Packaging edible food without adjustment

Abstract

To provide a suitable packaging of an edible material without adjustment.SOLUTION: A method of manufacturing an edible material includes: providing an edible material mass (22); forming the edible material mass into an edible material structure (26) in a preferred shape using a formation station (20); and applying a packaging material (54) to a surface of the edible material structure (26) while the edible material structure is still in contact with a part of the formation station (20).SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a method and system for manufacturing edible products, and more particularly, to a method and system for directly packaging edible products after the formation and sizing of the edible products.

Background Art

[0002] Typically, the process of manufacturing and packaging edible products such as candies or chewing gums is time-consuming and involves a significant amount of equipment. For example, the process of manufacturing and packaging a gum product can include mixing and producing the finished gum as a non-uniform output, extruding and forming the finished gum into a loaf, conditioning the loaf of the finished gum, extruding the loaf into a thin continuous sheet of the finished gum, rolling the continuous sheet through a series of rollers to a uniform thin thickness, cutting the sheet and dividing it into individual cut sheets, conditioning the individual sheets in a conditioning room, dividing the sheets into gum pieces, and packaging the gum pieces. Such a process for making and packaging a gum product is disclosed in U.S. Patent No. 6,254,373, which was assigned to a merged company in which the present assignee was involved, and U.S. Patent Application No. 12 / 352,110, which was assigned to the present assignee, and the teachings and disclosures of those are incorporated herein by reference in their entirety to the extent that they do not conflict with the present disclosure.

[0003] Candies are typically adjusted after being formed into the desired size and shape to increase the hardness of the candies and make them less susceptible to damage during subsequent processing. The adjustment typically involves removing the candies from the production line and holding them in a room with the desired temperature and humidity for a given time at a temperature below room temperature, such as about 10°C. This interruption in the manufacturing process increases the overall time required to produce the candies and requires manual labor to move the candies to and from the production line, thus reducing manufacturing efficiency. Furthermore, since this manufacturing system cannot be an "inline" system, both additional time and space are required to manufacture the edible product.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Patent Document 2

Summary of the Invention

Means for Solving the Problems

[0005] According to one embodiment, a method of manufacturing an edible product includes providing an edible product mass, using a forming station to form the edible product mass into an edible product structure having a desired shape, and applying a packaging material to the surface of the edible product structure while the edible product structure is still in contact with a portion of the forming station.

[0006] In addition to or as an alternative to one or more of the above features, in a further embodiment, the forming station includes at least one roller having a plurality of cavities formed around the outer circumference of the at least one roller, and the roller is a portion of the forming station with which the edible product structure is still in contact.

[0007] In addition to one or more of the above features, or alternatively, in a further embodiment, forming the edible mass into an edible structure having a desired shape includes pushing the edible mass into a plurality of cavities.

[0008] In addition to one or more of the above features, or alternatively, in a further embodiment, each of the plurality of cavities defines at least a portion of a desired shape.

[0009] In addition to one or more of the above features, or alternatively, in a further embodiment, the plurality of cavities define a plurality of different shapes.

[0010] In addition to one or more of the above features, or alternatively, in a further embodiment, each of the plurality of cavities is associated with an edible.

[0011] In addition to one or more of the above features, or alternatively, in a further embodiment, each of the plurality of cavities is associated with a plurality of edible pieces.

[0012] In addition to one or more of the above features, or alternatively, in a further embodiment, applying the packaging material to the edible structure includes positioning the packaging material between a first packaging roller and at least one roller of the forming station.

[0013] In addition to one or more of the above features, or alternatively, in a further embodiment, removing the edible structure from at least one roller of the forming station is included.

[0014] In addition to one or more of the above features, or alternatively, in a further embodiment, removing the edible structure from at least one roller occurs via the affinity of the edible structure for the packaging material, which is greater than the affinity of the edible structure for the surface of the at least one roller when the at least one roller rotates about an axis.

[0015] In addition to one or more of the above features, or alternatively, in a further embodiment, it includes applying another packaging material to another surface of the edible food structure.

[0016] In addition to one or more of the above features, or alternatively, in a further embodiment, another surface is on the opposite side of the surface of the edible food structure.

[0017] In addition to one or more of the above features, or alternatively, in a further embodiment, adjacent to the edible food structure, it includes cutting the packaging material and another packaging material, and sealing the packaging material to the another packaging material to substantially enclose the edible food structure.

[0018] In addition to one or more of the above features, or alternatively, in a further embodiment, sealing the packaging material to the another packaging material to substantially enclose the edible food structure occurs within 5 minutes of formation.

[0019] In addition to one or more of the above features, or alternatively, in a further embodiment, sealing the packaging material to the another packaging material to substantially enclose the edible food structure occurs within 1 minute of formation.

[0020] In addition to one or more of the above features, or alternatively, in a further embodiment, sealing the packaging material to the another packaging material to substantially enclose the edible food structure occurs within 30 seconds of formation.

[0021] In addition to one or more of the above features, or alternatively, in a further embodiment, the temperature of the substantially enclosed edible food is within 10 °C of the temperature of the edible food mass during formation.

[0022] In addition to one or more of the above features, or alternatively, in a further embodiment, sealing the packaging material to the another packaging material to substantially enclose the edible food structure occurs before the edible food structure reaches ambient temperature.

[0023] In addition to one or more of the above features, or as an alternative thereto, in a further embodiment, the edible product is chewing gum.

[0024] In addition to one or more of the above features, or as an alternative thereto, in a further embodiment, the edible product has a Young's modulus of 75 kP to 120 kP.

[0025] In addition to one or more of the above features, or as an alternative thereto, in a further embodiment, the edible product has a Young's modulus of 20 kP to 80 kP.

[0026] In addition to one or more of the above features, or as an alternative thereto, in a further embodiment, the edible product has a Young's modulus of 30 kP to 70 kP.

[0027] In addition to one or more of the above features, or as an alternative, in a further embodiment, the edible product has a Young's modulus of 40 kP to 60 kP.

[0028] In addition to one or more of the above features, or as an alternative, in a further embodiment, forming an edible product mass into an edible product structure having a desired shape using a forming station is caused by applying pressure to the edible product mass.

[0029] In addition to one or more of the above features, or as an alternative thereto, in a further embodiment, the edible product is at least one of chocolate, gummy candy, soft candy, and biscuit.

[0030] In addition to one or more of the above features, or as an alternative, in a further embodiment, intentional cooling of the edible product structure does not occur between forming the edible product into an edible product structure having a desired shape and applying a packaging material to the surface of the edible product.

[0031] In addition to one or more of the above features, or as an alternative thereto, in a further embodiment, the forming station includes a chain cutter device.

[0032] According to another embodiment, a system for forming and packaging edible food along a forming and packaging line, the system including a forming station positioned along the forming and packaging line for receiving the edible food and forming and sizing the edible food into an edible food structure having a desired shape. Packaging material is receivable by the forming and packaging line. The packaging material is positioned in contact with the edible food structure while the edible food structure is in contact with the forming station.

[0033] In addition to or as an alternative to one or more of the above features, in a further embodiment, the forming station includes at least one component, the at least one component including a plurality of cavities for receiving the edible food.

[0034] In addition to or as an alternative to one or more of the above features, in a further embodiment within the plurality of cavities, the edible food is at least partially formed into the desired shape.

[0035] In addition to or as an alternative to one or more of the above features, in a further embodiment, the edible food is at least partially formed into the desired shape by a scraping knife that cooperates with at least one component.

[0036] In addition to or as an alternative to one or more of the above features, in a further embodiment, the at least one component includes a first roller and a second roller, the first roller having a substantially smooth surface.

[0037] In addition to or as an alternative to one or more of the above features, in a further embodiment, the at least one component includes a first roller and a second roller, the first roller including a plurality of first cavities, and the second roller including a plurality of second cavities.

[0038] In addition to or as an alternative to one or more of the above features, in a further embodiment, the plurality of first cavities and the plurality of second cavities cooperate to form and size the edible food into the desired shape.

[0039] In addition to one or more of the above features, or alternatively, in a further embodiment, the affinity between the edible material and the plurality of second cavities is greater than the affinity between the edible material and the plurality of first cavities.

[0040] In addition to one or more of the above features, or alternatively, in a further embodiment, at least one roller includes a first roller and a second roller, a gap is defined between the first roller and the second roller, and the edible structure still contacts the second roller downstream of the gap.

[0041] In addition to one or more of the above features, or as an alternative thereto, in a further embodiment, a blade is provided for removing excess material from the surface of at least one component.

[0042] In addition to one or more of the above features, or alternatively, in a further embodiment, the forming station includes a first roller and a second roller, and the packaging roller cooperates with a portion of the second roller at a position downstream of the first roller.

[0043] In addition to one or more of the above features, or alternatively, in a further embodiment, the affinity of the edible structure for the packaging material is greater than the affinity of the edible structure for the second roller.

[0044] In addition to one or more of the above features, or alternatively, in a further embodiment, the packaging station further includes another packaging roller configured to apply another packaging material to the edible structure.

[0045] In addition to one or more of the above features, or alternatively, in a further embodiment, the other packaging roller is configured to apply another packaging material to the edible structure when the edible structure is separated from the forming station.

[0046] In addition to one or more of the above features, or alternatively, in a further embodiment, the packaging station further comprises a packaging machine for sealing a packaging material and another packaging material around the edible structure.

[0047] In addition to one or more of the above features, or alternatively, in a further embodiment, the packaging station further comprises a cutting device for forming at least one cut in the packaging material.

[0048] In addition to one or more of the above features, or as an alternative thereto, in a further embodiment, intentional cooling of the edible structure does not occur downstream of the forming station.

[0049] According to another embodiment, a method of manufacturing an edible food comprises providing an edible food mass, forming the edible food mass into an edible structure having a desired shape via a forming station, and packaging the edible structure in a packaging material. The edible structure is provided continuously directly from the forming station to the packaging material, and / or the packaging material is provided continuously directly to the forming station.

[0050] In addition to one or more of the above features, or alternatively, in a further embodiment, packaging the edible structure is continuous to completely enclose the edible structure within the package.

[0051] In addition to one or more of the above features, or as an alternative thereto, in a further embodiment, the packaging station does not include a holding station.

[0052] In addition to one or more of the above features, or as an alternative thereto, in a further embodiment, the edible structure is not accumulated within the packaging station.

[0053] In addition to one or more of the above features, or as an alternative thereto, in a further embodiment, adjustment of the edible structure does not occur, or occurs only rarely, between forming and packaging.

[0054] In addition to, or as an alternative to, one or more of the above features, in a further embodiment, the forming station includes at least one movable component, and the packaging of the edible structure is initiated while the edible structure is in contact with at least one movable component.

[0055] In addition to, or as an alternative to, one or more of the above features, in a further embodiment, the packaging of the edible structure further includes applying a first packaging material to a first surface of the edible structure and applying a second packaging material to a second surface of the edible structure.

[0056] In addition to, or as an alternative to, one or more of the above features, in a further embodiment, the forming station includes at least one component, and the edible structure contacts at least one component when the first packaging material is applied to the edible structure.

[0057] In addition to, or as an alternative to, one or more of the above features, in a further embodiment, it includes removing the edible structure from at least one component.

[0058] In addition to, or as an alternative to, one or more of the above features, in a further embodiment, the affinity of the edible structure for the first packaging material is greater than the affinity of the edible structure for the surface of at least one component.

[0059] In addition to, or as an alternative to, one or more of the above features, in a further embodiment, the packaging of the edible structure further includes sealing the first packaging material to the second packaging material to enclose the edible structure.

[0060] In addition to, or as an alternative to, one or more of the above features, in a further embodiment, the packaging of the edible structure further includes cutting at least one of the first packaging material and the second packaging material.

[0061] In addition to, or alternatively to, one or more of the above features, in a further embodiment, intentional cooling of the edible structure does not occur between forming the edible into an edible structure having a desired shape and applying the packaging material to the surface of the edible.

[0062] In addition to, or alternatively to, one or more of the above features, in a further embodiment, the edible is chewing gum.

[0063] In addition to, or alternatively to, one or more of the above features, in a further embodiment, the edible structure is continuously provided from a forming station to a conveyor that communicates with a first packaging roller.

[0064] In addition to, or alternatively to, one or more of the above features, in a further embodiment, the forming station includes a chain cutter device.

[0065] According to another embodiment, a system for forming and packaging an edible along a forming and packaging line includes a forming station positioned along the forming and packaging line for receiving the edible and forming and sizing the edible into an edible structure having a desired shape. The packaging material is receivable by the forming and packaging line. The packaging material is positioned such that the edible structure is continuously provided directly from the forming station to the packaging material.

[0066] In addition to, or alternatively to, one or more of the above features, in a further embodiment, the forming station includes a component having at least one cavity for receiving the edible.

[0067] In addition to, or alternatively to, one or more of the above features, in a further embodiment, the edible is formed into the desired shape by compression within at least one cavity.

[0068] In addition to, or as an alternative to, one or more of the above features, in a further embodiment, the packaging station includes a packaging roller for applying the packaging material to the surface of the edible structure.

[0069] In addition to, or as an alternative to, one or more of the above features, in a further embodiment, the forming station includes a first roller and a second roller, and the packaging cooperates with the second roller at a position downstream of the first roller.

[0070] In addition to, or as an alternative to, one or more of the above features, in a further embodiment, the packaging station applies the packaging material to the edible structure while the edible is in contact with the forming station.

[0071] In addition to, or as an alternative to, one or more of the above features, in a further embodiment, the packaging station further comprises another packaging roller configured to apply another packaging material to the edible structure.

[0072] In addition to, or as an alternative to, one or more of the above features, in a further embodiment, the another packaging roller is configured to apply another packaging material to the edible after the edible is removed from the forming station.

[0073] In addition to, or as an alternative to, one or more of the above features, in a further embodiment, the packaging station further comprises a packaging machine for sealing the packaging material and the another packaging material around the edible structure.

[0074] In addition to, or as an alternative to, one or more of the above features, in a further embodiment, the packaging station further comprises a cutting device for forming at least one cut in the packaging material and the another packaging material.

[0075] In addition to, or as an alternative to, one or more of the above features, in a further embodiment, intentional cooling of the edible structure does not occur downstream of the forming station and before the packaging material is placed in contact with the edible structure.

[0076] According to another embodiment, a method of packaging an edible food item includes providing a mass of the edible food item, shaping the mass of the edible food item into an edible food structure having a desired shape, and packaging the edible food structure within a packaging material, wherein the edible food structure avoids direct contact with a force generating component of a packaging station during application of the packaging material.

[0077] In addition to or as an alternative to one or more of the above features, in a further embodiment, the force generating component includes a knife.

[0078] In addition to or as an alternative to one or more of the above features, in a further embodiment, any intentional conditioning of the edible food structure occurs while the edible food structure is within the packaging.

[0079] In addition to or as an alternative to one or more of the above features, in a further embodiment, intentional chilling of the edible food structure does not occur during shaping the edible food item into an edible food structure having a desired shape and applying the packaging material to a surface of the edible food item.

[0080] In addition to or as an alternative to one or more of the above features, in a further embodiment, the desired shape is the final shape of the edible food item.

[0081] According to another embodiment, a method of packaging an edible food item includes providing a mass of the edible food item, shaping the mass of the edible food item into an edible food structure having a desired shape, and packaging the edible food structure within a packaging material. Any change in a property of the edible food structure that occurs downstream of the shaping occurs while the edible food structure is in contact with the packaging material.

[0082] In addition to or as an alternative to one or more of the above features, in a further embodiment, the change in the property includes a change in the hardness of the edible food structure.

[0083] In addition to or as an alternative to one or more of the above features, in a further embodiment, the change in the property includes a change in the rigidity of the edible food structure.

[0084] In addition to one or more of the above features, or as an alternative thereto, in a further embodiment, changes in the properties do not affect the packaging.

[0085] According to another embodiment, a system for forming and packaging a food product along a forming and packaging line includes a forming station for receiving the food product and forming and sizing the food product into a food product structure having a desired shape. The packaging station is disposed downstream of the forming station. The food product provided to the packaging station has a Young's modulus of less than 120 kP.

[0086] In addition to one or more of the above features, or as an alternative thereto, in a further embodiment, the food product provided to the packaging station has a Young's modulus greater than 75 kP.

[0087] In addition to one or more of the above features, or as an alternative, in a further embodiment, the food product provided to the packaging station has a Young's modulus of 20 kP to 80 kP.

[0088] In addition to one or more of the above features, or as an alternative thereto, in a further embodiment, the food product has a Young's modulus of 30 kP to 70 kP.

[0089] In addition to one or more of the above features, or as an alternative thereto, in a further embodiment, the food product has a Young's modulus of 40 kP to 60 kP.

[0090] In addition to one or more of the above features, or as an alternative thereto, in a further embodiment, the food product is provided to a packaging station having a temperature greater than 30°C.

[0091] According to another embodiment, a method of manufacturing an edible product includes providing an edible product mass, forming the edible product mass into an edible product structure having a desired shape using a forming station, and applying a packaging material to the surface of the edible product. Forming the edible product mass into the edible product structure and applying the packaging material to the surface of the edible product occur without any intentional cooling of the edible product mass and the edible product structure.

[0092] In addition to or as an alternative to one or more of the above features, in a further embodiment, the packaging material is applied to the surface of the edible product while the edible product is in contact with the forming station.

[0093] In addition to or as an alternative to one or more of the above features, in a further embodiment in the desired shape, the edible product structure has a depth of 0.3 mm to 10 mm.

[0094] According to another embodiment, the edible product includes a chewing gum body formed in a desired shape. An edible product having a hardness below 80 kP.

[0095] In addition to or as an alternative to one or more of the above features, in a further embodiment, the hardness is 20 kP to 80 kP. The present invention provides, for example, the following. (Item 1) A method of manufacturing an edible product, the method comprising: providing an edible product mass; using a forming station to form the edible product mass into an edible product structure having a desired shape; applying a packaging material to the surface of the edible product structure while the edible product structure is still in contact with a portion of the forming station. (Item 2) The method according to item 1, wherein the forming station includes at least one roller, the at least one roller has a plurality of cavities formed around the outer periphery of the at least one roller, and the roller is a part of the forming station where the edible structure still remains in contact. (Item 3) The method according to item 2, wherein forming the edible mass into an edible structure having a desired shape includes pushing the edible mass into the plurality of cavities. (Item 4) The method according to item 2, wherein each of the plurality of cavities defines at least a part of the desired shape. (Item 5) The method according to item 4, wherein the plurality of cavities define a plurality of different shapes. (Item 6) The method according to item 2, wherein each of the plurality of cavities is associated with an edible. (Item 7) The method according to item 2, wherein each of the plurality of cavities is associated with a plurality of edible pieces. (Item 8) The method according to item 1, wherein applying the packaging material to the edible structure includes positioning the packaging material between a first packaging roller and at least one roller of the forming station. (Item 9) The method according to item 1, further including removing the edible structure from at least one roller of the forming station. (Item 10) The method according to item 9, wherein removing the edible structure from the at least one roller occurs via an affinity of the edible structure for the packaging material that is greater than an affinity of the edible structure for the surface of the at least one roller when the at least one roller rotates about an axis. (Item 11) The method according to item 1, further including applying another packaging material to another surface of the edible structure. (Item 12) The method according to item 11, wherein said another surface is on the side opposite to said surface of said edible structure. (Item 13) Cutting said packaging material and said another packaging material adjacent to said edible structure; The method according to item 11, further comprising sealing said packaging material to said another packaging material to substantially enclose said edible structure. (Item 14) The method according to item 13, wherein said sealing of said packaging material to said another packaging material to substantially enclose said edible structure occurs within 5 minutes of said formation. (Item 15) The method according to item 13, wherein said sealing of said packaging material to said another packaging material to substantially enclose said edible structure occurs within 1 minute of said formation. (Item 16) The method according to item 13, wherein said sealing of said packaging material to said another packaging material to substantially enclose said edible structure occurs within 30 seconds of said formation. (Item 17) The method according to item 13, wherein the temperature of said substantially enclosed edible is within 10 °C of the temperature of said edible mass during said formation. (Item 18) The method according to item 13, wherein said sealing of said packaging material to said another packaging material to substantially enclose said edible structure occurs before said edible structure reaches ambient temperature. (Item 19) The method according to item 1, wherein said edible is chewing gum. (Item 20) The method according to item 1, wherein said edible has a Young's modulus of 75 kP - 120 kP. (Item 21) The method according to item 1, wherein said edible has a Young's modulus of 20 kP - 80 kP. (Item 22) The method according to item 21, wherein said edible has a Young's modulus of 30 kP - 70 kP. (Item 23) The method according to item 22, wherein the edible product has a Young's modulus of 40 kP to 60 kP. (Item 24) The method according to item 1, wherein forming the edible product mass into an edible product structure having a desired shape using a forming station is effected by applying pressure to the edible product mass. (Item 25) The method according to item 1, wherein the edible product is at least one of chocolate, gummy candy, soft candy, and biscuit. (Item 26) The method according to item 1, wherein intentional cooling of the edible product structure does not occur between forming the edible product into an edible product structure having a desired shape and applying a packaging material to the surface of the edible product. (Item 27) The method according to item 1, wherein the forming station includes a chain cutter device. (Item 28) A system for forming and packaging an edible product along a forming and packaging line, comprising: a forming station positioned along the forming and packaging line for receiving the edible product and forming and sizing the edible product into an edible product structure having a desired shape; and a packaging material receivable by the forming and packaging line and positioned in contact with the edible product structure while the edible product structure is in contact with the forming station. (Item 29) The system according to item 28, wherein the forming station includes at least one component including a plurality of cavities for receiving the edible product. (Item 30) The system according to item 29, wherein within the plurality of cavities, the edible product is at least partially formed into the desired shape. (Item 31) The system according to item 30, wherein the edible product is at least partially formed into the desired shape by a scraping knife cooperating with the at least one component. (Item 32) The system according to item 29, wherein the at least one component includes a first roller and a second roller, and the first roller has a substantially smooth surface. (Item 33) The system according to item 29, wherein the at least one component includes a first roller and a second roller, the first roller includes a plurality of first cavities, and the second roller includes a plurality of second cavities. (Item 34) The system according to item 33, wherein the plurality of first cavities and the plurality of second cavities cooperate to form and size the edible material into the desired shape. (Item 35) The system according to item 33, wherein the affinity between the edible material and the plurality of second cavities is greater than the affinity between the edible material and the plurality of first cavities. (Item 36) The system according to item 29, wherein the at least one component includes a first roller and a second roller, a gap is defined between the first roller and the second roller, and the edible structure still contacts the second roller downstream of the gap. (Item 37) The system according to item 28, further comprising a blade for removing excess material from the surface of the at least one component. (Item 38) The system according to item 29, wherein the forming station includes a first roller and a second roller, and the packaging roller cooperates with a portion of the second roller at a position downstream of the first roller. (Item 39) The system according to item 29, wherein the affinity of the edible structure for the packaging material is greater than the affinity of the edible structure for the second roller. (Item 40) The system according to item 28, further comprising another packaging material applied to the edible structure. (Item 41) The system according to item 40, wherein when the edible structure is separated from the forming station, the other packaging material is applied to the edible structure. (Item 42) The system according to item 40, further comprising a packaging machine for sealing the packaging material and the other packaging material around the edible structure. (Item 43) The system according to item 28, further comprising a cutting device for forming at least one cut in the packaging material. (Item 44) The system according to item 28, wherein intentional cooling of the edible structure does not occur downstream of the forming station and before the packaging material is placed in contact with the edible structure. (Item 45) A method of manufacturing an edible product, the method comprising: providing an edible mass; forming the edible mass into an edible structure having a desired shape via a forming station; packaging the edible structure within a packaging material; performing at least one of continuously providing the edible structure directly from the forming station to the packaging material and continuously providing the packaging material directly to the forming station. (Item 46) The method according to item 45, wherein packaging the edible structure is continuous to completely enclose the edible structure within the package. (Item 47) The method according to item 46, wherein packaging the edible structure within the packaging material does not include accumulating the edible structure. (Item 48) The method according to item 45, wherein adjustment of the edible structure does not occur or occurs only minimally between the forming and the packaging. (Item 49) The method according to item 45, wherein the forming station includes at least one movable component, and the packaging of the edible structure is initiated while the edible structure is in contact with the at least one movable component. (Item 50) The packaging of the edible structure further includes applying a first packaging material to a first surface of the edible structure, and applying a second packaging material to a second surface of the edible structure, the method according to item 45. (Item 51) The method according to item 50, wherein the forming station includes at least one movable component, and when the first packaging material is applied to the edible structure, the edible structure is in contact with the at least one movable component. (Item 52) The method according to item 51, further including removing the edible structure from the at least one movable component. (Item 53) The method according to item 52, wherein the affinity of the edible structure for the first packaging material is greater than the affinity of the edible structure for the surface of the at least one movable component. (Item 54) The method according to item 50, wherein the packaging of the edible structure further includes sealing the first packaging material to the second packaging material to enclose the edible structure. (Item 55) The method according to item 50, wherein the packaging of the edible structure further includes cutting at least one of the first packaging material and the second packaging material. (Item 56) The method according to item 45, wherein intentional cooling of the edible structure does not occur while forming the edible structure into an edible structure having a desired shape and while applying the packaging material to the edible structure. (Item 57) The method according to item 45, wherein the edible is chewing gum. (Item 58) The method according to item 45, wherein the edible structure is continuously provided from the forming station to a conveyor in communication with a first packaging roller. (Item 59) The method according to item 45, wherein the forming station includes a chain cutter device. (Item 60) A system for forming and packaging an edible food along a forming and packaging line, comprising: A forming station positioned along the forming and packaging line for receiving an edible food and forming and sizing the edible food into an edible structure having a desired shape; and Packaging material receivable by the forming and packaging line, the packaging material being positioned such that the edible structure is continuously provided directly from the forming station to the packaging material. (Item 61) The system according to item 60, wherein the forming station includes a component having at least one cavity for receiving the edible food. (Item 62) The system according to item 61, wherein the edible food is formed into the desired shape by being compressed within the at least one cavity. (Item 63) The system according to item 60, further comprising a packaging roller for applying the packaging material to the surface of the edible structure. (Item 64) The system according to item 63, wherein the forming station includes a first roller and a second roller, and the packaging is performed in cooperation with the second roller at a position downstream of the first roller. (Item 65) The system according to item 63, wherein the packaging material is positioned in contact with the edible structure while the edible structure is in contact with the forming station. (Item 66) The system according to item 63, further comprising another packaging material receivable by the forming and packaging line so as to be positioned in contact with the edible structure. (Item 67) The system according to item 66, wherein the other packaging material is positioned in contact with the edible structure after the edible structure is removed from the forming station. (Item 68) The system according to item 66, further comprising a packaging machine for sealing the packaging material and the other packaging material around the edible structure. (Item 69) The system according to item 68, further comprising a cutting device for forming at least one cut in the packaging material and the other packaging material. (Item 70) The system according to item 60, wherein intentional cooling of the edible structure does not occur downstream of the forming station and before the packaging material is disposed in contact with the edible structure. (Item 71) A method of packaging an edible food, comprising: providing an edible food mass; forming the edible food mass into an edible structure having a desired shape via a forming station; packaging the edible structure in a packaging material, wherein the edible structure is prevented from directly contacting a force generating component of a packaging station during application of the packaging material. (Item 72) The method according to item 71, wherein the force generating component includes a knife. (Item 73) The method according to item 71, wherein all intentional adjustments of the edible structure occur while the edible structure is in contact with the packaging material. (Item 74) The method according to item 71, wherein intentional cooling of the edible structure does not occur while the edible food is formed into an edible structure having a desired shape. (Item 75) The method according to item 71, wherein the desired shape is the final shape of the edible product. (Item 76) A method of packaging an edible product, comprising: providing a mass of the edible product; forming the mass of the edible product into an edible product structure having a desired shape; packaging the edible product structure with a packaging material, wherein any change in the properties of the edible product structure that occurs downstream of the forming occurs while the edible product structure is in contact with the material of the package. (Item 77) The method according to item 76, wherein the change in the properties includes a change in the hardness of the edible product structure. (Item 78) The method according to item 76, wherein the change in the properties includes a change in the rigidity of the edible product structure. (Item 79) The method according to item 76, wherein the change in the properties does not affect the packaging. (Item 80) A system for forming and packaging an edible product along a forming and packaging line, comprising: a forming station positioned along the forming and packaging line for receiving the edible product and forming and sizing the edible product into an edible product structure having a desired shape; a packaging station disposed downstream of the forming station, wherein the edible product provided to the packaging station has a Young's modulus of less than 120 kP. (Item 81) The system according to item 80, wherein the edible product provided to the packaging station has a Young's modulus of greater than 75 kP. (Item 82) The system according to item 81, wherein the edible product provided to the packaging station has a Young's modulus of between 20 kP and 80 kP. (Item 83) The system according to item 82, wherein the edible product has a Young's modulus of between 30 kP and 70 kP. (Item 84) The system according to item 82, wherein the edible product has a Young's modulus of 40 kP to 60 kP. (Item 85) The system according to item 81, wherein the edible product is provided to the packaging station having a temperature exceeding 30°C. (Item 86) A method for manufacturing an edible product, the method comprising: providing an edible product mass; using a forming station to form the edible product mass into an edible product structure having a desired shape; applying a packaging material to a surface of the edible product structure, wherein the forming of the edible product mass into the edible product structure and the applying of the packaging material to the surface of the edible product structure occur without any intentional cooling of the edible product mass and the edible product structure. (Item 87) The method according to item 86, wherein the packaging material is applied to the surface of the edible product while the edible product is in contact with the forming station. (Item 88) The method according to item 86, wherein the edible product structure has a depth of 0.3 mm to 10 mm in the desired shape. (Item 89) An edible product comprising a chewing gum body formed in a desired shape, wherein the edible product body has a hardness below 80 kP. (Item 90) The edible product according to item 89, wherein the hardness is 20 kP to 80 kP.

Brief Description of the Drawings

[0096] The accompanying drawings, which are incorporated herein and form a part hereof, illustrate several aspects of the present invention and, together with the description, serve to explain the principles of the present invention.

[0097]

Figure 1

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Figure 2

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Figure 3

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Figure 4

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Figure 5

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Figure 6

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Figure 7

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Figure 8

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Figure 9

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Figure 10

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Figure 11

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Figure 12

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Figure 13A

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Figure 13B

DETAILED DESCRIPTION OF THE INVENTION

[0111] Examples of the edible products considered in this specification include, but are not limited to, chewing gums (at any stage including elastomers, partially completed bases, completed chewing gum bases, and completed chewing gums), confections (which can be synonymous with chewing gums and candies), chocolates, gummy candies, soft candies, sweet and fragrant biscuits, and any other type of edible product. For the sake of simplicity, the edible product will be referred to as chewing gum for the remainder of this description. Certain compositions of chewing gum can have a non-uniform texture and / or be multi-layered.

[0112] Referring now to the figures, forming station 20 is used during the manufacture of an edible product. As described herein, "forming" that occurs at forming station 20 can be interpreted to include manipulating or shaping the edible mass 22 into one or more shapes having a desired size. Sizing may occur simultaneously with forming. Any forming station 20 capable of performing any type of forming operation is within the scope of the present disclosure. Examples of forming operations that can be performed by forming station 20 include, but are not limited to, compression, hot stamping, three-dimensional printing, and rotational extrusion forming.

[0113] In the non-limiting embodiments shown in FIGS. 1-7, forming station 20 includes a pair of rollers 30 including a first roller 32 and a second roller 34. However, embodiments in which at least one of the rollers is replaced with another component or a movable wall, such as a conveyor including, for example, a flat surface, are also contemplated herein. Each of rollers 32, 34 may be provided with a motor such that the rotational speed of each of rollers 32, 34 is independently controlled. The rotational speed of each of rollers 32, 34 can be selected according to the physical properties of the edible mass 22 and the desired amount of heat transfer through rollers 32, 34.

[0114] In one embodiment, the edible mass 22 provided to forming station 20 is a finished chewing gum. As is generally well known, a finished chewing gum typically includes a water-soluble bulk portion, a water-insoluble gum base portion, and one or more flavoring agents. The water-soluble portion dissipates over a period of time while the gum base portion is retained in the mouth through the chewing process. Further, the edible mass 22 may include a single composition or may include a plurality of compositions, such as, for example, those stacked in layers.

[0115] It should be further understood that the edible mass 22 may be provided to the forming station 20 in any suitable form. In one embodiment, the edible mass 22 is in the form of an unformed edible mass having an irregular or non-uniform thickness (see FIG. 3). An “unformed” gum mass may be defined as any mass that is not in its current state, size, or formed through extrusion, deformation, or any other means, although it should be noted that the gum mass may have been mixed or formed in such a way prior to its current state. Alternatively, the edible mass 22 provided to the pair of rollers 30 may be a sheet, slab, continuous ribbon, or rope having a substantially constant or uniform cross-sectional area over its length, as shown in FIG. 1. In embodiments where the edible mass 22 has a uniform shape, the edible mass 22 may be sized via any suitable method at a forming station (not shown) positioned upstream of the forming station 20. For example, the edible mass 22 may be extruded through an extruder die, or alternatively, the edible mass 22 may be provided to one or more sizing rollers. In one embodiment, the pair of rollers 30 of the forming station 20 may also form part of a series of rollers that form, for example, conventional rolling and cutting lines.

[0116] The pair of rollers 30 may be arranged such that the first roller 32 and the second roller 34 are offset horizontally and / or vertically relative to each other. In one embodiment, the first roller 32 and the second roller 34 are arranged such that a space or gap 36 is formed between the roller 32 and the roller 34. In another embodiment, the pair of rollers 30 are positioned such that there is no gap between the first roller 32 and the second roller 34. In such an embodiment, at least one outer circumference of the pair of rollers 30 may have a coating formed around its outer surface to minimize friction and wear resulting from the engagement of the rollers 32, 34.

[0117] The first roller 32 and the second roller 34 are configured to rotate in opposite directions, for example, to pull the edible food mass 22 between the roller 32 and the roller 34, for example, through the gap 36. In the embodiment shown in FIG. 1, the first roller 32 rotates in the clockwise direction indicated by the arrow R1, while the second roller 34 rotates in the counterclockwise direction indicated by the arrow R2. When the edible food mass 22 is supplied between the rollers 32, 34, the counter-rotating rollers 32, 34 pull the edible food mass 22 between the rollers 32, 34 and apply a compressive force thereto. Thus, the formation of the edible food occurring in the pair of rollers 30 occurs under pressure.

[0118] An example of the second roller 34 of the forming station 20 of FIGS. 1-7 is shown in more detail in FIG. 2. In one embodiment, the outer periphery defining the continuous forming surface 38 of the second roller 34 has a plurality of cavities 40 that extend inwardly into the roller 34. As shown, the cavities 40 are axially (parallel to the axis of rotation) circumferentially spaced cutout depressions around the roller 34. Each of the plurality of cavities 40 may be the same or different. In the exemplary, non-limiting embodiment shown, the roller 34 has eight cavities formed over its axial width. However, it should be understood that rollers having any suitable number of cavities are contemplated herein. In one embodiment, the roller 34 may have 5 to 50 axially spaced cavities 40, more specifically 5 to 40, and 8 to 30 axially spaced cavities 40. The lands 42 are positioned between adjacent cavities 40 in both the axial and circumferential directions. In one embodiment, the size of each cavity 40, i.e., the axial width, the circumferential length, and the depth (measured parallel to the radius), may be approximately equal to the size of the finished edible food, such as a single piece of gum or candy. Alternatively, the cavities 40 may define a plurality of edible food pieces by having an internal contour that defines or delineates the adjacent edible food pieces within or defines the shape of the edible food.

[0119] Furthermore, portions of the cavities 40, such as a plurality of cavities 40 extending axially within a column across the width of the roller 34 measured perpendicular to the machine direction, may form a pattern associated with the grouped edible material. For example, the pattern defined by the columns of cavities 40 may define a plurality of pieces of gum within a pack of gum. Further, in embodiments where the roller 34 includes a plurality of patterns, the patterns may have the same or different configurations.

[0120] The first roller 32 may have a substantially smooth surface, as shown in FIG. 1. Alternatively, as best shown in FIGS. 3 and 4, the first roller 32 may also have a plurality of cavities 44 or may have cutout depressions formed in the roller 32. In such embodiments, each of the plurality of cavities 44 is generally complementary to and configured to align with a corresponding cavity 40 formed within the second roller 34 to form a further shaped confectionery or edible material. Embodiments in which both the first roller 32 and the second roller 34 include cavities 40, 44 may be configured to form a three-dimensionally contoured edible material having a complex shape. For example, the plurality of contoured surfaces of the edible mass 22 may be formed by each of the cavities 40, 44.

[0121] In one embodiment, the first knife or scraping device 46 is configured to contact the surface of the first roller 32 that is substantially adjacent to or downstream of the gap 36 and remove edible material from the surface of the first roller 32. However, in some embodiments, when the gap 36 between the first roller 32 and the second roller 34 is very small or there is no gap, for example, it may not be necessary to include the knife 46. Alternatively, or in addition, the second knife or scraping device 48 may be positioned adjacent to the outlet of the gap 36. The second knife 48 abuts against the surface 38 of the second roller 34 to separate excess compressed material, i.e., material not received within the cavity 40, and / or in some embodiments, material extending beyond the surface 38 of the second roller 34 toward the first roller 32. The excess material removed by either the first scraping device 46 or the second scraping device 48 may be discarded or reused by the manufacturing system.

[0122] When the edible food mass 22 is compressed between the first roller 32 and the second roller 34, the edible food mass 22 fills a plurality of cavities 40 around the outer circumference of the second roller 34 and, in some embodiments, a plurality of cavities 44 of the first roller 32. By including the cavities 44 in the first roller 32 and / or the second roller 34, the movement of the edible food mass 22 can be facilitated, for example, by pulling the edible food material toward the gap 36. Due to the compression force and / or adhesive properties used to fill the cavities 40, the edible food mass 22 is retained within the cavities 40 when rotating away from the gap 36. In embodiments where both the first roller 32 and the second roller 34 have cavities 44, 40, the release properties of the first roller 32 may be greater than the release properties of the second roller 34. As a result, when the cavities 44, 40 of the first roller 32 and the second roller 34 rotate out of alignment, the formed edible food or edible food structure 26 is pulled from the cavity 44 by the second roller 34 and remains within the cavity 40. In one embodiment, a release agent, such as oil, can be used to reduce or prevent adhesion between the edible food and the cavity 44 of the first roller 32.

[0123] After the food mass 22 is compressed into the cavity 40 and / or the cavity 44 to form a plurality of formed food structures 26, the food structures 26 are packaged via a packaging station 50 that is downstream of and in line with the forming station 20. More specifically, the packaging station 50 is configured to cooperate with at least a portion of the forming station 20. The food structures 26 formed by the cavities 40 and / or 44 of the rollers 34, 32 are continuously provided to the packaging station 50 for packaging. As a result, little or no adjustment of the food structures 26 occurs between forming and packaging. Further, no intentional adjustment of the food occurs between forming and packaging.

[0124] In the non-limiting embodiments shown in FIGS. 1 and 3-5, the packaging station 50 is configured to directly cooperate with at least a portion of the forming station 20. As shown, the packaging station 50 includes a first packaging roller 52 disposed adjacent to a portion of the second roller 34 that is downstream of the gap 36 formed by the first roller 32. The first packaging roller 52 is positioned directly adjacent to the second roller 34 such that the first packaging roller 52 or the packaging material moving therewith contacts the second roller 34. The first packaging material 54 is at least partially wound around the first packaging roller 52. In one embodiment, a roll 56 of the first packaging material 54 is in communication with the first packaging material 54 and is configured to supply the first packaging material 54 to the first packaging roller 52. Rotation of the first packaging roller 52 drives rotation of the roll 56 of the first packaging material 54 to enable the first packaging material 54 to be rewound as needed during operation of the system 50. Alternatively, the packaging material may be pulled from the roll 56 when the packaging material 54 is compressed between the second roller 34 and the first packaging roller 52 as the second roller 34 rotates.

[0125] The first packaging material 54 may be any suitable single or multi-layer packaging material or composite material, including, but not limited to, a flexible film formed from, for example, a polyolefin, a polyamide, or a polyester. In the embodiments shown in FIGS. 1 and 3-5, when the first packaging roller 52 rotates about its axis, the first packaging material 54 is positioned between the first packaging roller 52 and the second roller 34 of the forming station 20. The first packaging material 54 is disposed in direct contact with not only the surface 38 of the second roller 34 but also the first lower or bottom surface of the formed edible food structure 26 pieces formed within the cavity 40 of the second roller 34.

[0126] In embodiments where the first roller 32 includes a plurality of cavities 44, the first packaging roller 52 may similarly include a plurality of cavities 58 that are substantially identical to the cavities 44 of the first roller 32. When the cavity 40 of the second roller 34 having the edible food structure 26 therein rotates toward the first packaging roller 52, the portion of the edible food structure 26 that extends beyond the surface 38 of the second roller 34 is received within the cavity 58 formed within the first packaging roller 52. When the edible food structure 26 that extends beyond the surface 38 of the second roller 34 is received within the cavity 58 of the first packaging roller, the edible food structure 26 can push the first packaging material 54 into the cavity 58 at the position between the surface of the cavity 58 and the edible food structure 26.

[0127] The first packaging material 54 may be disposed around the outer surface 60 of the first packaging roller 52 as shown in FIG. 3. When the edible food structure 26 is received within the cavity 58, a portion of the first packaging material 54 is similarly received within the cavity 58 between the formed edible food 26 and the inner surface of the cavity 58. Alternatively, the first packaging material 54 may generally be contoured to form a liner as shown in FIG. 4, such that the first packaging material 54 is positioned within the cavity 58 of the roller 52 before receiving the formed edible food structure 26 therein.

[0128] The formed edible structure 26 is configured to completely separate from the cavity 40 when the second roller 34 rotates away from the interface with the packaging material 54 wound around the first packaging roller 52. In one embodiment, the edible food 26 within the plurality of cavities 40 has a higher affinity for the first packaging material 54 than for the cavity 40. As a result, the adhesion between the first packaging material 54 and the edible structure 26 pulls the edible structure 26 from the cavity 40. In one embodiment, the first packaging material 54 has an adhesive applied thereto to bond pieces of the edible food 26 to the material 54.

[0129] In another embodiment, the edible structure 26 may be released from the cavity 40 of the second roller 34 before being supplied to the packaging station 50. As shown in FIG. 6, the packaging station 50 includes a first packaging roller 52 and a transfer mechanism 62, such as a conveyor, for supplying the edible structure 26 from, for example, the forming station 20 to the first packaging roller 52.

[0130] In one embodiment, the adhesion between the edible structure 26 within the cavity 40 and the surface of the transfer mechanism 62 may be sufficient to pull the edible structure 26 formed from the cavity 40 as the second roller 34 rotates away from the interface with the transfer mechanism 62. Alternatively, a mechanism 63 associated with the roller 34 may be used to eject the edible structure 26 from the cavity disposed vertically on the transfer mechanism 62. In the non-limiting embodiment shown in FIG. 7, the mechanism 63 is mounted inside the roller 34 and is operable to apply a force to a portion of the edible structure 26 located within the cavity 40 positioned adjacent to the transfer mechanism 54. By applying a mechanical, pneumatic, or other suitable force towards the outer periphery of the roller 34, the edible structure 26 can be disengaged or separated from the cavity 40. The mechanism 63 has been described with respect to the second roller 34, but the mechanism 63 may be adapted for use with any roller at the forming station 20 or alternatively at the packaging station 50. However, it should be understood that the mechanism 63 may also be used to assist in removing the formed edible structure 26 from the cavity 40 in embodiments where the edible structure 26 is output directly onto the packaging material 54.

[0131] Regardless of whether the edible structure 26 is provided directly or indirectly from the roller of the forming station 20 to the packaging station 50, once the edible structure is separated from the forming station 20 and contacts the first packaging material 54, the first packaging material 54 and the edible structure 26 located thereon are moved via a transfer mechanism 64 such as, for example, a conveyor. The transfer mechanism 64 is configured to transfer the at least partially packaged edible structure 26 to a downstream portion of the packaging station 50 and will be described in more detail below.

[0132] In one embodiment, although best shown in FIGS. 1, 2-4, and 6, the packaging station 50 additionally includes a second packaging roller 65 disposed substantially downstream from the first packaging roller 52. The second packaging roller 65 is configured to apply a second packaging material 66 to the second upper surface of the edible food structure 26. In one embodiment, the lower surface of the edible food structure 26 disposed in contact with the first packaging material 54 and the upper surface of the edible food structure 26 disposed in contact with the second packaging material 66 may be disposed on opposite sides of each other.

[0133] The second packaging material 66 may be at least partially wound around the outer periphery of the second packaging roller 65 oriented to contact the edible food structure 26. In one embodiment, a roll 68 of the second packaging material 66 is disposed in communication with the second packaging roller 65. The second packaging material 66 may also be any suitable material, may be the same as the first packaging material 54, or may be different.

[0134] The second packaging roller 65 may have a substantially smooth contour or, alternatively, may include a plurality of cavities 70. The plurality of cavities 70 may be substantially identical to the plurality of cavities 40 formed within the second roller 34. Alternatively, the plurality of cavities 70 may be larger than the cavities 40, such that a gap is formed between the second packaging material 66 and the corresponding portion of the edible food structure 26.

[0135] When the second packaging roller 65 rotates about its axis, the second packaging material 66 is disposed between the second packaging roller 65 and the surface of the edible product 26. The second packaging material 66 may be disposed around the outer surface 71 of the second packaging roller 65, as shown in FIG. 4. When the edible product structure 26 is received within the cavity 70, a portion of the second packaging material 66 is similarly received within the cavity 70 between the formed edible product 26 and the inner surface of the cavity 70. Alternatively, the second packaging material 66 may generally be contoured to form a liner, as shown in FIG. 5, such that the second packaging material 66 is positioned within the cavity 70 of the roller 64 before receiving the edible product structure 26 formed therein.

[0136] In another embodiment, the second roller 34 of the forming station 20 is used in place of the second packaging roller 65. Referring now to FIG. 5, the second packaging material 66 provided from the roll 68 at least partially wraps around the second roller 34. In the exemplary non-limiting embodiment shown, the second packaging material 66 extends over approximately 180 degrees of the outer circumference of the roller 34. As previously described with respect to the first and second packaging rollers 52, 65, the second packaging material 66 may be disposed around the outer surface 38 of the second roller 34. In such an embodiment, the second packaging material 66 is received within the cavity 40 during compression of the edible product mass 22 between the two rollers 32, 34 at a position between the surface of the cavity 40 and the edible product mass 22. Alternatively, the second packaging material 66 may generally be contoured to form a liner having an internally formed cavity that is generally complementary to the cavity 40 of the second roller 34. When the second packaging material 66 is unwound, the cavity of the packaging material 66 is positioned within the cavity 40 of the roller 34 before receiving the formed edible product structure 26 therein.

[0137] In various configurations of the packaging station 50, the edible structure 26 is sandwiched between a first packaging material 54 and a second packaging material 66. Since the packaging materials 54, 66 are disposed between the edible structure 26 and the rollers 52, 65, 34, the edible structure 26 does not come into direct contact with any component of the packaging station 50 other than the first packaging material 54 and the second packaging material 66.

[0138] In another embodiment, as best shown in FIG. 8, the forming station 20 includes a chain cutter device. The chain cutter device includes a pair of continuous chains 100, 102. Each chain 100, 102 is supported for continuous rotation about a pair of spaced rollers 104. In one embodiment, each chain 100, 102 is configured to rotate at the same speed and is driven by a suitable motor and gear mechanism (not shown). In one embodiment, the rollers 104 that support the chains 100, 102 include sprocket members that engage and move along the chains 100, 102.

[0139] In an illustrative non - limiting embodiment, each strand 100, 102 includes a plurality of die members 106 that respectively define open die cavity portions 108, 110. The open die cavity portion 108 of the first strand 100 is arranged in alignment with the open die cavity portion 110 of the second strand 102 to form a closed die cavity 112 within which a food piece is formed. However, it should be understood that embodiments in which only one of the strands 100, 102 includes open die cavity portions 108, 110, or alternatively, embodiments in which a plurality of open die cavity portions 108, 110 of each strand 100, 102 are aligned with mating flanges 114, 116 of the opposite strand 100, 102 are also within the scope of the present disclosure. Similar to the previous embodiments, each of the closed die cavities 112 defined between a pair of continuous strands 100, 102 may be the same or different. Further, in one embodiment, the size of each closed die cavity 112 may generally be equal to the size of a finished food product, such as a single piece of gum or candy. Alternatively, the closed die cavity 112 may define a plurality of food pieces by having an internal contour that delineates the boundaries of adjacent internal food pieces or defines the shape of the food product.

[0140] A food mass 22, such as a finished piece of gum for example, is supplied between the open die cavities 108, 110 of the strands 100, 102. In one embodiment, the food mass 22 provided to the strand cutter device is an unformed food mass 22 having an irregular or non - uniform thickness. However, in other embodiments, the food mass 22 provided to the strand cutter device may be sized and / or formed at a forming station (not shown) located upstream of the strand cutter device via any suitable method. For example, the food mass 22 provided to the strand cutter device may be a rope having a substantially uniform cross - section over the length of the rope (measured parallel to the flow direction). Alternatively, the food mass 22 provided to the strand cutter device may be a sheet, slab, or continuous ribbon having a substantially constant or uniform cross - sectional area over its length.

[0141] As best shown in FIG. 9, the mating flanges 114, 116 on the chains 100, 102 are each positioned between adjacent open die cavities 108, 110. As the chains 100, 102 move, the mating flanges 114, 116 cross and contact between each of the die cavities 108, 110. When the mating flanges 114, 116 converge, the die cavity portions 108, 110 approach around the food mass 22 and effectively form and cut the food mass 22 at those points to form individual pieces of food within the closed die cavity 112. Continued movement of the chains 100, 102 discharges the individual pieces from the closed die cavity 112. For example, when the chains 100, 102 separate adjacent to the downstream roller 104, the formed food structure 26 within each closed die cavity 112 should remain within the open die cavities 108, 110 formed in either the upper chain 100 or the lower chain 102. When the open die cavity 110 of the lower chain 102 passes through the roller 104, the formed food structure 26 is provided to a first transfer mechanism, such as a chute or conveyor, generally indicated at 118, and may be carried onto an adjacent second transfer mechanism 120 (see FIG. 10). Similar to embodiments where the forming station 20 includes a pair of rollers, a release agent, such as oil or powder, for example, need not be used to reduce or prevent adhesion between the food and the cavities 108, 110 of one or both of the chains 100, 102.

[0142] In one embodiment, the first transfer mechanism 118 may control the speed, positioning, or orientation of the structure 26, which are delivered to the second transfer mechanism 120. However, embodiments where the food structure 26 is provided directly to the transfer mechanism 120 are also contemplated herein.

[0143] In embodiments where the forming station 20 includes a chain cutter, the food structure 26 formed by the closed die cavity 112 may be continuously provided to a downstream packaging station 150 for its packaging. In such embodiments, little or no adjustment of the food structure 26 occurs between forming and packaging. Further, no intentional adjustment of the food structure 26 occurs between forming and packaging.

[0144] As shown, the packaging station 150 includes a first packaging roller 152 disposed adjacent to a transfer mechanism 120 and configured to receive a plurality of formed structures 26 output from the forming station 20. In the non-limiting embodiment shown, the first packaging roller 152 may be disposed adjacent to the upstream end 122 of the transfer mechanism 120 and configured to rotate at the same speed as the transfer mechanism 120. The first packaging material 154 is at least partially wound around the first packaging roller 152 and deposited on the upper surface 124 of the transfer mechanism 120. In one embodiment, a roll 156 of the first packaging material 154 is in communication with the first packaging material 154 and configured to supply the first packaging material 154 to the first packaging roller 152. However, embodiments in which the roll 156 of the first packaging material 154 is incorporated into the first packaging roller 152 are also contemplated herein.

[0145] Rotation of the first packaging roller 152 drives rotation of the roll 156 of the first packaging material 154 to enable rewinding of the first packaging material 154 as needed during operation of the packaging station 150. Alternatively, when the packaging material 154 is delivered onto the upper surface 124 of the transfer mechanism 120, the first packaging material 154 can be pulled from the roll 156. As described above, a plurality of formed edible structures 26 output from the forming station 20 are provided to the transfer mechanism 120 via a chute 118. Since the first packaging material 154 is disposed on the exposed surface 124 of the transfer mechanism 120, the formed edible structures 26 are deposited on the transfer mechanism 120 with the first packaging material 154 disposed therebetween. The transfer mechanism 120 is configured to transfer at least partially packaged structures 26 to a downstream portion of the packaging station 150.

[0146] In one embodiment, the packaging station 150 additionally includes a second packaging roller 165 disposed substantially downstream from the first packaging roller 152. In such an embodiment, the second packaging roller 165 may be configured to apply a second packaging material 166 to a second upper surface of the plurality of formed edible structures 26. In one embodiment, the lower surface of the edible structure 26 disposed in contact with the first packaging material 154 and the upper surface of the edible structure 26 disposed in contact with the second packaging material 166 may be disposed on opposite sides of each other.

[0147] The second packaging material 166 may be at least partially wound around the outer circumference of the second packaging roller 165 oriented to contact the edible structure 26. In one embodiment, a roll 168 of the second packaging material 166 is disposed in communication with the second packaging roller 165. However, embodiments in which the roll 168 of the second packaging material 166 is incorporated into the second packaging roller 165 are also contemplated herein. The second packaging material 166 may also be any suitable material, may be the same as the first packaging material 154, or may be different.

[0148] The second packaging roller 165 may have a substantially smooth contour, as shown in the figures. In such an embodiment, when the second packaging roller 165 rotates about its axis, the second packaging material 166 is disposed between the second packaging roller 165 and the surface of the edible structure 26.

[0149] Referring now to FIG. 11, in another embodiment, the second packaging roller 165 may have a plurality of cavities 170 formed therein. In such an embodiment, the plurality of cavities 170 formed in the second packaging roller 165 may be substantially identical to the plurality of open die cavities 108 formed in the first chain 100. Alternatively, the plurality of cavities 170 may be larger than the cavities 108, such that a gap is formed between the second packaging material 166 and the corresponding portion of the edible structure 26. In such an embodiment, when the edible structure 26 is received within the cavity 170, a portion of the second packaging material 166 is similarly received within the cavity 170 between the shaped edible 26 and the inner surface of the cavity 170. Alternatively, the second packaging material 166 may generally be contoured to form a liner, such that the second packaging material 166 is positioned within the cavity 170 of the second packaging roller 165 before receiving the edible structure 26 formed therein.

[0150] In yet another embodiment, the packaging station 150 may be configured to cooperate directly with the forming station 20. For example, at least one of the first packaging material 154 and the second packaging material 166 may be supplied to the forming device 20 simultaneously with the edible mass 22. In the non-limiting embodiment shown in FIG. 12, the first packaging roller 152 and / or the second packaging roller are disposed adjacent to the upstream end of the forming station 20. When the first packaging roller 152 rotates about its axis, the first packaging material 154 is disposed between the die member 106 of the second lower chain 102 of the forming station 20 and the edible mass 22. The first packaging material 154 may be disposed in direct contact not only with the surface of the die member 106 such as the fitting flange 114 and the open die cavity 108, but also with the first lower surface or bottom surface of the formed edible food structure 26 pieces formed in the cavity 108. Similarly, when the second packaging roller 165 rotates about its axis, the second packaging material 166 is disposed between the die member 106 of the first upper chain 100 of the forming station 20 and the edible mass 22. The second packaging material 166 may be disposed in direct contact not only with the surface of the die member 106 such as the fitting flange 116 and the open die cavity 110, but also with the second lower surface or bottom surface of the formed edible food structure 26 pieces formed in the cavity 110. In such an embodiment, the fitting flanges 114, 116 converge, the die cavity portions 108, 110 are close to the edible mass 22, the first packaging material 154 and / or the second packaging material 166, and effectively form and cut the edible mass 22 and the packaging material at these points to form individual edible food pieces at least partially packaged within the closed die cavity 112.

[0151] Referring now to FIGS. 13A and 13B, in one embodiment, the packaging stations 50, 150 additionally include a cutting device 72, such as a cutting roller, configured to cut the first packaging materials 54, 154 and the second packaging materials 66, 166 at positions between adjacent food items, as schematically indicated by line 74. Alternatively or additionally, the cutting device 72 may be configured to cut the first packaging materials 54, 154 and the second packaging materials 66, 166 between adjacent rows of food items in a direction extending transversely to the machine direction, as schematically indicated by line 76. Through this cutting operation, the packaging materials 54, 154, 66, 166, and the food structure 26 may be separated into a plurality of individually packaged food items 28, or alternatively, into groups of partially packaged food items 28. Although referred to herein as a cutting operation, the cutting operation is intended to include any suitable method for dividing the food structure 26 into individual food items 28, including, but not limited to, cutting, shearing, and scoring.

[0152] A plurality of partially packaged edible items 28 may be provided to a downstream packaging machine 78 configured to seal a first packaging material 54, 154 adjacent to a first surface of the partially packaged edible item 28 to a second packaging material 66, 166 adjacent to a second, opposite surface of the partially packaged edible item 28. In one embodiment, the packaging machine 78 forms a heat seal, generally indicated at 80, between the first packaging material 54, 154 and the second packaging material 66, 166 along at least one edge of a perimeter portion of the partially packaged edible item 28. The packaging machine 78 may be configured to seal the first packaging material 54, 154 and the second packaging material 66, 166 along a plurality of edges of a perimeter portion of the partially packaged edible item 28 to substantially enclose the edible item between the first packaging material 54, 154 and the second packaging material 66, 166. In one embodiment, the total time elapsed between forming the edible item in a pair of rollers 30 and enclosing the edible item structure 26 within the package may be 5 minutes or less, 3 minutes or less, 1 minute or less, and 30 seconds or less. The packaging machine 78 is described as forming a heat seal, but embodiments where the packaging machine 78 forms a cold seal for sealing the packaging materials together to enclose the edible item structure 26, or applies a hot or cold adhesive, are also within the scope of the present disclosure. Further, any type of packaging machine suitable for connecting the first packaging material 54, 154 and the second packaging material 66, 166 is contemplated herein. The packaging station 50 is shown and described with the packaging machine 78 disposed downstream of the cutting device 74, but embodiments where the first packaging material 54, 154 and the second packaging material 66, 166 are joined prior to or during the cutting operation are also contemplated herein.

[0153] The first packaging materials 54, 154 and the second packaging materials 66, 166 are applied to opposing surfaces of the edible food structure 26 during or immediately after the edible food structure 26 is formed, so that while the edible food structure 26 is in contact with at least one of the packaging materials 54, 154, 66, 166, any and all changes in one or more properties of the edible food structure that occur after the edible food is formed occur. For example, all intentional adjustments of the edible food structure 26 downstream of formation may occur while the edible food is in contact with one or more of the packaging materials 54, 154, 66, 166 or, alternatively, within the package defined by the first packaging materials 54, 154 and the second packaging materials 66, 166. As a result, the edible food structure packaged via the system 10 and process described herein may have lower rigidity than an edible food formed via a conventional process. For example, an edible food as described herein may have a hardness or Young's modulus of 10 kP to 100 kP, more specifically, for example, 20 kP to 80 kP, up to a maximum of 120 kP such as 75 - 120 kP, or less than about 110 kP of the conventional hardness of a slab. However, in some embodiments, the intentional adjustment of the edible food structure 26 occurs downstream of the pair of rollers 30. Additionally, the temperature of the edible food when packaged may be greater than 30°C and the coefficient of friction of the edible food may be greater than 0.25. As used herein, the term "conditioning" is intended to describe any process by which the edible food is placed in an environment having one or more controlled parameters so that the edible food can reach one or more optimal properties such as temperature, viscosity, and moisture content for quality and processing purposes. Further, in some embodiments, conditioning may include intentional cooling of the edible food or edible food structure via controlled convection, i.e., flow from a fan or blower, or conduction. It should be understood that natural cooling that may occur due to the difference between the temperature of the edible food and the temperature of the ambient environment surrounding the edible food is not considered intentional.

[0154] Furthermore, the packaging of the edible structure 26 shown and described herein does not require any direct contact between the edible food and the parts of the equipment or components that apply force to the edible food. Without such adjustment, the edible food requires an adjustment period because it adheres to the force application component and stops the operation. For this reason, the elimination of this operation eliminates the need for adjustment and enables the manufacture and packaging of gums having a Young's modulus different from what was previously possible.

[0155] All references, including publications, patent applications, and patents listed herein, are hereby incorporated by reference in their entirety as if each reference were individually and specifically indicated as being incorporated by reference to the same extent as if it were set forth in full herein.

[0156] The use of the terms "a", "an", "the", and similar indicators is to be construed to include both the singular and the plural in the context of describing the invention (in particular, in the context of the following claims), unless otherwise indicated herein or unless there is an obvious contradiction in the context. The terms "comprising", "having", "including", and "containing" are open-ended shall be construed as being in the form of (i.e., meaning "including but not limited to"). The recitation of a range of values herein is merely intended to serve as a shorthand reference to each individual value falling within that range, and each individual value is incorporated herein as if it were individually recited herein, unless otherwise indicated herein. All methods described herein can be performed in any suitable order, unless otherwise indicated herein or unless clearly inconsistent with the context. The use of any and all examples, or exemplary language (e.g., "such as") provided herein is merely intended to clarify the invention and does not limit the scope of the invention unless otherwise recited in the claims. No term in this specification shall be construed as indicating any element essential to the practice of the invention that is not recited in the claims.

[0157] Preferred embodiments of the invention are described herein, including the best mode known to the inventors for practicing the invention. Variations of those preferred embodiments will be apparent to those skilled in the art upon reading the foregoing description. The inventors expect those skilled in the art to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this disclosure includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Further, any combination of the above-described elements in all possible variations thereof is included in the invention unless otherwise indicated herein or unless clearly inconsistent with the context.

Claims

1. A method of packaging an edible product, comprising: providing a mass of the edible product; forming the mass of the edible product into an edible structure having a desired shape via a forming station including a pair of forming rollers, the forming including compressing the mass of the edible product into the edible structure having the desired shape; packaging the edible structure, the packaging including contacting packaging material with a surface of the edible structure downstream of the forming, wherein the edible structure does not directly contact any force - applying component downstream of the forming station, and the force - applying component is a component for applying force to the edible product; A method comprising the above steps.

2. The method of claim 1, wherein the force - applying component includes a knife.

3. The method of claim 1, wherein all intentional cooling of the edible structure occurs while the edible structure is in contact with the packaging material.

4. The method of claim 1, wherein intentional cooling of the edible structure does not occur during the forming of the edible product into an edible structure having a desired shape.

5. The method of claim 1, wherein the desired shape is the final shape of the edible product.

6. A method of packaging an edible product, comprising: providing a mass of the edible product; forming the mass of the edible product into an edible structure having a desired shape via a forming station including a pair of forming rollers, the forming including using the pair of forming rollers to compress the mass of the edible product into the edible structure having the desired shape; packaging the edible structure within packaging material, the packaging including directly and continuously providing the edible structure from at least one of the pair of forming rollers to the packaging material; A method comprising the above steps, wherein any change in hardness or rigidity of the edible structure that occurs downstream of the forming occurs while the edible structure is in contact with the packaging material.

7. A method of manufacturing an edible product, the method comprising: providing a mass of the edible product; Forming the edible mass into an edible structure having a desired shape via a forming station including a pair of forming rollers, the forming including compressing the edible mass into the edible structure having the desired shape using the pair of forming rollers, Packaging the edible structure within a packaging material comprising the packaging of the edible structure including bringing the packaging material into contact with the surface of the edible structure, the packaging of the edible structure within the packaging material including directly and continuously providing the edible structure from at least one of the pair of forming rollers to the packaging material, a method.

8. The method according to claim 7, wherein the packaging material is positioned in contact with the surface of the edible while the edible is in contact with the forming station.

9. The method according to claim 7, wherein in the desired shape, the edible structure has a depth of 0.3 mm to 10 mm.

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