System and method for continuously forming a jelly confection

Abstract

A method of forming a jelly confection includes providing an enclosure (22) including an inlet (26), and outlet (28), a plurality of zones (40, 42, 44) including at least one upstream zone and a downstream zone. A confection flow path extending between said inlet and said outlet through said plurality of zones. The method includes continuously moving a jelly confection material along said confection flow path, heating said jelly confection material within said at least one upstream zone of said enclosure, removing moisture from said jelly confection material within said at least one upstream zone of said enclosure and cooling said jelly confection material within said downstream zone of said enclosure.

Description

SYSTEM AND METHOD FOR CONTINUOUSLY FORMING A JELLY CONFECTIONCROSS REFERENCE TO RELATED APPLICATIONSThis application claims the benefit of U.S. Application No. 63 / 649,731, filed on May 20, 2024, which is incorporated herein by reference in its entirety.FIELD

[0001] The disclosure relates generally to a system and method for forming a confection, and more particularly to a system and method for continuously forming a jelly confection.BACKGROUND

[0002] Jelly confection is typically formed using a stoving process where a jelly slurry is deposited into cavities pressed into a starch-based slab. The starch-based slab with the jelly deposits is heated / cured at approximately 50°C to 70°C in an oven type environment for approximately 20 to 70 hours. As the jelly deposits cure, moisture is removed and structure is created in the individual deposits to form jelly pieces. In addition to the time required to cure the jelly confection in the oven, the manufacturing process requires several hours of down time, such as while the trays of j elly confection are loaded and unloaded into an oven or while waiting for an oven to become available.

[0003] A more time efficient process for forming a jelly confection is desirable.SUMMARY

[0004] According to an embodiment, a method of forming a jelly confection includes providing an enclosure including an inlet, and outlet, a plurality of zones including at least one upstream zone and a downstream zone. A confection flow path extending between the inlet and the outlet through the plurality of zones. The method includes continuously moving a jelly confection material along the confection flow path, heating the jelly confection material within the at least one upstream zone of the enclosure, removing moisture from the jelly confection material within the at least one upstream zone of the enclosure and cooling the jelly confection material within the downstream zone of the enclosure.

[0005] In addition to one or more of the features described above, or as an alternative, in further embodiments the removing moisture from the jelly confection material and heating the jelly confection material occur within a same zone of the at least one upstream zone.

[0006] In addition to one or more of the features described above, or as an alternative, in further embodiments the at least one upstream zone includes a first zone and a second zone. Heating the jelly confection material occurs within the first zone and the removing moisture from the jelly confection material occurs within the second zone.

[0007] In addition to one or more of the features described above, or as an alternative, in further embodiments the downstream zone is a third zone the cooling the jelly confection material occurring in the third zone. The cooling of the jelly confection material occurs after the removing moisture form the jelly confection material.

[0008] In addition to one or more of the features described above, or as an alternative, in further embodiments the jelly confection material provided to the third zone is a high solids jelly confection material.

[0009] In addition to one or more of the features described above, or as an alternative, in further embodiments the jelly confection material is arranged within the first zone for a first length of time, the jelly confection material is arranged within the second zone for a second length of time, and the jelly confection material is arranged within the third zone for a third length of time. The second length of time is greater than both the first length of time and the third length of time.

[0010] In addition to one or more of the features described above, or as an alternative, in further embodiments the second length of time is greater than the first length of time and the third length of time in combination.

[0011] In addition to one or more of the features described above, or as an alternative, in further embodiments the third length of time is greater than the first length of time.

[0012] In addition to one or more of the features described above, or as an alternative, in further embodiments a temperature within the first zone is greater than a temperature within the second zone and the third zone.

[0013] In addition to one or more of the features described above, or as an alternative, in further embodiments a temperature of the third zone is less than a temperature of the first zone and a temperature of the second zone.

[0014] In addition to one or more of the features described above, or as an alternative, in further embodiments the jelly confection material provided to the at least one upstream zone of the enclosure is a low solids jelly confection material.

[0015] In addition to one or more of the features described above, or as an alternative, in further embodiments supplying a flow of conditioned air to at least one of the at least one upstream zone and the downstream zone, exhausting the flow of conditioned air from arespective one of the at least one upstream zone and the downstream zone, and directing the flow of conditioned air toward the jelly confection material within the respective one of at least one upstream zone and the downstream zone.

[0016] According to an embodiment, a curing system for forming a jelly confection material includes an enclosure having an inlet, and outlet, and a plurality of zones. Each zone of the plurality of zones has an environment different than the environment of an adjacent zone of the plurality of zones. At least one transport mechanism is arranged within the enclosure. The at least one transport mechanism defines a confection flow path connecting the inlet and the outlet and extending through the plurality of zones.

[0017] In addition to one or more of the features described above, or as an alternative, in further embodiments the plurality of zones includes at least one upstream zone and a downstream zone arranged in series along the confection flow path.

[0018] In addition to one or more of the features described above, or as an alternative, in further embodiments a length of the confection flow path within the at least one upstream zone is greater than a length of the confection flow path in the downstream zone.

[0019] In addition to one or more of the features described above, or as an alternative, in further embodiments the at least one upstream zone includes a first zone and a second zone and the downstream zone is a third zone. A length of the confection flow path within the second zone is greater than a length of the confection flow path in the first zone and a length of the confection flow path in the third zone.

[0020] In addition to one or more of the features described above, or as an alternative, in further embodiments a length of the confection flow path within the second zone is greater than a length of the confection flow path in the first zone and a length of the confection flow path in the third zone, in combination.

[0021] In addition to one or more of the features described above, or as an alternative, in further embodiments a temperature within the first zone is greater than a temperature within the second zone and the third zone.

[0022] In addition to one or more of the features described above, or as an alternative, in further embodiments a temperature of the third zone is less than a temperature of the first zone and a temperature of the second zone.

[0023] In addition to one or more of the features described above, or as an alternative, in further embodiments adjacent zones of the plurality of zones are separated by a divider.

[0024] In addition to one or more of the features described above, or as an alternative, in further embodiments the divider is a wall.

[0025] In addition to one or more of the features described above, or as an alternative, in further embodiments the divider is an air curtain.

[0026] In addition to one or more of the features described above, or as an alternative, in further embodiments a blocking mechanism is arranged within at least one of the plurality of zones. The blocking mechanism directs a flow of air within the at least one of the plurality of zones.

[0027] In addition to one or more of the features described above, or as an alternative, in further embodiments the confection flow path is arranged within a single plane.

[0028] In addition to one or more of the features described above, or as an alternative, in further embodiments the confection flow path is arranged within a horizontal plane.

[0029] According to an embodiment, a method of manufacturing a jelly confection material includes automatically stacking a plurality of trays at a plurality of vertical levels to form a stack of trays, conveying the stack of trays to a curing system, and continuously moving the stack of trays through the curing system to remove moisture from the jelly confection material within each tray of the stack of trays.

[0030] In addition to one or more of the features described above, or as an alternative, in further embodiments the stacking the plurality of trays at a plurality of vertical levels includes stacking the plurality of trays within a tray collection device.

[0031] In addition to one or more of the features described above, or as an alternative, in further embodiments the tray collection device is a cage.

[0032] In addition to one or more of the features described above, or as an alternative, in further embodiments the plurality of trays are stacked in direct contact with one another.

[0033] In addition to one or more of the features described above, or as an alternative, in further embodiments the stack of trays is automatically conveyed to the curing system by a robot.

[0034] In addition to one or more of the features described above, or as an alternative, in further embodiments the stack of trays is automatically conveyed to the curing system by a transport mechanism.

[0035] According to an embodiment, a method of forming a jelly confection via a manufacturing system includes preparing a tray having at least one mold filled with a jelly confection material and providing the tray to a curing system to transform the jelly confection material into the jelly confection. The jelly confection material in the at least one mold of the tray is cured while the tray continuously moves through the curing system. The tray is movable within a closed loop of the manufacturing system.

[0036] In addition to one or more of the features described above, or as an alternative, in further embodiments providing the tray from an outlet of the curing system to a tray emptying station and separating the jelly confection from the tray at the tray emptying station.

[0037] In addition to one or more of the features described above, or as an alternative, in further embodiments the at least one mold is formed from a starch material and the starch material is movable along another closed loop of the manufacturing system.

[0038] In addition to one or more of the features described above, or as an alternative, in further embodiments separating the jelly confection from the starch material at the tray emptying station.

[0039] In addition to one or more of the features described above, or as an alternative, in further embodiments collecting the starch material separated from the tray and the jelly confection.

[0040] In addition to one or more of the features described above, or as an alternative, in further embodiments returning the starch material to a source. The source is operably coupled with a system associated with preparing the tray having the at least one mold.

[0041] In addition to one or more of the features described above, or as an alternative, in further embodiments cleaning the tray at a tray cleaning station. The tray cleaning station is arranged downstream from the tray emptying station.

[0042] In addition to one or more of the features described above, or as an alternative, in further embodiments providing the tray from the tray cleaning station to a system associated with the preparing the at least one mold of the tray.

[0043] In addition to one or more of the features described above, or as an alternative, in further embodiments movement of the tray along the closed loop is driven by at least one transport mechanism.BRIEF DESCRIPTION OF THE DRAWINGS

[0044] The accompanying drawings incorporated in and forming a part of the specification embodies several aspects of the present disclosure and, together with the description, serves to explain the principles of the present disclosure. In the drawings:

[0045] FIG. 1 is a schematic diagram of a curing system of a jelly confection manufacturing system according to an embodiment;

[0046] FIG. 2 is a plan view of a continuous confection flow path of a curing system according to an embodiment;

[0047] FIG. 3 is a perspective view of a curing system having another continuous confection flow path according to an embodiment;

[0048] FIG. 4 is a plan view of a continuous confection flow path of a curing system defined by a plurality of transport mechanisms according to an embodiment;

[0049] FIG. 5 is a schematic diagram of an enclosure of a curing system having a plurality of zones according to an embodiment,

[0050] FIG. 6 is a perspective view of an enclosure of a curing system having a plurality of zones according to an embodiment;

[0051] FIG. 7 is a schematic diagram of a zone of a curing system according to an embodiment;

[0052] FIG. 8 is a schematic diagram of a zone of a curing system according to another embodiment;

[0053] FIG. 9 is a schematic diagram of a zone of a curing system according to another embodiment;

[0054] FIG. 10A is a schematic diagram of a portion of a jelly confection manufacturing system according to an embodiment;

[0055] FIG. 10B is a schematic diagram of a portion of a jelly confection manufacturing system according to an embodiment;

[0056] FIG. 11 is a perspective view of a cage for storing a plurality of trays and movable along a continuous confection flow path according to an embodiment; and

[0057] FIG. 12 is a schematic diagram of a portion of a jelly confection manufacturing system according to an embodiment.DETAILED DESCRIPTION

[0058] Embodiments disclosed herein are related to a system and method of forming a jelly. As used herein, the term “jelly” is intended to describe a confection containing various sugars and water, as well as at least one of a boiled starch, pectin, gelatin, and similar hydrocolloids. Jelly may also contain one or more of a color, flavor, and food acids. Furthermore, a jelly may transform between various stages during the forming process. Examples of these stages include a low solids jelly, a high solids jelly, and a stable high solids jelly discussed herein. As used herein the phrase “low solids jelly” is intended to describe a jelly having a percentage of solids less than 80%, and in some embodiments less than 78%. In some embodiments, the percentage of solids of a low solids jelly is typically between about 72% and about 78% for example. As used herein the phrase “high solids jelly” is intended todescribe a jelly having a percentage of solids greater than the percentage of solids associated with the low solids jelly. A high solids jelly may have a percentage of solids greater than 78%, and in some embodiments, greater than 80%. In some embodiments, the percentage of solids of a high solids jelly is typically between about 82% and about 90% for example. As used herein the phrase “stable high solids jelly” is intended to describe a high solids jelly after curing of the jelly has occurred. Curing, also known as stoving, is a process resulting in one or more of moisture removal, the formation of a skin, the formation of a desired gel strength and / or gel texture, and sugar inversion. After curing, the jelly has a shape that is stable at room temperature.

[0059] With reference to FIG. 1 a schematic diagram of a curing system 20, such as for removing moisture from a jelly material for example, is illustrated. Accordingly, the material output from the curing system 20 has a greater percentage of solids than the material input to the curing system 20. In an embodiment, the curing system 20 is operable to transform a low solids jelly into a high solids jelly or a stable high solids jelly. However, embodiments where both the jelly material provided to the curing system 20 and the jelly material output from the curing system 20 are a low solids jelly and / or embodiments where the jelly material provided to the curing system 20 and the jelly material output from the curing system 20 are a high solids jelly or stable high solids jelly are also contemplated herein. In an embodiment, the curing system 20 includes an oven or enclosure 22 having an interior 24 within which a temperature and / or a humidity is controlled. A jelly confection material is continuously movable along a confection flow path, such as defined by one or more transport mechanisms 25 for example, through the interior 24 of the enclosure 22. As will be described in more detail below, the jelly confection material may be provided to the curing system 20 in the form of individual trays 10 having at least one mold formed therein and the jelly confection material being arranged within the molds. Alternatively, a plurality of trays 10 having molds filled with jelly confection material may be grouped together, as will be described in more detail below, and the group of trays may be provided to the curing system 20 as a solitary unit, represented at 12. Accordingly, it should be understood that the jelly confection material as described relative to the curing system 20 may be in any of these disclosed configurations or another suitable configuration.

[0060] The confection flow path may have any suitable configuration. In an embodiment, the confection flow path includes a plurality of bends or turns such that the confection flow path makes multiple passes between an inlet 26 and an outlet 28 of the enclosure 22. In the illustrated, non-limiting embodiment, the multiple passes are arranged within a single plane. For example, as shown in FIG. 2, the jelly confection material may moveback and forth between the lateral sides 30, 32 of the enclosure 22 as it moves over the length of the enclosure 22. In the non-limiting embodiment of FIG. 2, the jelly confection material does not move vertically within the enclosure 22. However, in other embodiments, the jelly confection material may move vertically up and down within the enclosure 22 (see FIG. 3) as the jelly confection material moves between the inlet 26 and outlet 28 of the enclosure 22. This vertical movement may be as an alternative to or in addition to the lateral movement Further, in embodiments of the confection flow path having multiple passes, the turns connecting adjacent passes of the confection flow path may have a smooth or curved configuration (FIGS. 1-2), or alternatively, may have a configuration including a plurality of distinct turns formed therein. (FIG. 4).

[0061] In the non-limiting embodiment of FIG. 2, a single transport mechanism 25 extends between an inlet 26 and an outlet 28 of the enclosure 22 and may define the entire confection flow path within the interior 24 of the enclosure 22. Although the inlet 26 and the outlet 28 are illustrated as being arranged at opposite ends 34, 36 of the enclosure 22, it should be appreciated that embodiments where the inlet 26 and the outlet 28 are arranged at adjacent sides of the enclosure 22, or alternatively, or at the same side of the enclosure 22 (see FIG. 5) are also within the scope of the disclosure. In other embodiments, such as shown in FIG. 4, a plurality of transport mechanisms are arranged in series to define a continuous confection flow path through the interior 24 of the enclosure 22. For example, a first transport mechanism 25a may be associated with and extend inwardly from the inlet 26 of the enclosure 22 and a second transport mechanism 25b may be associated with an outlet 28 of the enclosure 22. A downstream end of the first transport mechanism 25a and an upstream end of the second transport mechanism 25b may be positioned directly adjacent to one another and aligned relative to a flow of the jelly confection material such that a jelly confection material transfers directly from the first transport mechanism 25a to the second transport mechanism 25b. However, in other embodiments such as shown in FIG. 4, one or more intermediate transport mechanisms may be arranged between the downstream end of the first transport mechanism 25a and an upstream end of the second transport mechanism 25b to define a continuous confection flow path through the enclosure 22. Although the non-limiting embodiment includes 27 intermediate transport mechanisms 25cl-25c27 arranged between and connecting the first and second transport mechanisms 25a, 25b to define the continuous confection flow path, it should be understood that embodiments including any number of intermediate transport mechanisms are within the scope of the disclosure.

[0062] It should be appreciated that although only a single confection flow path is illustrated within the interior 24 of the enclosure 22, embodiments including a plurality of confection flow paths, such as arranged in parallel for example, are within the scope of the disclosure. In such embodiments, each of the plurality of flow paths may be associated with the same inlet 26 and outlet 28, or alternatively, may have a respective inlet 26 and outlet 28. Inclusion of a plurality of separate flow paths allows for slower transport speed and therefore a reduced enclosure size without having to adjust the interval at which the jelly confection material is provided to the enclosure 22.

[0063] The total length of time that the jelly confection material will spend within the enclosure 22 may be similar, and in some embodiments, may be substantially identical to the time (i.e., approximately 20-70 hours) required to the stoving time of a conventional curing operation. However, in other embodiments, such as where only a portion of the moisture removal required to form a jelly confection occurs within the curing system, the total length of time within the enclosure 22 may be reduced, such as to a length of time between 10 hours and about 50 hours. In some embodiments, the jelly confection material is positioned within the enclosure 22 for less than 24 hours, and in some instances, less than 23 hours, less than 22 hours, less than 21 hours, less than 20 hours, less than 19 hours, less than 18 hours, less than 17 hours, less than 16 hours, less than 15 hours, less than 14 hours, less than 13 hours, or even less than 12 hours, less than 11 hours, less than 10 hours, less than 9 hours, less than 8 hours, less than 7 hours, less than 6 hours, less than 5 hours, less than 4 hours, less than 3 hours, less than 2 hours, or less than 1 hour. Several parameters may be varied to achieve a continuous confection flow path that moves the jelly confection material continuously from the inlet 26 of the enclosure 22 to the outlet 28 of the enclosure 22 while removing a desired amount of moisture from the jelly confection material. For example, the size of the enclosure 22, the total length of the confection flow path defined by the at least one transport mechanism, the speed at which the jelly confection material moves along the confection flow path, and the environment within the enclosure 22, such as the temperature and humidity for example, may affect the time of a jelly confection material within the enclosure 22.

[0064] The enclosure 22 of the curing system 20 may be designed such that the interior 24 includes a plurality of different zones, such as at least one upstream zone and at least one downstream zone. With reference to FIG. 5, in the illustrated, non-limiting embodiment, the enclosure 22 includes a first zone 40, a second zone 42, and a third zone 44. The first zone 40 may be associated with the inlet 26 of the enclosure 22 such that from the inlet 26, a jelly confection material is provided directly into the first zone 40. Similarly, the third zone 44 maybe associated with the outlet 28 of the enclosure 22 such that a cured jelly confection material is provided from the third zone 44 directly to the outlet 28 of the enclosure 22. The second zone 42 may be connected to, and in some embodiments is positioned within the interior 24 of the enclosure 22 between, the first zone 40 and the third zone 44. Accordingly, in such embodiments, the confection flow path extends through each of the plurality of zones, i.e., the first zone 40, second zone 42, and third zone 44, of the enclosure 22. As will be described in more detail below, the zones in which the jelly confection material is heated and moisture is removed therefrom may be considered upstream zones, and the zones in which the jelly confection material is cooled may be considered downstream zones. Although an enclosure 22 having only three zones is illustrated and described herein it should be appreciated that an enclosure having a single zone, two zones, or more than three zones are also contemplated herein.

[0065] The plurality of zones 40, 42, 44 within the enclosure 22 may be substantially physically and fluidly separated from one another. Any area where neighboring zones are not physically or fluidly separated may be limited to the area where the continuous confection flow path passes between adjacent zones. In the illustrated, non-limiting embodiment of FIG. 5, one or more walls substantially separate adjacent zones 40, 42, 44 within the enclosure 22. As shown, a first internal divider 46a is arranged at an interface between the first zone 40 and the second zone 42, and a second internal divider 46b is arranged at an interface between the second zone 42 and the third zone 44. In an embodiment, at least one of the first and second dividers 46a, 46b is a wall, such as an insulated wall operable to limit heat transfer between the zones 40, 42, 44 on opposing sides of the wall.

[0066] In some embodiments, a physical structure is not used to form a barrier between adjacent zones 40, 42, 44. Rather, as shown in FIG. 6, the zones 40, 42, 44 may be fluidly separated, such as by an air curtain 48a, 48b. The air curtain 48a, 48b may be formed by one or more respective blowers or fans 50a, 50b (FIG. 7), such as a downward-facing fan arranged near a ceiling 38 of the enclosure 22 at or proximate to the interface between two adjacent zones 40, 42, 44.

[0067] Each of the plurality of zones 40, 42, 44 is associated with a respective portion of the continuous confection flow path and the one or more transport mechanisms that define the respective portion of the continuous confection flow path. Each portion of the continuous confection flow path associated with a respective zone of the plurality of zones 40, 42, 44 may have a different configuration. In an embodiment, the variation in configuration between zones 40, 42, 44 results in the jelly confection material spending a different time in each respectivezone 40, 42, 44. The jelly confection material may spend a first time in the first zone 40, a second time in the second zone 42, and a third time in the third zone 42. For example, the second time may be greater than both the first time and the third time, respectively. Further, in some embodiments, the second time may be greater the total of the first time that the jelly confection material spends in the first zone 40 and the third time that the jelly confection material spends in the third zone 44, in combination. Also, the length of time that the jelly confection material spends in the first zone 40 may be less than the length of time that the jelly confection material spends in the third zone 44. However, embodiments, where the length of time that the jelly confection material spends in the first zone 40 is equal to or even greater than the length of time that the jelly confection material spends in the third zone 44 are also within the scope of the disclosure.

[0068] The variation in time that the jelly confection material spends within each of the plurality of zones 40, 42, 44 of the enclosure 22 may be achieved by controlling one or more parameters associated with the portion of the continuous confection flow path arranged within each zone 40, 42, 44. Accordingly, in an embodiment, each of the plurality of zones 40, 42, 44 may be associated with a specific number of passes or length of the continuous confection flow path. For example, ten percent of the total continuous confection flow path may be arranged within the first zone 40, seventy percent of the continuous confection flow path may be arranged within the second zone 42, and twenty percent of the continuous confection flow path may be arranged within the third zone 44. As a result, the overall size of each of the plurality of zones 40, 42, 44 within the enclosure 22 may be determined based on the portion of the continuous confection flow path arranged therein. In other embodiments the overall size of each of the plurality of zones 40, 42, 44 relative to the enclosure 22 may be substantially identical; however, the configuration of the continuous confection flow path or the speed at which the jelly confection material moves along the continuous confection flow path within each zone 40, 42, 44 may vary.

[0069] In an embodiment, adjacent zones 40, 42, 44 within the enclosure have distinct or different environmental conditions. For example, the first zone 40 may be configured as a heating or warming zone. Within the first zone 40, the jelly confection material is heated from a temperature associated with the jelly confection material directly upstream from the inlet 26 of the enclosure to a curing temperature at which the jelly confection material is cured. To heat the jelly confection material rapidly, the temperature within the first zone 40 may be greater than the stable curing temperature of the jelly confection material. The second zone 42 may be configured as a holding zone during which the substantial majority of the moisture removal orcuring of the jelly confection material occurs. Accordingly, the temperature within the second zone 42 of the enclosure 22 may be equal to the curing temperature. In an embodiment, sufficient moisture is removed within the second zone 42 to transform the jelly confection material from a low solids jelly confection material to a high solids jelly confection material therein. The third zone 44 of the enclosure 22 may be configured as a cooling zone. Within the third zone 44, the high solids jelly may be cooled to form a stable high solids jelly at a temperature suitable for further processing. Therefore, in an embodiment, the at least one upstream zone includes both the first zone and the second zone and the third zone is a downstream zone of the enclosure 22. In an embodiment the temperature of the cured stable high solids jelly provided at the outlet of the enclosure 22 is between about 15°C and about 50°C, such as less than 45°C , less than 40°C , less than 35°C , less than 30°C, less than 25°C , or less than 20°C . To cool the high solids jelly, the temperature within the third zone 44 may be less than the temperature in the first and second zones 40, 42. For example, the temperature within the third zone 44 may be between about 0°C and about 50°C, such as less than 45°C , less than 40°C , less than 35°C , less than 30°C, less than 25°C , less than 20°C, less than 15°C, less than 10°C, and less than 5°C.

[0070] Although an enclosure having three zones is illustrated and described herein in other embodiments, the enclosure may have only a first zone and a second zone located downstream from the first zone. In such embodiments, the first zone may be the at least one upstream zone operable to heat the jelly confection material to a curing temperature and to maintain the jelly confection material at the curing temperature to remove a desired amount of moisture therefrom. The second zone may therefore be the downstream zone used to cool the jelly confection material, such as to form a stable high solids jelly at a temperature suitable for further processing.

[0071] To achieve the different conditioned temperatures associated with each zone 40, 42, 44, conditioned air may circulate within each respective zone 40, 42, 44. In an embodiment, each zone 40, 42, 44 includes at least one supply inlet 52 through which a flow of conditioned air is delivered into the zone 40, 42, 44 and at least one exhaust outlet 54 through which exhaust air is drawn out of the zone 40, 42, 44. The one or more supply inlets 52 and exhaust outlets 54 may be disposed on opposite sides of the zone 40, 42, 44, and / or on opposite sides of the continuous confection flow path such that conditioned air flows across the jelly confection material as it moves through the zone 40, 42, 44. In such embodiments, the direction of flow of the conditioned air between the supply inlet 52 and the exhaust outlet 54 may be oriented generally perpendicular or orthogonal to the direction of movement of the jelly confectionmaterial along one or more passes of the continuous confection flow path within that zone 40, 42, 44.

[0072] In an embodiment, a flow of air, such as from outside the enclosure is conditioned, for example heated and / or dehumidified, before being delivered to a zone via a supply inlet 52. The air after having flowed across the jelly confection material and removed from the zone via the exhaust outlet 54 may then be exhausted outside of the enclosure, such as into the ambient environment, away from the inlet. However, in other embodiments, at least a portion of the flow of conditioned air associated with each zone 40, 42, 44 may be continuously recirculated to reduce the energy required to condition the air upstream from the supply inlet 52. For example, the air removed from a zone via an exhaust outlet 54 may pass through a conditioning device, such as a heater or humidification device for example, before returning to the zone via the supply inlet 52. Further, although each zone 40, 42, 44 is illustrated and described herein as having its own conditioned air flow, it should be appreciated that air from a common source may be conditioned and supplied to more than one of the zones 40, 42, 44, such as the first and second zone for example. Alternatively, or in addition, air may be configured to flow between adjacent zones, such as between the first zone 40 and the second zone 42 for example.

[0073] In an embodiment, the supply inlet 52 and the exhaust outlet 54 may be arranged at a same surface of the enclosure 22, such as at the ceiling 38 of the enclosure 22 for example. In an embodiment, shown in FIG. 7, the supply inlet 52 and the exhaust outlet 54 are located inwardly and separate from a corresponding air curtain 48a, 48b or other divider 46a, 46b separating adjacent zones 40, 42, 44 within the enclosure 22. In other embodiments, such as shown in FIG. 8, the supply inlet 52 and exhaust outlet 54 may be integrated into the respective dividers 46a, 46b. As shown, one or more plenums may be formed in the dividers 46a, 46b through which the air flow may pass. In other embodiments, such as shown in FIG. 9, the supply inlet 52 and the exhaust outlet 54 may be arranged at different sides or surfaces of the enclosure 22. For example, the exhaust outlet 54 is illustrated as being positioned at a ceiling 38 of the enclosure 22 and the supply inlet 52 is shown being positioned at a floor 39 of the enclosure 22. In such embodiments, the supply inlet 52 may be in the form of a ground vent.

[0074] In an embodiment, one or more blocking mechanisms 60 may be arranged within a respective zone 40, 42, 44 between the supply inlet 52 and the exhaust outlet 54. The at least one blocking mechanism 60 may be associated with at least one tray 10 containing molds fdled with jelly confection material moving through the respective zone 40, 42, 44. In some embodiments, the blocking mechanism 60 may extend from a surface of the enclosure22 toward the at least one tray 10 (or one or a group 12 of trays) so as to prevent a portion of the flow from bypassing the jelly confection material contained therein. Accordingly, the position and / or the configuration of the one or more blocking mechanisms 60 used to direct all or substantially all of the air flow from the supply inlet 52 across the jelly confection material may vary based on the configuration of the trays 10 within the enclosure (i.e., single or grouped) and a relative location of the supply inlet 52 and the exhaust outlet 54. In the nonlimiting embodiment of FIGS. 7 and 9, a blocking mechanism 60 extends from the ceiling 38 to an upper surface 58 associated with a group 12 of trays to prevent a flow from passing between the ceiling 38 and the upper surface 58.

[0075] The curing system 20 as illustrated and described herein eliminates the inefficiencies of loading and unloading of trays of jelly confection into a stationary batch oven configured to cycle through each of the three environments (i.e., warming, holding, and cool down environments). As a result, the time between when a jelly confection material is deposited into a mold and when the tray of jelly confection material is provided to the inlet of the enclosure 22 and curing of the jelly confection material is initiated may be less than an hour, and in some embodiments, less than 50 minutes, less than 45 minutes, less than 40 minutes, less than 35 minutes, less than 30 minutes, less than 25 minutes, less than 20 minutes, less than 15 minutes, or less than 10 minutes. In addition, by forming an enclosure having a plurality of different zones with different environments the need to repeatedly heat and cool the same area is eliminated, resulting in an energy savings.

[0076] A curing system, such as curing system 20, may be part of a larger manufacturing system operable to perform other processes associated with forming a jelly confection. In an embodiment, one or more of these other processes are alternatively or additionally performed continuously. The stations or systems of the manufacturing system 100 associated with these processes may be located upstream from and / or downstream from the curing system 20. With reference now to FIG. 10A, in an embodiment, the manufacturing system 100 includes a mold preparation station 102, a filling or depositing station 104 located upstream from the curing system 20. In some embodiments, as shown in FIG. 10B and will be described in more detail below, the manufacturing system 100 may additionally include a stacking station 106 located downstream from the depositing station 104 and upstream from the curing system 20. One or more of the mold preparation station 102, the depositing station 104, and the stacking station 106 may be operable such that a corresponding tray 10 is movable without human interference along a tray movement path. In an embodiment, each of the mold preparation station 102, the depositing station 104, and the stacking station 106 is associatedwith movement of a tray 10 along the continuous tray movement path. The continuous tray movement path may be defined by a single transport mechanism, or alternatively, by a plurality of connected transport mechanisms, schematically represented at 108.

[0077] In an embodiment, a clean tray 10 is provided to and is configured to pass through the mold preparation station 102. The mold preparation station 102 may include a distribution device 110, such as a nozzle for example, connected to a source 112 of a starch material, such as corn starch, pea starch, or any other material suitable to form a mold associated with a jelly confection. The distribution device 110 is operable to distribute a predetermined amount of material received from the source 112 to a respective tray 10 for a corresponding jelly operation. Providing the material S to the tray 10 may further include spreading the material S over one or more specific areas of the tray 10, or in an embodiment, over a substantial entirety of a surface area of the tray 10. Further, one or more molds 114 may then be formed in the material S at the mold preparation station 102. In an embodiment, the molds 114 are formed by pressing one or more shaped dies 116 into the material S on the tray 10. Although the dies 116 are illustrated as being arranged about a roller, it should be understood that any suitable mechanism for manipulating a die 116, or alternatively, any suitable device for forming a mold 114 is within the scope of the disclosure. The dies 116, and therefore the resulting molds 114, may but need not have a two or three-dimensional shape complementary to the final shape of the jelly confection to be formed by the manufacturing system 100. Although providing the material S to the tray 10 and forming molds 114 in the material S are generally described herein as two separate sequential steps, it should be appreciated that in some embodiments, the molds 114 may be formed in the material S at the same time or substantially simultaneously with the deposition of the material S on the tray 10.

[0078] In other embodiments, the manufacturing system 100 need not include a mold preparation station 102. In such embodiments, molds, similar to molds 114 used to shape a confection may be pre-formed into the body of the tray 10. For example, a tray 10 may include a silicone mat having one or more cavities or molds formed therein, thereby eliminating the need to form a mold.

[0079] From the mold preparation station 102, the tray 10 is provided to a downstream jelly confection material deposition station 104. The tray 10 may move automatically to and / or through the jelly confection material deposition station 104 via one or more transport mechanisms. In an embodiment, the depositing station 104 includes one or more depositing nozzles 118 fluidly connected to a supply of jelly confection material, illustrated schematically at 120, such as a low solid jelly confection material I for example. The one or more depositingnozzles 118 are operable to deliver a predetermined amount of the jelly confection material J, into each of the plurality of molds 114 on a respective tray 10. In an embodiment, all the molds 114 of a respective tray 10 may be filled by the one or more depositing nozzles 118 at the same time. However, in other embodiments, only a portion of the plurality of molds 114 of a tray 10 are filled with jelly confection material J simultaneously. In such instances, the molds 114 of a tray 10 may be filled with a jelly confection material J individually and sequentially, or the molds 114 may be filled in groups, such as respective rows of molds 114 formed on a tray 10 for example. It should be understood that the molds 114 of a tray may be substantially identical, or alternatively may have varying configurations, and the process for filling of the molds 114 with jelly confection material J may depend on such a configuration.

[0080] In an embodiment shown in FIG. 10A, a tray 10 having a plurality of molds 114 filled with the jelly confection material J may be provided to the inlet 28 of the enclosure 22 and deposited onto the continuous confection flow path. This movement of the tray 10 from the depositing station 104 directly to the inlet 26 may occur automatically and in some embodiments continuously after the molds 114 are filled. However, in other embodiments, such as shown in FIG. 10B, a stacking station 106 is located downstream from the depositing station 104. In such embodiments, the stacking station 106 is operable to arrange a plurality of trays 10 into groups 12. In an embodiment, the stacking station 106 is operable to arrange a predetermined number of trays 10 in a vertical configuration, such as a vertical stack for example. In some embodiments, the predetermined number of trays 10 within a group are stackable directly on top of one another. In other embodiments, the predetermined number of trays 10 within a group may be deposited into a corresponding tray collection device 124, such as a cabinet or cage for example. An example of a tray collection device 124 is shown in more detail in FIG. 11. The tray collection device 124 may include a plurality of supports or shelves for arranging the trays 10 at a plurality of different vertical levels within the interior of the tray collection device 124. It should be appreciated that any mechanism or system suitable for stacking a plurality of trays 10 upon one another or within a tray collection device 124 is within the scope of the disclosure. In embodiments where the trays 10 are stacked either directly upon one another or via a tray collection device 124, the trays 10 are spaced such that air is able to flow around and between adjacent trays 10 within the stack.

[0081] Regardless of whether the trays 10 are stacked directly on top of one another or within a tray collection device 124, the group 12 of stacked trays is movable as a unit to the inlet 26 of the enclosure 22. The group 12 of stacked trays may be manually moved from the stacking station 106 to the inlet 26 of the curing system 20 or alternatively, may beautomatically movable thereto. For example, the group 12 of stacked trays may be delivered from the stacking station to the inlet 26 via a conveyor 126. In another embodiment, an automated robot may be connectable to the stack of trays to drive the stack of trays to the inlet 26. Upon reaching the inlet 26 and depositing the stack of trays onto the confection flow path of the enclosure 22, the automated robot may disconnect from the stack of trays and return to the stacking station.

[0082] The manufacturing system 100 may further include one or more of a destacking station 130, a tray emptying station 132, a products cleaning station 134, and a tray cleaning station 138. In embodiments where the trays 10 of the jelly confection material are stacked in groups 12 before being delivered to the enclosure 22, the manufacturing system 100 may include a destacking station 130 arranged directly downstream from the outlet 28 of the enclosure 22. The destacking station 130 may be operably coupled to the outlet 28 of the enclosure by transport mechanism 140, such as a conveyor for example. Alternatively, an automated robot (not shown) may be operable to drive the stacked trays 10 from the outlet 28 of the enclosure to the destacking station 130. The destacking station 130 may but need not be substantially similar to the stacking station 106. The destacking station 130 is operable to automatically separate a tray 10 containing molds 114 filled with stable high solids jelly confection material from a stack or group 12 of trays. This separation may include separating a tray 10 from an adjacent tray, or alternatively, may include removing a tray 10 from a corresponding shelf within a tray collection device 124. In either configuration, the destacking station 130 is further operable to provide each of the plurality of trays 10 individually and with a predetermined spacing onto the adjacent transport mechanism 140. Any suitable mechanism or system for destacking the trays 10 is within the scope of the disclosure.

[0083] The individual trays 10 having molds 114 filled with stable, high solids jelly confection material may then be provided, such as via transport mechanism 140, to a tray emptying station 132. Within the tray emptying station 132, the pieces of stable, high solids jelly confection material are separated from their respective trays. In an embodiment, the tray emptying station 132 is operable to flip or invert each tray 10 to empty the contents of the tray 10 at a desired location. In some embodiments, the tray emptying station 132 is additionally operable to separate the pieces of stable, high solids jelly confection material, illustrated at 142 from the material S that formed the molds 114 of the tray 10. It should be appreciated that the individual pieces 142 of stable, high solids jelly confection material once separated from a respective mold 114 may be considered a jelly confection. Further, these pieces of jellyconfection 142 may have a final size and shape of a final jelly confection produced via the manufacturing system 100.

[0084] In an embodiment, such as where the molds 114 are starch molds for example, the tray emptying station 132 is operable to invert the tray 10 such that the contents of the tray 10 are emptied onto or into a filter or sieve 144. The sieve 144 is sized to allow the small particles of material S to pass therethrough while capturing the pieces of jelly confection therein. In an embodiment, the particles of material S that pass through the sieve 144 may be collected and returned to the source 112 associated with the mold preparation station 102. Accordingly, at least a portion of the material S used to form the molds 114 on a tray 10 is recycled within the manufacturing system 100 and reused to form molds 114 on a subsequent tray 10.

[0085] The pieces of jelly confection 142 retained within the sieve 144 may be in a condition for further processing via one or more suitable downstream processes. In an embodiment, the pieces of jelly confection 142 are delivered from the tray emptying station 132 to a downstream processing station via a transport mechanism 146. In an embodiment, the pieces of jelly confection 142 may be provided to a cleaning station 148 where any remaining material S is removed from a surface of the jelly confection 142. Such material S may be removed via a flow of air or another fluid configured to pass over one or more surfaces of the jelly confection 142, or alternatively or additionally, by rubbing the exterior surface of the jelly confection 142 to polish the exterior surface thereof.

[0086] From the tray emptying station 132, the now empty trays 10 may be provided to a downstream tray cleaning station 138. In an embodiment, the empty trays 10 are automatically provided to the tray cleaning station 138 from the tray emptying station 132 via one or more transport mechanisms 150. Within the tray cleaning station 138, one or more surfaces of a tray 10, such as the surface upon which the starch S and jelly confection material J are deposited is cleaned. As described herein, the cleaning process includes removal of substantially all remaining particles of starch material S and / or jelly confection material J in contact with a surface of the tray 10. Such a cleaning operation may be a continuous process performed in any suitable manner, such as by applying a cleaning solvent to a surface of the tray and / or scrubbing the surface of the tray 10. In an embodiment, the cleaning process performed at the tray cleaning station 138 may further include drying the tray 10 to minimize the adhesion of the material S applied to the surface of the tray 10 in the future. Once the cleaning operation is completed, the resulting clean tray 10 may be provided to the mold preparation station 102 to repeat the jelly confection manufacturing process. In someembodiments, the clean trays 10 output from the tray cleaning station 138 are continuously provided to the mold preparation station 102.

[0087] As described herein, in an embodiment, the manufacturing system may include a first continuous, closed loop associated with the flow of the trays within the manufacturing system and / or may include a second continuous, closed loop flow associated with the flow of the starch material within the manufacturing system.

[0088] energy savings are achieved by using an enclosure having a plurality of different zones with different environments,

[0089] The term “about” is intended to include the degree of error associated with measurement of the particular quantity based upon the equipment available at the time of filing the application. For example, “about” can include a range of ± 8% or 5%, or 2% of a given value.

[0090] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. As used herein, the singular forms “a,” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and / or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, element components, and / or groups thereof.

[0091] While the present disclosure has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the essential scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this present disclosure.

Claims

1. CLAIMS1. A method of forming a jelly confection comprising: providing an enclosure including an inlet, and outlet, a plurality of zones including at least one upstream zone and a downstream zone, and a confection flow path extending between said inlet and said outlet through said plurality of zones; continuously moving a jelly confection material along said confection flow path; heating said jelly confection material within said at least one upstream zone of said enclosure; removing moisture from said jelly confection material within said at least one upstream zone of said enclosure; and cooling said jelly confection material within said downstream zone of said enclosure.

2. The method of claim 1, wherein said removing moisture from said jelly confection material and heating said jelly confection material occur within a same zone of said at least one upstream zone.

3. The method of claim 1, wherein said at least one upstream zone includes a first zone and a second zone, said heating said jelly confection material occurring within said first zone and said removing moisture from said jelly confection material occurring within said second zone.

4. The method of claim 3, wherein said downstream zone is a third zone, said cooling said jelly confection material occurring in said third one, wherein said cooling said jelly confection material occurs after said removing moisture form said jelly confection material.

5. The method of claim 4, wherein said jelly confection material provided to said third zone is a high solids jelly confection material.

6. The method of claim 4, wherein said jelly confection material is arranged within said first zone for a first length of time, said jelly confection material is arranged within said second zone for a second length of time, and said jelly confection material is arranged within said third zone for a third length of time, wherein said second length of time is greater than said first length of time and said third length of time.

7. The method of claim 6, wherein said second length of time is greater than said first length of time and said third length of time in combination.

8. The method of claim 6, wherein said third length of time is greater than said first length of time.

9. The method of claim 4, wherein a temperature within said first zone is greater than a temperature within said second zone and said third zone.

10. The method of claim 4, wherein a temperature of said third zone is less than a temperature of said first zone and a temperature of said second zone.

11. The method of claim 1, wherein said jelly confection material provided to said at least one upstream zone of said enclosure is a low solids jelly confection material.

12. The method of claim 1 further comprising: supplying a flow of conditioned air to at least one of said at least one upstream zone and said downstream zone; exhausting said flow of conditioned air from a respective one of said at least one upstream zone and said downstream zone; and directing said flow of conditioned air toward said jelly confection material within said respective one of at least one upstream zone and said downstream zone.

13. A curing system for forming a jelly confection material, the curing system comprising: an enclosure having an inlet, and outlet, and a plurality of zones, wherein each zone of said plurality of zones has an environment different than said environment of an adjacent zone of said plurality of zones; and at least one transport mechanism arranged within said enclosure, said at least one transport mechanism defining a confection flow path connecting said inlet and said outlet and extending through said plurality of zones.

14. The curing system of claim 13, wherein said plurality of zones includes at least one upstream zone and a downstream zone arranged in series along said confection flow path.

15. The curing system of claim 14, wherein a length of said confection flow path within said at least one upstream zone is greater than a length of said confection flow path in said downstream zone.

16. The curing system of claim 14, wherein said at least one upstream zone includes a first zone and a second zone and said downstream zone is a third zone, a length of said confection flow path within said second zone being greater than a length of said confection flow path in said first zone and a length of said confection flow path in said third zone.

17. The curing system of claim 16, wherein a length of said confection flow path within said second zone being greater than a length of said confection flow path in said first zone and a length of said confection flow path in said third zone, in combination.

18. The curing system of claim 16, wherein a temperature within said first zone is greater than a temperature within said second zone and said third zone.

19. The curing system of claim 16, wherein a temperature of said third zone is less than a temperature of said first zone and a temperature of said second zone.

20. The curing system of claim 13, wherein adjacent zones of said plurality of zones are separated by a divider.

21. The curing system of claim 20, wherein the divider is a wall.

22. The curing system of claim 20, wherein the divider is an air curtain.

23. The curing system of claim 13, further comprising a blocking mechanism arranged within at least one of said plurality of zones, said blocking mechanism directing a flow of air within said at least one of said plurality of zones.

24. The curing system of claim 13, wherein said confection flow path is arranged within a single plane.

25. The curing system of claim 24, wherein said confection flow path is arranged within a horizontal plane.

26. A method of manufacturing a jelly confection material, the method comprising: automatically stacking a plurality of trays at a plurality of vertical levels to form a stack of trays; conveying said stack of trays to a curing system; and continuously moving said stack of trays through said curing system to remove moisture from the jelly confection material within each tray of said stack of trays.

27. The method of claim 26, wherein said stacking said plurality of trays at a plurality of vertical levels includes stacking said plurality of trays within a tray collection device.

28. The method of claim 27, wherein said tray collection device is a cage.

29. The method of claim 26, wherein said plurality of trays are stacked in direct contact with one another.

30. The method of claim 26, wherein said stack of trays is automatically conveyed to said curing system by a robot.

31. The method of claim 26, wherein said stack of trays is automatically conveyed to said curing system by a transport mechanism.

32. A method of forming a jelly confection via a manufacturing system, the method comprising: preparing a tray having at least one mold filled with a jelly confection material;providing said tray to a curing system to transform said jelly confection material into the jelly confection, wherein said jelly confection material in said at least one mold of said tray is cured while said tray continuously moves through said curing system; and wherein said tray is movable within a closed loop of the manufacturing system.

33. The method of claim 32, further comprising: providing said tray from an outlet of said curing system to a tray emptying station; and separating said jelly confection from said tray at said tray emptying station.

34. The method of claim 33, wherein said at least one mold is formed from a starch material and said starch material is movable along another closed loop of the manufacturing system.

35. The method of claim 34, further comprising separating said jelly confection from said starch material at said tray emptying station.

36. The method of claim 35, further comprising collecting said starch material separated from said tray and said jelly confection.

37. The method of claim 36, further comprising returning said starch material to a source, said source being operably coupled with a system associated with preparing said tray having said at least one mold.

38. The method of claim 34, further comprising cleaning said tray at atray cleaning station, said tray cleaning station being arranged downstream from said tray emptying station.

39. The method of claim 38, further comprising providing said tray from said tray cleaning station to a system associated with said preparing said at least one mold of said tray.

40. The method of claim 32, wherein movement of said tray along said closed loop is driven by at least one transport mechanism.

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