Equipment for introduction

Abstract

1. An apparatus for introducing a food product, the apparatus comprising: a nozzle having a pressurized chamber and an outlet for the food product; a valve needle movable between a closed position and one of a plurality of discrete open positions; and an actuator configured to set the position of the valve needle relative to the outlet, the nozzle being further operable in use to vary the flow direction of the food product introduced by the apparatus.

Description

[Technical field]

[0001] The present invention relates to an apparatus for depositing a food product. More particularly, but not exclusively, the present invention relates to such an apparatus for use in filling mould cavities for confectionery products. [Background technology]

[0002] Confectionery products are generally produced by introducing a food product into a mold. Food products that can be introduced using such a method include chocolate (such as aerated chocolate containing macro- or micro-bubbles), caramel, mousse, and many others.

[0003] One existing technique for introducing a food product into a mold uses a piston-type depositor, which includes chambers into which the food product is fed and which undergo a series of piston movements. As the series of pistons retract, a given volume of food product is drawn into and stored in each corresponding piston chamber, which includes an exit orifice. The pistons are moved through the piston chambers to force the food product through the exit orifice.

[0004] An alternative technique for introducing the food product into the mould uses a jet depositor. A jet depositor comprises a chamber which contains the food product under pressure (typically 1-15 bar) and the chamber comprises an exit orifice through which the food product is introduced. A needle valve is provided which seals the orifice and can be moved to expel the food product.

[0005] The molds are typically presented along a moving track to allow multiple molds to be filled in rapid succession, and the depositor often moves in a linear motion synchronous with the molds to allow for longer loading times.

[0006] The inventors have identified an improved apparatus for introducing food product which offers a number of advantages: the apparatus of the present invention allows for greater control over the introduction of food product, including greater control over the amount of food product introduced per mold and the distribution of the food product in each mold, as well as allowing for minimizing the amount of food product that is wasted.

[0007] The apparatus of the present invention provides the additional benefit of reducing space requirements within a factory, thereby providing cost savings. In addition, the apparatus allows for a larger number of molds to be filled per minute compared to comparable jet depositor systems. Summary of the Invention

[0008] Aspects of the invention are set out in the accompanying claims.

[0009] According to a first aspect of the present invention there is provided an apparatus for introducing a food product comprising: a nozzle having a chamber for receiving the food product under positive pressure, the chamber comprising an outlet for the food product, the outlet comprising a first sealing surface; and a valve needle comprising a second sealing surface, the valve needle being moveable relative to the outlet between a closed position in which the first sealing surface is adjacent to the second sealing surface and one of a plurality of open positions discrete relative to the outlet.

[0010] The apparatus further comprises an actuator configured to set a position of the valve needle relative to the outlet, the actuator being operable to set the position of the valve needle between a closed position and any one of a plurality of open positions for introducing food product, and the nozzle is further configured to rotate in use to vary the flow direction of food product being introduced by the apparatus.

[0011] Thus, an apparatus is provided which allows precise control of the introduction of food product, including the amount of food product introduced, the timing of introduction, and the location of introduction within the mould cavity.

[0012] Furthermore, the apparatus of the first aspect of the invention offers the advantage of saving space as, due to the rotation of the nozzle in use, there is no need to move the nozzle laterally to successively introduce food products into the moving mould cavities and therefore components required to enable such linear movement are not essential to the apparatus.

[0013] The precise injection control provided by the nozzle further facilitates implementation of a nozzle rotation mechanism because, as the valve needle height is adjusted, the food product can be injected uniformly throughout the mold cavity using rotational motion. That is, the combined valve needle control of the present invention provides the necessary level of precision control for the injection of food product and eliminates the need for synchronized linear motion.

[0014] Furthermore, the high level of injection control allows the flow rate to be, for example, gradually tapered to provide precise shut-off times, thus preventing waste of food product due to overflow. Additionally, the present invention allows for precise injection of food product throughout the mold cavity, thereby reducing the level of mold vibration required after injection to achieve smooth coverage of the food product within the mold cavity.

[0015] The first sealing surface is defined as being adjacent to the second sealing surface in the closed position, although the precise distance between these two sealing surfaces may vary depending on, for example, the viscosity of the food product. As an example, for a non-viscous food product, the first sealing surface may abut the second sealing surface in the closed position, whereas for a highly viscous food product, the first and second sealing surfaces may not necessarily abut in the closed position. However, this dependency of the closed position on the viscosity of the food product is not necessary, and preferably the needle is fully closed against the nozzle regardless of the mass viscosity.

[0016] Advantageously, the apparatus may further comprise a mould cavity transporter configured, in use, to move one or more mould cavities relative to the rotating nozzle for introducing the food product into the one or more mould cavities. For example, the mould cavity transporter may be a conveyor belt, or a chain system, or any other means capable of moving a mould cavity relative to the depositor.

[0017] Thus, one or more mold cavities may be moved under the nozzle. It is therefore not necessary for the nozzle to move laterally in synchronism with the mold cavities to continuously introduce food products into the mold cavities. Thus, mechanical stresses and inertia in the apparatus may be significantly reduced compared to systems utilizing linear motion of the depositor.

[0018] In some embodiments, the apparatus may further comprise a controller configured to control the actuator to set the position of the valve needle, and to control the rotation of the nozzle in use. Such a system allows precise control of the introduction of the food product, as the controller can regulate the flow rate (by adjusting the position of the valve needle) depending on the (rotational) position of the nozzle.

[0019] Additionally, the controller may be configured to control the actuator to set the position of the valve needle to at least two different open positions during introduction of the food product, thereby allowing the rate of introduction of the food product to be varied during introduction into a single mold cavity, thereby allowing precise control of the amount and distribution of the food product within the mold cavity.

[0020] In some aspects, the controller may be configured to cause the actuator to change the position of the valve needle to an open position at a first angular position of the nozzle to begin introducing the food product, and the controller may be configured to cause the actuator to change the position of the valve needle to a closed position at a second angular position, different from the first angular position.

[0021] Such an arrangement allows the food product to be introduced into a given mold cavity without reducing the number of molds that can be filled per minute, and therefore allows the flow rate of food product during introduction to be reduced, allowing for more precise control of the amount of food product introduced.

[0022] Additionally, the controller may be configured to rotate the nozzle from the second angular position to the first angular position after the valve needle is closed, such that a single nozzle can introduce food product into multiple consecutive mold cavities, allowing a large number of mold cavities to be filled per minute.

[0023] In addition, the angular velocity of the nozzle during rotation from the second angular position to the first angular position may be greater than the angular velocity of the nozzle during introduction of the food product.

[0024] Such an arrangement prevents "tailing" of the food product, where a small amount of food product falls out of the nozzle and lands in the space between the mold cavities after the nozzle is closed. This embodiment allows the "tail" to be introduced into the same mold cavity, thereby reducing food product waste. As an example, the nozzle may move at up to about 800 mm / sec during rotation from the second angular position back to the first angular position.

[0025] In some aspects, the controller may be configured to cause the actuator to adjust the position of the valve needle within the nozzle while simultaneously controlling the angular position of the nozzle to cause the nozzle to introduce the food product across multiple portions of the mold cavity.

[0026] The apparatus therefore provides precise control over the location of introduction within the mould cavity, allowing the food product to be introduced with great precision into different areas (e.g. corners) of the mould cavity. Furthermore, the location of introduction within the mould cavity can be varied during introduction to provide an even distribution of the food product within the mould cavity.

[0027] Advantageously, the rotation of the nozzle may be synchronized, in use, with the movement of one or more mold cavities, thus improving the accuracy of introduction into a given mold cavity. For example, the rotation of the nozzle may generally be synchronized with the movement of the mold cavities, such that small adjustments to the timing of the rotation, as well as adjustments to the position of the valve needle, can be made, thereby allowing the apparatus to compensate for small misalignments between the mold cavities.

[0028] In some aspects, the valve needle may have a substantially conical shape and the outlet may have a substantially cylindrical shape, and in an open position, the valve needle may form an annular orifice between an outer surface of the valve needle and an inner surface of the substantially cylindrical outlet, and the position of the valve needle may determine the size of the annular orifice.

[0029] Thus, the device provides precise control of orifice size; by moving the nozzle in a particular direction, the orifice size increases and the flow rate increases, and by moving the nozzle in the opposite direction, the orifice size decreases and the flow rate decreases.

[0030] Advantageously, the side of the valve needle may be angled relative to the wall of the substantially cylindrical outlet, preferably the angle between the side of the valve needle and the wall of the substantially cylindrical outlet is between 1 and 45 degrees, more preferably the angle between the side of the valve needle and the wall of the substantially cylindrical outlet is between 10 and 30 degrees, even more preferably the angle between the side of the valve needle and the wall of the substantially cylindrical outlet is 20 degrees. Thus, the flow rate of the food product can be precisely controlled during introduction. The above angles result in small changes in flow rate for a given movement of the valve needle, thereby allowing the flow rate to be precisely controlled.

[0031] In some embodiments, the apparatus may include multiple nozzles, and the valve needle position and rotational position can be controlled independently for each nozzle. Thus, multiple nozzles can be used, for example, to introduce food products into a single mold to uniformly and precisely fill a large mold. This allows a large mold to be uniformly filled with food products without the need to significantly vibrate the mold after introduction to achieve smooth coverage of the food product in each mold cavity.

[0032] Furthermore, independent control of each nozzle allows for accounting for misalignments in the mold (or different target products) and therefore for consistent filling of the mold, and further allows for compensation of any pressure / flow variations along the depositor chamber to optimize process / weight control of the final product.

[0033] In such an embodiment, the nozzles may be arranged in multiple nozzle groups, each nozzle group may include one or more nozzles, and each nozzle group may be configured to introduce food product into a separate mold cavity. Thus, the apparatus can introduce food product into multiple molds simultaneously, greatly increasing the number of molds that can be filled per minute.

[0034] Advantageously, the apparatus may further comprise a plurality of nozzle rows, the actuator being configured to cause each nozzle row to selectively deposit the food product into a different mould cavity. This may take the form of a plurality of depositors arranged in series, or a single depositor may comprise a plurality of consecutive nozzle rows.

[0035] That is, the mold cavities may move through the apparatus in a continuous fashion, with each nozzle only introducing food product into every other mold cavity. In other words, a first nozzle will introduce food product into a given mold cavity, but not into the next mold cavity that passes under the nozzle. The first nozzle will then introduce food product into the next mold cavity that passes under the nozzle. In this example, a second nozzle in a different nozzle row will introduce food product into the mold cavity into which the first nozzle did not introduce food product.

[0036] Any number of nozzle rows can be provided, for example, three nozzle rows can be provided with each nozzle configured to introduce food product into every third mold cavity that passes under the nozzle.

[0037] Such an arrangement allows the mold cavities to be placed closer together without reducing the rate at which each nozzle introduces food product, thereby increasing the number of mold cavities that can be filled per minute without significantly increasing the size of the equipment.

[0038] In some embodiments, the food product may be an aerated chocolate. The device thus allows the aerated chocolate to be introduced evenly throughout the mould cavity, reducing the amount that the aerated chocolate must be vibrated. In the case of micro-aerated chocolate, reduced vibration is particularly beneficial as it reduces the coalescence and expansion of the air bubbles. [Brief description of the drawings]

[0039] Embodiments of the invention will now be described, by way of example only, with reference to the following figures: According to one or more embodiments of the present invention, the figure shows: [Figure 1] 1 shows a conventional apparatus for introducing a food product into a mold cavity. [Figure 2A] 1 shows the introduction device in a first stage of use. [Figure 2B] 1 shows the introduction device in a second stage of use. [Figure 2C] 1 shows the introduction device in a third stage of use. [Figure 2D] 1 shows the introduction device in a fourth stage of use. [Figure 3A] 1 shows different views of the nozzle in a closed state. [Figure 3B] 1 shows different views of the nozzle in a closed state. [Figure 4A] 3A-3C show different views of the nozzle in a first open state. [Figure 4B] 3A-3C show different views of the nozzle in a first open state. [Figure 5A] 4A-4C show different views of the nozzle in a second open state. [Figure 5B] 4A-4C show different views of the nozzle in a second open state. [Figure 6] 1 shows a graph of the cross-sectional area of ​​an annular orifice versus the height of a valve needle. [Figure 7] A graph of the average weight of food product introduced by the nozzle in a given time interval for a particular valve needle height is shown for multiple angles between the side of the valve needle and the nozzle outlet wall. [Figure 8] 1 shows an introduction device including multiple nozzles. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0040] Any reference to a prior art document in this specification should not be taken as an admission that such prior art is well known or forms part of the common general knowledge in the art.

[0041] As used herein, the words "comprises," "comprising," and similar words should not be construed in an exclusive or exhaustive sense. In other words, they are intended to mean "including, but not limited to."

[0042] The present invention will be further described with reference to the following examples. It will be understood that the claimed invention is in no way intended to be limited by these examples. It will be further recognized that a person skilled in the art will understand from the teachings of this specification that the integers and features of different embodiments can be used in any suitable and advantageous combination.

[0043] 1 shows a conventional apparatus for introducing a food product 105 into a mold cavity 110. The apparatus includes a nozzle 130 for introducing the food product 105. The nozzle 130 includes a chamber 135 for holding the food product 105 and an orifice 140. The orifice can be opened or closed and is located at one end of the nozzle 130 through which the food product 105 is introduced.

[0044] The nozzle 130 further includes a mounting portion 145 that mounts the nozzle 130 to a rail 150. The apparatus 100 includes a track 120 for transporting the mold cavities. In use, the track 120 moves the mold cavities 110 along a linear path and the nozzle 130 moves in a linear path along the rail 150.

[0045] Nozzle 130 introduces food product 105 into first mold cavity 110(1) by expelling food product 105 through orifice 140 while nozzle 130 moves along rail 150 in synchronization with first mold cavity 110(1). After nozzle 130 introduces food product 105 into first mold cavity 110(1), nozzle 150 moves along rail 150 to position orifice 140 above second mold cavity 110(2), which is moving along track 120.

[0046] Nozzle 130 then introduces food product 105 into second mold cavity 110(2) by expelling food product 105 through orifice 140 while nozzle 130 moves along rail 150 in synchronization with second mold cavity 110(2). After nozzle 130 introduces food product 105 into second mold cavity 110(2), a similar process is performed for third mold cavity 110(3).

[0047] Once the food product 105 is introduced into the mold cavity 110, the mold cavity 110 is typically vibrated to ensure that the food product 105 fills the mold cavity 110 evenly and that the resulting product is of the desired shape.

[0048] The introduction of the food product into the mold cavity 110 can be controlled by increasing the pressure at which the food product 105 is delivered, opening the orifice 140 for a longer or shorter duration, or by increasing or decreasing the speed of movement of the nozzle 130 relative to the mold cavity 110.

[0049] However, such a system may require significant factory space to implement due to the space required for the components necessary to linearly move the nozzle 130, such as the rail 150, and may not provide the ability to manage food product pressure / flow fluctuations resulting in inconsistent total product weight.

[0050] 2A-2D show an exemplary apparatus 200 for introducing a food product 205 into a mold cavity 210(1). A mold transport 220 is provided that moves the mold cavity 210(1) relative to a nozzle 230. The mold transport 220 may form part of the apparatus 200 or may be considered separate from the apparatus 200. The mold cavity transport 220 may be, for example, a conveyor belt or chain system, although any system capable of transporting the mold cavity 210(1) under the nozzle 230 may be used.

[0051] The apparatus 200 comprises a nozzle 230 including an orifice 240 for introducing the food product 205. The orifice 240 can be opened and closed to control the introduction of the food product. The apparatus 200 may additionally comprise an actuator (not shown) for controlling the opening and closing of the orifice 240. The orifice 240 can be opened to a number of different open positions to control the flow rate of the food product 205 from the nozzle, as described below in connection with Figures 3A-5B. The apparatus 200 may further comprise a controller 260 that can control the opening of the nozzle 230 through the actuator.

[0052] 2A shows the apparatus 200 in a first stage of use with the orifice 240 of the nozzle 230 in a closed position. As shown, the nozzle 230 is at an angle relative to the mold cavity 210(1). Although not shown, in this position, the controller is configured to open the orifice 240 of the nozzle 230 to begin introducing the food product 205.

[0053] The angle of the nozzle 230 in the first state introduces the food product 205 non-perpendicularly. Thus, the food product may be directed toward a non-central region (or portion) of the mold cavity 210(1). Although the nozzle 230 is shown directing the food product toward a front portion of the mold cavity 210(1) (as the mold cavity moves from left to right in FIG. 2A), the nozzle may instead direct the food product 205 toward a rear portion of the mold cavity 210(1).

[0054] As the mold carrier 220 moves the mold cavity 210(1) under the nozzle 230, the nozzle 230 rotates to change the angle of introduction relative to the mold cavity 210(1). Thus, the nozzle 230 can introduce the food product 205 into the mold cavity 210(1) over a particular range of movement of the mold cavity 210(1).

[0055] The nozzle 230 may rotate generally synchronously with the movement of the mold cavities 210. Small adjustments to the timing of the rotation of the nozzle 230, as well as adjustments to the open position of the orifice 240, can be made, allowing the apparatus 200 to compensate for small misalignments between the mold cavities 210.

[0056] Figure 2B shows the apparatus 200 in a second stage of use after the first stage of use shown in Figure 2A. In this second stage of use, after the mold cavity 210(1) has been moved by the mold carrier 220 and the nozzle 230 has been rotated, the nozzle 230 is at a substantially perpendicular angle to the mold cavity 210(1). Thus, the food product 205 is introduced nearly vertically, which allows the food product 205 to be directed to a substantially central region of the mold cavity 210(1).

[0057] During the first stage (shown in FIG. 2A) and the second stage (shown in FIG. 2B), the nozzle 230 may continuously introduce the food product 205 by maintaining the orifice 240 in an open state. Alternatively, the orifice 240 may be closed and reopened, possibly multiple times, between the first and second states, such that the food product 205 is not continuously introduced. Moreover, the introduction rate of the food product 205 may be varied (possibly multiple times) between the first and second states by adjusting the open position of the orifice 240.

[0058] Moreover, the lateral position of the nozzle 230 may remain substantially unchanged between the first state and the second state, in other words, the nozzle 230 is not translated between the first state and the second state.

[0059] Figure 2C shows apparatus 200 in a third stage of use after the second stage of use shown in Figure 2B. In this third stage, mold cavity 210(1) has been moved further by mold cavity carrier 220 under nozzle 230. Thus, nozzle 230 has been further rotated to change the angle of nozzle 230 relative to mold cavity 210(1) to allow food product 205 to be introduced into mold cavity 210(1) between the second and third stages.

[0060] The angle of the nozzle 230 in the third state introduces the food product 205 non-perpendicularly. Thus, the food product 205 may be directed to a non-central region of the mold cavity 210(1) that is different from the non-central region of the mold cavity 210(1) to which the food product 205 was directed in the first state. Although the nozzle 230 is shown directing the food product 205 toward a rear portion of the mold cavity 210(1) (as the mold cavity moves from left to right in FIG. 2C), the nozzle 230 may instead direct the food product 205 toward a front portion of the mold cavity. Alternatively, the mold cavity may rest below the depositor.

[0061] As described in relation to Figure 2B, similar to the second stage (shown in Figure 2B) and the third stage (shown in Figure 2C), the nozzle 230 may continuously introduce the food product 205 by maintaining the orifice 240 in an open state. Alternatively, the orifice 240 may be closed and reopened, possibly multiple times, between the second and third states, such that the food product 205 is not continuously introduced. Moreover, the introduction rate of the food product 205 may be varied between the second and third states by adjusting the open position of the orifice 240.

[0062] Moreover, the lateral position of the nozzle 230 may remain substantially unchanged between the second state and the third state, in other words, the nozzle 230 is not translated between the second state and the third state.

[0063] Once a desired amount of food product 205 has been introduced into mold cavity 210(1) and a desired coverage of food product 205 throughout mold cavity 210(1) has been achieved, orifice 240 is moved to a closed state to terminate the introduction of food product 205 into mold cavity 210(1).

[0064] By introducing the food product 205 evenly throughout the mold cavity 210(1), the amount of vibration required to achieve smooth coverage of the food product 205 is reduced. This is particularly advantageous in embodiments where the food product 205 is an aerated chocolate, as excessive vibration can reduce the coalescence and expansion of the air bubbles, which may be undesirable (especially in micro-aerated chocolate). For macro-aerated chocolate, a smooth and precise distribution is also advantageous, as any secondary layers subsequently applied to the food product will remain flat and evenly distributed. Overall, this improves final weight control and production efficiency.

[0065] After the orifice 240 is moved to a closed state, the nozzle 230 may need to begin introducing the food product 205 into the second mold cavity 210(2) being moved by the mold transport body 220 for a short period of time to ensure that the desired amount of food product 205 can be introduced into the second mold cavity 210(2) with the desired coverage before the mold transport body 220 moves the second mold cavity 210(2) out of range of the nozzle 230.

[0066] Thus, the nozzle 230 performs a return motion to rapidly move the nozzle 230 from the angular position shown in Figure 2C to the angular position shown in Figure 2D, which is the same as the angular position shown in Figure 2A. Thus, as shown in Figure 2D, the nozzle 230 can finish introducing the food product 205 into the first mold cavity 210(1) and immediately begin introducing the food product 205 into the front portion of the second mold cavity 210(2).

[0067] As an example, the end of the nozzle where the orifice 240 is provided may move at about 1-800 mm / sec during the return motion. The rapid return motion prevents "tailing" of the food product 205 between the mold cavities 210(1) and 210(2). That is, the return motion introduces any residual food product 205 remaining around the orifice 240 after the orifice 240 is closed into the first mold cavity 210(1) before introduction into the second mold cavity 210(2) begins. Thus, in addition to reducing wastage of food product 205, cleanliness can be increased, which increases production efficiency over time. The return motion may be performed in an opposite rotational direction to the rotational motion shown across Figures 2A-2C, or the return motion may be performed in the same rotational direction.

[0068] Throughout the rotational movement of the nozzle 230, the nozzle may remain in substantially the same lateral position. That is, the nozzle 230 may rotate about a particular axis without translational movement. Thus, the linear movement of the nozzle 230 may be reduced, which reduces mechanical stresses in the device and reduces component failure and wear. However, the nozzle 230 may move laterally in addition to the rotational movement.

[0069] 3A shows a cross-sectional view of a nozzle 230 configured to introduce a food product in a downward direction as shown. The nozzle 230 includes a chamber 305 defined by chamber walls 320. The chamber 305 also includes an outlet 330 through which the food product is introduced. The outlet 330 includes a first sealing surface 315. In some examples, the first sealing surface may be an edge between the outlet 330 and a wall of the chamber 305.

[0070] The nozzle 230 further includes a valve needle 310. The valve needle 310 is movable vertically relative to the outlet 330 (and chamber wall 320) and includes a second sealing surface 315. In some examples, the second sealing surface may be an edge. The valve needle 310 may be movable by an actuator (not shown).

[0071] In FIG. 3A, the first sealing surface 315 and the second sealing surface 325 are in close proximity to one another (although the sealing surfaces 315 and 325 are shown abutting one another, this is not necessary depending on the viscosity of the food product). Thus, the nozzle 230 is in a closed state and the food product cannot flow from the chamber 305 to the outlet 330. The chamber 305 can contain the food product under a positive pressure (e.g., a pressure greater than atmospheric pressure) such that the approximation of the first and second sealing surfaces 315 and 325 prevents the flow of the food product to the outlet 330, the pressure being greater than 1.0 bar, greater than 1.1 bar, greater than 1.25 bar, greater than 1.5 bar, or greater than 2.0 bar, for example, between 1.0 bar and 20.0 bar, between 1.0 bar and 15.0 bar, between 1.5 bar and 12.5 bar, between 2.0 bar and 10.0 bar, or between 3.0 bar and 7.0 bar.

[0072] As shown, the outlet 330 may have a substantially cylindrical shape and the valve needle 310 may have a substantially conical shape. Thus, the side of the valve needle 310 may be angled relative to the inner surface 335 of the outlet 330. Alternatively, the outlet 330 and the valve needle 310 may have other complementary shapes that allow the nozzle 230 to be placed in a closed state. For example, the valve needle may have a generally four-sided pyramid shape and the outlet may have a generally square prism shape.

[0073] Figure 3B shows an alternative view of the nozzle 230 shown in Figure 3A, showing the second sealing surface 325 as viewed from below the nozzle 230. As shown, there is no gap between the valve needle 310 and the chamber wall 320 through which food product can flow. Thus, the nozzle 230 is in a closed state.

[0074] FIG. 4A shows the nozzle 230 in the first open state, viewed from the same perspective as FIG. 3A. As shown, the valve needle 310 is moved in a vertically upward direction with respect to the orifice 330 and the chamber wall 320. Thus, the first sealing surface 315 of the valve needle 310 is not close to the second sealing surface 325 of the outlet 330. Thus, an orifice 340 indicated by a dashed line is formed, through which food product can flow from the chamber 305 to the outlet 330.

[0075] As shown in FIG. 4B showing the nozzle 230 viewed from the same perspective as FIG. 3B, the orifice 340 has an annular shape. Food product can flow through this orifice 340 such that food product can be introduced.

[0076] FIG. 5A shows the nozzle 230 in the second open state, viewed from the same perspective as FIGS. 3A and 4A. As shown, the valve needle 310 is moved further in a vertically upward direction compared to the first open state shown in FIG. 4A. Thus, the cross-sectional area (or size) of the orifice 340 indicated by the dashed line is increased compared to the first open state.

[0077] As shown in FIG. 5B showing the nozzle 230 viewed from the same perspective as FIGS. 3B and 4B, the size of the annular orifice 340 is increased compared to the first open state shown in FIG. 4B. Thus, food product can flow from the chamber 305 to the outlet 330 at a faster rate in the second open state than in the first open state.

[0078] When introducing food product, the position of the valve needle 310 may be set to any one of a plurality of different open states (e.g., the first and second open states shown in FIGS. 4 and 5, respectively). That is, the valve needle 310 is not limited to passing through a specific open position to reach a single open state. Rather, the valve needle 310 can be maintained in any given open state as desired during introduction and adjusted as necessary.

[0079] For example, during the introduction process, the valve needle 310 may start out in a closed state. The valve needle 310 may then move to a second open state at a first time and then move to the first open state at a second time. The valve needle may then move back to the second open state at a third time and then move to the closed state.

[0080] The valve needle 310 may be adjusted in height increments by an actuator, allowing precise control of the cross-sectional area of ​​the orifice 340, and therefore the flow rate of the food product. For example, the valve needle 310 may be set to a particular height in increments of 0.01 mm, although other increments such as 0.005 mm to 0.1 mm could be used instead. Thus, the cross-sectional area of ​​the orifice can be adjusted very precisely.

[0081] Figure 6 shows an exemplary graph of the cross-sectional area of ​​the orifice versus the valve needle height for a conical valve needle and a cylindrical outlet. The curve shown has a regular shape with a gentle slope. Thus, small adjustments to the cross-sectional area can be made by making similarly small adjustments to the valve needle height. Thus, the flow rate of the food product can be finely controlled.

[0082] Furthermore, the change in cross-sectional area of ​​the orifice, and therefore the change in flow rate of food product for a given change in valve needle height, depends on the angle between the side of the valve needle and the outlet wall. Figure 7 shows a graph illustrating the average weight of food product introduced by the nozzle in a set time interval versus valve needle height for three different angles between the side of the valve needle and the outlet wall.

[0083] The graph includes curves for total angles (i.e. the sum of the angles on both sides of the needle) of 10 degrees, 20 degrees, and 30 degrees, i.e. the angles between the side of the valve needle and the wall of the outlet are 5 degrees, 10 degrees, and 15 degrees on each side of the needle. However, other individual angles such as 1 to 45 degrees can be used (i.e. total angles of 2 to 90 degrees). In this embodiment, the needle is preferably essentially symmetrical. That is, the total angle of 2 to 90 degrees relates to the sum of two angles of the same value of 1 to 45 degrees. Although a total angle of 10 degrees or 30 degrees between the side of the valve needle and the wall of the outlet can be utilized, a total angle of 20 degrees results in a gentler curve in the graph of FIG. 7 than these angles. Thus, a total angle of 20 degrees between the side of the valve needle and the wall of the outlet allows for smaller adjustments of the flow rate of the food product for a given change in the valve needle height, thus resulting in a more precise control of the amount of food product introduced.

[0084] 8 shows an exemplary apparatus 800 for introducing a food product. The apparatus 800 includes multiple nozzles 810 arranged in a line such that the mold cavities can move simultaneously in parallel under the nozzles. Thus, the number of mold cavities that can be filled per minute is greatly increased without a significant increase in the overall size of the apparatus.

[0085] Furthermore, the nozzles 810 may be arranged in groups 820, with each group 820 introducing the food product into a different mold cavity. Thus, a large mold can be filled evenly, and the vibration level required to obtain uniform coverage in the mold cavity can be reduced. Furthermore, the introduction rate required by each nozzle can be reduced without any loss in the introduction rate of the overall food product, allowing finer control over the amount and coverage of the food product in the mold. In the exemplary apparatus 800 shown in FIG. 8, the apparatus 800 includes thirteen groups 820 for introducing up to thirteen mold cavities at a time.

[0086] Each group 820 includes three nozzles, and each nozzle 810 in the group 820 introduces the food product into the same mold cavity. The chamber of each nozzle 810 in the group 820 is in fluid communication with the other nozzles 810 in the group 820. However, the nozzles 810 in the group 820 (and in different groups) may be independently controlled. That is, both the opening and closing of the nozzles 810, and the rotation of the nozzles 810, can be adjusted separately for each nozzle 810. Thus, misalignment between the mold cavities can be individually accounted for, allowing each mold cavity to be filled stably. Similarly, the independence of the control of the nozzles 810 allows compensation for any pressure / flow rate variations along the depositor chamber to optimize the process / weight control of the final product.

[0087] If the mold is misaligned with respect to the apparatus 800 (i.e., not perpendicular to the direction of movement) such that certain portions of the mold reach the nozzles 810 before other portions of the mold, each nozzle 810 may begin introducing food product at different times and rotational positions, may introduce food product at different rates, and may introduce different total amounts of food product based on the degree of misalignment.

[0088] For example, when a mold cavity passes under the apparatus 800 in a misaligned (or distorted) orientation, a first nozzle of the nozzle group 820 configured to introduce food product into the misaligned mold cavity may begin introducing food product at a first speed at a first rotational position at a first time and may introduce a first amount of food product. A second nozzle of the nozzle group 820 may then begin introducing food product into the misaligned mold cavity at a second speed at a second rotational position at a second time and may introduce a second amount of food product. One or more of the second time, second rotational position, second speed, and second amount may each be different from the first time, first rotational position, first speed, and first amount. Each additional nozzle in the nozzle group 820 may begin introducing food product at a different time, different rotational position, different speed, and / or each may introduce a different amount.

[0089] Thus, even if the mold is substantially misaligned, this misalignment can be compensated for by combining independent precise control of the nozzle opening and nozzle rotation so that the mold can be filled uniformly regardless of the mold orientation.

[0090] Instead, the nozzle groups can be controlled collectively, with each nozzle group being controlled independently of the other nozzle groups, to compensate for variations in placement between the various molds passing through the apparatus.

[0091] The apparatus 800 may include multiple rows of nozzle rows 810. This may take the form of multiple depositors arranged in series, or a single depositor may include multiple rows of nozzles in series. For example, multiple parallel rows of nozzles may be provided in the apparatus 800. In such an example, if there are N rows, then each nozzle in the row will introduce food product into only every Nth mold cavity.

[0092] For example, if two rows are provided, a first nozzle in the first row will introduce food product into a given mold cavity, but not into the next mold cavity that passes under the nozzle. The first nozzle will then introduce food product into the next mold cavity that passes under the nozzle. In this example, a second nozzle in the second row of nozzles will introduce food product into mold cavities into which the first nozzle did not introduce food product, but will not introduce food product into mold cavities into which the first nozzle introduced food product.

[0093] Any number of nozzle rows can be provided, for example, three nozzle rows can be provided with each nozzle configured to introduce food product into every third mold cavity that passes under the nozzle.

[0094] Such an arrangement allows the mold cavities to be placed closer together without reducing the rate at which each nozzle introduces food product, thereby increasing the number of mold cavities that can be filled per minute without significantly increasing the size of the equipment.

[0095] Additionally, although the introducing device has been described with respect to introducing a food product into a mold cavity, the food product need not be introduced into a mold cavity, rather the food product may be introduced onto any target, which may be a target surface or product.

[0096] As an example, the techniques and apparatus described above may be used to coat a layer of food product with a filling (or other ingredients) in a confectionery product (e.g., in a bar shape, although other shapes may be used). If desired, multiple layers of food product may be applied to the confectionery product, which may be done sequentially by different depositors or may be done by the same depositor.

[0097] The above-described technique can also be used to introduce droplets of a food product onto a conveyor belt (or other surface) to create precisely metered button-shaped confectionery products or substantially any other shaped confectionery products. Thus, the techniques described above are not applicable only to the filling of molds.

[0098] Accordingly, an apparatus for introducing a food product is described, the apparatus comprising a nozzle having an outlet for the food product, a valve needle movable between a closed position and one of a plurality of individual open positions, and an actuator configured to set the position of the valve needle relative to the outlet, the nozzle being further rotatable in use to vary the flow direction of the food product introduced by the apparatus.

Claims

1. 1. An apparatus for introducing a food product, said apparatus comprising: a nozzle having a chamber for containing a food product under positive pressure, said chamber comprising an outlet for the food product, said outlet comprising a first sealing surface; a valve needle having a second sealing surface, the valve needle being movable relative to the outlet between a closed position in which the first sealing surface is adjacent to the second sealing surface and one of a plurality of separate open positions relative to the outlet; an actuator configured to set a position of the valve needle relative to the outlet, the actuator being operable to set the position of the valve needle to the closed position and to any one of the plurality of open positions for introducing the food product; the nozzle is further configured to rotate in use to vary a flow direction of food product being introduced by the apparatus; The apparatus further comprises a controller, the controller comprising: controlling the actuator to set the position of the valve needle; and configured, in use, to control rotation of the nozzle; the controller is configured to cause the actuator to change a position of the valve needle to an open position at a first angular position of the nozzle to begin introducing the food product, and the controller is configured to cause the actuator to change a position of the valve needle to the closed position at a second angular position different from the first angular position; The apparatus, wherein the controller is configured to rotate the nozzle from the second angular position to the first angular position after the valve needle is closed.

2. 2. The apparatus of claim 1, further comprising a mold cavity transporter configured, in use, to move the one or more mold cavities relative to the rotating nozzle to introduce the food product into one or more mold cavities.

3. 3. The apparatus of claim 2, wherein the controller is configured to control the actuator to set the position of the valve needle to at least two different open positions during introduction of the food product.

4. 4. The apparatus of claim 3, wherein an angular velocity of the nozzle during rotation from the second angular position to the first angular position is greater than an angular velocity of the nozzle during introduction of the food product.

5. 5. The apparatus of claim 3 or 4, wherein the controller is configured to control an angular position of the nozzle to cause the actuator to adjust a position of the valve needle within the nozzle while simultaneously causing the nozzle to introduce food product over multiple portions of the mold cavity.

6. An apparatus according to any preceding claim, wherein rotation of the nozzle, in use, is synchronised with movement of one or more mould cavities.

7. 7. Apparatus as claimed in any one of the preceding claims, wherein the valve needle has a substantially conical shape and the outlet has a substantially cylindrical shape, and in an open position the valve needle defines an annular orifice between an outer surface of the valve needle and an inner surface of the substantially cylindrical outlet, the position of the valve needle determining the size of the annular orifice.

8. 8. Apparatus according to any one of the preceding claims, wherein a side of the valve needle is at an angle to a wall of the substantially cylindrical outlet, the angle between the side of the valve needle and the wall of the substantially cylindrical outlet being between 1 and 45 degrees.

9. An apparatus according to any preceding claim, wherein the apparatus comprises a plurality of nozzles, and wherein the valve needle position and the rotational position are independently controllable for each nozzle.

10. 10. The apparatus of claim 9, wherein the plurality of nozzles is arranged in a plurality of nozzle groups, each nozzle group comprising one or more nozzles, each nozzle group configured to introduce the food product into a separate mold cavity.

11. The apparatus of any one of claims 1 to 10, further comprising a plurality of nozzle rows, the actuator being configured to cause each nozzle row to selectively introduce the food product into a different mould cavity.

12. Apparatus according to any one of claims 1 to 11, wherein the food product is an aerated chocolate.

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