A method and system of estimating a pick-up value related parameter

Abstract

A method and system of establishing an estimated pick-up value related parameter of an ice cream item type, said method comprises the following steps: selecting said ice cream item type, providing one or more ice cream items of said ice cream item type to a coating station, coating said one or more ice cream items with a coating material 5 from a coating container at the coating station, determining one or more pick-up value related parameters for said one or more ice cream items, establishing said estimated pick-up value related parameter for said one or more ice cream items based on said one or more pick-up value related parameters.

Description

A METHOD AND SYSTEM OF ESTIMATING A PICK-UP VALUE RELATED PARAMETERField of the invention

[0001] The present invention relates to a method and a system of estimating a pickup value related parameter.Background of the invention

[0002] In the production industry of ice cream products, it is critical to optimize the quality of the ice cream products to be able to deliver ice cream products with the correct amount of coating, also known as pickup, or the right amount of weight. It is also critically to optimize the yield of the ice cream products produced in a production line to avoid too much waste of ice cream and coating during the production and prevent breakdowns in the production line. Traditionally a lot of ice cream products are being discarded because of not being conveyed correctly along the production line. Another problem would be that the ice cream products would also not be suitable for sale due to an incorrect weight compared to packaging declaration. Thus, an adjustment of the production line of ice cream products which allows for effective production of ice cream products is highly desirable.Summary of the invention

[0003] The inventors have identified the above-mentioned problems and challenges related to ice crem production, and subsequently made the below-described invention which may increase the quality of ice cream products.

[0004] The invention relates to a method of establishing an estimated pick-up value related parameter of an ice cream item type, said method comprises the following steps: selecting said ice cream item type,providing one or more ice cream items of said ice cream item type to a coating station, coating said one or more ice cream items with a coating material from a coating container at the coating station, determining one or more pick-up value related parameters for said one or more ice cream items, establishing said estimated pick-up value related parameter for said one or more ice cream items based on said one or more pick-up value related parameters.

[0005] It may be advantageous to estimate a pick-up value related parameter without measuring. An estimated pick-up value related parameter may indicate if any actions are required for an ice cream production prior to actually having e.g., a specific product to evaluate or prior to being able to measure the pick-up value related parameters on a final ice cream product. Based on an estimated pick-up value related parameters it may be possible to e.g., prevent production of ice cream products with cracked coating or pinholes, or take action earlier in the process of producing ice cream products to prevent such faulty products. Such actions could e.g. be reducing the coating layer e.g. by adjusting control parameters of the production system / production line manually or automatically. This is especially advantageous when the coating material is expensive.

[0006] The term pick-up value may be understood as weight, volume or thickness of a coating material on a coated ice cream item. The pick-up value may typically be understood as the weight or volume of the coating material for an ice cream product which is ready for sale. The pick-up value may also be measured or estimated for coated ice cream items when the coating material is hardened and / or when excess coating material has run off or been blown off. Typically, a tip of e.g., a chocolate coating material may be cut off prior to measuring the pick-up value for a coated ice cream item. A coated ice cream item may be fully covered with a coating material or only a part of the coated ice cream item may be coated. A part of the coating material may be applied to a stick which may be intended or unintended according to which icecream item type is being produced. The pick-up value may be understood as a pick-up value for a single layer of coating material applied to an ice cream item. In other embodiments of the invention the pick-up value may be understood as the sum of a plurality of layers of coating material where the coating material may be of the same type, coating material of different types or a combination thereof.

[0007] The term pick-up value related parameter may be understood as any kind of parameter which may have an effect on the pick-up value i.e. which may have an effect on the total amount of coat on the final ice cream product. The pick-up value related parameters may be any kind of coating property like the temperature of the coating material, the viscosity of the coating material, the composition of the coating material, the type of coating material or any other properties of the coating material affecting the resulting pick-up value. The term pick-up value related parameters may further be understood as parameters relating to the uncoated ice cream items e.g., like the core temperature of the ice cream items, the surface temperature of the ice cream item, the surface area of the ice cream item, the ice cream item type or any other parameter relating to the ice cream items in that such parameters has an effect on the result of the coating of the ice cream item. The term pick-up value related parameter may further be understood as any kind of property affected by the ice cream production system e.g., the coating time of the ice cream items, the speed of the conveyor, the speed and acceleration of the dipping process both going up and down, the freezing temperature of the hardening tunnel or any other system related parameter. The ambient condition may also be understood as a pick-up value related parameter.

[0008] The pick-up value related parameter may also be values related to the composition or recipe of the coating material. The composition of oil and water may vary from recipe to recipe and may vary over time when the coating material has been in contact with multiple ice cream items. The ice cream items may actually melt a small amount in the coating material, which typically may migrate a bit of water in the coating material which may be a challenge due to an oil-based coating material, since it can affect for instance viscosity and hereby the resulting pick-up value. It may be advantageous to determine pick-up value related parameter and thereby estimate if achange in a coating recipe may be needed or if the coating material may be replaced with a new fresh coating material. It may also be advantageous to add emulsifiers to get a desired pick-up value for an ice cream product. The emulsifiers may typically be Lecithin or PGPR.

[0009] The term estimated pick-up value related parameter may be understood as a parameter or property which has been established or calculated based on one or more of the above-mentioned pick-up value related parameter. These pick-up value related parameters may be determined from sensors, calculations, correlation, interpolation, etc. The estimated pick-up value related parameter may be of the same parameter or property as determined pick-up value related parameter or a related category e.g., coating material property. The estimated pick-up value related parameter may be understood as coating material properties e.g., like temperature of the coating material, composition of the coating material, weight of the coating material when been picked- up, volume of the coating material when been picked-up or any property related to the coating material. The estimated pick-up value related parameter may be a pick-up value of a coated ice cream item which may be understood as the total volume or weight of the coating material on a coated ice cream item when a coating procedure is done. The estimated pick-up value related parameter may be understood as ice cream properties e.g., surface temperature of an ice cream item, core temperature of an ice cream item, volume of an ice cream item, composition of an ice cream item or any other property related to an ice cream item. The estimated pick-up value related parameter may be understood as system or ambient properties e.g., like a conveyor speed, dipping time, temperature in a hardening tunnel, ambient temperature, ambient humidity or anything related to the system of the production line of ice cream products or the surrounding environment.

[0010] An estimated pick-up value related parameter may be established on the basis of one pick-up value related parameter. An estimated pick-up value related parameter may further be established based on a plurality of pick-up value related parameters, where the pick-up value related parameters may be of different types e.g., temperature, composition and viscosity of a coating material. A determined pick-up value relatedmay establish a plurality of estimated pick-up value related parameters of different types, e.g., volume, thickness and weight of a coated ice cream item.

[0011] The term coating material may be understood as any kind of material used for coating ice cream items. The coating material may be understood as material which has not been applied to the ice cream items. Typically, the coating material may be in a container or box. The coating material may also be understood as coating material applied to an ice cream item prior to a hardening of the coating material when the coating material is e.g., chocolate or caramel. The coating material may also be understood as any kind of dry coat like nuts, dust or other edibles applied to an ice cream item. The coating material may in some productions for ice cream products be understood as water ice which is coated on ice cream. A coating material may further be understood as a mix of coating materials e.g., a chocolate coating comprises nuts or the like.

[0012] The term coating station may be understood as a location along a production line for ice cream products where ice cream items may be coated one or more times. Typically, the coating stations may coat multiple ice cream items simultaneously by spraying, dipping, airbrushing or covering the ice cream items with a specific coating material. The coating station may also coat a part of an ice cream item with a coating material. The coating station may typically be located downstream a hardening tunnel to ensure ice cream items have been cooled to a specific temperature. The specific temperature of the ice cream items may prevent the ice cream items from melting when e.g., being dipped into a warm coating material like melted chocolate. The coating station typically comprises a coating container which contains the coating material. The coating container may be understood as a container or box, where a coating material is placed. The coating container may also be understood as a container for a spraying device. The coating container may be located in e.g., a water bath, next to heating elements or other element to ensure a stable temperature of the coating material. Typically, the temperature of the coating material may be affected by receiving multiple ice cream items which has been hardened by cooling. The temperature of the coating material may further be affected by an ambient temperaturewhich may typical be lower than the temperature of the coating material. It may therefore be advantageous to have elements next to the coating container to keep a steady and stable temperature, flow, viscosity and / or other pick-up value related parameters for the coating material.

[0013] The term ice cream item may be understood as an ice cream item anywhere along the way of a production line until the end of the production line. The ice cream item is to be understood as the same ice cream item along the production line where the ice cream item may be refined and enhanced along the production line until an ice cream product is made. The first ice cream item may be defined as an ice cream item, e.g., when a cone is placed on the transportation surface, when a mass of ice cream is shaped and divided from an ice cream former, when a coating has been added, when a wrapping is added or anywhere along the production line. The production line for producing ice cream item may comprise a freezer, a mixer, an ice cream former, a hardening tunnel, a coating station, a wrapping stations, a packaging station or any other processing units related to making ice cream products located along the production line.

[0014] The term ice cream item may be a container for holding a mass of ice cream, such as e.g., a cone, an ice boat, a biscuit, a cookie or anything other edible for receiving ice cream. The ice cream item may be defined as when the first part of the ice cream product is being placed on a transportation surface. The transportation surface may in some embodiments be understood as a conveyor. This may be when e.g., a cone or a biscuit is placed in e.g., a hole or on a tray of a transportation surface before being filled with ice cream. The first part of the ice cream item may also be when a mass of ice cream is being shaped and individual divided and positioned on a transportation surface or in a non-edible cup. The term ice cream item may be used until the final ice cream product is made, which may typically be when an ice cream product is removed from the production line wrapped in and ready for sale.

[0015] The term ice cream item could be understood as a mass of ice cream manufactured prior to the ice cream former. The ice cream item type is a frozen dessert and could be any of the following: ice cream, lemonade ice, water ice, popsicle, icecream-sandwich, ice cream-cone, a lolly, gelato, frozen yogurt, frozen dairy product, granita, sorbet, kulfi, dondurma or any combination thereof. The ice cream item type could be in the size of a popsicle stick, a sandwich, a cone, an ice cream boat or an ice cream cake. The ice cream item type could further comprise other edible parts like caramel, chocolate, fruit juice, edible decoration, jam or any combination thereof. The ice cream item type could further be a vegan produced ice cream item. The ice cream could also be several different flavors of ice cream item and / or colours. The ice cream item type may also refer to a specific brand or model of ice cream products.

[0016] Furthermore, the ice cream item could comprise a stick, a container, a cone, or any other relevant part for holding the ice cream item when eaten. The parts related to holding the ice cream item when eaten could be of an edible material like e.g., a waffle or cookie. The part related to holding the ice cream items could also be a nonedible like a stick or a cup of plastic or wood.

[0017] The ice cream item type could be an ice cream item type without any holding means which is only wrapped in paper or a box. The ice cream item types without any means for holding the ice cream item could be like a sandwich, a boat, a bar, or bites which would typically be eaten by hand. The ice cream item type without any means for holding the ice cream item could also be in the size of a cake which would typically be eaten by flatware.

[0018] The term providing is to be understood as a sum of actions and adjustments done before determining one or more pick-up value related parameters. Providing the ice cream item may be understood as providing an ice cream item from a first location on the conveyor to a second location on the conveyor downstream the production line.

[0019] The production of the ice cream items may be understood as having a mass of ice cream inside a freezer, where the mass of ice cream is being guided to an ice cream former with an ice cream former outlet. The mass of ice cream could be one mass of ice cream or a mix of flavours and / or colours. In the ice cream former the mass of ice cream is being shaped and individually divided through the ice cream former outlet. The dividing may be by cutting the mass of ice cream and thereby anice cream item is formed. When forming the ice cream item, the ice cream item may also be placed on a transportation surface, e.g., a conveyor. The ice cream item may also be placed in a container both edible and non-edible before being conveyed along the production line. The ice cream item may be conveyed along an ice cream process line where the ice cream item may be e.g., cooled in a hardening tunnel, covered in chocolate, wrapped in paper, a biscuit may be added or anything other related for processing ice cream items. At the end of the process line the ice cream item is fully manufactured and the ice cream item would therefore be labelled as an ice cream product. The production of ice cream items may also be understood as a moulding process, where juice or mix is inserted into a cooled mould, in a rotational or linear progressing machine. In such a line, the ice cream items are typically both moulded and hardened, so the ice cream items can be transferred directly to a coating station. Such a line can be implemented without freezers and hardenings tunnels, although freezers are sometimes used to precool the mix prior to the moulding.

[0020] In a preferred embodiment, the method comprises an additional step of evaluating said estimated pick-up value related parameter for said one or more ice cream items with respect to requirements of a coated ice cream item.

[0021] In a preferred embodiment, the method comprises an additional step of evaluating said estimated pick-up value related parameter for said one or more ice cream items with respect to requirements of said ice cream item type.

[0022] It may be advantageous to evaluate an estimated pick-up value for ice cream items to be able to react faster in a coating process. The reaction may be done earlier and even prior to ice cream items being coated by estimating the pick-up value related parameter based on one or more of the different determined pick-up value related parameters. This may help the production of ice cream items to optimize the amount of coat on different ice cream products. The amount of coat may be understood as both a volume of coat, a thickness of a coat, a weight of a coat or any other parameter related to the coat. This may prevent the ice cream items collecting too much coat when being dipped into e.g., a bath of coating material like chocolate.

[0023] The evaluation may provide feedback to a controller or an operator early in the production process to ensure an optimal amount of coat is used for ice cream items. This is contrary to prior art systems where pick-up values are first determined once the ice cream item is coated and thus if something need to be adjusted, a huge number of ice cream items may be faulty coated before the control is updated. Thus, this early control may help save the amount of chocolate used in production for ice cream products comprising a chocolate coating. Chocolate may be a very expensive ingredient to use and therefore it may be of high importance to use the exact amount of coating in the ice cream production.

[0024] The term coated ice cream item may be understood as an ice cream item where a coating material has been applied and where excess coating material has run off or been removed from the ice cream item. The coating material may be dripping off, air blown or cut by a wire when a ‘dripping nose’ has to be removed from the coated ice cream item. The coated ice cream item may comprise multiple layers of coating material and several stages of coating the ice cream item may be done by e.g., multiple dipping or spraying layers. The coated ice cream item may in some embodiments of the invention be understood as an ice cream product which is ready to be sold or an ice cream item ready to be wrapped in a foil or packaging.

[0025] The requirements for a coated ice cream item may be similar to the requirements of an ice cream product ready for sale. In other embodiments of the invention the requirements for a coated ice cream item may be understood as a specific pick-up value for a coated ice cream item which e.g., is to be coated again or double coated.

[0026] In a preferred embodiment, the pick-up value related parameter is a viscosity of said coating material and is presented to a user via a user interface.

[0027] The estimated pick-up value related parameter may be related to a viscosity of the coating material where the viscosity of the coating material may be presented to a user on a user interface. It may be advantageous for a user to have the viscosity presented for the coating material thereby an experienced user is able to determine ifadjustments to the production line are needed. Alternatively, e.g. a number reflecting the state of the viscosity may be accompanied with an indication on type of adjustments to the production line is needed if any, i.e. such number can be used to guide and / or shown what the user may have to do to optimize the production of ice cream items.

[0028] In a preferred embodiment, the estimated pick-up value related parameter is a pick-up value of a coat of an ice cream item.

[0029] The term pick-up value may be understood as the amount of coat on an ice cream item after hardening of the coat. The pick-up value may include any kind of chocolate, caramel or any other coating material typically used for coating ice cream items. Determining an estimate for the pick-up value is advantageous in that it has the effect, that an estimate of how well the expected final ice cream product comply with requirements to coat is provided before the ice cream product is produced.

[0030] In a preferred embodiment, the requirements define pick-up value related parameters of said coated ice cream item.

[0031] It may be advantageous to have requirements for coated ice cream items to ensure a specific ice cream item type has the right composition which is later labelled on the wrapping or packaging of the ice cream product.

[0032] In a preferred embodiment, the coated ice cream item is an ice cream product.

[0033] It may be advantageous to have a coated ice cream item as an ice cream product to evaluate the estimated pick-up value related parameter with respects to requirements of ice cream products which are to be produced.

[0034] In a preferred embodiment, the estimated pick-up value related parameter is compared to a pick-up value related parameter of a coated ice cream item.

[0035] The term compared may be understood as a verification of a pick-up value related parameter. When the estimated pick-up value related parameter is compared to a coated ice cream product it may be compared directly to an exact value of the finalproduct or it may be compared to a derived value from other properties or parameters from the ice cream production system. This may be advantageous to get a more optimal pick-up value related parameter during the day of production, e.g., before and after lunch where other conditions, like ambient temperature or coating composition, may affect the production of ice cream products. Hence, the estimates made are verified against the values of the resulting product. It may also be advantageous when different types of ice cream items are produced to ensure optimal pick-up value related parameters for the specific ice cream item type which is to be or is being produced. It may in every production be advantageous to have optimal pick-up value related parameters since e.g., chocolate is very expensive and thereby overcoating has to be avoided while still achieving a minimum threshold value for a coat.

[0036] It may be advantageous to calibrate a device or system in the ice cream production line based on a verification of an estimated pick-up value related parameter. When calibrating equipment based on the verified value it may result in a smaller tolerance for the equipment. The smaller tolerance may lead to less material e.g., coating material being used in the production of ice cream products. An example may be a production with a prescribed coating of 17g with a tolerance of 3g will have to aim for a mean value of 18.5g be sure to reach the prescribed amount of coating. When using a verified estimated pick-up value related parameter, the producer may be available to reduce the tolerance to maybe 1g or 2g which could lead to a mean value of 17.5g or 18g of the coating. This may be advantageous to save on the coating material since typically up to 43.000 ice cream items may be produced within an hour.

[0037] In a preferred embodiment, the result of said evaluation is an estimated pickup value of a coated ice cream item.

[0038] It may be advantageous to evaluate an estimated pick-up value of a coated ice cream item to have the knowledge of how much coating material is to be applied to the ice cream item. By having the estimate of the pick-up value an operator or controller may have some basis based on which to adjust any pick-up value related parameter to adjust the actual pick-up value for the ice cream product which is being made. Thereby the continuous adjustment of the production line, which as indicatedabove is typically needed during the day, is not made on experience and what the operator think, but instead on foundation made based on actual measurements and historical data of the system. In that way a production may have a higher quality ice cream product and / or at the same time save coating material.

[0039] The estimated pick-up value may vary according to the amount of ice cream which have migrated into the coating material during processing of the ice cream items. In a non-limiting example, when the coating material in a coating container contains 0% ice cream it may results in e.g., a pick-up value of 23g depending on pickup value related parameters such as e.g., temperature and flow. The higher temperature of a coating material may lead to a migration of ice cream into the coating container and thereby maybe 1% of ice cream in the coating material. The higher percentage of ice cream in the coating material may lead to a higher viscosity which typically is not desired. The 1% ice cream in the coating material may lead to an increased pick-up value of 26g. The pick-up value may further increase to 30g when the amount of ice cream reach 2%. It may be advantageous to adjust any pick-up value related parameter to bring the pick-up value back to the desired 23g. Another way to adjust the coating material may further be by using an emulsifier to get the desired pick-up value. When using emulsifiers or adjusting the pick-up value related parameters it may help to extend the lifetime of a bath of coating material e.g., chocolate and thereby save coating material and save money.

[0040] In a preferred embodiment, a result of said step of evaluating is compared to a setpoint value.

[0041] The term setpoint value may be understood as any kind of target value for a production to aim for in a production of ice cream products. The setpoint value may be related to the total weight of the ice cream product, the composition of the ice cream product, simply the weight (pick-up value) of a coat of the ice cream product or any other value which is desirable to aim for in the production of ice cream products. The setpoint value may be an exact value, an exact value with a variance or an interval. The setpoint value may also be related to any pick-up value related parameter like the temperature of a coating material or a viscosity of a coating material. It may beadvantageous to have a setpoint value and evaluate estimated values according to the setpoint value to know if any action may be required in the ice cream production.

[0042] It may be advantageous to evaluate the estimated pick-up value related parameter by comparing it too e.g., a setpoint in that in this way the estimated value is compared to a target value. The setpoint may be any desired or predetermined value indicating a specific condition or configuration to ensure an ice cream product specification may be complied with the ice cream product.

[0043] It may be advantageous to use a result from an evaluation to approve pick-up value related parameters to ensure a correct or optimal production of ice cream items. The results may further be advantageous in approving if a minimum required value has been reached to approve any given pick-up value related parameter or condition for the ice cream product which is to be produced. Further, the results may be advantageously used to check the quality of the ice cream products which are to be made. The result may be compared to a specific pick-up value related parameter or to an interval of pick-up value related parameter to approve and perform quality check the pick-up value related parameters and the production of the ice cream products.

[0044] It may be advantageous to use an evaluation of an estimated pick-up value related parameter to approve and / or quality check a pick-up value related parameter to control an ice cream production. Evaluating the quality of the ice cream production prior to making the ice cream products may prevent deformed ice cream products, products with pinholes in the coating or a coating layer that are too thick for the ice cream product. This may help ensure that when the production of ice cream products is started, a higher yield of ice cream products may be achieved. Typical an operator may increase a coating temperature of e.g., chocolate when the pick-up value goes up due to increased viscosity of the coating material. This increase in temperature increases the risk of pinholes, where for instance ice cream escapes out of a small pinhole in the coating, resulting in a very visual defect. There is a high contrast to a dark coating to white ice cream, resulting in less quality. When evaluating prior to making the ice cream items the operator may adjust the viscosity of the coating material and thereby prevent a temperature adjustment.

[0045] The result may be used to either turn on, turn off or adjust any properties along the ice cream production.

[0046] In a preferred embodiment, a result of said evaluation is presented to a user via a user interface.

[0047] In a preferred embodiment, the result is said one or more pick-up value related parameters.

[0048] The term result may be understood as any kind of pick-up value related parameters which have been evaluated according to an estimated pick-up value related parameter. Thus, the result may be a residue between what is measured or derived (pick-up value related parameter) and what was expected to be measured. The result may present an exact value, a threshold value or an interval via a user interface. The result may further be presented as graphic illustration, number(s), symbols or color(s), where e.g., colors like red and green typically may indicate if the result is okay or an action may be required from the user. The user may also be guided by symbols like arrows pointing up or down to show the user which pick-up value related parameter has to be modified and in what direction.

[0049] A user interface may be understood as any kind of monitor, signal or screen which is capable of presenting a result of an evaluation of an estimated pick-up value related parameter. The user interface may simply present a result to an operator or user which manually may have to make adjustments to modify the pick-up value related parameters in order to get the desired ice cream product in the production. The user interface may also provide a guide or suggestion to the user when an adjustment has to be made to any of the pick-up value related parameters. The user may be assisted in potential adjustment from the user interface when presenting a result from the evaluation of the estimated pick-up value related parameter. The guide from the user interface may indicate that one or more pick-up values related parameters may have to be adjusted in order to obtain the desired ice cream product. It may also indicate that everything in the production is fine and no adjustments are required at the moment. If two parameters can be adjusted with similar effect, the controller may, via the userinterface, present to the user the benefits and drawbacks of using one over the other. Such benefits / drawbacks may include price, production speed, etc.

[0050] In a preferred embodiment, a result of said evaluation is used by a controller to adjust one or more pick-up value related parameters.

[0051] It may be advantageous to control different aspects or locations along a production line for ice cream products. The controller may be used to adjust any kind of property of a station, location or material of the ice cream production to get a desired ice cream product. The controller may adjust coating material property, system property, ambient property, ice cream item property or anything related or any combination thereof to ensure a higher yield and / or greater quality of ice cream products. It may be changing the coating material to a fresh new batch of coating material. The controller may automatically regulate one or more pick-up value related parameter directly or indirectly by adjusting one or more properties for the production of ice cream products.

[0052] In a preferred embodiment, the result of said evaluating is used to normalize said pick-up value related parameters.

[0053] A normalized sequence of pick-up value related parameters may be understood as one or more ice cream item properties of said ice cream product sequence which are within a tolerance of + / - 10 percent, such as + / - 8% percent, such as + / - 5% percent, such as + / - 4% percent, such as + / - 3% percent, such as + / - 2% percent, such as + / - 1% percent, such as + / - 0.5% percent.

[0054] A normalized pick-up value related parameter sequence may be understood as a sequence of pick-up value related parameters e.g., pick-up value where the ice cream products all are within a predetermined threshold, tolerance, or margin. The normalized pick-up value related parameters may be according to the entire ice cream products or according to any of the pick-up value related parameters e.g., weight, volume, amount of air in the ice cream product, temperature, visual-characteristics or any other property relevant to the ice cream product.

[0055] The normalizing of the pick-up value related parameters may also be according to a portion or local part of the ice cream product, which may e.g., be the coating or decorations of the ice cream product. The part of the ice cream product may be normalized at different locations along the production line e.g., the volume of the ice cream product may be normalized at a location prior to coating and the volume of the ice cream in the ice cream item is not adjusted further in the process to becoming an ice cream product.

[0056] The above stated percentages examples may refer to the relevant ice cream item properties such as weight, dimensions (e.g., volume), temperature, amount or air in the ice cream product, visual-characteristics or any other relevant ice cream item property or measure thereof.

[0057] In a preferred embodiment, the determining is a measuring of pick-up value related parameters.

[0058] It may be advantageous to measure pick-up value related parameters to have either a direct or indirect measurement for the pick-up value related parameters. The measuring of either temperature, viscosity, flow of coating material and the like is some of the typical pick-up value related parameters to measure.

[0059] In a preferred embodiment, the pick-up value related parameters are derived from an additional measuring of said one or more pick-up value related parameters.

[0060] Pick-up value related parameters may be grouped into different aspects of the ice cream production like coating material property, ambient property, system property, ice cream item property, any other property related to ice cream production or a combination thereof. A pick-up value related parameter may be measured directly or derived from measurements of other values including pick-up value related parameters.

[0061] When measuring pick-up value related parameters, it may be understood as a continuous measurement where a sensor keeps providing a measurement e.g., like a thermometer. Continuous measuring may also be understood as a measurementrepeated at a given time interval e.g., a measurement is taken every minute, hour or any given time interval. The continuous measuring may be performed after a specific number of ice cream items has passed through a location along the production line for ice cream products. The measuring of pick-up value related parameters may also be understood as discrete measurements where a measurement is done arbitrary to check status of a production of ice cream products.

[0062] In a preferred embodiment, the pick-up value related parameters are ice cream item property.

[0063] In a preferred embodiment, the ice cream item property is least one selected from the list comprising: core temperature of ice cream item, surface are of ice cream item and surface temperature of ice cream item.

[0064] It may be advantageous to determine any ice cream item property to estimate pick-up value related parameter. When estimating the ice cream item property it may help to have an earlier correction for upcoming ice cream items without having to measure on already made ice cream items. Thereby it may be possible to gain a higher yield of quality ice cream products. The yield may be enlarged for ice cream products produced in general and the yield may be enlarged for quality products e.g., ice cream products without pinholes, crack coating or coating layer too thick.

[0065] In a preferred embodiment, the pick-up value related parameters are a coating material property.

[0066] The term coating material property may be understood as any kind of property relating to the coating material like temperature, viscosity, composition or a combination thereof. The composition of the coating material may vary from recipe to recipe or may be adjusted during a production by emulsifiers.

[0067] In a preferred embodiment, the coating material property is least one selected from the list comprising: temperature, viscosity, flow in container, composition and age of coating material.

[0068] It may be advantageous to determine any coating material property to estimate a pick-up value related parameter which may be used to adjust a pick-up value related parameter to optimize an ice cream production for ice cream products.

[0069] In a preferred embodiment, the viscosity is derived from a resistance or current preferably in a stirring stick.

[0070] It may be advantageous to determine a pick-up value related parameter by deriving the value from additional measuring(s). A viscosity of a coating material may be derived from a measurement e.g., of a resistance of a stirring or reciprocating stick in the coating material. Viscosity may also be derived from a distance of flow over an edge of a coating container from an edge of coating container, pumping pressure in a pipe or flow through a nozzle or in a cup.

[0071] In a preferred embodiment, the pick-up value related parameters are ambient parameters.

[0072] In a preferred embodiment, the pick-up value related parameters are system parameters.

[0073] The term system parameters may refer to any parameter related to any part or location along the production line for ice cream products. It may be ice cream former, hardening tunnel, molding machine, coating station, conveyor or any other part of the system for producing ice cream products.

[0074] The term system parameters may be understood as parameters which e.g. can be controlled and regulated to adjust the ice cream item output from e.g., the hardening tunnel. A system parameter could be the temperature inside the hardening tunnel, tunnel temperature, which could control how much the hardening tunnel should cool down the ice cream items being conveyed through the hardening tunnel. Another system parameter could be airflow, where a velocity of fans can be controlled for a better distribution of the air inside the hardening tunnel. The airflow could also be changed by changing the position of different air guides or deflectors to optimizeairflow in certain volumes inside the hardening tunnel. It could also be the brine temperature, providing the cooling in a molding machine

[0075] Another system parameter may be the humidity inside the hardening tunnel. The humidity could be dependent on the process of manufacturing the ice cream items which would lead to frost inside the hardening tunnel. Frost may e.g. alter air flow over the ice cream items within the hardening tunnel and thereby cause changed cooling of the ice cream items. The humidity could be controlled by dehumidifiers to ensure the right humidity in the hardening tunnel depending on the ice cream item type being hardened.

[0076] Another system parameter could be air-balancing, which would be how to keep the freezing air in the hardening tunnel and to prevent warmer ambient air, compared to inside the hardening tunnel, to get in the hardening tunnel. This could be fans, airguides, or airblowers which would blow and guide the freezing air inside the tunnel to stay inside especially around the inlet and outlet of the conveyor. The airbalancing system could therefore typically generate an overpressure inside the hardening tunnel.

[0077] The velocity of the conveyor could also be a system parameter which would define for how long a given ice cream item is cooled down inside the hardening tunnel. The velocity of the conveyor could be advantages to increase to get a greater output on the number of ice cream items. On the other hand, would a greater velocity make the time in the hardening tunnel less for the ice cream items and thereby reduce the freezing time.

[0078] Another system parameter could be the number of ice cream items in the hardening tunnel or production in total. The number of ice cream items could affect the temperature due to the ice cream items coming into the hardening tunnel having a higher temperature than the temperature in the hardening tunnel. The ice cream items could also affect the humidity in the hardening tunnel and therefore the number of ice cream items in the freezing tunnel could affect the humidity inside the hardening tunnel.

[0079] Another system parameter could be the timing of evaporator defrost. The evaporators in the hardening tunnel could be timed to defrost one at a time, especially in case of a hardening tunnel comprising more than two evaporators. In this case a minimum of two evaporators could still be cooling while a third evaporator could be defrosting. The system parameter could also be the timing of hardening tunnel defrost, where the entire hardening tunnel are being defrosted.

[0080] In a preferred embodiment, the system parameters is least one selected from the list comprising: coating speed, conveyor speed, temperature of brine for molding and temperature of hardening tunnel.

[0081] In a preferred embodiment, the step of establishing said estimated pick-up value related parameters for said one or more ice cream items is based on a plurality of pick-up value related parameters selected from different groups of pick-up value related parameters.

[0082] It may be advantageous to establish an estimated pick-up value related parameter based on a plurality of pick-up values related parameters selected from different groups to get a more accurate estimate. A more accurate estimate may further be advantageous when evaluating the estimated pick-up value related parameter for a more accurate result and thereby optionally a more accurate adjustment of one or more pick-up value related parameter to control the ice cream production.

[0083] Another aspect of the invention relates to an ice cream production system comprising: a hardening tunnel or molding machine, a coating station comprising a coating container, a conveyor for providing ice cream items to said coating station, one or more sensors for determining one or more pick-up value related parameters, a controller, a user interface, wherein said controller is configured to establish an estimated pick-up value related parameter of an ice cream item type, based on said one or more pick-up value related parameters derived from input from said one or more sensors.

[0084] In a preferred embodiment, the ice cream item type is selected by a user via said user interface.

[0085] It may be advantageous to have a user interface to present or guide a user with a result from an evaluation of an estimated pick-up value related parameter to keep or adjust a good ice cream production. The user may typically select a type of ice cream item type which is to be produced in a production via a user interface in order to get the right settings at a coating station.

[0086] The ice cream item type may also be selected by a controller.

[0087] A hardening tunnel may be understood as a freezing tunnel for producing ice cream products. The hardening tunnel freezes down the ice cream items manufactured at a somewhat higher temperature to ensure the right hardening and core temperature of the ice cream items. The hardening tunnel could typically comprise a conveyor with a length in the size ratio of 100, 500, or 1000 meters. The temperature in the hardening tunnel may be above minus 45°C, such as between minus 35°C and minus 40°C.

[0088] The term hardening tunnel could be understood as a tunnel in a production line for e.g., ice cream products. A hardening tunnel could also be understood as a freezing tunnel, a cooling tunnel, or an ice cream tunnel. The hardening tunnel could be used to lower the temperature of the ice cream items in the production line and thereby harden the ice cream items. A hardening tunnel could typically comprise a long conveyor for the ice cream items used for transporting the ice cream items through the hardening tunnel. In the hardening tunnel there could also be elements for regulating the temperature and thereby freeze the ice cream products. The hardening tunnel could further comprise apparatus and devices for controlling, regulating, and guiding the airflow inside the hardening tunnel to optimize the hardening process of the ice cream items. The hardening tunnel could typically comprise an air-balancing system to keep the freezing inside the hardening tunnel and the warmer air outside the hardening tunnel. The air-balancing could be fans or air blowers which could generate a pressure inside the hardening tunnel to keep the freezing air inside. Especially at the inlet and outlet of the conveyor, the hardening tunnel could use the air-balancing system to prevent the warmer air compared to the freezing air in the hardening tunnel to get into the hardening tunnel. In the same aspect the air-balancing system in thehardening tunnel could also prevent the freezing air to get out of the hardening tunnel by the air-balancing system.

[0089] A conveyor may be understood as a conveyor where the ice cream items may be positioned on. The conveyor may be a band or belt for conveying the ice cream items. The conveyor may also comprise rollers with space between each roller. The conveyor may also include plates, trays, wrapping foil or bowls which are placed on a conveyer and conveyed, where the plates, trays, wrapping foil or bowls may form the surface upon which the ice cream items are conveyed. Carriers may e.g. include plates, trays, etc. upon which ice cream items are carried.

[0090] A controller may be distributed to multiple locations along the production line, where the controllers would be seen as one controller for the production line. The controller may be centrally located or decentralized with respect to determining locations of the production line or to the production line itself. The controller may be communicatively coupled with the different processing units and sensors along the production line for ice cream products.

[0091] The term ice cream processing unit may be understood as any unit along the production line of ice cream products, where the ice cream items are being processed or adjusted in the making of ice cream products. Examples of processing units may be an ice cream former, hardening tunnel, wrapping foil station, coating device or any other unit for processing the ice cream items.

[0092] In a preferred embodiment, the controller is furthermore configured to evaluate said estimated pick-up value related parameter for said one or more ice cream items with respect to requirements of a coated ice cream item.

[0093] The term requirements of a coated ice cream item may be understood as setpoints, thresholds, intervals or other parameters which are desirable for producing ice cream products.

[0094] In a preferred embodiment, the ice cream production system is configured for carrying out the method mentioned above.The drawings

[0095] Various embodiments of the invention will in the following be described with reference to the drawings where: fig. 1 illustrates a coating station along a production line, fig. 2 illustrates an ice cream production line, fig. 3 illustrates a method of the invention, fig. 4 illustrates a method of the invention, and fig. 5 illustrates a coating station.Detailed description

[0096] Fig. 1 illustrates an embodiment of the invention where ice cream items ICI are being coated at a coating station CS along a production line PL for producing ice cream products. The ice cream items ICI are being provided by a conveyor CONV in a conveying direction COND in three lines next to each other. The ice cream items ICI may be provided in lines other than three (not shown) ice cream items in other embodiments of the invention. The provided ice cream items ICI reaches a coating station CS where the ice cream items ICI is being coated with a coating material from a coating container CC. Typically, the ice cream items is dipped into a coating container CC with coating material, but may in other embodiments be sprayed or airbrushed onto the ice cream items. In another embodiment of the invention ice cream items may be coated by spraying or coating being held over the ice cream items (not shown). For dry coat, the ice cream item can also be dipped into a field of moving inclusions, like in a glass blower. The coating station CS is connected to a sensor SENS where the sensor SENS is configured for measuring one or more pick-up value related parameters PUPR for the ice cream items type at the coating station CS. The sensor SENS may be configured to measure e.g., a temperature of the coating material, flow of the coating material, viscosity of the coating material or any other pick-up value related parameter PUPR with respect to coating material properties. The sensor SENS is communicatively connected to a controller CCS to which the measured pick-up value related parameters PUPR is transmitted. The controller CCS may also be understood as a cooling control system CCS. The controller CCS is configured to establish an estimated pick-up value related parameter EPUV based on the measured pick-up value related parameter PUPR. The controller CCS is communicatively coupled with a user interface UI where the estimated pick-up value related parameter EPUV may be presented directly to an operator OPE. The estimated pick-up value related parameter EPUV may also be evaluated with respect to requirements of coated ice cream item CICI to be produced in the production line PL. The evaluation may be done by the controller CCS before sending any information about the estimated pickup value related parameter EPUV and the evaluation thereof to the user interface UI. The controller CCS may send a guide to the operator OPE (also sometimes referred toas a user) based on the evaluation of the estimated pick-up value related parameter EPUV. The evaluation may also be done by the operator OPE when the operator OPE is being presented to the estimated pick-up value related parameter EPUV on the user interface UI. The controller CCS is further illustrated as being communicatively coupled with the coating station CS where the controller CCS is configured for automatically using the evaluation of the estimated pick-up value related parameter EPUV to adjust one or more coating material properties at the coating station CS. The controller CCS may be configured to adjust e.g., the temperature of the coating material or the viscosity of the coating material in the coating container CC based on the evaluation of the estimated pick-up value related parameter EPUV. The evaluation of the estimated pick-up value related parameter EPUV may be used to automatically or semi-automatically make adjustments along the production line PL to affect or regulate the next measured pick-up value related parameters PUPR.

[0097] Fig. 1 illustrates a production line PL for production ice cream products. The production line PL is illustrated with one sensor SENS but may in other embodiments of the invention comprise a plurality of sensor for measuring pick-up value related parameters PUPR. The production line may also include an external sensor, which can be used manually to determine pick-up value related parameters, where the external sensor is not a part of the production line. The sensor(s) may be located to measure pick-up value related parameters PUPR along the entire production line PL at e.g., a hardening tunnel (not shown), coating station CS, conveyor CONV, ice cream former (not shown) or at a location for measure the ice cream item properties. The different locations of the sensors may all provide pick-up value related parameters PUPR to a cooling control system CCS comprising multiple controllers or to a common controller CCS for the production line PL. The sensors may provide pick-up value related parameters PUPR before starting the production of ice cream products at the production line, but the sensors may also be used continuously during the production.

[0098] The production line PL is illustrated with one coating station CS but may in other embodiments comprise a plurality of coating stations depending on what ice cream item type is being produced. The ice cream item may have to be coated morethan one time and in some embodiments with different types of coating material. The different types of coating material may typically vary from chocolate, caramel or nuts. In other embodiments of the invention another ice cream item type e.g., water ice may be coated on ice cream. The embodiments illustrated in fig. 1, e.g., the coating station, controller or sensor may be implemented in the production line illustrated in fig. 2 e.g., designated as coating station CS in fig. 2.

[0099] Fig. 2 system illustrates the principles of an optional layout of a production line PL for ice cream products having an ice cream hardening tunnel HT applied according to an embodiment within the scope of the invention. An illustrated production line PL comprising a conveyor CONV extending from four freezers F and four ice cream formers ICF through the hardening tunnel HT to gripping arrangement GRA where the ice cream items can be coated at a coating station CS and further to a wrapping foil station (not shown). Each ice cream former ICF makes a manufacturing lane (not shown) of ice cream items and therefore the production line PL is illustrated in the figure comprises four manufacturing lanes of ice cream items (not shown) but may not by limited to four manufacturing lanes. The conveyor CONV being movable in a direction indicated by associated arrows in a conveying direction COND by an automatic adjustable drive system (not shown) under the control of a cooling control system CCS. Along the conveyor CONV a plurality of measuring locations LOC is provided for measuring the one or more pick-up value related parameters PUPR and communicatively send the measured one or more pick-up value related parameters to the cooling control system CCS. The cooling control system CCS may also be understood as a controller for the production line PL. The measuring locations LOC along the production line PL are not limited to these locations but may be placed at any location or embodiment along the production line PL.

[0100] One or more of the individual measuring location LOC may establish the relevant measurements and then the measured data may be applied as a basis for establishing an estimated pick-up value related parameter EPUV. Further a controller CCS of the production line may use the estimated pick-up value related parameter toindicate for a user on a user interface UI what has been estimated and / or what adjustment has to be made in the production.

[0101] In other words, a controller CCS of the production line controlling the evaluation of estimated pick-up value related parameter and adjustments of e.g., ice cream item properties, coating material properties or the like may be fed with measurement data from one or more measuring locations. Thereby the controller is configured for the adjustment of pick-up value related parameters based on data from one or more measuring locations.

[0102] Moreover, data from one measuring location may be fed to not only one location, e.g. an ice cream former, but also to controllers relevant for other adjustment locations (i.e. devices to be controlled) of the process. The cooling control system CCS may also be referred to as a controller or control system.

[0103] The cooling control system CCS may control a coating station CS according to an embodiment of the invention. The controller CCS may be used to estimate pickup value related parameters for coated ice cream items. The controller CCS may further be used to evaluate the estimated pick-up value related parameter and provide the evaluation as information to an operator on a user interface. The operator may then make adjustment along the production line PL based on the evaluation of the user interface UI or based on a guide to the evaluation from the controller CCS.

[0104] Moreover, the ice cream hardening tunnel HT includes an adjustable cooling arrangement (not shown) also controlled by the cooling control system CCS controlling cooling temperature and optionally also adjustably controlling air flow within the hardening tunnel HT.

[0105] It should be noted that the cooling control system CCS may be a singular arrangement or a number of co-functioning controllers. The illustrated cooling control system CCS is communicatively coupled with a user interface UI by means of which an operator has access to modify properties of ice cream items ICI, properties of coating material, properties of the system or any other pick-up value related parameter along the production line PL or any devices related to on the basis of the estimatedpick-up value related parameter. It may be advantageous to measure pick-up value related parameters only with an addon measuring device along the production line, upstream, thereby making it possible for an operator, or the control system, making timely adjustment of the pick-up value related parameters by modifying the production line parameters.

[0106] Upstream the hardening tunnel HT ice cream items may be positioned on the conveyor CONV by an ice cream item former ICF, here in the form of four individual stations connected to a mixer MIX, a freezers F, an ingredients feeder typically between a freezer and ice cream former, ice cream formers, stick inserters and / or a cutter / valve, thereby facilitating a continuous and automatic placement of ice cream items (not shown) on the conveyor CONV prior to being transported along the production line PL. One freezer may be connected to four ice cream formers (not shown) when producing an ice cream product with one type of ice cream. Two or more freezers may also be connected to one ice cream former (not shown) for making an ice cream product comprising two or more different types of ice cream, e.g., when making an ice cream product with vanilla and strawberry ice cream.

[0107] The mixer MIX mixes ingredients relevant for the recipe of the ice cream items to be produced and the freezers F provides the desired extruding temperature for the applied ice cream formers ICF of the ice cream item ICI. The desired weight or dimensions for the ice cream prior to the ice cream former ICF from the freezer is applied according to e.g., keeping the desired flow of ice cream to the ice cream former in order to keep the correct volume or weight for the ice cream items leaving the ice cream former ICF.

[0108] Inside the ice cream hardening tunnel HT the conveyor CONV extends through the hardening tunnel HT so as to facilitate a cooling of the ice cream items ICI from a temperature the ice creams items may have upstream the tunnel, to a temperature of the ice cream items which is lower when the ice cream items leaves the ice cream hardening tunnel HT downstream the hardening tunnel HT.

[0109] The length of the conveyor CONV, the cooling applied by the cooling system (not shown) including optional internal ventilation, movement of cool air within the hardening tunnel HT, the speed of the conveyor CONV, etc will determine the resulting cooling from one temperature, e.g. minus 5 degrees Celsius to e.g. minus 18 degrees Celsius, measured as core temperature.

[0110] Some of these parameters are referred to as pick-up value related parameters, and these pick-up value related parameters may be adjusted manually and / or automatically.

[0111] Fig. 2 illustrates an output of a hardening tunnel controlled within the scope of the invention. An ice cream hardening tunnel HT has an exit of the hardening tunnel HT through which a conveyor CONV extends towards an ice cream item transferring system via an optional ice cream loosener LOS. In the present embodiments, the conveyor CONV is implemented to transport ice cream items ICI on conveyor plates or trays. The conveyor is moving in the direction of the arrows during operation. If a reference to a conveyor is made, the reference may be made with respect to a / the surface of the conveyor plates or trays if such plates are applied. The illustrated embodiment includes a sensor for measuring ice cream item properties as a pick-up value related parameter, where the sensor is a core temperature measuring system CMS, here placed just outside the hardening tunnel HT. The core temperature measuring system may in other embodiments of the invention be located at other locations along the production line PL.

[0112] Fig. 3 illustrates a flow chart of the steps of the method according to an embodiment of the invention for establishing an estimated pick-up value related parameter according to an embodiment o. The method comprises a first step SI where a sensor determines one or more pick-up value related parameters for one or more ice cream items. The determined pick-up value related parameters may be determined at any location along a production line for producing ice cream products e.g., like the production lines illustrated in fig. 1-2. The method illustrated in fig. 3 may be implemented and carried out by the embodiments illustrated in fig. 1-2. In a specific production line for a specific ice cream item type a location may be more relevant fordetermining pick-up value related parameters for ice cream items than compared to other production lines or other ice cream item types.

[0113] Fig. 3 illustrates a second step S2 of the method of establishing an estimated pick-up value related parameter of an ice cream type. The second step S2 is used to establish an estimated pick-up value related parameter based on the determined pickup value related parameters in step SI. The determined pick-up value related parameters may come from one or more sensors located at one or more places along the production line for ice cream products. In step S2 of the method the estimated pickup value related parameter may be presented to an operator by a user interface. The establishing of the estimated pick-up value related parameter may typically be done by a controller and thereafter presented to an operator by a user interface.

[0114] In an optional third step S3 of the method an evaluation of the estimated pickup value related parameter may be done. The evaluation may be done by an operator when the operator is presented with the estimated pick-up value related parameter on a user interface. The operator may have experience to know how to used the evaluation for the production of ice cream products or the operator may look in a manual or the like.

[0115] The evaluation may also be done by a controller. The controller may present the evaluation of the estimated pick-up value related parameter on the user interface to guide an operator what adjustment that may be required at one or more locations along the production line. The controller may also evaluate the estimated pick-up value related parameter and use the evaluation to automatically make adjustments along the production line. The controller may e.g., adjust the temperature of the coating material, adjust the viscosity of the coating material, adjust the temperature or humidity of the hardening tunnel, the dipping time of the ice cream items or anything other controlling a pick-up value related parameter.

[0116] The method may comprise an optionally step SO where ice cream items are provided. The ice cream items may typically be provided by some sort of conveyor. The ice cream items may be provided prior to determining one or more pick-up valuerelated parameters and / or establishing an estimated pick-up value related parameter. In some embodiments of the invention step SO is not executed prior any of steps Sl- S3 of the method for a more accurate ice cream product to be produced. The step SO may further include a step of selecting the ice cream item type which is to be produced in the production.

[0117] The optional first step SO may comprise setting up the production line based on historic data collected at earlier productions. The historic data may be understood as settings for different devices or stations along the production line based on pick-up value related parameters, e.g., the temperature of the coating material or the temperature of the hardening tunnel. The historic data may be understood as determined pick-up value related parameters from previous productions of ice cream products. The historic data may be selected based on what ice cream item type or ice cream product is to be produced. The historic data may be used at given ambient conditions where pick-up value related parameters have been determined in a previous production.

[0118] Fig. 4 illustrates an example of establishing an estimated pick-up value related parameter in the form of the viscosity. This example of establishing an estimated viscosity may be carried out by embodiments of the production system illustrated in fig. 1 and fig. 2 with a coating system CS as illustrated in fig. 5. Before the ice cream production starts, initial decisions are taken such as type of ice cream item type, size of ice cream, details of coating, etc.

[0119] In this example, in a first step SI the ice cream manufacturing process is started. However, it should be noted that it may not be necessary to determine the viscosity of a coating material to start production. In this example only the stirrer needs to be started stirring the coating material. Thus, the production may be stated after the pick-up value related parameter is estimated.

[0120] Setting up the production system both in terms of mechanical calibration and in terms of operation parameter values in the control software may be based on based on historic data and / or ambient conditions.

[0121] In a second step S2 a pick-up value related parameter PUPR is determined which is relevant to viscosity of the coating material. Such parameters could be temperature of coating material, composition of coating material, etc. In this example, the pick-up value related parameter PUPR is the resistance of the stirrer which may be derived e.g. from measured motor current of the motor of the stirrer or from a force measured by a force-sensor of the stirrer.

[0122] In a third step S3 the e.g. the motor current determined in the second step is by a controller used to establish an estimated pick-up value related parameter EPUV, in this case the viscosity of the coating material. This is possible in that there is a link between the viscosity of the coating material and the motor current. If the viscosity is high, the coating material is thick and the motor current is high and vice versa.

[0123] Alternatively, or in addition in step S3 an estimated pick-up value of a coated ice cream item may be established by the controller based on the resistance / current determined in the second step. Hence, it is possible to go one step further and use the knowledge of the viscosity of the coating material just established / estimated to estimate the pick-up value of the coated ice cream.

[0124] Alternatively, or in addition, an estimated thickness of the coating of an ice cream item could be established based on the pick-up value related parameter PUPR determined in step S2. In this case the thickness i.e. the expected thickness of the coating of the final ice cream product would be the estimated pick-up value established based on the estimated viscosity which again is based on e.g. the measure motor current.

[0125] In a fourth step S4A the viscosity estimated in step S3 is compared by the computer to the viscosity required to provide the optimal / required coating of the final ice cream product.

[0126] If this comparison / evaluation results in a difference between the estimated viscosity and the viscosity required to provide the optimal / required coating of the final ice cream product, adjustment is needed. Such adjustment could be done by e.g., adding an emulsifier, adjust temperature of coating material to change the viscosity ofthe coating material (pick-up value related parameter), adjust dipping time, etc. such adjustment may automatically be done by the controller.

[0127] If the result of the comparison / evaluation is acceptable i.e. if the estimated viscosity is equal to the required viscosity or with an acceptable range of the required viscosity to provide the optimal coating of the final ice cream product no action is required. The method may return to step S2 and start over again e.g. by measuring motor current.

[0128] In this way, the method may be executed continuously i.e. as one loop is done, the next will start. However, as it would often take time for the viscosity of the coating material to change in response to an adjustment such as a new temperature setpoint, a subsequent loop may be executed after a certain period of time, after a certain number of produced ice cream products, etc. Such time period may depend on the parameter used to adjust the viscosity.

[0129] An additional / optional step (not illustrated) may be a verification step where an estimated value is compared to a value measured at / of the final ice cream product. Hence, the verification step may include a comparison of an estimated weight of a coat for an ice cream product and a measured weight of the coat of the final ice cream product. The verification step may also be a comparison of an estimated viscosity of the coating material and the actual measured viscosity of the coating material.

[0130] In an alternative fourth step S4B the viscosity estimated in step S3 is presented to the operator of the production line e.g., via a user interface. The operator then manually evaluates the presented estimated viscosity and decides if any adjustments are needed.

[0131] Thus, in the fourth step S4B the evaluation of needed adjustments are made by an experienced operator and thus require so. If the operator of the production line is not experienced, it may be preferred to use the fourth step S4A and let the controller perform the needed adjustments.

[0132] It should be noted that the operator of the product line may have lookup tables with relationship between velocity of coating material and pick-up value of the final ice cream product. Such table may be more or less detained so that it may also comprise information of ambient conditions such as humidity and temperature, stirrer motor current or force / torque, etc. Thereby, if the operator is presented with an estimated viscosity, the operator may then obtain such additional information and determine which one (or more) of the parameters that should be adjusted to arrive at the viscosity required for the final ice cream product to get the required pick-up value. Obviously, the controller may have the same information and thus, perform the adjustment(s) automatically with automatic feedback for further adjustments. As mentioned above, continuous adjustments are needed during the day as the viscosity inevitably will change during the day as ambient conditions change and as ice cream items are dipped in the coating material.

[0133] It should be mentioned that in step S4B, optionally the controller may provide a guide to the operator along with the presented estimated viscosity, such guide to the operator is advantageous in that it may indicate to the operator if adjustments should be made to either increase or decrease the viscosity. In fact, such guide may also include a suggestion to a parameter that can be adjust up or down to achieve the desired viscosity.

[0134] It should further be noted that in step S4B, the operator may suggest an adjustment and based on such suggestion, the controller may estimate the result i.e. the effect of the adjustment e.g. on the viscosity or of the pick-up value.

[0135] Accordingly, the automatic evaluation and adjustment in step S4A and manual evaluation and adjustment in step S4B may be combined to a semi-automatic evaluation and adjustment.

[0136] As indicated above, the parameters used in the example of fig. 4 are only examples and others could be used as well as other values of the final ice cream product than mentioned could be relevant to estimate.

[0137] In another embodiment of the invention the pick-up value related parameter may be understood as visual characteristics of a coated ice cream item. The visual characteristics may be understood as pin-holes of the coating, the composition of the coating, the colors of the coating, the distribution of coating material, the pattern of the coating material or anything other visible on the coated ice cream item visible to an operator.

[0138] Fig. 5 illustrates an example of a coating station CS implemented in a production line for ice cream products similar as illustrated in fig. 1 and fig. 2. The coating station CS may be configured to carry out the method explained with reference to fig. 3-4. The coating station CS shows an ice cream item ICI which has been taken off / from another conveyor (not shown) after a hardening tunnel (not shown). The ice cream item ICI is to be conveyed to a first coating container CC1 comprises a coating material. The coating material in the first coating container CC1 is in a liquid state and could e.g. be chocolate or caramel. A sensor (not shown) may be used to determine a pick-up value related parameters in the coating container CC1, e.g., coating material properties (temperature, composition or viscosity of coating material). A pick-up value related parameter PUPR used as described with reference to fig. 3-4. The ice cream item may be dipped into the first coating container CC1 and lifted back up with a liquid mass of coating material on the outside. The ice cream item is now a coated ice cream item which is being conveyed further along the production line in the coating station CS. Upon the coated ice cream item being conveyed to a second coating container CC2 the liquid coating material on the coated ice cream item may run off while the hardening process is undergoing. The coated ice cream item may reach the second coating container CC2 within a certain time which may be determined by the hardening process. The second coating container CC2 is illustrated comprising a dry coating material, e.g., nuts. In another embodiment of the invention the second coating container may comprise a liquid coating material, where the liquid coating material may be of the same type, or a different type as compared to the coating material in the first coating container. The coated ice cream item is dipped into the dry coat of the second coating container CC2 and lifted up with the dry coating material being coated into the first coating material. In this example, the coated ice cream item CICI has thenbeen coated twice and is being conveyed further along the production line. The coated ice cream item CICI is at first being conveyed over a location where coating material from the second coating container may run or fall off. The coated ice cream item CICI may after hardening or while hardening be conveyed to typically a wrapping station (not shown) to wrap in the coated ice cream item.

[0139] List of reference signs:AMP Ambient propertyCC Coating containerCCS Controller / cooling control systemCICI Coated ice cream itemCM Coating materialCMP Coating material propertyCOND Conveying directionCONV ConveyorCS Coating stationEPUV Estimated pick-up value related parameterF FreezerGRA Gripping arrangementHT Hardening tunnelICI Ice cream itemICIP Ice cream item propertyICIT Ice cream item typeICP Ice cream productLOS Ice cream loosenerMIX MixerOPE OperatorPL Production line (for ice cream products)PUPR Pick-up value related parameterPUV Pick-up valueSENS Sensor(s)UI User interface.

Claims

Claims1. A method of establishing an estimated pick-up value related parameter (EPUV) of an ice cream item type (ICIT), said method comprises the following steps: selecting said ice cream item type (ICIT), providing one or more ice cream items (ICI) of said ice cream item type (ICIT) to a coating station (CS), coating said one or more ice cream items (ICI) with a coating material (CM) from a coating container (CC) at the coating station (CS), determining one or more pick-up value related parameters (PUPR) for said one or more ice cream items (ICI), establishing said estimated pick-up value related parameter (EPUV) for said one or more ice cream items (ICI) based on said one or more pick-up value related parameters (PUPR).

2. A method according to claim 1, wherein said method comprises an additional step of evaluating said estimated pick-up value related parameter (EPUV) for said one or more ice cream items (ICI) with respect to requirements of a coated ice cream item (CICI).

3. A method according to any of the preceding claims, wherein said method comprises an additional step of evaluating said estimated pick-up value related parameter (EPUV) for said one or more ice cream items (ICI) with respect to requirements of said ice cream item type (ICIT).

4. A method according to any of the preceding claims, wherein said pick-up value related parameter (PUPR) is a viscosity of said coating material (CM) and is presented to a user via a user interface (UI).

5. A method according to any of the preceding claims, wherein said estimated pick-up value related parameter (EPUV) is a pick-up value (PUV) of a coat of an ice cream item (ICI).

6. A method according to any of the preceding claims, wherein said requirements define pick-up value related parameters of said coated ice cream item (CICI).

7. A method according to any of the preceding claims, wherein said coated ice cream item (CICI) is an ice cream product (ICP).

8. A method according to any of the preceding claims, wherein said estimated pick-up value related parameter is compared to a pick-up value related parameter of a coated ice cream item (CICI).

9. A method according to any of the preceding claims, wherein a result of said evaluation is an estimated pick-up value (EPUV) of a coated ice cream item (CICI).

10. A method according to any of the preceding claims, wherein a result of said step of evaluating is compared to a setpoint value.

11. A method according to any of the preceding claims, wherein a result of said evaluation is presented to a user via a user interface (UI).

12. A method according to any of the preceding claims, wherein said result is said one or more pick-up value related parameters (PUPR).

13. A method according to any of the preceding claims, wherein a result of said evaluation is used by a controller (CON) to adjust one or more pick-up value related parameters (PUPR).

14. A method according to any of the preceding claims, wherein said result of said evaluating is used to normalize said pick-up value related parameters.

15. A method according to any of the preceding claims, wherein said determining is a measuring of pick-up value related parameters (PUPR).

16. A method according to any of the preceding claims, wherein said pick-up value related parameters (PUPR) is derived from an additional measuring of said one or more pick-up value related parameters (PUPR).

17. A method according to any of the preceding claims, wherein said pick-up value related parameters (PUPR) are ice cream item property (ICIP).

18. A method according to any of the preceding claims, wherein said ice cream item property (ICIP) is least one selected from the list comprising: core temperature of ice cream item, surface are of ice cream item and surface temperature of ice cream item.

19. A method according to any of the preceding claims, wherein said pick-up value related parameters (PUPR) are a coating material property (CMP).

20. A method according to any of the preceding claims, wherein said coating material property (CMP) is least one selected from the list comprising: temperature, viscosity, flow in container, composition and age of coating material.

21. A method according to any of the preceding claims, wherein said viscosity is derived from a resistance or current preferably in a stirring stick.

22. A method according to any of the preceding claims, wherein said pick-up value related parameters (PUPR) are ambient parameters (AMP).

23. A method according to any of the preceding claims, wherein said pick-up value related parameters (PUPR) are system parameters (SP).

24. A method according to any of the preceding claims, wherein said system parameters (SP) is least one selected from the list comprising: coating speed, conveyor speed, temperature of brine for moulding and temperature of hardening tunnel.

25. A method according to any of the preceding claims, wherein said step of establishing said estimated pick-up value related parameters (EPUV) for said one or more ice cream items (ICI) is based on a plurality of pick-up value related parameters (PUPR) selected from different groups of pick-up value related parameters (PUPR).26.. An ice cream production system comprising: a hardening tunnel or molding machine, a coating station (CS) comprising a coating container (CC), a conveyor (CONV) for providing ice cream items (ICI) to said coating station (CS), one or more sensors (SENS) for determining one or more pick-up value related parameters (PUPR), a controller (CON), a user interface (UI), wherein said controller (CON) is configured to establish an estimated pick-up value related parameter (EPUV) of an ice cream item type (ICIT), based on said one or more pick-up value related parameters (PUPR) derived from input from said one or more sensors (SENS).

27. A system according to claim 26, wherein said ice cream item type (ICIT) is selected by a user via said user interface (UI).

28. A system according to any of claims 26-27, wherein said controller is furthermore configured to evaluate said estimated pick-up value related parameter (EPUV) for said one or more ice cream items (ICI) with respect to requirements of a coated ice cream item (CICI).

29. A system according to any of claims 26-28, wherein said ice cream production system is configured for carrying out the method in claims 1-25.

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