A method for controlling an ice cream hardening tunnel, an ice cream hardening tunnel and an ice cream production line

Abstract

The invention relates to a method for controlling a hardening tunnel comprising: setting adjustable tunnel parameters for the hardening tunnel, upstream said hardening tunnel providing a plurality of ice cream items on a transportation surface carried by a hardening tunnel conveyor, conveying said ice cream items through said hardening tunnel on said conveyor and generating an adhesion between said ice cream items and said transportation surface, within said hardening tunnel and / or downstream said hardening tunnel continuously measuring said adhesion of said ice cream items, continuously adjusting said tunnel parameters based on said measured adhesion.

Description

A METHOD FOR CONTROLLING AN ICE CREAM HARDENING TUNNEL, AN ICECREAM HARDENING TUNNEL AND AN ICE CREAM PRODUCTION LINEField of the invention

[0001] The present invention relates to a method for controlling an ice cream hardening tunnel an ice cream hardening tunnel and an ice cream production line.Background of the invention

[0002] Ice cream items manufacturing in an industrial scale is a mature technical art, and ice cream manufacturing lines have been available for decades. Ice cream state of the art manufacturing lines have developed significantly over the many last years meeting requirement from the users in terms of design, taste, price, texture, etc.

[0003] An example of such state of the art system is disclosed in EP 2 934 168 Bl dealing in particular with how to control what may be referred to as an ice cream hardening tunnel. An ice cream hardening tunnel may in short be described as a tunnel continuously cooling ice cream items fed to the hardening tunnel upstream while the ice cream items are transported through the ice cream hardening tunnel. The basic functioning of the ice cream hardening tunnel is to harden ice cream items which has been produced having ice cream temperatures warm enough to be able to manufacture and form the items at least partly. The hardening is obtained by reducing the temperature of the ice cream, enough to harden the ice cream to have a stable form to pack and store the produced item in a reliable way and obtaining a robust manufacturing process.

[0004] A challenge of the disclosed hardening tunnel is that it is difficult to control and the result of this is e.g., an unnecessarily high energy consumption depending highly on the human control. In order to assist this difficult controlling of the disclosed hardening tunnel the system of EP 2 934 168 Bl measure the surface temperature of the ice cream items and the lifting torque. A challenge with the suggested control approach is that the operating of the hardening tunnel and the entire ice cream manufacturing line is difficult and that defective products may very likely be the resultof this type of operation thereby not only risking lower yield but more importantly leading to challenges and quality issues further downstream the ice cream manufacturing line.Summary of the invention

[0005] The invention relates to a method for controlling a hardening tunnel comprising: setting adjustable tunnel parameters for the hardening tunnel, upstream said hardening tunnel providing a plurality of ice cream items on a transportation surface carried by a hardening tunnel conveyor, conveying said ice cream items through said hardening tunnel on said conveyor and generating an adhesion between said ice cream items and said transportation surface, within said hardening tunnel and / or downstream said hardening tunnel continuously measuring said adhesion of said ice cream items, continuously adjusting said tunnel parameters based on said measured adhesion.

[0006] The hardening tunnel may be understood as a freezing tunnel for producing ice cream products. The hardening tunnel freezes down the ice cream items manufactured at a somewhat higher temperature to ensure the right hardening and core temperature of the ice cream items. The hardening tunnel could typically comprise a conveyor with a length in the size ratio of 100, 500, or 1000 meters.

[0007] The term hardening tunnel could be understood as a tunnel in a production line for e.g., ice cream products. A hardening tunnel could also be understood as a freezing tunnel, a cooling tunnel, or an ice cream tunnel. The hardening tunnel could be used to lower the temperature of the ice cream items in the production line and thereby harden the ice cream items. A hardening tunnel could typically comprise a long conveyor for the ice cream items used for transporting the ice cream items through the hardening tunnel. In the hardening tunnel there could also be elements for regulating the temperature and thereby freeze the ice cream products. The hardening tunnel could further comprise apparatus and devices for controlling, regulating, and guiding the airflow inside the hardening tunnel to optimize the hardening process of the ice cream items. The hardening tunnel could typically comprise an air-balancingsystem to keep the freezing inside the hardening tunnel and the warmer air outside the hardening tunnel. The air-balancing could be fans or air blowers which could generate a pressure inside the hardening tunnel to keep the freezing air inside. Especially at the inlet and outlet of the conveyor, the hardening tunnel could use the air-balancing system to prevent the warmer air compared to the freezing air in the hardening tunnel to get into the hardening tunnel. In the same aspect the air-balancing system in the hardening tunnel could also prevent the freezing air to get out of the hardening tunnel by the air-balancing system.

[0008] The term tunnel parameters are to be understood as parameters which can be controlled and regulated to adjust the ice cream item output from the hardening tunnel. A tunnel parameter could be the temperature inside the hardening tunnel, tunnel temperature, which could control how much the hardening tunnel should cool down the ice cream items running through the hardening tunnel. Another tunnel parameter could be airflow, where a velocity of fans can be controlled for a better distribution of the air inside the hardening tunnel. The airflow could also be changed by changing position of different air guides or deflectors to optimize airflow in certain volumes inside the hardening tunnel.

[0009] Another tunnel parameter may be the humidity inside the hardening tunnel. The humidity could be dependent on the process of manufacturing the ice cream items which would lead to frost inside the hardening tunnel. Frost may e.g. alter air flow over the ice creams items within the hardening tunnel and thereby cause changed cooling of the ice cream items. The humidity could be controlled by dehumidifiers to ensure the right humidity in the hardening tunnel depending on the ice cream item type being hardened.

[0010] Another tunnel parameter could be air-balancing, which would be how to keep the freezing air in the hardening tunnel and to prevent a warmer ambient air compared to inside the hardening tunnel to get in the hardening tunnel. This could be fans, airguides, or airblowers which would blow and guide the freezing air inside the tunnel to stay inside especially around the inlet and outlet of the conveyor. The air-balancing system could therefore typically generate an overpressure inside the hardening tunnel.

[0011] The velocity of the conveyor inside the hardening tunnel could also be a tunnel parameter which would define for how long a given ice cream item is cooled down inside the hardening tunnel. The velocity of the conveyor could be advantages to go faster to get a greater output on the number of ice cream items. On the other hand, would a greater velocity make the time in the hardening tunnel less for the ice cream items and thereby reduce the freezing time.

[0012] Another tunnel parameter could be the number of the ice cream items in the hardening tunnel. The number of ice cream items could affect the temperature due to the ice cream items coming into the hardening tunnel having a higher temperature than the temperature in the hardening tunnel. The ice cream items could also affect the humidity in the hardening tunnel and therefore the number of the ice cream items in the freezing tunnel could affect the humidity inside the hardening tunnel.

[0013] Another tunnel parameter could be the timing of evaporator defrost. The evaporators in the hardening tunnel could be timed to defrost one at a time, especially in case of a hardening tunnel comprising more than two evaporators. In this case a minimum of two evaporators could still be cooling while a third evaporator could be defrosting. The tunnel parameter could also be the timing of hardening tunnel defrost, where the entire hardening tunnel are being defrosted.

[0014] In an advantageous embodiment of the invention said ice cream items are transferred from said hardening tunnel conveyor by an ice cream transferring system to a further conveyor downstream the hardening tunnel conveyor.

[0015] In an advantageous embodiment of the invention said ice cream items are transferred from said hardening tunnel conveyor by an ice cream transferring system to a further conveyor downstream the hardening tunnel conveyor and wherein said ice cream transferring system comprises lifting equipment.

[0016] In an advantageous embodiment of the invention said ice cream items comprises respective ice cream sticks and where said ice cream items are transferred from said hardening tunnel conveyor by an ice cream transferring system to a further conveyor downstream the hardening tunnel conveyor and wherein said ice cream transferring system lifts said ice cream items by ice cream item grippers.

[0017] The term ice cream item grippers may be understood as mechanism that grips the ice cream items with e.g., a mechanical gripper around an ice cream item, a mechanical gripper around an ice cream item stick or a vacuum gripper.

[0018] The term adhesion may be understood as the adhesion between ice cream items and the transportation surface. The term adhesion could also be understood as the attachment or connection between the ice cream items and the conveyor established or at least modified by the ice cream hardening tunnel when ice creams are conveyed through the ice cream hardening tunnel for the purpose of hardening the ice cream. The adhesion between the ice cream items and conveyor are initiated upstream the hardening tunnel when the ice cream items are produced from a mass of ice cream e.g. by extrusion. The adhesion may typically change when the ice cream item(s) are moved through the hardening tunnel until the ice cream items are lifted or moved away from the conveyor and transferred to ice cream processing equipment located downstream of the ice cream manufacturing line. The temperature of the ice cream items may e.g. be around - 4 to - 8 degrees Celsius when the ice cream items are formed and positioned on the hardening tunnel conveyor upstream the ice cream hardening tunnel.

[0019] The adhesion between the ice cream items and the conveyor may as mentioned change during the process in the hardening tunnel. This change of adhesion may be a little unpredictable and may thus result in either a stronger adhesion of the ice cream items to the degree that the ice cream items are adhered too much to the transportation surface when the ice cream items are due for transferring away from the hardening tunnel conveyor or the adhesion may be too low, and thereby invoke that the ice cream items falls of the conveyor within the ice cream hardening tunnel

[0020] When producing the ice cream items the adhesion are at its best within in an interval. The interval of the adhesion may typically have two limits, an upper limit and a lower limit, where the one limit could be the stronger adhesion. The stronger adhesion could be equal to the limit where the ice cream item could just be released from the conveyor without damaging the ice cream item. The stronger adhesion limit appears more often the softer the ice cream item is. When attempting to lift an ice cream item which have too high adhesion, the ice cream item might disintegrate, breaking for instance the stick or tearing it out of the ice cream body. The ice cream body could also disintegrate. When an ice cream item may be lifted and sticks to the conveyor the ice cream item may be damaged. The avoiding of damaging the ice cream item when lifting the ice cream item may imply that ice cream items do not keep sticking to the conveyor after e.g., attempting to lift the ice cream item e.g. in a stick of the ice cream item. Another damage to the ice cream item could be when the lifting pulls out or breaks the stick or any holding means of the ice cream item. At the point when the lifting starts damaging the ice cream item the adhesion could be characterized as to strong and would have exceeded the limit of the adhesion interval. The lifting of the ice cream item may be done with difficulty the ice cream item could end up in another position. The new position of the ice cream item could be out of the aligned position for the gripper.

[0021] The lower limit of the adhesion interval would be when the adhesion of the ice cream product is too weak. The lower limit may be when the ice cream items are too hard, and the adhesion is so weak, so that the ice cream items may change position in a curve along the conveyor pulling the ice cream item in a direction out of the curve. This could typically be the centrifugal force pulling the ice cream items out of position or even invoking that the ice cream items fall of the conveyor. When the ice cream items changes position it may be difficult or impossible e.g. for a lifting robot to lift away the ice cream items from the conveyor downstream the hardening tunnel conveyor, due to the planned motion.

[0022] For both cases when the adhesion exceeds one of the two interval limits it may end up with ice cream items being discarded or the ice cream manufacturingprocess being disrupted, also invoking critical disruption of e.g. a downstream coating process of the ice cream manufacturing line or wrapping process. Therefore, the need for measuring the adhesion and adjusting the adjustable tunnel parameters controlling the cooling and operation of the hardening tunnel with respect to the adhesion is very advantageous. Running the line at optimum adhesion could imply that higher capacity can be achieved and / or lower energy consumption.

[0023] By measuring the adhesion continuously (at a suitable rate), may be possible to push the manufacturing line to its limit in relation to adhesion, and thereby bring the system closer to the point where the ice cream items may fall off inside (or outside) the hardening tunnel, if the adhesion is to small. In conventional system where regulation is purely based on when ice cream items fall of, the system provides a possibility of a predictable setting close to the systems limit, but without ice cream items falls off. Likewise the conveyor speed may be increased if the adhesion is safely without the acceptable range.

[0024] The adhesion may be measured in numerous different ways e.g. by means of lifting mechanism, where the lifting mechanism may typically be automatic. The lifting mechanism may be placed downstream the hardening tunnel, e.g. downstream the hardening tunnel, just outside the hardening tunnel, where it can measure the adhesion. The lifting mechanism may also be a part of the robot that lifts the ice cream items from the conveyor and to the next par in the production line.

[0025] The adhesion may be measured as the force needed to pull away the ice cream item from the conveyor. The force measured to pull away the ice cream items may be expressed e.g. as a lifting force, torque, rotational force, tilt force, a displacement of the ice cream items (shear forces) or any combination thereof.

[0026] The term conveyor may be understood as a conveyor where the ice cream items may be positioned on. The conveyor may be a band or belt for conveying the ice cream items. The conveyor may also comprise rollers with space between each roller. The conveyor may also include plates, trays or bowls which are placed on a conveyer and conveyed, where the plates, trays or bowls may form the surface upon which theice cream items are conveyed. The term transportation surface may thus refer to whatever surface the ice cream items are positioned on, be it the conveyor as such; e.g. a conveyor belt or it may refer the surface of “loose” carriers such as the above mentioned plates, trays or bowls.

[0027] The invention may improve the freezing process of the ice cream items. The tunnel parameters of a hardening tunnel may be the same over time but changes in the hardening tunnel could still occur e.g., frosting or leftovers from the last batch of ice cream items. The frosting and leftovers could change airflow, humidity and other environmental parameters in the hardening tunnel which would influence how the freezing process of the ice cream items would work. Therefore, the need for setting and adjusting the hardening tunnel parameters is important to keep the same adhesion of the ice cream items over time. The method of this invention could keep the adhesion within an adhesion interval over time for both different ice cream item types and the same ice cream item types.

[0028] The term continuously measuring could be understood as a live measuring of the adhesion of the ice cream items that keeps measuring all the time while the freezing and hardening process is ongoing. The term continuously measuring could also be a giving time interval where the adhesion of the ice cream items could be measured at some point in time and repeatedly with the same time interval. The time interval for continuously measuring the adhesion of the ice cream items could be within the range of seconds, minutes, hours, or days. The continuously measuring could also be sequentially measuring where the adhesion is measured at a given time interval, and where the time interval changes over time according to e.g., the adhesion and / or the core temperature of the ice cream items or for how long the hardening tunnel has been running.

[0029] The term continuously adjusting the tunnel parameters could be understood as a live adjusting of the hardening tunnel parameters with respect to the measuring of the adhesion of the ice cream items. The term continuously adjusting could also be an adjustment where the hardening tunnel parameters are adjusted after a specific time interval over and over again. The time interval for continuously adjusting thehardening tunnel parameters could be within the range of seconds, minutes, hours or days. The continuously adjusting could also be understood as sequentially adjusting the hardening tunnel parameters after time intervals, where the time intervals could vary according to the measured adhesion of the ice cream items, for how long the hardening tunnel has been freezing, or related to the adjustable tunnel parameters itself.

[0030] It is difficult to change the tunnel parameters during an ice cream production and keep the quality of the ice cream items good enough. The results of changing adjustable tunnel parameters may typically first be seen after a giving time interval in the adhesion of the ice cream items, e.g. 30 minutes, during which numerous ice cream items have passed through the hardening tunnel. It could be an advantage to adjust the tunnel parameters continuously to keep the adhesion as desired e.g. within a desired predefined adhesion force interval. If this value is measured this may be applied as a basis for manual or automatic adjustment of adjustable tunnel parameters, e.g. supplemented by input of other relevant measured process characterizing parameters.

[0031] In an advantageous embodiment of the invention said adhesion is measured as said ice cream items are being lifted away from said conveyor downstream said hardening tunnel.

[0032] In an advantageous embodiment of the invention said adhesion is measured downstream said hardening tunnel and prior to any optional active loosening of the ice cream items from said hardening tunnel conveyor downstream said hardening tunnel.

[0033] In an advantageous embodiment of the invention said continuously adjusting said tunnel parameters based on said adhesion of said ice cream items to provide adhesion of said ice cream items within an adhesion interval.

[0034] In an advantageous embodiment of the invention adhesion is measured as torque when lifting the ice cream in their respective stick.

[0035] The torque measuring of the adhesion could be understood as a lifting mechanism which is fixed next to the conveyor and the lifting mechanism could lift and turn around the fixed point of the lifting mechanism. The lifting of the ice creamitems by the lifting mechanism could be downstream said hardening tunnel or the lifting could be done at the point on the conveyor where the ice cream items are be moved further down the line of the production.

[0036] The lifting mechanism of the adhesion measuring may e.g. be a robotic arm, lever, or the like.

[0037] It is advantageous to measure the adhesion in torque then the adhesion can be measured at the same time as the ice cream items are being moved away from the conveyor.

[0038] In an advantageous embodiment of the invention adhesion is measured as force / torque when lifting the ice cream, e.g. by means of a gripper and / or suction device

[0039] In an advantageous embodiment of the invention adhesion is measured as lifting force.

[0040] The adhesion could be measured as a lifting force from e.g., a robotic arm, linear lift and / or turn system.

[0041] In an advantageous embodiment of the invention adhesion is measured as rotational force.

[0042] In an advantageous embodiment of the invention adhesion is measured as displacement force.

[0043] In an advantageous embodiment of the invention adhesion is measured as tilt force.

[0044] In an advantageous embodiment of the invention adhesion is measured as a displacement resulting from a test force.

[0045] In an advantageous embodiment of the invention said test force is a predetermined well defined test force.

[0046] It may be advantageous to use a test force to measure the adhesion, i.e. measuring e.g. how much force is required for the ice cream item to slip and / or measuring how much an ice cream item is displaced with a certain fixed test force.

[0047] In an advantageous embodiment of the invention said step of measuring adhesion is placed inside said hardening tunnel, downstream said hardening tunnel or prior to releasing said ice cream items from said conveyor.

[0048] It is advantageous to measure the adhesion inside the hardening tunnel to change the tunnel parameters earlier in the process and thereby getting within the predetermined adhesion interval. When getting in the predetermined adhesion interval more ice cream items could be produced over time.

[0049] In an advantageous embodiment of the invention the transportation surface is subject to measuring indicating the condition of the transportation surface prior to the providing of a plurality of ice cream items on the hardening tunnel conveyor.

[0050] It may be advantageous to measure the transportation surface prior to putting ice cream items on the conveyor. It may be an advantage to measure if there is any frosting or ice cream item leftovers on the conveyor, which could affect the adhesion. The measuring could be done by vision, where a camera could be used to detect if there is any frosting or leftovers or not. The vision-based measuring may also be performed with a laser measuring if there is any refraction or how big a refraction is measured. The refraction may indicate if there is a layer of either frosting, ice cream leftovers, or anything else placed on the conveyor by comparing the refraction with the refraction on a clean conveyor.

[0051] It may also be advantageous measuring the hardening tunnel transportation surface temperature.

[0052] The measuring could also be measured as a weight of the conveyor. The conveyor could be plates where the weight of each plate is known. The weight of the plates could be measured prior to putting ice cream items on the plates and the weight could be compared with the originally weight of the plates. If there is a difference inweight of the plate and the originally weight of the plate it could indicate ice cream leftovers or frosting on the plate.

[0053] The measuring of the characteristics of the conveyor could also be measured by conductivity. The transportation surface may also have a conductivity which is measured when the conveyor is clean and before starting up the production and hardening tunnel. The conductivity of the clean conveyor may be compared to the conductivity of a conveyor which has been running through the hardening tunnel. A difference between the conductivity of the clean conveyor and the conductivity of the conveyor which has been through the hardening tunnel may indicate that e.g., frost or leftovers could be on the conveyor are thereby the adhesion could have changed.

[0054] In an advantageous embodiment of the invention the transportation surface is subject to measuring the condition of the transportation surface of the hardening tunnel conveyor and modifying the condition on the basis of the measured condition.

[0055] A condition to be measure and modify of said transportation surface may e.g., include transportation surface temperature, transportation surface frost-condition, transportation surface ice cream item leftover, transportation surface humidity, transportation surface impurities, adjustable adhesion parameters, etc.

[0056] In an advantageous embodiment of the invention the transportation surface is subject to measuring the condition of the transportation surface of the hardening tunnel conveyor and modifying the condition on the basis of the measured condition in a transportation surface cooling arrangement / tunnel upstream said hardening tunnel.

[0057] The modification may thus be made in a separate tunnel by simple temperature regulation, but it may also be obtained by dedicated fans located upstream or just inside the hardening tunnel.

[0058] In an advantageous embodiment of the invention said adjustable tunnel parameters may further include anyone of the following: tunnel temperature, airflow (speed of fan(s)), conveyor speed, humidity, air-balancing, number of ice cream items,defrosting of evaporators, defrost of tunnel, rate of upstream effective infeed of ice cream items and / or any combination thereof.

[0059] In an advantageous embodiment of the invention said core temperature is measured by inserting a temperature sensor inside said ice cream item and measuring said adhesion by pulling said sensor while said temperature sensor is placed inside said ice cream item.

[0060] In an advantageous embodiment of the invention said step of measuring the core temperature of said ice cream items also comprises measuring a tunnel temperature and / or an ambient temperature.

[0061] In an advantageous embodiment of the invention said step of adjusting said adjustable tunnel parameters is also based on said tunnel temperature and / or said ambient temperature.

[0062] It is advantageous to adjust the cooling process of the ice cream items in the hardening tunnel according to the temperature in the hardening tunnel and the ambient surrounding temperature. The ambient temperature could have an impact on the ice cream items along the production line after the hardening tunnel, where it would be an advantage to ensure the ice cream items would not be softening, melting or too adhesive to the conveyor.

[0063] The ambient temperature could be understood as the temperature in the room where the ice cream production is going on. The ambient temperature could be measured at different locations along the production line of the ice cream items. The different locations along the production line of the ice cream items could be upstream or downstream the hardening tunnel, but it could also be any other place along the production line. The ambient temperature could be an average value of all the temperatures measured in the room of the ice cream item production, or any combination of temperatures measured and averaged.

[0064] It is advantageous to adjust the hardening tunnel according to the ambient temperature when setting up different productions for ice cream items around theworld where the ambient temperature could vary a lot. A hardening tunnel in Denmark could be exposed for different ambient temperatures compared to USA, India, or other places in the world. It would be advantageous to control the hardening tunnel in the same way independently on where the hardening tunnel is placed on earth.

[0065] In an advantageous embodiment of the invention said continuously measuring a core temperature of said ice cream items and continuously adjusting said adjustable tunnel parameters based on said core temperature of said ice cream items is performed automatically.

[0066] It is advantageous to have the continuously adjusting done automatically to ensure a correct adjustment according to the continuously measuring of the core temperature. The person skilled in the art of freezing tunnels would try some setting and see if it has the right effect on the production of the ice cream items. The effect of the change in setting would not be seen right away, so if the wrong change in hardening adjustable tunnel parameters has been done it would take even longer timer to have the right production of the ice cream items.

[0067] In an advantageous embodiment of the invention said measured adhesion of the ice cream items are designated measured core temperature data.

[0068] In an advantageous embodiment of the invention said measured adhesion of the ice cream items are a subset of measurement data.

[0069] In the present context, measured data refers to any measured data of an ice cream manufacturing line, including the ice cream hardening tunnel. The measurement data could be any of measured core temperature data, measured adhesion data.

[0070] In an advantageous embodiment of the invention said adjustable tunnel parameters are monitored.

[0071] In an advantageous embodiment of the invention said adjustable tunnel parameters are monitored and designated measured adjustable tunnel parameters.

[0072] In an advantageous embodiment of the invention said measured adjustable tunnel parameters are a subset of measured adjustable parameters.

[0073] In the present context, measured adjustable parameters refer to any adjustable parameter set, e.g. by an operator, in an ice cream manufacturing line, including adjustable tunnel parameters.

[0074] In an advantageous embodiment of the invention said measured adhesion of the ice cream items are stored as measured adhesion data in a memory.

[0075] In an advantageous embodiment of the invention said measured adhesion of the ice cream items are stored as measured adhesion data associated with ice cream item type data in a memory.

[0076] In an advantageous embodiment of the invention said measured adhesion of the ice cream items are designated measured adhesion data and is a subset of measured data.

[0077] In an advantageous embodiment of the invention said step of measuring the adhesion of the ice cream items are stored as adhesion data related to an associated ice cream item type and optionally further measurement data and / or further measured adjustable parameters.

[0078] The adhesion data may be stored in associated memory and retrieved for use when initiating production of the same of ice cream item type later on after other ice cream items have been manufactured and controlled on the basis of other and different adhesion data relevant for this or these ice cream item type.

[0079] In an advantageous embodiment of the invention said adhesion data are used in a step of the method to correlate said adhesion data to a specific ice cream item type.

[0080] In an advantageous embodiment of the invention said adhesion data are used in a step of the method to correlate said adhesion of said ice cream items to an adjustment of said hardening tunnel.

[0081] It is advantageous to save and collect the measured adhesion over time for optimizing the adjustment of the hardening tunnel. The correlation between the measured adhesion of the ice cream items and the tunnel parameters or the ice cream item types would be advantageous to secure a more stable production with ice cream items downstream the hardening tunnel with an adhesion inside the predefined core temperature interval. This would lead to a higher production of ice cream items, better quality and reduced costs.

[0082] In an advantageous embodiment of the invention said ice cream items are being conveyed further to coating, packaging or any other working station downstream said conveyor.

[0083] It is advantageous to process the ice cream items further downstream the production line after measuring the core temperature of the ice cream items. The ice cream items could be conveyed to a station for coating the ice cream items. The ice cream could bypass the station for coating and be conveyed directly to a packaging station.

[0084] In an advantageous embodiment of the invention said measured adhesion of said ice cream items are automatically applied at least partly for adjustment of said adjustable tunnel parameters.

[0085] In an advantageous embodiment of the invention said measured adhesion of said ice cream items are automatically applied for at least partly adjustment of said adjustable tunnel parameters by means artificial intelligence.

[0086] In an advantageous embodiment of the invention said measured adhesion of said ice cream items are automatically applied for at least partly adjustment of said adjustable tunnel parameters by means artificial intelligence, the adjustment being established by means of supervised machine learning.

[0087] In an advantageous embodiment of the invention said measured adhesion of said ice cream items are automatically applied for at least partly adjustment of saidadjustable tunnel parameters by means artificial intelligence, the adjustment being established by means of non-supervised machine learning.

[0088] In an advantageous embodiment of the invention said measured data and said measured adjustable parameters are applied as training data for a machine learning model of said artificial intelligence.

[0089] In an advantageous embodiment of the invention said measured data, such as measured core temperature data and / measured adhesion data and / or said measured adjustable parameters, such as measured adjustable tunnel parameters are applied as training data for a machine learning model of said artificial intelligence.

[0090] In an advantageous embodiment of the invention said measured data and said measured adjustable parameters are applied as training data for a machine learning model in combination with data defining ice cream item type of said artificial intelligence.

[0091] In an advantageous embodiment of the invention said measured data, such as measured core temperature data and / measured adhesion data and / or said measured adjustable parameters, such as measured adjustable tunnel parameters are applied as training data for a machine learning model in combination with data defining ice cream item type of said artificial intelligence.

[0092] In an advantageous embodiment of the invention said measured adhesion of said ice cream item are measured automatically.

[0093] In an advantageous embodiment of the invention said measured adhesion of said ice cream item are measured manually.

[0094] In an advantageous embodiment of the invention the adhesion of said ice cream items is between said transportation surface of the conveyor and the ice cream items.

[0095] In an advantageous embodiment of the invention the adhesion of said ice cream items is between said transportation surface and said ice cream items and wherethe transportation surface is a surface of carriers such as plates, tray and or pockets upon which the ice cream items are located.

[0096] Carriers may e.g. include plates, trays, etc. upon which ice cream items are carried and the transportation surface is then regarded as the surface of the carriers carrying the ice cream items.

[0097] In an advantageous embodiment of the invention the transportation surface is integral with the conveyor or a part that is carried by the conveyor such as a carrier.

[0098] In an advantageous embodiment of the invention said transportation surface has been coated e.g. by teflon or other low adhesion coating.

[0099] A fast operating line will have less frozen products, which could imply the adhesion is too high.

[0100] If the hardening tunnel conveyor needs to run slower to achieve the needed adhesion, less products is produced per time interval and the products might be more frozen than needed for downstream processing, implying excessive use of energy.

[0101] Use of coating could hence reduce the adhesion at fast speed, implying optimum productivity and use of energy.

[0102] In an advantageous embodiment of the invention said method comprises a step of measuring a temperature of said ice cream item.

[0103] In an advantageous embodiment of the invention said measuring of said temperature of said ice cream item is an ice cream item core temperature.

[0104] In an advantageous embodiment of the invention said measuring of said temperature of said ice cream item is a surface temperature.

[0105] In an advantageous embodiment of the invention said method comprises also adjusting adjustable hardening tunnel parameters at least partly with reference to ice cream item type.

[0106] In an advantageous embodiment of the invention said measured core temperature is applied as a basis for manual and / or automatic adjustment of adjustable tunnel parameters in combination with said measured adhesion.

[0107] The invention further relates to an ice cream hardening tunnel comprising: an ice cream hardening tunnel conveyor, the ice cream hardening tunnel conveyor extending through said hardening tunnel, an adhesion measuring system arranged within said ice cream hardening tunnel and / or outside and downstream said hardening tunnel, a cooling control system configured for manual and / or automatic adjustment of adjustable tunnel parameters on the basis of measured adhesion by said adhesion measuring system.

[0108] In an advantageous embodiment of the invention said adhesion measuring system is arranged upstream to any optional active ice cream loosener associated to said ice cream hardening tunnel conveyor.

[0109] In an advantageous embodiment of the invention said hardening tunnel is further associated with a core temperature measuring system arranged within said ice cream hardening tunnel and / or outside and downstream said hardening tunnel.

[0110] In an advantageous embodiment of the invention the conveyor has a length of at least 200 meters within the hardening tunnel, such as at least 300 meters, such as at least 400 meters.

[0111] The invention further relates to an ice cream manufacturing line comprising: a hardening tunnel, upstream said hardening tunnel an ice cream item provider, an automatic ice cream item transferring system, an optional ice cream coater, an ice cream packaging system.

[0112] In an advantageous embodiment of the invention the hardening tunnel of the ice cream manufacturing line is operated according to the method for controlling a hardening tunnel.

[0113] The invention further relates to an ice cream manufactured by the method for controlling a hardening tunnel.

[0114] The invention further relates to an ice cream product formed by a coated ice cream item the ice cream item comprises a coating and where the weight of the coating of the ice cream product has a tolerance of less than + / - 15% by weight of the coating, such as less than 10% by weight, such as less than 8% by weight of the coating, such as less than 5% by weight, such as less than 2.5% by weight, such as less than 1% by weight of the coating.

[0115] In an embodiment the invention relates to an ice cream product manufactured on the basis of an ice cream item hardened by the method for controlling a hardening tunnel, wherein the ice cream item comprises as coating and where the weight of the coating of the ice cream product has a tolerance of less than + / - 15% by weight of the coating, such as less than 10% by weight, such as less than 8% by weight of the coating, such as less than 5% by weight, such as less than 2.5% by weight, such as less than 1% by weight of the coating. .

[0116] The stated tolerance above is preferably based on a batch of more than 1000 ice cream items consecutively manufactured item cream products of an ice cream manufacturing line including in ice cream hardening tunnel being operated according to the invention, i.e. according to the claims 1 to 55. The reason for the improved tolerance is that the measured core temperature of the ice cream items facilitate both a more efficient operation of the hardening tunnel but also because it is now possible to feed ice cream items with stable core temperatures to a downstream coating apparatus which may now be easier to control in a predictable way as the coating of the ice cream items depends heavily on the core temperature of the ice cream items when these are undergoing coating. If too cold, too much coating will stick to the ice cream item, and if the ice cream item core temperature, is too high, less coating will be deposited, at best.

[0117] The drawings

[0118] Various embodiments of the invention will in the following be described with reference to the drawings where: fig. 1, la, lb illustrate principles of embodiments of the invention, fig. 2 illustrates the principles of an optional layout of an ice cream hardening tunnel within the scope of the invention, fig. 3 illustrates a downstream of a hardening tunnel controlled within the scope of the invention, fig. 4 illustrates a closer view of fig. 3 focusing on an embodiment of an adhesion measuring system, fig. 5 illustrates a view of the adhesion measuring system of fig. 3 and 4, now seen from another side, fig. 6 illustrates a closer view of the adhesion measuring system of fig. 5, fig. 7 illustrates a variant of the adhesion core temperature measuring system of fig. 3 to 6, fig. 8 illustrates a closer view of the ice cream item transferring system of fig. 3, fig. 9-12 illustrates different ways of measuring measurement data and adjustable tunnel parameters in embodiments of the invention, fig. 13-14 illustrate two different types of control embodiments and where fig. 15-17 illustrate different implementation of control systems embodied in a cooling control system, fig. 18a-18b illustrates a block diagram of the process of making ice cream products.Detailed description

[0119] Fig. 1 illustrates some principal components of an embodiment of the invention. Further explanation will follow in relation to other figures below regarding features, method of operation, configuration of equipment, etc.

[0120] Fig. 1 illustrates an ice cream hardening tunnel HT having an upstream US and a downstream DS end. In the present embodiment, the terminology of upstream and downstream will be made with reference to the hardening tunnel HT, unless otherwise noted.

[0121] An ice cream item positioning system IIP is positioned upstream US the ice cream hardening tunnel HT and the ice cream item positioning system IIP is established for positioning of individual ice cream items II on an ice cream tunnel conveyor HTC.

[0122] The ice cream item positioning system IIP may also within the art in specific applications be referred to as a cutter arranged with an extruder by means of which ice cream items are extruded and cut slightly above the surface if the ice cream tunnel conveyor HTC, optionally including insertion of a stick into the ice cream item. This system and variations thereof are known and well-described within the art.

[0123] The ice cream positioning may be performed by one or more robots or other aggregates e.g. extruding or cutting ice cream items II from ice cream formulations / item (not shown) provided further upstream the ice cream positioning system IIP. This part of the process may be performed with equipment / method already available to the skilled person in the art. The ice cream items II may in some embodiments be provided with sticks.

[0124] The ice cream hardening tunnel conveyor HTC extends form an input of the ice cream hardening tunnel HT, though the ice cream hardening tunnel HT and out of the ice cream hardening tunnel hardening tunnel HT to an ice cream item transferring system IITS via an ice cream item adhesion measuring system AMS.

[0125] Such ice cream item transferring system IITS has the purpose transferring ice cream items II from the ice cream tunnel conveyor HTC to other systems of an ice cream manufacturing line, such as a coating system IIC, a packaging system IPP, a boxing system IPB, etc via further conveyors FC.

[0126] Fig la illustrates three different related adhesion zones of the ice cream hardening tunnel conveyor described above. A part of the hardening tunnel transportation surface being upstream the tunnel conveyor has a first type of adhesion, here referred to as pre-tunnel adhesions PRTA designating the adhesion arising when just produced ice cream items II are positioned at the tunnel conveyor HTC just before they are conveyed into the hardening tunnel HT. When the ice cream items enter the hardening tunnel HT, these will gradually harden as they are cooled to temperatures below the temperatures they were initially produced at. There will thus be a temperature development and the core temperature of the ice cream items will gradually lower through the tunnel, e.g. from minus 5 degrees Celsius to e.g. minus 18 degrees Celsius depending on numerous factors. This, together with many other factors, result in a modification of the adhesion between said ice cream items and said transportation surface, and this adhesion is here referred to as tunnel adhesion TA. Subsequently, the ice cream items II will exit the hardening tunnel HT, and due to the ambient temperature which is typically higher than the temperature within the hardening tunnel HT and the adhesion will then again be influenced to a larger and smaller degree depending on many factors, such as ambient temperature, distance covered from the exit of the hardening tunnel until the ice creams arrived at the ice cream item transferring system IITS, conveyor speed, ice cream item type, etc. The tunnel adhesion TA and / or the post tunnel adhesion POTA may be measured at one or more points as a representation for adhesion and the measured adhesion if the ice cream items may be applied as a basis for control of the hardening tunnel, i.e. by adjusting the adjustable tunnel parameters.

[0127] Fig. lb illustrates a variant of the system of fig 1. and fig la, where a product loosener LOS has been positioned at or just before the ice cream items reaches the ice cream item transferring system IITS. When the ice cream items has been loosenedfrom the transportation surface, e.g. from trays or plates carrying the ice cream items to that these can be lifted or removed from the hardening tunnel conveyor HTC, the adhesion between the ice cream items and the hardening tunnel conveyor is no longer representative of what has happened in the tunnel in a way that is attractive for controlling the hardening tunnel, i.e. for adjusting the adjustable tunnel parameters. Subsequent to active loosening of the ice cream items the adhesion is thus no longer referred to and understood as the above mentioned post tunnel adhesion POTA but as a post loosener adhesion PA.

[0128] It is very difficult or maybe even impossible to establish any practical relationship between the measured adhesion and what has happened in the tunnel.

[0129] Fig. 2 illustrates the principles of an optional layout of an ice cream hardening tunnel HT applied according to an embodiment within the scope of the invention. The illustrated ice cream hardening tunnel HT is associated with a hardening tunnel conveyor HTC extending through the ice cream hardening tunnel HT, the conveyor being movable in a direction indicated by associated arrows by an automatic adjustable drive system (not shown) under the control of a cooling control system CCS.

[0130] Moreover, the ice cream hardening tunnel includes an adjustable cooling arrangement (not shown) also controlled by the cooling control system CCS controlling cooling temperature and optionally also adjustably controlling air flow within the hardening tunnel HT.

[0131] It should be noted that the cooling control system CCS may be a singular arrangement or a number of co-functioning controllers. The illustrated cooling control system CCS is communicatively coupled with an operator interface OI by means of which an operator has access to modify adjustable tunnel parameters on the basis of the inventive measuring of adhesion of ice cream items. It is thus noted that many state of the art ice cream hardening tunnels may be controlled according to the invention only with an addon measuring adhesion of the ice cream items inside the hardening tunnel or outside, downstream, thereby making it possible for an operator makingtimely adjustment of the effective cooling of hardening tunnel by modifying the adjustable tunnel parameters.

[0132] At an upstream US end of the ice cream hardening tunnel HT the hardening tunnel conveyor HTC projects into the hardening tunnel HT. Upstream US the hardening tunnel HT ice cream items (not shown) may be positioned on the hardening tunnel conveyor HTC by an ice cream item positioning system IIP, here in the form of four individual stations connected to a mixer MIX, including freezers F / extruders, stick inserters and a cutter, thereby facilitating a continuous and automatic placement of ice cream items (not shown) on the hardening tunnel conveyor HTC prior to being transported into the ice cream hardening tunnel HT.

[0133] The mixer MIX mixes ingredients relevant for the recipe of the ice cream items to be produced and the freezers F provides the desired extruding temperature for the applied extruders of the ice cream item positioning system IIP.

[0134] Inside the ice cream hardening tunnel HT the hardening tunnel conveyor HTC extends through the hardening tunnel so as to facilitate a cooling of the ice cream items from a temperature the ice creams items may have upstream the tunnel, to a temperature of the ice cream items which is lower when the ice cream items leaves the ice cream hardening tunnel HT downstream DS the hardening tunnel HT.

[0135] The length of the hardening tunnel conveyor HTC, the cooling applied by the cooling system (not shown) including optional internal ventilation, movement of cool air within the hardening tunnel HT, the speed of the hardening tunnel conveyor HTC, etc will determine the resulting cooling from one temperature, e.g. minus 5 degrees Celsius to e.g. minus 18 degrees Celsius, measured as core temperature.

[0136] Some of these parameters are referred to as adjustable tunnel parameter, and these adjustable tunnel parameters may be adjusted manually and / or automatically.

[0137] The hardening tunnel conveyor HTC then exits the hardening tunnel HT and projects to an ice cream item transferring system IITS via an ice cream adhesion measuring system AMS and an optional product loosener LOS.

[0138] The ice cream item transferring system IITS is designed to transfer the cooled ice cream items (not shown) to further equipment further downstream the ice cream item manufacturing line (not shown). The present figure only illustrates a part of a further conveyor transporting the ice cream items further down to optional coating, further conveyors adapted to their specific purposes, packaging, boxing and whatever may be necessary and relevant.

[0139] The ice cream adhesion measuring station AMS is here located a position close to the exit of the ice cream hardening tunnel HT, at the downstream end DS, to reduce the influence of the ambient conditions, e.g., temperature, to an adhesion measurement of the ice cream items transported by the hardening tunnel conveyor HTC or a subset of the ice cream items transported by the hardening tunnel conveyor HTC.

[0140] In an advantageous embodiment the adhesion measuring system AMS designed to perform the measurement(s) of adhesion of the ice cream items inline, hereby meant that the measurements are performed without interrupting the movement of the hardening tunnel conveyor HTC.

[0141] It is in particular noted that the position of the adhesion measuring system may be other than the indicated position just outside downstream the hardening tunnel HT.

[0142] Thus, the adhesion measuring system may thus in an alternative embodiment be incorporated and working with the ice cream item transferring system IITS if this is feasible, e.g. performing measurement of ice cream item adhesion while or just prior to when ice cream items are transported from the hardening tunnel conveyor to some other conveyor mechanism COND further downstream the ice cream manufacturing line.

[0143] A further possible way of performing the measurement of adhesion of the relevant ice cream items may be that of positioning the measuring adhesion measuring system AMS within the hardening tunnel HT.

[0144] A further possible way of performing the measurement of adhesion of the relevant ice cream items may be that of positioning two or more adhesion measuring systems AMS at points within the hardening tunnel HT and / or outside downstream DS the hardening tunnel HT as indicated above.

[0145] The measured adhesion may be applied as a basis for manual, semi automatic and / or automatic adjustment of adjustable tunnel parameters, i.e. in a broader perspective an adjustment of the effective cooling performed within the ice cream hardening tunnel based on the measured adhesion of the relevant ice cream item whether these are real ice cream items, ice cream items dummies or not.

[0146] The above illustrated system includes a number of relevant components shown for explanatory purposes. It goes without saying that the principles of the invention may be applied in other configurations and with other designs of the ice cream hardening tunnel HT and associated equipment.

[0147] The hardening tunnel includes one or more heat exchangers, elsewhere referred to as evaporators. If two or more evaporators are applied the hardening tunnel could defrost one of the evaporators while the remaining evaporator(s) are cooling thereby make it possible to defrost evaporators while the hardening tunnel is functioning. The number of active evaporators may those become an adjustable tunnel parameter ATP if available and desired.

[0148] Fig. 3 illustrates a downstream output of a hardening tunnel controlled within the scope of the invention. An ice cream hardening tunnel HT, e.g. the ones explained in relation to fig. 1 and 2, has a downstream DS end, here an exit of the hardening tunnel HT through which a hardening tunnel conveyor HTC extends towards an ice cream item transferring system IITS via an optional ice cream loosener LOS. In the present embodiments, the hardening tunnel conveyor HTC is implemented to transport ice cream items II on conveyor plates CP. The conveyor is moving in the direction of the arrows during operation. If a reference to a transportation surface is made, the reference will be made with respect to a / the surface of the conveyor plates CP if such plates are applied. If, the conveyor transports the ice cream items II directly on theconveyor elements, a transportation surface is to be understood as the surface upon which the ice cream items are conveyed. Other implementations of the conveyor may thus of course be applicable within the scope of the invention, with or without “loose” plates or trays positioned on the top of the underlying conveyor, although easy removal plates / trays / etc are advantageous as these may easily be positioned and removed on the conveyor and easy to clean in a run-time environment. Furthermore, it will be easier to make format changes, if for instance the removal plates / trays / are specifically designed / formed to carry or keep specific ice cream item types (e.g. if ice cream items are carried in “pockets”). The illustrated embodiment includes an adhesion measuring system AMS, here placed just outside the hardening tunnel HT.

[0149] In the present embodiment, the adhesion measuring system AMS is designed to perform measurement of adhesion of selected ice cream items II and then interface the result to an operator by a suitable interface which may be visual, audio, tactile, etc (not shown) and thereby facilitate an valuable assistance to an operator facilitating proper adjustment of adjustable tunnel parameter of the ice cream hardening tunnel HT and thereby modifying the effective cooling of the ice cream hardening tunnel HT if the measured adhesion is different from the intended adhesion e.g. predetermined for the specific ice cream item type. If the hardening tunnel HT is in a process of switching operation from hardening of one ice cream item type to another ice cream item type, the needed adjustment of adjustable tunnel parameter may be somewhat more intense as different ice cream item types may require some “major” adjustment, during an initial period, whereas it is expected that the adjustment of adjustable tunnel parameters may be made with a lower frequency and with “minor” adjustment during a subsequent maintenance period, where the process is running and the adjustment of adjustable tunnel parameters are merely made in other to maintain a stable state of the processing of ice cream items. In reality, the stable state is not completely stable, e.g. because of frosting on the components inside the hardening tunnel affecting the effective cooling of the ice cream items carried on the hardening tunnel conveyor. By tracking this “drifting”, it may be possible to make adjustment to the process based on measured core temperature during the maintenance period and reduce or maybe even avoid any disruption in the hardening process (such drifting would typically only bediscovered when the ice cream items are not OK anymore or e.g. if the process as such are negatively and physically impacted by the drifting).

[0150] Also here, it is noted that the inventive control of the hardening tunnel makes is possible to make minor adjustment of adjustable tunnel parameters even if small deviations from the intended adhesion is measured and when this is detected prior to consequential unwanted process conditions which are normally applied as a basis for adjustment of adjustable tunnel parameters, and thereby making it possible to reduce the impact of the unwanted process condition or even avoid the unwanted process condition.

[0151] Also here, it is noted that measured ice cream item adhesion may serve as a basis for automatic adjustment of the ice cream tunnel.

[0152] Fig. 4 illustrates a closer view of fig. 3 focusing on the adhesion measuring system AMS.

[0153] Fig. 5 illustrates a view of the adhesion measuring system of fig. 3 and 4, now seen from another side. The adhesion measuring system AMS illustrated may include optional core temperature measuring equipment CME mounted on a movable adhesion measuring system head AMSH. The adhesion measuring system head AMSH is movable back and forth in the moving direction of the hardening tunnel conveyor HTC indicated by the arrow.

[0154] The core temperature measuring equipment CME includes a core temperature measuring equipment probe CMEP which may be moved down to be probed into an ice cream item to be measured and up again, when the probe has been inserted long enough to get a reliable and representative core temperature measurements representing the core temperature of the ice cream items measured.

[0155] In the illustrated embodiment the conveyor is continuously moving in the direction of the arrow, e.g. 20 cm per secund and the adhesion measuring system head AMSH is thus arranged and automatically controlled to follow the movement of an ice cream item, e.g. the illustrated first ice cream item III to be probed, when the probeis being inserted with a measuring point close to the internal part of the first ice cream item III intended to be measured, while it is inserted and when exiting the ice cream in question.

[0156] After the core temperature have been obtained and the probe has been extracted from the ice cream item the adhesion measuring system head AMSH will return to its original position ready for a new measurement.

[0157] The adhesion measuring AMS comprises adhesion measuring equipment AME including adhesion measuring pusher AMP which is also mounted on and moving with the adhesion measuring system head AMSH while the core temperature is measured by the core temperature measuring equipment probe CMSEP - thereby providing a movement of the adhesion measuring system head AMSH which is in sync with both the first ice cream item III and second ice cream item 112 on the moving conveyor, thereby at the same time / during the same time interval, measuring adhesion, here adhesion force between the surface of the ice cream hardening tunnel conveyor HTC and the second ice cream item 112 by means of an adhesion measuring pusher AMP pushing the second ice cream item 112 (slightly) in the direction of the movement of the conveyor and then measuring the force required for moving the second ice cream item 112 slightly in the movement direction of the conveyor indicated by the arrow. This measurement may then be applied as an input for manual and / or automatic adjustment of the adjustable tunnel parameters. After having made an invasive core temperature measurement the system may furthermore dispose the tested ice cream item III e.g., if the ice cream item has been damaged and cannot be used. The system may also be designed for systematic disposure of invasively tested ice crem items. The disposal may be performed in numerous different within the scoop of the invention e.g., by having the probe displacing the tested ice cream item III slightly so that the subsequent ice cream item transfer system IITS does not pick up the displaced ice cream item for transfer downstream the ice cream manufacturing line.

[0158] Fig. 6 illustrate a closer view of the adhesion measuring system of fig. 5.

[0159] Fig. 7 illustrates a variant of the adhesion measuring system AMS of fig. 5 and 6, where the optional core temperature measuring equipment CME now includes an infrared temperature measuring head ITMH measuring the surface temperature of one or more ice cream items. The measured surface temperature is then converted to a measured ice cream core temperature by use of data representing the e.g. geometry, weight, type of ice cream, ambient temperature, ambient humidity outside the hardening tunnel etc related to the specific ice cream item type. It is noted that this way of measuring the core temperature under some conditions may be less accurate and applicable the above illustrated invasive application of a probe, but on the other hand this way of measuring the ice cream item core temperature may in the specific inventive application be feasible as the inventive control is correlated to the relevant ice cream type, and the preestablished information of the ice cream type may highly improve the quality of the core temperature based on a measured surface temperature.

[0160] Fig. 8 illustrates the part of the system where ice cream items II are removed the hardening tunnel conveyor HTC by means of an ice cream transferring system IITS. In the specifically indicated implementation, the ice cream items II are gripped by ice cream item grippers IIG in their respective sticks and the ice cream items II are then lifted from the hardening tunnel conveyor HTC and handed over for further downstream processing of the ice cream items of the ice cream manufacturing line, such as coating, packaging, boxing, etc. The hardening tunnel conveyor is moving in the direction of the arrow and will then be ready for optional further steps before entering the ice cream hardening tunnel HT again for hardening of new ice cream items provided on the conveyor upstream the hardening tunnel HT. In the presently illustrated embodiment, the ice cream items may be subjected to mechanical actional by a product loosener LOS prior to being gripped by the ice cream item grippers IIG. This product loosener may also be referred to as hammer, as it effectually involves a mechanical hammering on the conveyor plates CP to mechanically loosen the ice cream items on the conveyor plate. It is however noted, that in an advantageous embodiment, due to the advanced control of the present invention based on the measured adhesion of the ice cream items to the surface of the conveyor, the product loosener LOS may even be omitted or at least be controlled to only hammer when it isabsolutely necessary, thereby reducing energy consumption and reducing the noise and minimizing the risk the product loosener causes the ice cream items to move to a degree that the ice cream transferring system may not pick up the relevant items, thereby causing waste.

[0161] Fig 9-12 illustrated various way of transmitting measurement data MD measured adjustable parameters MAP in relation to the embodiments of fig. 1.

[0162] In fig. 9 measurement data MD are established at various point of an ice cream manufacturing line and measured adjustable parameters MAP are gathered to keep track on how adjustable parameters are present set. These measured adjustable parameters are read and stored in a memory and may then be applied for automatic, semiautomatic or manual control of a hardening tunnel, e.g. by a cooling control system CCS.

[0163] Fig 10 illustrates a way of interfacing measurement data MD and measured adjustable parameters MAP to an artificial intelligence-based control Al and / or an artificial intelligence-based monitoring system Al.

[0164] Fig. 11-12 illustrate various ways of routing data to and from a cooling control system CCS in one of several applicable embodiments within the scope of the invention.

[0165] Fig. 13 illustrates a setup of a cooling control system CCS or any controller CSY of an ice cream manufacturing line (see e.g. fig. 15-17) according to the invention where measurement data MD, in particular measured adhesion data MAD established e.g. according to any of the above illustrated embodiment in fig. 1 to 12 and / or 14-17 are stored in a memory MEM. The measured data MD, e.g. measured adhesion data MAD, are obtained by relevant sensor(s) or whatever circuitry enabling establishment data relevant for controlling and / or monitoring the process of an ice cream manufacturing line, measurement data MD, in particular may preferably be associated with data determining the ice cream item type(s) to which the measured adhesion data MAD relates. These measured and stored adhesion data MAD are transmitted to the operator interface OI thereby facilitating an operator to adjust adjustable tunnelparameters ATP and transmit these to a cooling control system CCS of a respective hardening tunnel HT. The adjustable tunnel parameters ATP may thus be adjusted on the basis of currently measured adhesion data MAD of ice cream items II being currently processed in the hardening tunnel HT and also while using other relevant measured data MD as guidance, this measuring preferably being guided by predetermined setpoint of ice cream adhesion data likewise stored in the memory MEM. The measured data MD, including the measured adhesion data MAD may be shown visually to the operator and / or by any other suitable interfacing means, such as audio etc.

[0166] The comparison between setpoint stored adhesion data and the run-time measured adhesion data MAD should preferably be made with respect to the same ice cream item type.

[0167] Measured data may be any of the following, but not limited to:

[0168] Tunnel temperature (e.g. at various points), Tunnel humidity (e.g. at various points), tunnel air flow (e.g. at various points), actual conveyor speed, ice cream item core temperature, ice cream item adhesion to the transportation surface of the conveyor, number of ice cream items in the hardening tunnel, ice cream item rate, ambient temperature outside the hardening tunnel, amount of defrost, temperature of transportation surface, state of transportation surface, state of the ice cream extruder, including temperature, viscosity, rate; running time of the tunnel, on a broder perspective: cooling effect of the tunnel; weight of ice cream items, ice cream item waste, weight of ice cream item coating, temperature of the coating material, infeed of amount of coating material, coating rate (how many ice cream items are coating per time unit), coating / dipping time of the ice cream item, packaging rate such as packed ice cream items per time unit; boxed ice cream items per extruded ice cream item, e.g. per time unit, and / or any relevant measured data of an ice cream hardening tunnel and the remaining ice cream manufacturing line.

[0169] Adjustable parameters may be any of the following, but not limited to adjustable tunnel parameters such as conveyor speed, fan speed, tunnel temperature,tunnel humidity, number of active evaporators, any other setting effecting the cooling effect of the hardening tunnel, air balancing system, pre-cooling of transportation surface upstream, the infeed speed, the number of ice cream items fed through, etc. Other than adjustable tunnel parameters may include speed of ice cream item transferring system, coating material temperature, coating / dipping time, coating material composition, ice cream item composition, extruder rate packaging settings, boxing setting, etc.

[0170] Likewise, other adjustable parameters, e.g. adjustable tunnel parameters, may be monitored as measured adjustable parameters (in other words, the measured adjustable parameters in such content would rather refer to that adjustable parameters are monitored to reflect the current adjustable settings) and compared to run-time measured measurement data reflecting the current actual values related to such setting, if these exists.

[0171] An example may me that an operator set a tunnel fan speed of 30Hz which is registered and understood as a measured adjustable parameter whereas a run-time measurement of the actual tunnel fan speed delivered by the fan is e.g. 28.5 Hz and is understood as measured data

[0172] The setpoint stored adhesion data may be provided as a target adhesion, an interval of adhesion setpoint, a development of adhesion, etc, whatever applicable and practical as a guidance for the operator to adjust the adjustable tunnel parameter. The setpoint adhesion data may thus be provided for certain periods of time in order to assist the operator for a very optimal adjustment at any time during operation, e.g. as adhesion data related to an initial period Tinit or as adhesion data related to a maintenance period Tmain.

[0173] Likewise, it will be possible to automatically compare the stored setpoint adhesion data and the run-time measured adhesion data MAD and set an alarm to the operator if process conditions, e.g. the run-time measured ice cream item adhesion or other parameters, such a run-time measured core temperature if ice cream items (if measured) are developing in an undesired way.

[0174] Fig. 14 illustrates a variant of the invention where setpoint adhesion data and run-time measured adhesion data MAD are interfaced to the cooling control system CCS including a memory MEM as a basis for automatic adjustment of adjustable tunnel parameters (not shown). The algorithms invoking the automatic adjustment of the adjustable tunnel parameters may be stored and executed by the cooling control system CCS on the basis of the measured adhesion data MAD; the control being based on control algorithms correlated to the specific ice cream item type processed by the hardening tunnel in question.

[0175] It should be noted that the above referenced setpoint core temperature data also may be referred to a target core temperature data, i.e. data stating what the target should be for the particular ice cream item type.

[0176] It is of course still possible to facilitate overriding of automatic adjustment by an operator if so desired.

[0177] It should be noted that the measuring of the adhesion facilitates a much more predictable guidance to control than prior art parameters, as it should be noted that the conveyor of a hardening tunnel may be relatively long, very often extending 200-600 meters within the cooling tunnel, and therefore providing a significant delay in reaction to modification of the tunnel parameters.

[0178] It should be stressed that automated control based on measured adhesion may be performed analytically, e.g. based on a desired adhesion interval, e.g. for a specified ice cream type, but other control algorithms may also be applied within the scope of the invention, in particular by reacting to development of measured adhesion e.g. by means of P control, PID control loops, I control loops, etc.

[0179] An advantageous control may also be applied by means of artificial intelligence, e.g. by use of supervised or non-supervised machine learning, where the control is based on measured adhesion as an input.

[0180] Artificial intelligence may also be applied for actively providing an alarm or issuing guidance to an operator in order to facilitate an improved handling of the adjustable tunnel parameters.

[0181] Various advantageous ways of control has been described, including, e.g., control based on PID control loops. However, control based on artificial intelligence may also be applied. Notice that various types of machine learning control may be applied. E.g., machine learning control may be applied to approximate a nonlinear mapping from measured sensor data (sensor signals) to control signals or actuation commands. In this case, various types of neural network models may, e.g., be applied. The control may also be handled as a regression problem, wherein machine learning control may provide control of the adjustable tunnel parameters based on minimization of a cost function, e.g., a measured control performance. Furthermore, the control may advantageously be implemented based on reinforcement learning. Advantageously, reinforcement learning may enable the performance of the control to be optimized over time based on feedback from the measured data and rewards. Moreover, reinforcement learning may be highly adaptable to changes in the conditions of a system, which is advantageous. Altogether, non-limiting examples of algorithms that may be employed for control includes neural network, genetic algorithm based control, genetic programming control, reinforcement learning, regression trees, linear regression and non-linear regression models etc.

[0182] Advantageously, the machine learning models may be able to adapt to conditions to achieve optimal control, while other classical non-machine learning based control methods require preset parameters, and so these may be less adaptable to, e.g., changing conditions.

[0183] In an advantageous embodiment of the invention, control is based on a recurrent neural network model. This is advantageous in that the recurrent neural network model may learn dependencies between time steps of data. Hence, the model is able to apply control not only based on current knowledge of measured data, but based on sequential dependencies between adjustable tunnel parameters and actual measured data. This may provide more accurate and robust control.

[0184] Fig. 15 illustrates a schematical example of a control system CSY which may be part of an ice cream manufacturing line controller or a part of one of several controllers of an ice cream manufacturing line, such as a cooling control system described in fig. 2. The control system CSY is based on machine learning according to an embodiment of the invention. The system comprises a machine learning control model MLCM configured to output adjustable tunnel parameters ATP of a hardening tunnel HT, e.g., as disclosed in any of the figures and text included in this application. The sensor(s) SENS may be configured to measure measuring data MD (notably here including the measured core temperature data MCTD and / or measured adhesion data MAD), and a comparator unit CU. The comparator unit CU is configured to compare one or more received set point(s) SP, with measuring data MD e.g., the core temperature received from the sensor(s) SENS. The set point SP may e.g., be a desired ice cream item core temperature and / or an adhesion. The comparator unit CU compares the set point(s) with the received measuring data MD to provide a measure of error between the two, to the machine learning control algorithm. The setpoint may, e.g., be a core temperature, and the error may, e.g., be any measure of difference, including ratio etc.

[0185] The machine learning control model MLCM is configured to determine adjustable tunnel parameters ATP and provide these to control adjustable tunnel parameters of a hardening tunnel for a cooling control system CCS associated there to (not shown). The cooling control system CCS (not shown) of hardening tunnel receives the adjustable tunnel parameter ATP from the machine learning control model MLCM and control the hardening tunnel HT accordingly. The effect of the adjustment of the adjusted tunnel parameters is measured by a sensor that that measures measurement data, which may, e.g., be a core temperature of ice cream. The measurement data MD (which may include several other types of measurements performed in the hardening tunnel HL, in relation to the hardening tunnel HL or in relation to the ice cream manufacturing line) is received by the comparator unit CU, which compares the measured data MD with the setpoint to calculate an error between the two. In this example, the error is a difference between the measured data and the setpoint, and the set point is an ice cream core temperature value, while the measureddata is also an ice cream core temperature value. The difference is received by the machine learning control model MLCM, which may then adjust the adjustable tunnel parameters ATP to minimize the error between the measured data MD and the setpoint.

[0186] Optionally, more than one setpoint may be applied. Thereby, the machine learning control model may provide control according to more than one setpoint. The setpoint may include, e.g., core temperature, adhesion, hardening tunnel conveyor speed, tunnel temperature, humidity in the tunnel, wind speed, transportation surface temperature, etc.

[0187] In an optional exemplified embodiment of the invention, the machine learning control model MLCM is a long short-term memory network. This type of neural network is capable of accessing and utilizing long-term dependencies in the sequential data provided to the model. This may advantageously improve the accuracy of the model, e.g., provide control that results in the measured data MD being very close to the desired setpoint. Especially, when compared to models not capable of exploiting long-term dependencies.

[0188] The machine learning control model, including the exemplified long shortterm memory network model, of the present embodiment may be a supervised model, and hence, the model is trained on training data. The training data may e.g., comprise sets of historical data comprising measured data MD and corresponding adjustable tunnel parameter signals ATP. Advantageously, this may enable the model to learn relations between how the adjustable tunnel parameters ATP and the measured data. Optionally, one or more setpoint(s) may also be included in the training data.

[0189] In another optional exemplified embodiment of the invention, the machine learning control model may be a reinforcement learning mode. In this case the model is given a reward, e.g., when the action taken by a model results in the model minimizing an error between the measured data and the setpoint , e.g., corresponding to the model optimizing the rewards given or the accumulated rewards given based on the action taken by the reinforcement learning model. In other words, the model receives information of the state of the system that the model affects with the action itdetermines (the adjustable tunnel parameters). Information of the state of the system may be given, e.g., by measurements, e.g., sensor measurements, e.g. measurements of adhesion, e.g. based on torque. A reward system provides feedback to the agent in terms of the rewards. The reward is based on the outcomes of the models determined actions and guides the rewards can be understood as providing guiding to improve the decision-making strategy of the model, e.g., determining the adjustable tunnel parameters that optimizes the reward. Over time, the reinforcement learning model learns which actions that optimizes the rewards and thereby learns the best control strategy.

[0190] Machine learning based control models are advantageous, e.g., because the models may learn the system behavior based on data, and hence, the models may be optimized over time by retraining the models as more and more data are collected. The models are also adaptive because the models may be adapted by training the model based on different training data. Hence the model may be adapted to, e.g., provide control in production of various types of ice cream and adapted to various production line locations that may be characterized by differing in external operating parameters or conditions such as different ambience conditions, which may affect the production.

[0191] Different types of machine learning models may be utilized for the machine learning control model, including e.g., various types of reinforcement learning models, including deep reinforcement learning, and Q-learning, etc. Further models that may be utilized as the machine learning control model includes one or more of the following reinforcement learning control models: deep deterministic policy gradient (DDPG) algorithm, Proximal Policy Optimization (PPO), actor critic algorithms including soft actor critic (SAC), deep Q-network (DQN). We note that also genetic programming may be utilized according to an embodiment of the invention.

[0192] The deep deterministic policy gradient (DDPG) algorithm is a model -free, off-policy reinforcement learning method, which may advantageously be implemented as a machine learning control model, according to an embodiment of the invention. A DDPG agent is an actor-critic reinforcement learning agent that searches for an optimal policy that maximizes the expected cumulative long-term reward, concurrently learnsa Q-function and a policy. The algorithm uses off-policy data and the Bellman equation to learn the Q-function and uses the Q-function to learn the policy.

[0193] Proximal policy optimization (PPO) may be utilized as a machine learning control model according to an embodiment of the invention. The PPO may be classified as a policy gradient method for training an agent’s policy network. The policy network is the function that the agent uses to make decisions. To train the right policy network, PPO takes a small policy update (step size), so that the agent may reliably reach the optimal solution. A too-big step may direct policy in the false direction, thus having little possibility of recovery; a too-small step lowers overall efficiency. Consequently, PPO implements a clip function that constrains the policy update of an agent from being too large or too small. Advantageously, PPO strikes a balance between performance and comprehension.

[0194] The Deep Q-network (DQN) algorithm is a model -free, off-policy reinforcement learning method, which may advantageously be implemented as a machine learning control model, according to an embodiment of the invention. Deep q-network agent is a value-based reinforcement learning agent that trains a critic to estimate the expected discounted cumulative long-term reward when following the optimal policy. DQN may be considered a variant of Q-learning that features a target critic and an experience buffer. DQN may be considered a relatively simple and effective model. Moreover, DQN may mitigate data correlation. In essence, DQN combines principles of deep neural networks with Q-leaming, enabling agents to learn optimal policies in the complex control of the hardening tunnel etc. DQN may utilize experience replay, which may advantageously help in decorrelating the sequential experiences by storing them in a replay memory buffer. This memory buffer is randomly sampled during the network update to break the temporal dependencies and stabilize learning.

[0195] Soft Actor Critic (SAC) is an algorithm that optimizes a stochastic policy in an off-policy way, forming a bridge between stochastic policy optimization and DDPG-style approaches. While the SAC algorithm may be best suited for continuousaction spaces, it may be implemented as a machine learning control model according to an embodiment of the invention.

[0196] A machine learning control model, e.g., based on reinforcement learning may take long time to train, in turn, potentially resulting in lots of products, such as ice cream product being wasted, as the reinforcement learning model trains by testing different parameters such as the adjustable tunnel parameters, and learning from the corresponding feedback (rewards) given in response to these actions, e.g. adhesion, e.g., based on torque etc., as described elsewhere in this disclosure.

[0197] Optionally, reward shaping and / or imitation learning may be utilized to train the reinforcement learning control model. Advantageously, in imitation learning, an expert in ice cream making is determining the adjustable tunnel parameters to achieve a given desired quality, and furthermore, the expert is evaluating the quality of the produced product, e.g., including the adhesion etc. as described elsewhere in this disclosure, given the determined adjustable tunnel parameters, and giving feedback as to whether the quality (adhesion etc.) matches the desired quality and / or adhesion etc. The expert may during production adjust parameters and when adjusting the parameters continuing to evaluate the quality including measures of adhesion etc. The reinforcement learning control model is then capable of learning from the expert, which parameters that maximizes the reward (provides the desired quality, adhesion etc.). Advantageously, imitation learning may vastly minimize the amount of training iterations it takes before the reinforcement learning control model becomes capable of performing at a level that provides the desired product quality, adhesion etc. Optionally, the training of the reinforcement learning control model may be continued without the imitation learning, to improve the performance of the reinforcement learning model.

[0198] Notice that the concept of imitating the adjustable tunnel parameters determined by a human expert may be implemented using various types of machine learning, including different types of supervised learning and thereby not only reinforcement learning. However, while reinforcement learning may sometimes betime consuming to train, reinforcement learning control models may typically outperform traditional supervised learning algorithms.

[0199] The reinforcement learning models may be trained and operated on various data related to, e.g., the tunnel and produced product, including, e.g., ambience external operational parameters such as, e.g., including parameters to ambience conditions. The type of data, including, e.g., external operational parameters, that may be used to train machine learning control models, have already been described elsewhere, and we note that these data may also be applied to train other machine learning models according to the invention, including reinforcement learning models such as those described above.

[0200] Optionally, the training of machine learning control models according to the invention may include using a model of the hardening tunnel and of the ice it produces and the adhesion of the ice etc., as a starting point and use that as a first best guess of the system. E.g., an analytical model or an empirically determined model. Optimally, the machine learning model may first be trained to copy or approximate an Al model to become a copy of the mathematical model of the system and then the machine learning control model having approximated the model may be trained based on training data. This may advantageously minimize the iterations required to train the machine learning control model from this initial guess.

[0201] In an optional embodiment of the invention, the control may be based on a genetic algorithm. A genetic algorithm approach may further advantageously be combined with machine learning control approaches, including those already described in this disclosure. Advantageously, genetic algorithms may be said to breed the solution to the control problem using an interactive process involving probabilistic selection of the fittest solutions by means of a set of genetic operators.

[0202] Fig. 16 illustrates a schematical example of a cooling control system CCS that may be implemented to perform automatic control based on a machine learning control model (not illustrated). The cooling control system may be implemented to use various types of machine learning models, including, e.g., the model(s) described in relationto fig. 15. This particular example illustrates the use of the controller for training a machine learning control model based on measured data and measured adjustable control parameters. Notice that machine learning control models of the invention may be trained using other types of hardware. E.g., utilizing one or more processors PU, memory unit MUT, including GPUs, CPUs etc. Further notice that the machine learning control model may optionally be optimized using various types of hyper parameter optimization techniques.

[0203] The controller receives measured data MD and measured adjustable parameters / hardening tunnel parameters MAP. The data pairs of measured data and corresponding measured adjustable tunnel parameters are used as training data, where the measured data is input data while the measured adjustable tunnel parameters are the output, also sometimes referred to as the target. The measured adjustable tunnel parameters may be obtained from manual control of the adjustable tunnel parameters by one or more experienced person(s). E.g., one or more experienced person(s) adjust the adjustable tunnel parameters to achieve a specific setpoint such as, e.g. a specific core temperature and these data may then be stored to be utilized for training data alongside the measured data. This may enable the machine learning control model to model the relation between measured data and the measured adjustable tunnel parameters. By training the machine learning control model utilizing this type of training data, the machine learning control model may enable the machine learning model to mimic the control provided by the one or more experienced person(s). These training data may be utilized for training various kinds of machine learning models, including artificial neural networks, recurrent neural networks, probability based machine learning models, etc.

[0204] Optionally, setpoint and / or error between the setpoint and measured data may also be utilized for training data.

[0205] It should be appreciated that irrespective of which training data is utilized, when a neural network type algorithm is utilized as machine learning control model, the model may vary in architecture, e.g., in depth, in number of nodes per layer, in types of nodes used in the layers etc. Also notice that training may be performed usingvarious numbers of epoch. Furthermore, the performance of the machine learning control models may be evaluated using many types of performance test methods and measures.

[0206] It should be noted that the above examples of control algorithms whether it is based on artificially intelligence or not are advantageously and preferably related to specific ice cream item types.

[0207] Fig. 18a illustrates a block diagram of the process along the production line of producing ice cream products. The production line PL comprises a plurality of working stations according to the location along the production line PL. At first, different ice cream ingredients are fed o a mixer MIX (technically optional) where ingredients (a mixture of ice cream compounds) are being mixed. The substance from the mixer MIX is then transferred to a freezer SF where the substance is being processed into an ice cream composition. The mix is being added to the freezer SF and at the same end of the freezer air is added. Air may also be understood as an ice cream ingredient typically fed into the freezer through a separate dedicated inlet. In the step in the freezer SF the input ice cream ingredients (mixture and air) is processed while being cooled and partly frozen, and thereby crystallizing parts of the ice cream composition and / or changing the ice cream composition. The ice cream composition is cooled to a temperature below zero degrees Celsius through the freezer SF to get the desired ice cream quality with the right size and shape of the ice cream foam-structure. At the input end of the freezer SF air is continuously fed into the freezer SF. Within the freezer, the ice cream composition is subject to shear e.g. by a dasher in a freezing cylinder to make the ice cream composition more soft and less cold to eat.In the next step of the process the ice cream composition is guided to an ice cream former ICF where the ice cream composition is being shaped and divided into ice cream items. The ice cream former ICF may be an ice cream cutter, where a flow of the ice cream composition is being guided to an outlet shaped as the desired ice cream product. A stick inserter may typically be placed at the end of the outlet of the ice cream former ICF when the ice cream item type is an ice cream on a stick. At the end of the ice cream cutter a metal wire is placed to divide the ice cream composition intoice cream items and let the ice cream items drop to a conveyor. The ice cream former ICF may also be an ice cream filler, where a valve divides the stream of the ice cream composition. After the ice cream composition has been divided by the valve the ice cream may be push by a piston into an ice cream container like e.g., a waffle, biscuit or non-edible container.The ice cream items are being conveyed from the ice cream former ICF to a hardening tunnel HT where the ice cream items are cooled down through the hardening tunnel HT. The hardening tunnel may vary in type from each production line according to what type of ice cream item types are being made. The hardening tunnel may e.g. be one as illustrated in fig. 3 where ice cream items are being conveyed on a transportation surface. Such type of hardening tunnel HT typically comprises air ventilation, vaporisers, heat exchanger and other things (not shown) related to controlling the temperature in a uniform way within the hardening tunnel HT. Other types of hardening tunnels may be hardening tunnels where the conveyor comprises a casting form. The hardening tunnels with conveyors with casting forms may be circular and rotating in an approximately horizontal plan around a centre. Ice cream items are shaped and divided into the casting forms of the conveyor and after that conveyed in a rotational motion. At the bottom side of the casting form a cooling liquid is applied to hardening the ice cream items in the casting forms. Another type of hardening tunnel with casting forms may also be used. The casting form are conveyed in a linear direction and the casting forms are connected as slits in a belt. The slits with the casting forms are filled with ice cream items in one end and conveyed in a linear direction with the casting form on top. After releasing the ice cream items from the casting forms the casting forms turns 180 degrees at the end of the belt and is being conveyed back to the ice cream former. At the ice cream former the casting forms may once again be filled with ice cream items. The number of casting forms perpendicular to the conveying direction may vary from e.g., 2-12 or even more according to the specific production of ice cream products. For both hardening tunnels with casting forms cooling fluid may be applied from below to cool the ice cream items by spraying it on the top and let the cooling fluid run down along the outside of the casting forms as in a so-called cascade system. More often, the system is a bath, where the cold liquid iscoming in from below and the slightly heated fluid is flowing over the outsides of the casting forms. All three types of hardening tunnels is used for hardening and cooling ice cream items after the ice cream former. The ice cream items may be conveyed through the hardening tunnel HT in multiple minutes or even hours to ensure a uniform frozen temperature through the ice cream item. Through the hardening tunnel HT an adhesion between the ice cream items and the surface where the ice cream items are being conveyed on may be established. The adhesion may also evolve through the hardening tunnel due to the cooled conditions. In some production lines PL a hardening tunnel is optional and the ice cream items are cooled prior to the ice cream former in the freezer. This is typically a very expensive process to cool the freezer enough and further very complicated to process the ice cream composition through the ice cream former due to a stiffer ice cream composition.The next step along the production line of the ice cream product is a packing station PACK, where the ice cream items are being wrapped in typically a foil. The ice cream items may be placed in a longitudinal foil which are being welded together to enclose typically one ice cream item. Afterwards the foil is being cutted and divided so one ice cream item is packed and enclosed in a foil. The packing station PACK may also be a packing station PACK where ice cream items are being packed directly in boxes of cardboard or paper without any foil. The packing station PACK may also comprise a secondary packing station PACK where the individually foil-enclosed ice cream items are being packed into boxes. The ice cream items may be packed in the boxes or containers by hand or by a robot.Along the entire production line PL one or more sensor (not shown) may be placed at different locations to measure different properties, parameters and / or characteristics of the ice cream composition, ice cream characteristics and / or different stations (ice cream former, hardening tunnel, freezer, mixer, coating station, packing station, ingredients feeder, etc.). The sensor may further be connected to one or more controllers (not shown) with a wire or wireless to send the observed or measured properties, parameters and / or characteristics to the one or more controllers. The one and more controllers may further be connected to the different stations along theproduction line PL to adjust the different working stations based on measurements and / or observations. The location of the one or more sensors SENS may be used for any upstream adjustments of the ice cream composition, ice cream item or any parameters related to upstream working stations by the controller.The one or more sensors may be a weight sensor, vision, camera, flow sensor, pressure sensor, temperature sensor, distance sensor or any other sensor for observing any kind of ice cream characteristics, parameters or properties. The sensors may also be used to measure the parameters of any of the working stations.Through the different steps along the production line PL illustrated in fig. 18 an ice cream composition ICO is made in the freezer SF from ingredients ICN in the mixer MIX. The ice cream composition ICO is being shaped and divided into an ice cream item ICI at the ice cream former ICF. The ice cream item ICI are being processed through the production line PL where the hardening tunnel and packaging station refines the ice cream item. At the end of the production line PL a ice cream product is made which is ready for sale. This may be an individually ice cream product in a foil which typically is bought in small shop. The ice cream product may also be a box with multiple foiled ice cream products which may be bought in a super market.

[0208] Fig. 18b illustrates the same embodiment as illustrated in fig. 18a with one or more optionally parts added to the production line PL of ice cream products. Before the ice cream former ICF an optional ingredients feeder INF may be placed to mix the ice cream composition from the freezer SF with small pieces of chocolate, berries, cake, caramel or any other edible things.Fig. 18b further illustrates that after the ice cream items have left the hardening tunnel HT one or more optional coating stations COA is placed along the production line PL. The coating station COA may typically be a station where the ice cream item is being dipped into a bath of warm chocolate. The ice cream items are then being lifted with the coated chocolate dripping off the ice cream items, but with a new layer added to the ice cream item. The ice cream item may also be coated with other edible things or different types of chocolate. After the first dip of coating an additional coating may beprovided in form of another layer of chocolate or solid small pieces of chocolate, berries or any other edible solid stuff.

[0209] Additional optional working stations along the production line PL which is not shown may be any of the following: Smart Cutter, Coating check station, serialization, packaging check station, a manual station, a cleaning station, or any other working station related to the production of ice cream products.

Claims

Claims1. A method for controlling a hardening tunnel comprising: setting adjustable tunnel parameters (ATP) for the hardening tunnel, upstream said hardening tunnel providing a plurality of ice cream items on a transportation surface (TP) carried by a hardening tunnel conveyor (HTC), conveying said ice cream items through said hardening tunnel on said conveyor and generating an adhesion between said ice cream items and said transportation surface, within said hardening tunnel (HT) and / or downstream said hardening tunnel (HT) continuously measuring said adhesion of said ice cream items, continuously adjusting said tunnel parameters based on said measured adhesion.

2. A method according to claim 1, wherein said ice cream items are transferred from said hardening tunnel conveyor (HTC) by an ice cream transferring system IITS to a further conveyor downstream the hardening tunnel conveyor (HTC).

3. A method according to any of the previous claims, wherein said ice cream items are transferred from said hardening tunnel conveyor (HTC) by an ice cream transferring system IITS to a further conveyor downstream the hardening tunnel conveyor (HTC) and wherein said ice cream transferring system IITS comprises lifting equipment.

4. A method according to any of the previous claims, wherein said ice cream items comprises respective ice cream sticks and where said ice cream items are transferred from said hardening tunnel conveyor (HTC) by an ice cream transferring system IITS to a further conveyor downstream the hardening tunnel conveyor (HTC) and wherein said ice cream transferring system (IITS) lifts said ice cream items by ice cream item grippers (IIG).

5. A method according to any of the previous claims, wherein said adhesion is measured as said ice cream items are being lifted away from said conveyor downstream said hardening tunnel.

6. A method according to any of the previous claims, wherein said adhesion is measured downstream said hardening tunnel and prior to any optional active loosening of the ice cream items from said hardening tunnel conveyor (HTC) downstream said hardening tunnel.

7. A method according to any of the previous claims, wherein said continuously adjusting said tunnel parameters based on said adhesion of said ice cream items to provide adhesion of said ice cream items within an adhesion interval.

8. A method according to any of the previous claims, wherein adhesion is measured as torque when lifting the ice cream in their respective stick.

9. A method according to any of the previous claims, wherein adhesion is measured as force / torque when lifting the ice cream, e.g. by means of a gripper and / or suction device.

10. A method according to any of the previous claims, wherein adhesion is measured as lifting force.

11. A method according to any of the previous claims, wherein adhesion is measured as rotational force.

12. A method according to any of the previous claims, wherein adhesion is measured as displacement force.

13. A method according to any of the previous claims, wherein adhesion is measured as tilt force.

14. A method according to any of the previous claims, wherein adhesion is measured as a displacement resulting from a test force.

15. A method according to any of the previous claims, wherein said test force is a predetermined well defined test force.

16. A method according to any of the previous claims, wherein said step of measuring adhesion is placed inside said hardening tunnel, downstream said hardening tunnel or prior to releasing said ice cream items from said conveyor.

17. A method according to any of the previous claims, wherein the transportation surface is subject to measuring indicating the condition of the transportation surface prior to the providing of a plurality of ice cream items on the hardening tunnel conveyor (HTC).

18. A method according to any of the previous claims, wherein the transportation surface is subject to measuring the condition of the transportation surface of the hardening tunnel conveyor (HTC) and modifying the condition on the basis of the measured condition.

19. A method according to any of the previous claims, wherein the transportation surface is subject to measuring the condition of the transportation surface of the hardening tunnel conveyor (HTC) and modifying the condition on the basis of the measured condition in a transportation surface cooling arrangement / tunnel upstream said hardening tunnel.

20. A method according to any of the previous claims, wherein said adjustable tunnel parameters may further include anyone of the following: tunnel temperature, airflow (speed of fan(s)), conveyor speed, humidity, air-balancing, number of ice cream items, defrosting of evaporators, defrost of tunnel, rate of upstream effective infeed of ice cream items and / or any combination thereof.

21. A method according to any of the previous claims, wherein said core temperature is measured by inserting a temperature sensor inside said ice cream item and measuring said adhesion by pulling in said sensor while said temperature sensor is placed inside said ice cream item.

22. A method according to any of the previous claims, wherein said step of measuring the core temperature of said ice cream items also comprises measuring a tunnel temperature and / or an ambient temperature.

23. A method according to any of the previous claims, wherein said step of adjusting said adjustable tunnel parameters is also based on said tunnel temperature and / or said ambient temperature.

24. A method according to any of the previous claims, wherein said continuously measuring a core temperature of said ice cream items and continuously adjusting said adjustable tunnel parameters based on said core temperature of said ice cream items is performed automatically.

25. A method according to any of the previous claims, wherein said measured adhesion of the ice cream items are designated measured core temperature data (MAD).

26. A method according to any of the previous claims, wherein said measured adhesion (MAD) of the ice cream items are a subset of measurement data (MD).

27. A method according to any of the previous claims, wherein said adjustable tunnel parameters (ATP) are monitored.

28. A method according to any of the previous claims, wherein said adjustable tunnel parameters (ATP) are monitored and designated measured adjustable tunnel parameters (MATP).

29. A method according to any of the previous claims, wherein said measured adjustable tunnel parameters (MATP) are a subset of measured adjustable parameters (MAP).

30. A method according to any of the previous claims, wherein said measured adhesion of the ice cream items are stored as measured adhesion data (MAD) in a memory.

31. A method according to any of the previous claims, wherein said measured adhesion of the ice cream items are stored as measured adhesion data (MCTD) associated with ice cream item type data (IITD) in a memory.

32. A method according to any of the previous claims, wherein said measured adhesion of the ice cream items are designated measured adhesion data (MCTD) and is a subset of measured data (MD).

33. A method according to any of the previous claims, wherein said step of measuring the adhesion of the ice cream items are stored as adhesion data related to an associated ice cream item type and optionally further measurement data (MD) and / or further measured adjustable parameters.

34. A method according to any of the previous claims, wherein said adhesion data are used in a step of the method to correlate said adhesion data to a specific ice cream item type.

35. A method according to any of the previous claims, wherein said adhesion data are used in a step of the method to correlate said adhesion of said ice cream items to an adjustment of said hardening tunnel.

36. A method according to any of the previous claims, wherein said ice cream items are being conveyed further to coating, packaging or any other working station downstream said conveyor.

37. A method according to any of the previous claims, wherein said measured adhesion of said ice cream items are automatically applied at least partly for adjustment of said adjustable tunnel parameters.

38. A method according to any of the previous claims, wherein said measured adhesion of said ice cream items are automatically applied for at least partly adjustment of said adjustable tunnel parameters by means artificial intelligence.

39. A method according to any of the previous claims, wherein said measured adhesion of said ice cream items are automatically applied for at least partly adjustment of saidadjustable tunnel parameters by means artificial intelligence, the adjustment being established by means of supervised machine learning.

40. A method according to any of the previous claims, wherein said measured adhesion of said ice cream items are automatically applied for at least partly adjustment of said adjustable tunnel parameters by means artificial intelligence, the adjustment being established by means of non-supervised machine learning.

41. A method according to any of the previous claims, wherein said measured data (MD) and said measured adjustable parameters (MAP) are applied as training data for a machine learning model of said artificial intelligence.

42. A method according to any of the previous claims, wherein said measured data (MD), such as measured core temperature data (MCTD) and / measured adhesion data (MAD) and / or said measured adjustable parameters (MAP), such as measured adjustable tunnel parameters (MATP) are applied as training data for a machine learning model of said artificial intelligence.

43. A method according to any of the previous claims, wherein said measured data (MD) and said measured adjustable parameters (MAP) are applied as training data for a machine learning model in combination with data defining ice cream item type of said artificial intelligence.

44. A method according to any of the previous claims, wherein said measured data (MD), such as measured core temperature data (MCTD) and / measured adhesion data (MAD) and / or said measured adjustable parameters (MAP), such as measured adjustable tunnel parameters (MATP) are applied as training data for a machine learning model in combination with data defining ice cream item type of said artificial intelligence.

45. A method according to any of the previous claims, where said measured adhesion of said ice cream item are measured automatically.

46. A method according to any of the previous claims, wherein said measured adhesion of said ice cream item are measured manually.

47. A method according to any of the previous claims, wherein the adhesion of said ice cream items is between said transportation surface of the conveyor and the ice cream items.

48. A method according to any of the previous claims, wherein the adhesion of said ice cream items is between said transportation surface and said ice cream items and where the transportation surface is a surface of carriers such as plates, tray and or pockets upon which the ice cream items are located.

49. A method according to any of the previous claims, wherein the transportation surface is integral with the conveyor or a part that is carried by the conveyor such as a carrier.

50. A method according to any of the previous claims, wherein said transportation surface has been coated e.g. by teflon or other low adhesion coating.

51. A method according to any of the previous claims, wherein said method comprises a step of measuring a temperature of said ice cream item.

52. A method according to any of the previous claims, wherein said measuring of said temperature of said ice cream item is an ice cream item core temperature.

53. A method according to any of the previous claims, wherein said measuring of said temperature of said ice cream item is a surface temperature.

54. A method according to any of the previous claims, wherein said method comprises also adjusting adjustable hardening tunnel parameters at least partly with reference to ice cream item type.

55. A method according to any of the previous claims, wherein said measured core temperature is applied as a basis for manual and / or automatic adjustment of adjustable tunnel parameters in combination with said measured adhesion.

56. An ice cream hardening tunnel comprising: an ice cream hardening tunnel conveyor (HTC),the ice cream hardening tunnel conveyor (HTC) extending through said hardening tunnel (HT), an adhesion measuring system (AMS) arranged within said ice cream hardening tunnel and / or outside and downstream said hardening tunnel (HT), a cooling control system (CCS) configured for manual and / or automatic adjustment of adjustable tunnel parameters (ATP) on the basis of measured adhesion by said adhesion measuring system (AMS).

57. An ice cream hardening tunnel according to claim 56, wherein said adhesion measuring system (AMS) is arranged upstream to any optional active ice cream loosener associated to said ice cream hardening tunnel conveyor (HTC).

58. An ice cream hardening tunnel according to claim 56, wherein said hardening tunnel is further associated with a core temperature measuring system (CMS) arranged within said ice cream hardening tunnel and / or outside and downstream said hardening tunnel (HT).

59. An ice cream hardening tunnel according to claim 56, wherein the conveyor has a length of at least 200 meters within the hardening tunnel, such as at least 300 meters, such as at least 400 meters.

60. An ice cream manufacturing line comprising: a hardening tunnel, upstream said hardening tunnel an ice cream item provider, an automatic ice cream item transferring system, an optional ice cream coater, an ice cream packaging system.

61. An ice cream manufacturing line according to claim 56, where the hardening tunnel of the ice cream manufacturing line is operated according to any of the claim 1 to 55.

62. An ice cream manufactured by the method of claim 1-55.

63. An ice cream product formed by a coated ice cream item the ice cream item comprises a coating and where the weight of the coating of the ice cream product has a tolerance of less than + / - 15% by weight of the coating, such as less than 10% by weight, such as less than 8% by weight of the coating, such as less than 5% by weight, such as less than 2.5% by weight, such as less than 1% by weight of the coating.

64. An ice cream product according to claim 63, manufactured on the basis of an ice cream item (II) hardened by the method of claim 1-55, wherein the ice cream item comprises as coating and where the weight of the coating of the ice cream product has a tolerance of less than + / - 15% by weight of the coating, such as less than 10% by weight, such as less than 8% by weight of the coating, such as less than 5% by weight, such as less than 2.5% by weight, such as less than 1% by weight of the coating.

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