Automatic forming method and apparatus for filling products

Abstract

To provide a handmade-like bean jam product with high productivity in order to solve such a problem that traditional Japanese-style confectionary obtained by squeezing bean jam made from chestnut and potatoes is handmade one by one by an artisan, and the number of production pieces is limited due to handmade nature, thereby popular products often cannot respond to the demand, and to respond to a variety of products with different shapes.SOLUTION: There is provided a bean jam product in which a pleat pattern substantially equivalent to a bean jam product handmade by an artisan is formed from a head part to a shoulder part of the beam jam by arranging a lower die below an upper die in which an empty chamber recessed on the underside is formed and a top part of Chakin is fixed to the empty chamber and furnished, and press-fitting the bean jam in the empty chamber of the upper die so as to form a fold pleat pattern of mountain folds and valley folds of the Chakin on an upper part of the bean jam, in forming means for conveying the bean jam made from chestnut and potatoes as a block of a predetermined amount to below a forming die by a conveyor so as to form the bean jam.SELECTED DRAWING: Figure 2

Description

Detailed Description of the Invention

Technical Field

[0001] This invention relates to an automatic forming method and apparatus for confectionery products that automatically wring out fillings made from chestnuts, taro, etc. using a tea towel.

[0002] Confectionery made by wringing out fillings made from chestnuts, taro, etc. using a tea towel is widely known, and particularly chestnut roll cakes are in high demand.

[0003] Conventionally, traditional confectionery made by wringing out fillings made from chestnuts, taro, etc. using a tea towel has been handmade one by one by craftsmen. Due to being handmade, there is a limit to the production quantity, and it is often unable to meet the demand for popular products.

[0004] Although various attempts have been made to automate for mass production, the shaped products made by ordinary molds have a uniform shape and lack a handmade feel. Those made by craftsmen have slightly different shapes from each other and look good as confectionery.

Background Art

[0005] For example, as an apparatus for forming a pleated pattern on the head of food in a tea towel wring shape like chestnut roll cakes of confectionery, there is Japanese Patent Publication No. 4-19830. (Patent Document 1) This apparatus automatically forms twists and pleats on the skin part of Chinese steamed buns, etc., and is "a twist and pleat attaching apparatus for steamed buns having a vertically movable central shaft 3' having three rotatable inner claws 4 at the tip, and three or more fingers 1, 1' having outer claws 2, 2' at each tip and a pulley 6 at the upper end, which are pivotally attached at fulcrums 8, 9 around the vertically movable outer shaft 3 incorporating the central shaft 3', and the opening and closing of the fingers are also caused by a tapered guide 5 for the vertical movement of the fingers, a guide groove 7 provided in the guide, a pulley sliding in the groove, and the fulcrum."

[0006] As a technique for forming confectionery products using a mold and a sheet, there is a manufacturing method for confectionery and other foods in Japanese Patent Application Laid-Open No. 6-181734. (Patent Document 2) This technology is a method for automatically molding plastic objects such as anko. It is characterized by "adhering a sheet material to the molding part of the mold, filling the food into the molding part, then inverting the mold, and while extruding the food downward with the sheet material still attached to the food, sequentially peeling the sheet material attached to the food from the food surface during this extrusion." "Characterized by blowing high-pressure gas from the back surface of the mold to peel the sheet material from the molding part while extruding the food downward with the sheet material still attached."

Prior Art Documents

Patent Documents

[0007]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0008] In the "twist and fold device" described in Patent Document 1 above, "twists and folds" are formed on the head and shoulders of Chinese steamed buns conveyed by a belt conveyor. However, since the filling made of chestnuts or taro (such as sweet potatoes) is softer and more likely to lose its shape compared to Chinese steamed buns, when force is applied to try to make "twists and folds" on the filling with the above device, the shape of the filling collapses, resulting in a poor-looking confectionery.

[0009] In the "molding method of confectionery and other foods" described in Patent Document 2 above, the sheet material corresponding to a tea towel is flat and not configured in a specific shape. Therefore, the outer surface of the food pressed against this sheet material has no unique unevenness like that of a tea towel wring, resulting in a poor-looking appearance.

[0010] This invention aims to simultaneously perform the molding of the filling and the formation of the fold pattern, and provide a filling product with no shape collapse and a beautiful shape.

Means for Solving the Problem

[0011] The automatic forming method and apparatus for filling made of chestnuts, taro, etc. according to the present invention convey a lump of filling material of a predetermined amount to the bottom of a mold by a conveyor, and press the lump of filling material into an upper mold having a hollow chamber recessed on the lower surface and a tea towel installed in the hollow chamber to form a filling product. A tea towel insertion hole is provided at the top of the hollow chamber. The central part of the tea towel is inserted through this tea towel insertion hole after being narrowed, and is further arranged along the inner surface of the hollow chamber. A plurality of rows of folding pleats in which mountain folds and valley folds are combined radially from the central part to the periphery of the tea towel are provided. By pressing these folding pleats onto the upper part of the filling material, a pleat pattern similar to that made by a craftsman's hand is formed from the head to the shoulder of the filling. When the tea towel is attached to the upper mold, the mountain folds and valley folds are arranged radially in a plurality of rows, and the peripheral edge protruding from the hollow chamber is wound around and fixed to the side surface of the upper mold.

[0012] The formed filling is discharged by compressed air jetted from the hollow chamber. At this time, alcohol is also jetted. By jetting alcohol, the hollow chamber, the tea towel, and the filling product are sterilized simultaneously. A time difference may be provided between the jetting of compressed air and the jetting of alcohol.

[0013] A through hole is provided in the upper mold so as to notch a part of the inner peripheral surface of the hollow chamber, and a tube with one end blocked is inserted through the through hole, and compressed air is injected into this tube. When compressed air is injected into the tube, the tube expands and protrudes toward the hollow chamber through the notch hole formed in the hollow chamber, and the top and the vicinity of the shoulder of the filling in the hollow chamber are deformed by the swelling of the tube.

[0014] The invention according to claim 1 is In an automatic forming method of a filling product, which has a concave hollow chamber for forming a filling on the lower surface side, has a plurality of passages communicating with the hollow chamber, and has an upper mold that can move up and down, and is provided with a tea towel installed along the hollow chamber of the upper mold, and arranges a filling material under the lower side of the upper mold and presses it into the hollow chamber of the upper mold to form a filling, and after the forming is completed, injects compressed air from the passage into the hollow chamber to discharge the filling from the hollow chamber, A method for automatically forming a filled product is provided. A tea towel insertion hole communicating with an empty chamber is provided substantially at the center of the upper mold. The center portion of the tea towel is constricted and inserted into the tea towel insertion hole. The tea towel disposed in the empty chamber is spread out to form a plurality of rows of radially arranged folding pleats in which mountain folds and valley folds are combined, and a filling material is press-fitted into the empty chamber to form a folding pleat pattern on the surface of the filling material.

[0015] Since the tea towel forms folding pleats when attached to the upper mold, different folding pleat shapes can be formed individually. Therefore, filled products with arbitrary folding pleat patterns can be produced for each upper mold. Filled products with a large number of folding pleats or a small number of folding pleats can be provided.

[0016] The invention according to claim 2 is The method for automatically forming a filled product according to claim 1, wherein after the forming is completed, when injecting compressed air, alcohol is injected into the empty chamber from a plurality of locations in the passage to perform alcohol disinfection on the empty chamber, the tea towel, and the filling.

[0017] By injecting alcohol into the empty chamber from a passage provided in the upper mold, disinfection of the empty chamber, the tea towel, and the filled product is performed simultaneously. Since the alcohol enters between the tea towel and the filled product through the mesh of the tea towel, separation between the tea towel and the filled product is promoted. If the separation between the tea towel and the filled product is accelerated, the forming speed can be increased.

[0018] The invention according to claim 3 is A through hole formed by notching a part of the inner peripheral surface of the empty chamber is provided horizontally or obliquely beside the empty chamber. A flexible tube that can be inflated by injecting compressed air is inserted into the through hole. One end of the tube is blocked, and compressed air is injected from the other end to cause a part of the tube to protrude into the empty chamber, and a part of the filling material is deformed by the inflated tube. The method for automatically forming a filled product according to claim 1.

[0019] When compressed air is injected into the tube, the outer peripheral surface of the tube expands due to pressure at the notch portion of the empty chamber, protruding toward the inside of the empty chamber and slightly deforming the top or shoulder of the filling. If the protruding condition of the tube is changed each time, a filling product rich in diversity with different shapes each time is provided.

[0020] The invention according to claim 4 is An automatic molding device for filling products, having a concave empty chamber for molding the filling on the lower surface side, having a plurality of passages communicating with the empty chamber, and an upper mold that can move up and down, and providing a dishcloth installed along the empty chamber of the upper mold. The filling material is placed under the upper mold and the filling material is pressed into the empty chamber of the upper mold to mold the filling. After the molding is completed, compressed air is injected into the empty chamber from the passage to discharge the filling from the empty chamber. An automatic molding device for filling products, in which a dishcloth insertion hole communicating with the empty chamber is provided at the central part of the upper mold, the central part of the dishcloth is narrowed and inserted into the dishcloth insertion hole, and the dishcloth arranged in the empty chamber is spread to form a plurality of rows of folding pleats in a radial pattern in which mountain folds and valley folds are combined.

[0021] Since the dishcloth is formed with folding pleats when attached to the upper mold, it can be formed into different folding pleat shapes individually. Therefore, filling products with arbitrary folding pleat patterns can be produced for each upper mold. Filling products with a large number of folding pleats or a small number of folding pleats can be provided.

[0022] The invention according to claim 5 is An automatic molding device for filling products, in which some of the passages provided in the upper mold are connected to an alcohol supply source.

[0023] When alcohol is injected into the empty chamber, the empty chamber, the dishcloth, and the filling product are disinfected simultaneously. This eliminates the need for the operator to spray alcohol for disinfection for each molding, and an improvement in the molding speed can be expected.

[0024] The invention according to claim 6 is A through hole that notches a part of the inner peripheral surface of the empty chamber is provided horizontally or obliquely beside the empty chamber, and a flexible tube that can be inflated by injecting compressed air is inserted into the through hole. One end of the tube is blocked, and the other end is provided so that compressed air can be injected. The automatic forming device for filled products according to claim 4, wherein a part of the tube bulges due to the injection of compressed air and protrudes into the empty chamber.

[0025] When compressed air is injected into the tube, the outer peripheral surface of the tube expands due to the pressure of the compressed air at the notched hole part of the empty chamber and protrudes toward the inside of the empty chamber, slightly deforming the top or shoulder of the filling material. If the protruding degree of the tube is changed each time, filled products with diverse and different shapes are provided each time.

Advantages of the Invention

[0026] According to the present invention, by providing folding pleats on the dishcloth, filled products with a pleat pattern similar to those made by craftsmen can be efficiently mass-produced and can meet many demands. The dishcloth is mounted along the inner surface of the empty chamber, and its apex part is fixed inside the empty chamber. Therefore, when compressed air is injected, the dishcloth does not protrude outside the empty chamber, it is easy to blow away the filling material clogged in the mesh of the dishcloth, and it is difficult to cause clogging even when used continuously. When mounting the dishcloth on the upper mold, the shape, number, width, etc. of the folding pleats can be determined each time, so it can cope with small lots. Even when operating using the same dishcloth, it is also possible to change to a different pleat pattern by simply shifting the folding pleats without removing the upper mold while keeping it attached after temporarily stopping the operation. Since the folding pleats are not fixed, it becomes possible to cope.

[0027] Also, after the forming is completed, when discharging the filled product from the upper mold by injecting compressed air, by injecting alcohol, the upper mold, the dishcloth, and the filled product can be disinfected simultaneously. Compared with the conventional method where the operator sprayed alcohol on each of them for disinfection every time of forming, an improvement in the forming speed can be expected.

[0028] If compressed air is injected into a flexible tube installed inside the upper mold, the outer peripheral surface of the tube expands due to the pressure of the compressed air, deforming the top or shoulder of the filling. Therefore, by changing the degree of protrusion of the tube into the air chamber, filling products with various different shapes can be provided.

Brief Description of the Drawings

[0029]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Embodiments for Carrying Out the Invention

[0030] Hereinafter, embodiments for carrying out this invention will be described based on the drawings.

[0031] Figs. 1 to 10 show embodiments of this invention, and Fig. 11 shows the operation. In the figures, reference symbol S indicates a mass of filling as a material, and W indicates a filling product such as a molded chestnut dumpling.

[0032] In FIGS. 2 to 4, the upper mold 1 is formed with a hollow chamber 2 recessed in a concave shape on the lower surface side corresponding to the shape of a filling product W such as chestnut dumplings, and a plurality of passages 3 communicating with the hollow chamber 2 are provided in the upper part of the upper mold 1. These passages 3 are connected to a compressed air supply source (not shown) and an alcohol supply source (not shown), and compressed air and alcohol set at a predetermined pressure are supplied.

[0033] The upper mold 1 is provided with a dishcloth insertion hole 4 formed in a circular or oval shape communicating with the hollow chamber 2. This dishcloth insertion hole 4 is provided for inserting the central part of the dishcloth in a narrowed state, and is formed, for example, in a circular or long hole shape. The central part 5a of the dishcloth 5 is pinched and narrowed as shown in FIG. 5, and the narrowed part 5a is inserted into the dishcloth insertion hole 4 from the side of the hollow chamber 2, and a band 6 made of metal, rubber, plastic, etc. is wound around the part protruding from the dishcloth insertion hole 4 so as not to fall out of the dishcloth insertion hole 4. It is also possible to clamp it with the following lid 7 attached to the upper surface of the upper mold 1 without providing the band 6.

[0034] A lid 7 is attached to the upper surface of the upper mold 1 while maintaining airtightness. A plurality of passages 8 are provided in an inverted L shape at positions corresponding to the passages 3 of the upper mold 1 on the lower surface side of the lid 7, and the passages 3 and the passages 8 communicate with each other. Some of the passages 8 are connected to a compressed air supply source, and the remaining ones are connected to an alcohol supply source.

[0035] As shown in FIG. 8, the dishcloth 5 is curved and installed along the inner surface of the hollow chamber 2, the peripheral edge 5b is taken out of the hollow chamber 2, and the peripheral edge 5b is wound around the side surface of the upper mold 1 so that a plurality of rows of folding pleats 5e, which are formed by repeating mountain folds 5c and valley folds 5d in a fan shape from the central part toward the peripheral edge 5b, are formed, and are detachably fixed with a band or the like 9. The folding widths of the mountain folds 5c and valley folds 5d of the dishcloth 5 are arbitrary.

[0036] Two through holes 19 are provided in parallel beside the empty chamber 2 so that a part of the inner peripheral surface of the empty chamber 2 is cut out. The cutout hole of the empty chamber 2 cut out by the through hole 19 is 2a. The through hole 19 may be provided inclined with respect to the horizontal. A tube 20 made of a highly flexible material that can be inflated by injecting compressed air is inserted into the through hole 19. One end of the tube 20 is closed, and compressed air can be injected from the other end. When compressed air is injected into the tube 20, since the tube 20 is made of a highly flexible material, it bulges into the inside of the empty chamber 2 at the cutout hole 2a of the empty chamber 2 and protrudes.

[0037] The upper mold 1 is linked to a lifting mechanism 10 such as an air cylinder and can be lifted and lowered. A lower mold 11 is arranged below the upper mold 1, and the lower mold 11 is linked to a lifting mechanism 12 such as an air cylinder and can be lifted and lowered. A guide plate 13 made of a resin with low friction is provided around the lower mold 11, and the lower mold 11 is guided by the guide plate 13 to move up and down. An endless sheet 14 with a high peeling effect is provided on the guide plate 13 and is wound around four guide rollers 15a, 15b, 15c, 15d to form a conveyor 16. One of the four guide rollers 15a, 15b, 15c, 15d is linked to a motor (not shown) so that the sheet 14 travels in the direction of arrow A. The lower mold 11, the lifting mechanism 12, and the guide plate 13 are arranged inside the conveyor 16 formed by the sheet 14.

[0038] A conveyor 17 for supplying the filling material is provided on the upstream side of the conveyor 16, and a conveyor 18 for discharging the filled product is arranged on the downstream side.

[0039] The folding creases 5e formed on the dishcloth 5 are basically formed when the dishcloth 5 is attached to the upper mold 1. However, it is also possible to pre-form a plurality of folding creases combining mountain folds and valley folds and fix them so that the mountain fold 5c and the valley fold 5d do not separate. The folding creases 5e may be provided in a straight state or a curved state at the folded-back portion.

[0040] In the above-described apparatus, when the upper mold 1 is in the raised position as shown in FIG. 2, the dishcloth 5 is attached along the inner surface of the empty chamber 2 of the upper mold 1. The conveyor 16 below the upper mold 1 is operated in synchronization with the conveyor 17 for supplying the filling material. When the filling material S supplied to the conveyor 16 stops at a predetermined position below the upper mold 1, the upper mold 1 starts to gradually descend by the operation of the elevating mechanism 10. As the upper mold 1 descends, the filling material S is inserted into the empty chamber 2 and adheres to the dishcloth 5 inside the empty chamber 2.

[0041] Subsequently, when the lower mold 11 rises by a predetermined distance by the operation of the elevating mechanism 12, the filling material S is pressed against the inner surface of the empty chamber 2 through the dishcloth 5. At this time, the fold pattern Wa formed by the fold creases 5e of the dishcloth 5 is formed on the filling material S. The texture (weave) of the dishcloth 5 is also transferred at the same time.

[0042] When compressed air with pressure P2 is injected into the tube 20 during molding, since the tube 20 is made of a highly flexible material, it expands at the notch hole 2a of the empty chamber 2 and protrudes toward the inner surface side of the empty chamber 2, pressing the vicinity of the top or shoulder of the filling material S. As a result, the filling material S is slightly deformed.

[0043] When a predetermined time has elapsed from the pressing state by the lower mold 11, the upper mold 1 starts to rise by the operation of the elevating mechanism 6, and at this time, compressed air with pressure P1 and alcohol are simultaneously injected from the passage 3. The compressed air and alcohol may be injected with a time difference. The lower mold 11 descends in a timely manner and returns to its original position. By injecting compressed air into the empty chamber 2 from a plurality of locations in the passage 3, the filled product W is discharged from the empty chamber 2. The compressed air enters between the dishcloth 5 and the filled product W through the numerous textures of the dishcloth 5, promoting the discharge of the filled product W. When injecting compressed air, if alcohol (for disinfection) is injected simultaneously, not only the empty chamber 2 but also the dishcloth 5 and the filled product W can be disinfected at the same time, eliminating the need for manual disinfection for each molding and enhancing safety. By injecting alcohol together with compressed air, alcohol enters between the filled product W and the dishcloth 5 from the texture of the dishcloth 5, enhancing the separation effect between the filled product W and the dishcloth 5. Therefore, the molding speed can be increased.

[0044] As the tea towel 5 comes to maintain a predetermined space with the filling product W as the upper mold 2 ascends, the conveyor 16 starts operating and sends out the completed filling product W to the downstream conveyor 18. By intermittently and continuously performing the above operations, a large quantity of filling products W with a folded pleat pattern are provided.

Explanation of Reference Numerals

[0045] 1 ··· Upper mold 2 ··· Empty chamber 2a ··· Notch hole 3 ··· Passage 4 ··· Tea towel insertion hole 5 ··· Tea towel 5a ··· Central part of the tea towel 5b ··· Periphery of the tea towel 5c ··· Mountain fold 5d ··· Valley fold 5e ··· Folded pleat 7 ··· Lid 8 ··· Passage 11 ··· Lower mold 19 ··· Through hole 20 ··· Tube S ··· Filling material W ··· Filling product Wa ··· Folded pleat pattern

Claims

1. An automatic forming method for a filling product, comprising: a top mold having a concave empty chamber for forming a filling on the lower surface side, the empty chamber having a plurality of passages communicating therewith, and being vertically movable; a dishcloth installed along the empty chamber of the top mold; placing a filling material below the top mold and pressing it into the empty chamber of the top mold to form the filling; and after the forming is completed, injecting compressed air from the passages into the empty chamber to discharge the filling from the empty chamber. In this method, a dishcloth through-hole communicating with the empty chamber is provided at approximately the center of the top mold, the center portion of the dishcloth is constricted and inserted into the dishcloth through-hole, the dishcloth disposed in the empty chamber is spread to form a plurality of radially formed folded pleats in which mountain folds and valley folds are combined, and the filling material is pressed into the empty chamber to form a folded pleat pattern on the surface of the filling material.

2. The automatic forming method for a filling product according to claim 1, wherein after the forming is completed, when injecting compressed air, alcohol is injected into the empty chamber from a plurality of locations of the passages to disinfect the inside of the empty chamber, the dishcloth, and the filling.

3. A through-hole, which is formed by notching a part of the inner peripheral surface of the empty chamber, is provided horizontally or obliquely beside the empty chamber. A flexible tube that can be inflated by injecting compressed air is inserted into the through-hole. One end of the tube is blocked, and compressed air is injected from the other end to make a part of the tube protrude into the empty chamber, and a part of the filling material is deformed by the inflated tube. The automatic forming method for a filling product according to claim 1.

4. An automatic forming apparatus for a filling product, comprising: a top mold having a concave empty chamber for forming a filling on the lower surface side, the empty chamber having a plurality of passages communicating therewith, and being vertically movable; a dishcloth installed along the empty chamber of the top mold; placing a filling material below the top mold and pressing the filling material into the empty chamber of the top mold to form the filling; and after the forming is completed, injecting compressed air from the passages into the empty chamber to discharge the filling from the empty chamber. In this apparatus, a dishcloth through-hole communicating with the empty chamber is provided at the center of the top mold, the center portion of the dishcloth is constricted and passed through the dishcloth through-hole, and the dishcloth disposed in the empty chamber is spread to form a plurality of radially formed folded pleats in which mountain folds and valley folds are combined.

5. The automatic forming apparatus for a filling product according to claim 4, wherein some of the passages provided in the top mold are connected to an alcohol supply source.

6. A through hole that cuts out a part of the inner peripheral surface of the empty chamber is provided on the side surface of the upper mold in the horizontal direction or the diagonal direction, a flexible tube that can be inflated by injecting compressed air is inserted into the through hole, one end of the tube is blocked, and the other end is provided so that compressed air can be injected. The automatic forming device for filled products according to claim 4, wherein a part of the tube bulges by injecting compressed air so as to protrude into the empty chamber.

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