Process and apparatus for producing an extrudable confection

Abstract

A process for the manufacture of a plurality of dimensionally similar extrudable confections, the process comprising the steps of: a) manufacturing a first extrudable confection and manufacturing a second extrudable confection, the two extrudable confections differing in colour and optionally also flavour; b) extruding a stream of the first extrudable confection and extruding a stream of the second extrudable confection and bringing the two streams together to provide a single co-extruded stream comprising a core of the first extrudable confection surrounded by an annulus of the second extrudable confection; followed by c) splitting the single co-extruded stream into two first-split co-extruded streams, each first-split co-extruded stream comprising streams from both first extrudable confection and second extrudable confection; followed by d) helically extruding the two first-split co-extruded streams; followed by e) bringing the two first-split co-extruded streams together to form a first rejoined co-extruded stream and the first rejoined stream into two second-split co- extruded streams, each splitting second-split co-extruded stream comprising streams from both the first-split co-extruded streams; f) helically extruding the two second-split co-extruded streams; followed by g) bringing the two second-split co-extruded streams together to form a second rejoined co-extrusion stream; followed by h) optionally carrying out further splitting, helically extruding and rejoining to form a final co-extrusion stream; i) cutting the final co-extrusion stream, each cut producing one of the plurality of dimensionally similar extrudable confections.

Description

[0001] PROCESS AND APPARATUS FOR PRODUCING AN EXTRUDABLE CONFECTION

[0002] Field of the invention

[0003] The invention relates to a process for the manufacture of a plurality of dimensionally similar extruded extrudable confections, especially frozen confections, having an interesting marbling pattern, an apparatus for carrying out the process and the extrudable confections made thereby.

[0004] Background of the invention

[0005] Confections that contain two or more components having different colours, and optionally different flavours, are known. In particular it is well-known to have frozen confections that are comprised of two or more different colours, and optionally different flavours, where there is little or no blending between the different colours, in a composite manner.

[0006] Additionally, it is also known to blend together the different coloured components to form an interesting visual pattern that may also provide an interesting taste experience due to the blending.

[0007] Such blending is commonly done in a regular manner, such that when a plurality of such frozen confections are manufactured in a factory environment, each frozen confection is not only dimensionally similar but also the patterns produced are similar.

[0008] It has been found to be desirable from an aesthetic and taste perspective if the blending of the two components is such that there is little or no mixing of the colours (i.e. the production of a third colour from intimate mixing), and wherein the two colours remain distinct but yet merged with each other, e.g. to produce a marbling effect.

[0009] WO 2006 / 059087 discloses an apparatus for producing a striped or variegated confectionery product, involving the steps of bringing together at least two differently coloured base products and co-extruding them as two rectangular layers sandwiched together, followed by dividing the co-extruded product into at least two separate sub- streams, each sub-stream containing layers of the at least two base materials. The two sub-streams are then helically rotated around each other and recombined to form a single recombined product stream, which may be followed by further split into further sub-streams that are also helically rotated and recombined, to sequentially multiply the number of layers. The layered product then exits the apparatus and is cut into two so as to expose the layered structure to produce a visual layered effect on the exterior of the finished frozen confection.

[0010] US 2,479,261 discloses an apparatus for producing a marbled effect from the mixing of two differently coloured ice creams. The ice creams are blended together through a series of static mixer operations to form a veining effect rather than a marbling effect.

[0011] To produce an extrudable confection, especially a frozen confection, that contains two or more components having different colours, that is only partially blended and not intensively mixed, and thus preserves the presence of the original colours with a marbled effect would be desirable.

[0012] Summary of the Invention

[0013] In a first aspect, the invention relates to a process for the manufacture of a plurality of dimensionally similar extrudable confections, the process comprising the steps of: a) manufacturing a first extrudable confection and manufacturing a second extrudable confection, the two extrudable confections differing in colour and optionally also flavour; b) extruding a stream of the first extrudable confection and extruding a stream of the second extrudable confection and bringing the two streams together to provide a single co-extruded stream comprising a core of the first extrudable confection surrounded by an annulus of the second extrudable confection; followed by c) splitting the single co-extruded stream into two first-split co-extruded streams, each first-split co-extruded stream comprising streams from both first extrudable confection and second extrudable confection; followed by d) helically extruding the two first-split co-extruded streams; followed by e) bringing the two first-split co-extruded streams together to form a first rejoined co-extruded stream and the first rejoined stream into two second-split coextruded streams, each second-split co-extruded stream comprising streams from both the first-split co-extruded streams; f) helically extruding the two second-split co-extruded streams; followed by g) bringing the two second-split co-extruded streams together to form a second rejoined co-extrusion stream; followed by h) optionally carrying out further splitting, helically extruding and rejoining to form a final co-extrusion stream; i) cutting the final co-extrusion stream, each cut producing one of the plurality of dimensionally similar extrudable confections.

[0014] The inventors have found that such a process of splitting and folding two co-extruded streams can produce an attractive visual effect that preserves regions of distinct first and second components with very little mixing of the colours but yet provides an interesting and attractive marbling effect blending. This also has the effect that the resulting frozen confection preserves regions having the distinct and non-mixed flavours of the original components, yet also a mixed effect, according to the region of the extrudable confection that is taken into the consumers mouth at any one time.

[0015] Additionally, the patterns produced in such frozen confections are unique to each individual extrudable confection, yet they all have the same overall formulation. Thus, an aspect of repeatable individuality is provided, which creates a more interesting and luxurious product that can be mass produced in a factory.

[0016] Preferably the extrudable confections are frozen confections. Frozen confection means a confection made by freezing a pasteurised mix of ingredients such as water, fat, sweetener, protein (normally milk proteins), and optionally other ingredients such as emulsifiers, stabilisers, colours and flavours. Frozen confections may be aerated. Frozen confections include ice cream, gelato, frozen yoghurt, sorbets, granitas, shaved ices and the like. Preferably the frozen confectionery is an ice cream. The frozen confectionery may be aerated. The term “aerated” means that gas has been intentionally incorporated into the product, such as by mechanical means. The gas can be any food-grade gas such as air, nitrogen or carbon dioxide. The extent of aeration is typically defined in terms of “overrun” (OR). In the context of the present invention, %overrun is defined in volume terms (measured at atmospheric pressure) as: volume of frozen aerated product - volume of premix at ambient temp

[0017] UR = - x tut) volume of premix at ambient temp

[0018] The amount of overrun present in the product will vary depending on the desired product characteristics. In the context of the present invention the level of overrun is typically from 0 to 150%, preferably from 60 to 150%, more preferably from 60 to 100%.

[0019] It has been found that the marbling effect is most effectively achieved when the annulus of second extrudable confection is present in an equal or greater amount than the core of first extrudable confection. Therefore preferably the ratio of the volumetric flow rate of the second extrudable confection to that of the first extrudable confection is from 4:1 to 1 :1.

[0020] Preferably the splitting splits the streams into split co-extruded streams of approximately equal volumetric flow rate.

[0021] It has also been found that the viscosity of the first and second extrudable confections are ideally fairly similar to each other. Preferably therefore the ratio of the viscosity of the first extrudable confection to the viscosity of the second extrudable confection is in the range of from 2: 1 to 1 :2 at a shear rate of 0.1 s-1.

[0022] Although applicable to a two colour pattern, the present invention is applicable equally well to a three colour pattern. If this is desired step a) comprises the manufacture of a third extrudable confection, differing in colour and optionally also flavour, to the first and second extrudable confections; step b) brings the three streams together to provide a single extruded stream.

[0023] As discussed above, the invention requires at least two splits, however preferably the process comprises at least one further splitting, helically extruding and rejoining to form a final co-extrusion stream. In a preferred embodiment there are from one to five further splitting (i.e. 3 to 7 in total), helically extruding and rejoining to form a final co-extrusion stream.

[0024] Preferably the helical extrusion helically extrudes the split streams through from 45 to 120 degrees, most preferably about 90°, before allowing rejoining of the split streams. This is believed to provide a folding action, rather than a mixing action, and leads to the end result of the marbling of the first and second extrudable confections.

[0025] Each helical insert may rotate the frozen confection in a clockwise or an anticlockwise sense, however, preferably all of the helical extrusions rotate in the same sense as each other. This has been found to provide a more effective folding action rather than a mixing action, and produces a high quality marbling effect.

[0026] In a second aspect, the invention relates to an apparatus for use in the process described herein, the apparatus comprising: a) a feed channel for extruding the stream of the first extrudable confection and a feed channel for extruding the stream of the second extrudable confection; b) a junction having inlets for bringing together the stream of the first extrudable confection and the stream of the second extrudable confection, and an outlet for providing the single co-extruded stream comprising a core of the first extrudable confection surrounded by an annulus of the second extrudable confection; c) the outlet leading to a co-extrusion channel, the co-extrusion channel comprising a first helical insert, for splitting the single co-extruded stream into the two first- split co-extruded streams followed by helically extruding the two first-split coextruded streams, and subsequently forming the first rejoined stream, d) the co-extrusion channel comprising second helical insert, for splitting the first rejoined stream into the two second-split co-extruded streams followed by helically extruding the two second-split co-extruded streams, and subsequently forming the second rejoined stream; e) optionally additional helical inserts, to produce the final co-extrusion stream; f) an outlet comprising a cutting device, for cutting the co-extrusion stream into the plurality of dimensionally similar frozen confections. In a third aspect, the invention relates to an extruded extrudable confection, obtainable by the process as described herein.

[0027] The invention will now be illustrated by way of example, and with reference to the following figures, in which:

[0028] Figure 1 is a side view partly in section and partly in elevation of a portion of an apparatus for use in the process of the present invention, showing five helical folding elements.

[0029] Figure 2 is a perspective view of the five helical folding elements shown in figure 1.

[0030] Figure 3 is an underside view of the concentric injection pipe used in the examples.

[0031] Figures 4a and 4b are images of frozen confections manufactured according to a process falling outside the present invention.

[0032] Figure 4c is an image of a frozen confection manufactured according to a process according to the present invention.

[0033] Figures 5a, 5b and 5c are images of frozen confections manufactured according to a process according to the present invention.

[0034] Turning to the figures, figure 1 shows a side view through a co-extrusion channel 10 in an apparatus according to the present invention. The channel 10 comprises five helical inserts 12, 14, 16, 18, 20 and a co-extruded stream comprising a core of the first extrudable frozen confection surrounded by an annulus of the second extrudable frozen confection flows through the channel in the direction of arrows 8. The first helical insert 12 begins with a straight edge 13 that divides the co-extruded stream into two equal first- split co-extruded streams. The first helical insert 12 is arranged to rotate the first-split coextruded streams by 90° before becoming rejoined at the beginning of the second helical insert 14. The second helical insert 14 begins with a straight edge 15 that divides the first rejoined co-extruded stream into two second-split co-extruded streams. This process repeats itself along the five helical inserts, sequentially splitting, folding and rejoining to create the marbled effect of the first and second extrudable frozen confections.

[0035] Examples

[0036] Example 1

[0037] A first frozen confection and a second frozen confection were manufactured to a conventional known formulation, that differed only in colour.

[0038] In a series of comparative examples, the two formulations were individually extruded along respective feed pipes that feed into a T-junction, and travel out of a single outlet providing a single extruded stream comprising both the first extrudable frozen confection and the second extrudable frozen confection, so that the first and second frozen confections travel side-by-side along the outlet. The outlet is a pipe with internal diameter of 1.5 inches.

[0039] In a series of examples according to the invention, the two formulations were individually extruded along respective feed pipes that feed into a concentric injection pipe, that leads to a single outlet providing a single extruded stream comprising both the first extrudable frozen confection and the second extrudable frozen confection, arranged concentrically, comprises a core of the first frozen confection surrounded by an annulus of the second frozen confection.

[0040] Different volumetric ratios were investigated, with ratios of the first to the second frozen confection being 80:20, 70:30 and 60:40.

[0041] In the outlet pipe is located a number of helical inserts (either 5 or 10) starting 22mm from the beginning of the outlet for splitting the stream into two split co-extruded streams followed by helically extruding the two split co-extruded streams, designed as shown in figures 1 and 2 in which each helical element extrudes the streams through 90 degrees before allowing rejoining of the split streams, and the helical element rotate the streams in the same sense (i.e. anticlockwise / anticlockwise / anticlockwise etc). The results showed that the best marbling effect was found with 5 helical inserts, and when the formulations were brought together with the concentric injection pipe. Images of the optimal results are shown in figure 4c. For comparison, the results where the formulations were brought together side-by-side are shown in figures 4a (10 helical inserts) and 4b (5 helical inserts), which are inferior, and do not give a good marbling effect.

[0042] The ratio of the first to the second frozen confection had little effect on the aesthetic result.

[0043] Example 2

[0044] In a second set of examples, the favourable results from example 1 in which each helical element extrudes the streams through 90 degrees before allowing rejoining of the split streams, and the helical element rotate the streams in the same sense (i.e. anticlockwise / anticlockwise / anticlockwise etc) were considered further, and with comparison to a known commercially available static mixer insert (helical static mixer model HT available from Stamixco, New York, USA), in which each helical element extrudes the streams through 180 degrees before allowing rejoining of the split streams, and the helical element rotate the streams in an alternating sense (i.e.clockwise / anticlockwise / clockwise etc).

[0045] The two formulations were individually extruded along respective feed pipes that feed into a concentric injection pipe, that leads to a single outlet providing a single extruded stream comprising both the first extrudable frozen confection and the second extrudable frozen confection, arranged concentrically, comprises a core of the first extrudable frozen confection surrounded by an annulus of the second extrudable frozen confection.

[0046] Figure 5a shows the results of 4 helical elements in the arrangement according to the present invention, and figure 5c shows the results of 5 helical elements in the arrangement according to the present invention. Figure 5b shows the results of the comparative mixer with 6 elements, which although less preferred still falls within the present invention.

[0047] It can be seen that the comparative mixer arrangement carries out a more intense mixing due to the alternating rotational sense of the helices and the fact that they rotate about 180°, resulting in loss of the marbling effect, whereas the arrangement according to the invention provides a high quality marbling effect.

Claims

Claims1. A process for the manufacture of a plurality of dimensionally similar extrudable confections, the process comprising the steps of: a) manufacturing a first extrudable confection and manufacturing a second extrudable confection, the two extrudable confections differing in colour and optionally also flavour; b) extruding a stream of the first extrudable confection and extruding a stream of the second extrudable confection and bringing the two streams together to provide a single co-extruded stream comprising a core of the first extrudable confection surrounded by an annulus of the second extrudable confection; followed by c) splitting the single co-extruded stream into two first-split co-extruded streams, each first-split co-extruded stream comprising streams from both first extrudable confection and second extrudable confection; followed by d) helically extruding the two first-split co-extruded streams; followed by e) bringing the two first-split co-extruded streams together to form a first rejoined co-extruded stream and splitting the first rejoined stream into two second-split co-extruded streams, each second-split co-extruded stream comprising streams from both the first-split co-extruded streams; f) helically extruding the two second-split co-extruded streams; followed by g) bringing the two second-split co-extruded streams together to form a second rejoined co-extrusion stream; followed by h) optionally carrying out further splitting, helically extruding and rejoining to form a final co-extrusion stream; i) cutting the final co-extrusion stream, each cut producing one of the plurality of dimensionally similar extrudable confections.

2. A process according to claim 1 , wherein the extrudable confections are frozen confections.

3. A process according to claim 1 , wherein the ratio of the volumetric flow rate of the first extrudable confection to that of the second extrudable confection is from 4:1 to 1 :1.

4. A process according to any one of the preceding claims, wherein the splitting splits the streams into split co-extruded streams of approximately equal volumetric flow rate.

5. A process according to any one of the preceding claims, wherein the ratio of the viscosity of the first extrudable confection to the viscosity of the second extrudable confection is in the range of from 2:1 to 1 :2 at a shear rate of 0.1s'1.

6. A process according to any one of the preceding claims, wherein: step a) comprises the manufacture of a third extrudable confection, differing in colour and optionally also flavour, to the first and second extrudable confections; step b) brings the three streams together to provide a single extruded stream.

7. A process according to any one of the preceding claims, which comprises at least one further splitting, helically extruding and rejoining to form a final co-extrusion stream.

8. A process according to claim 5, which comprises from one to five further splitting, helically extruding and rejoining to form a final co-extrusion stream.

9. A process according to any one of the preceding claims, wherein the helical extrusion helically extrudes the split streams through from 45 to 120 degrees before allowing rejoining of the split streams.

10. A process according to claim 8, wherein the helical extrusion helically extrudes the split streams through 90 degrees before allowing rejoining of the split streams.11 . A process according to any one of the preceding claims, wherein all of the helical extrusions rotate in the same sense as each other.

12. An apparatus for use in the process according to any one of the preceding claims, the apparatus comprising: a) a feed channel for extruding the stream of the first extrudable confection and a feed channel for extruding the stream of the second extrudable confection; b) a junction having inlets for bringing together the stream of the first extrudable confection and the stream of the second extrudable confection, and an outlet for providing the single co-extruded stream comprising a core of the first extrudable confection surrounded by an annulus of the second extrudable confection; c) the outlet leading to a co-extrusion channel, the co-extrusion channel comprising a first helical folding element, for splitting the single co-extruded stream into the two first-split co-extruded streams followed by helically extruding the two first-split co-extruded streams, and subsequently forming the first rejoined stream, d) the co-extrusion channel comprising second helical folding element, for splitting the first rejoined stream into the two second-split co-extruded streams followed by helically extruding the two second-split co-extruded streams, and subsequently forming the second rejoined stream; e) optionally additional helical inserts, to produce the final co-extrusion stream; f) an outlet comprising a cutting device, for cutting the co-extrusion stream into the plurality of dimensionally similar frozen confections.

13. An extruded extrudable confection obtainable by the process according to any one of claims 1 to 11.

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