seal the nozzle. The needle valve is in a retracted state during pouring, and the nozzle is unobstructed. When the mechanical cutter completes the cutting action in step S3, the control unit immediately triggers a signal to drive the micro pneumatic cylinder to push the needle valve forward, so that its conical head tightly embeds and blocks the nozzle outlet, and only retracts and opens just before the next pouring command is issued.

[0044] The cutter and needle valve work together to achieve clean cut-off and source sealing of the liquid material column. Specifically, the mechanical shearing action is performed by the cutter to physically cut off the liquid material column at the end of the pouring head after the pump pressure is turned off, so as to form an independent sugar body; immediately after the shearing action is completed, the pneumatically driven anti-drip needle valve closes immediately to physically seal the nozzle and prevent dripping or stringing caused by residual fluidity of the material from the source.

[0045] To address the problem of cumbersome and time-consuming disassembly and assembly processes when changing formulas or colors or performing routine cleaning and maintenance of the pouring head, in one embodiment, the pouring head is composed of a material chamber and a nozzle section connected by a quick-disassembly structure, with a sealing element, such as a quick-threaded connector, and a bidirectional sealing ring integrated on the mating surface.

[0046] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A method for processing gel candy, employing a control unit with multiple independent pouring units, each pouring unit including a pouring head and an independent temperature control module, characterized in that, Perform the following steps: S1: Initial Sensing and Parameter Setting: Before pouring begins, the initial temperature T0 and initial viscosity μ0 of the material in each pouring head are measured; based on T0 and μ0, the initial heating power P0 and initial pump pressure F0 are independently set for each pouring head; in the initial sensing and parameter setting step, the initial parameters are set according to the initial temperature T0 and initial viscosity μ0 as follows: when μ0 is higher than a preset viscosity threshold and T0 is lower than a preset temperature threshold, a combination of high initial heating power P0 and high initial pump pressure F0 is set; when both μ0 and T0 are in the middle range, a combination of medium initial heating power P0 and medium initial pump pressure F0 is set; when μ0 is lower than a preset viscosity threshold and T0 is higher than a preset temperature threshold, a combination of low initial heating power P0 and low initial pump pressure F0 is set. S2: Staged dynamic casting steps: S201: Start-up phase, pouring is initiated with P0 and F0, and continues for a predetermined start-up time Δt1; S202: In the stabilization phase, after Δt1, switch to the control mode based on real-time viscosity feedback, and adjust the heating power to maintain the real-time viscosity μ of the material within the target range [μ]. min μ max [Inside, and with the base pump pressure F] base Pour the water in. S3: Finishing Step: When the single pouring volume reaches the target value, the pump pressure is turned off and a mechanical shearing action is performed to cut off the material liquid column; the mechanical shearing action is performed by a cutter, and the shearing speed of the cutter is set based on the initial viscosity μ0: when μ0 is higher than the preset viscosity threshold, the shearing speed is set to a first speed; when μ0 is lower than the preset viscosity threshold, the shearing speed is set to a second speed, wherein the first speed is higher than the second speed; in the finishing step, there is a predetermined delay time Δt2 between turning off the pump pressure and performing the mechanical shearing action, and the delay time Δt2 is set based on the real-time viscosity μ last monitored in the stabilization phase: the higher the real-time viscosity μ, the longer the set delay time Δt2.

2. The processing method of a gel candy according to claim 1, characterized in that, The stabilization phase also includes a dynamic zoning control step: real-time calculation of the average viscosity μ of all working pouring heads. avg The real-time viscosity μ is higher than the average viscosity μ. avg The pouring head is marked as a high-viscosity unit, and the heating power of the high-viscosity unit is increased; the real-time viscosity μ is lower than the average viscosity μ. avg The pouring head is marked as a low-viscosity unit, and the heating power is reduced for the low-viscosity unit.

3. The processing method of a gel candy according to claim 1, characterized in that, The temperature control module is equipped with a temperature protection point, which is set to be 3°C to 5°C higher than the material gelation temperature.

4. The processing method of a gel candy according to claim 1, characterized in that, It also includes a visual monitoring unit, which is used to acquire images of the syrup feed column and identify two abnormal states of the column by performing edge detection and morphological analysis on the images: the first state is that the diameter of the column continuously becomes thinner and is accompanied by stringing; the second state is that the column drips discontinuously. When the first state is identified, the temperature control module is controlled to increase the heating power; when the second state is identified, the temperature control module is controlled to decrease the heating power.

5. The processing method of a gel candy according to claim 1, characterized in that, The pouring head is equipped with a pneumatically driven anti-drip needle valve at its end; after mechanical shearing is completed in each finishing step, the needle valve closes to seal the nozzle.

6. The processing method of a gel candy according to claim 1, characterized in that, The pouring head is composed of a material chamber and a nozzle section connected by a quick-disassembly structure, and a sealing element is provided at the connection.

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