Process for manufacturing frozen confection
The process of inserting sticks into a continuous stream of extruded frozen confection and using supporting carriages for cutting and conveyance addresses the challenge of high-speed production and equipment wear, achieving efficient, uniform frozen confection manufacturing without additional cooling.
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- MAGNUM IP HOLDINGS BV
- Filing Date
- 2025-11-18
- Publication Date
- 2026-05-21
AI Technical Summary
Existing methods for producing dimensionally similar sticked frozen confections, such as ice cream, struggle to achieve high production rates and often require additional cooling stages like hardening tunnels, leading to inefficiencies and equipment wear.
A process involving the sequential insertion of grippable sticks into a continuous stream of extruded aerated frozen confection, followed by cutting and support with carriages to maintain structural integrity, allowing for direct conveyance to subsequent processing steps without additional cooling, and using horizontal cutting to prevent deformation.
Enables high-speed production of uniform frozen confections with improved visual quality and reduced equipment wear, eliminating the need for hardening tunnels and enhancing process flexibility.
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Abstract
Description
[0001] PROCESS FOR MANUFACTURING FROZEN CONFECTION
[0002] Field of the invention
[0003] The invention relates to a process for the manufacture of a plurality of dimensionally similar frozen confections comprising a stick, and an apparatus for carrying out the process.
[0004] Background of the invention
[0005] Aerated frozen confections such as ice cream, is commonly produced by extruding a flow of continuous material that is then cut to produce the individual frozen confections. In a common arrangement, the extrusion is carried out vertically or horizontally on a belt after which the cut frozen confection falls under gravity onto a surface, which is then passed to a cooling tunnel to harden the frozen confection so that it can be passed through subsequent processing steps in a frozen state.
[0006] The use of extrusion to form frozen confections such as ice cream or sorbet are well-known. In an example of a commercial process, a continuous stream of extruded frozen confection is generated at around -6°C, which is cut into billets, and into which a stick may be inserted. Such processes are sometimes referred to as extrude-and-cut processes. In such processes a sequence of sticks is inserted, followed by the cutting, to produce a sequence of dimensionally similar sticked frozen confections. This is then followed by passing the sticked frozen confections through a hardening tunnel to reduce their temperature to around -18°C before subsequent processing steps such as coating, decorating and wrapping are carried out. This can produce the dimensionally similar frozen confections at a fast rate, e.g. around 180 per minute.
[0007] A discussion of a standard manufacturing process for frozen aerated confections is described in detail in, for example, “Ice Cream”, 6thEdition, chapters 6, 7 and 9. This consists of a number of steps: i) mixing the ingredients, ii) pasteurisation and homogenisation, iii) ageing, iv) aerating and partially freezing the mix in an ice cream freezer, and v) drawing the partially frozen aerated confection from the freezer, and vi) hardening. US 2005 / 0214416 discloses extrusion of aerated ice cream or sorbets from a twin screw extruder.
[0008] US 2006 / 0233919 A1 discloses a process for manufacture of a frozen aerated confection, wherein an initial freezing step is carried out in a preliminary freezing and aeration step, followed by further freezing in a cold extrusion step. Examples of extrusion temperatures are in the range of from -9°C to -15°C. However, the torque required to extrude the ice cream increases significantly as the temperature of extrusion drops over this range.
[0009] US 6228412 discloses a mon-screw extrusion process for manufacturing frozen aerated products, particularly ice cream.
[0010] W02009 / 068428 A1 discloses a method of producing an extruded, preferably unaerated, water-based frozen composition having a high ice content. In this case, the barrel is cooled with a coolant so as to form the frozen composition which remains extrudable, such as by a cooling jacket, but may be unchilled near the exit, so that the extruded confection may leave the extruder closer to ambient temperature.
[0011] However there remains a need to provide a continuous production of dimensionally similar sticked frozen confections at higher rates of production.
[0012] Summary of the Invention
[0013] The invention relates to a process for the manufacture of a plurality of dimensionally similar sticked aerated frozen confections, the process comprising the steps of
[0014] i) preparing a source of aerated frozen confection
[0015] ii) extruding a continuous flow of the aerated frozen confection in at least one screw extruder, such that a continuous stream of extruded aerated frozen confection leaves the screw extruder via a nozzle in an extrusion direction and at an extrusion speed, iii) sequentially inserting a plurality of grippable sticks into the continuous stream of extruded aerated frozen confection at equally spaced intervals, and such that a grippable length of each grippable stick protrudes from the aerated frozen confection,
[0016] iv) sequentially cutting through the continuous stream of extruded aerated frozen confection at locations between two adjacent inserted sticks, to produce a continuous sequence of dimensionally similar sticked frozen confections,
[0017] wherein during or before the cutting, each grippable length of stick is gripped by one of a plurality of spaced apart supporting carriages, such that each dimensionally similar sticked frozen confection is supported in free space during cutting and is subsequently conveyed by its respective supporting carriage to at least one subsequent processing step.
[0018] One of the main technical benefits of the present invention is that it enables the high production rate of a plurality of dimensionally similar frozen confections to be made.
[0019] Additionally, the inserted grippable sticks provide structural support during cutting. By stabilizing the continuous stream of extruded aerated frozen confection, they reduce the risk of deformation or collapse of the continuous stream of extruded aerated frozen confection as it is cut between two adjacent inserted sticks. Having a plurality of sticks, in the continuous stream of extruded aerated frozen confection before cutting, such as at least two sticks, at least three sticks, at least four sticks, at least five sticks, or at least six sticks, also allows continuous operation without stopping, which increases production speed.
[0020] 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 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:
[0021] volume of frozen aerated product - volume of premix at ambient temp
[0022] UR = - x 100
[0023] volume of premix at ambient temp
[0024] 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%.
[0025] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art (e.g. in frozen food manufacture). Definitions and descriptions of various terms and techniques used in frozen confectionery manufacture are found in “Ice Cream”, 7th Edition R.T. Marshall, H.D. Goff and R.W. Hartel, Kluwer Academic / Plenum Publishers, New York 2013.
[0026] It is particularly advantageous that the extruded aerated frozen confection is at a temperature of from -10°C to -19°C. Such a temperature is much lower than that typically extruded, and results in a harder material. Additionally, it has been found that no further cooling stages are needed, such as hardening tunnels, even if coatings are applied by dipping. This allows for a substantial increase in the processing speed, while minimizing equipment requirements and optimizing factory space.
[0027] Preferably the extrusion direction is a horizontal direction and the sticks are inserted in a direction that is within a vertical plane. This allows for greater dimensional stability of the sticked aerated frozen confection, as it can be supported by the stick and hang vertically therefrom.
[0028] Preferably, the process comprises sequentially cutting through the continuous stream of extruded aerated frozen confection in a horizontal cutting direction, the extrusion direction being horizontal and perpendicular to the cutting direction. Horizontal cutting avoids gravitational sagging, which may occur in processes that combine horizontal extrusion with vertical cutting, because the continuous stream remains supported in the same plane as extrusion, eliminating downward pull that could distort the product. In contrast, vertical cutting exposes the extruded stream to gravity, which may cause bending or drooping before the cut is completed, which can lead to uneven edges and deformation.
[0029] Preferably the nozzle comprises an elongate slit aligned in the extrusion direction exposing an elongate strip of extruded aerated frozen confection, the grippable sticks being inserted into the elongate strip of extruded aerated frozen confection.
[0030] Preferably the extrusion speed is greater than 5cm / s, preferably from 5 to 20cm / s, more preferably from 8 to 15 cm / s.
[0031] Preferably the velocity of the sticks during insertion have a component of velocity perpendicular to the extrusion direction and a component of velocity parallel to the extrusion direction. Preferably the component of velocity parallel to the extrusion direction is substantially the same as the extrusion speed. This provides the beneficial technical effect that there is no relative lateral movement between the sticks and the frozen confections, so the sticks may be inserted cleanly and neatly. This synchronization minimizes insertion resistance, which in turn decreases equipment wear and ensures consistent, reliable performance throughout the process.
[0032] It is also preferred that the velocity of the blade during cutting has a component of velocity perpendicular to the extrusion direction and a component of velocity parallel and in the same direction as the extrusion direction. Preferably the component of velocity parallel to the extrusion direction is substantially the same as the speed of extrusion. Again, this provides a clean cut through the extruded aerated frozen confection. The result is uniform product length and improved visual quality.
[0033] By using supporting carriages the distance between supported sticked frozen confections can also be governed. Thus, preferably the plurality of supporting carriages are adapted to have a variable separation between adjacent carriages. This can be conveniently achieved by the use of threaded scrolls, where each carriage is located within the rotating thread, and the spacings of the threads governs the spacings of the carriages. This can also be used to rotate the carriages, and therefore the sticked frozen confections, which could be particularly useful for subsequent processing operations such as decorating the surface of the frozen confection. Additionally, the size of the threads can be manipulated to control the spacing between the carriages.
[0034] It has been found to be particularly convenient to arrange the spacing between adjacent supporting carriages to increase during the cutting. This provides a smooth and timely separation of adjacent frozen confections at the moment of cutting. This controlled separation prevents collisions between adjacent confections, reducing breakage and improving line efficiency.
[0035] Preferably the plurality of spaced apart supporting carriages are mounted on an endless track. Such a track may then provide the general pathway that each carriage follows in three dimensions, and thus the pathway that each sticked frozen confection follows.
[0036] To give a further degree of freedom, preferably the plurality of supporting carriages are adapted such that each gripped stick is rotatable relative to the carriage. In particular, providing rotation where the axis of rotation is perpendicular to the track is particularly advantageous. This feature allows precise orientation for dipping, coating, or packaging, improving process flexibility and enabling complex decorative patterns.
[0037] In a preferred arrangement, each dimensionally similar sticked frozen confection is supported in free space as it is conveyed by its respective supporting carriage to and through a dipping stage. Furthermore, each dimensionally similar sticked frozen confection may be supported in free space as it is conveyed by its respective supporting carriage to a packaging stage. In this way, the various stages can be carried out sequentially with the sticked frozen confection being carried by its respective carriage.
[0038] Preferably, the frozen confection is supported in free space as it is conveyed by its respective supporting carriage to and through a dipping stage, and wherein, during the dipping, there is no lateral movement between the frozen confection and the coating liquid. This reduces the sideways forces on the frozen confection, so that it can withstand the forces of dipping without losing contact with the supporting stick.
[0039] As previously discussed, the present invention allows for the production of packaged sticked frozen confections without the need for a hardening tunnel. And therefore preferably each dimensionally similar sticked aerated frozen confection proceeds through at least one subsequent processing step without any additional cooling applied. Optionally cooling may be applied, or the entire process or part of it may be carried out in a cooled atmosphere, however this is not essential.
[0040] Preferably the coating may completely surround or partially surround the frozen confection. Suitable fat-based confections include chocolate (dark chocolate, white chocolate, milk chocolate), or a chocolate analogue or couverture. The term “chocolate” is not intended to be limited to compositions that can legally be described as chocolate in any particular country but includes any products having the general character of chocolate. It therefore includes chocolate-like materials which are made using fats other than cocoa butter (for example coconut oil). Chocolate usually contains non-fat cocoa solids, but it is not essential that it does so (e.g. white chocolate). The term chocolate analogue means chocolate-like fat-based confectionery compositions made with fats other than cocoa butter (for example cocoa butter equivalents, coconut oil or other vegetable oils). Such chocolate analogues are sometimes known as couvertures. Chocolate analogues need not conform to standardized definitions of chocolate which are used in many countries. In addition to fat and cocoa solids, chocolate and chocolate analogues may contain milk solids, sugar or other sweeteners and flavourings. A fatbased coating may consist essentially of vegetable oil and sugar, together with colours and I or flavours as required. Alternative coatings includes nut-based coatings, such as pistachio or similar material.
[0041] Coatings are typically applied to the frozen confection as liquids, but solidify over time as they cool down, for example as a result of contact with the frozen confection. Chocolates have complex solidification behaviour because they contain mixtures of different triglycerides which can crystallize in different forms. For example, cocoa butter can exist in six different crystalline forms (polymorphs). As chocolate solidifies, triglycerides begin to crystallize. Within a few seconds the chocolate becomes dry to the touch and has plastic or leathery texture.
[0042] Crystallization continues slowly, so that it typically takes several hours or days for the triglycerides to fully crystallize and so that the chocolate reaches its maximum brittleness. Chocolate made from fats other than cocoa butter displays similar behaviour but typically crystallizes over a narrower temperature range and reaches maximum brittleness more quickly. Preferably the coating is chocolate.
[0043] The thickness of any coating can vary according to the particular design of frozen confectionery. However coating thicknesses of from 0.5 to 3mm are preferred, more preferably from 1mm to 2mm.
[0044] The invention will now be illustrated by way of example, and with reference to the following figures, in which:
[0045] Figure 1 is a schematic perspective view of an initial portion of an apparatus for carrying out the process according to the present invention.
[0046] Figure 2 is a perspective view of a subsequent portion of the apparatus shown in figure 1 at a later point in time during a first coating stage.
[0047] Figure 3 is a perspective view of a subsequent portion of the apparatus shown in figure 1 at a later point in time during a second coating stage.
[0048] Figure 4 is a perspective view of a subsequent portion of the apparatus shown in figure 1 at a later point in time during a second coating stage.
[0049] Figure 5 is an image of a side view through an apparatus for carrying out the process of the present invention.
[0050] Figure 6 is a perspective view of the subsequent processing step of coating produced aerated frozen confections. Figure 7 is a perspective view of the subsequent processing step of packaging produced aerated frozen confections.
[0051] Turning to the figures, shown is a nozzle 10 through which is flowing a continuous stream of extruded aerated frozen confection 12 which leaves the screw extruder via a nozzle in a horizontal extrusion direction and at an extrusion speed. Above the nozzle 10 is a plurality of equally spaced apart supporting carriages 14 moveably mounted in a frame 16, and arranged to move in the horizontal extrusion direction and at essentially the same speed as the extrusion speed. Each carriage 14 grips a grippable length of a stick 18.
[0052] The continuous stream of extruded aerated frozen confection 12 has been previously screw extruded and is at a temperature of from -10°C to -19°C, which results in a hardened physical condition.
[0053] The nozzle 10 comprises an elongate slit 20 aligned in the extrusion direction exposing an elongate strip 22 of extruded aerated frozen confection.
[0054] In operation of the apparatus, as the carriages 14 are moved horizontally they also descend vertically, so that each gripped stick 18 is forced into the aerated frozen confection 22 as the carriage 14 moves horizontally in the direction of the elongate slit 20 in the nozzle 10. As the horizontal velocity of the carriages 14 is essentially the same as the extrusion speed, the sticks 18 are inserted with no relative horizontal movement between the sticks 18 and the extruded aerated frozen confection 22.
[0055] Once the aerated frozen confection 22 leaves the nozzle, a blade (not shown) cuts completely through the cross-section of the aerated frozen confection 22 at a location midway between the location of two adjacent inserted sticks 14. This can be mechanically arranged by synchronising the movement of the blade with the location of the carriages in the frame.
[0056] This results in a sequence of a plurality of dimensionally similar sticked frozen confections 24, supported in free space during and following cutting. As the aerated frozen confection 22 is already hardened, there is no need for a hardening tunnel, and the sticked frozen confections 24 can then be subsequently conveyed by its respective supporting carriage 14 directly to at least one subsequent processing step, such as coating, wrapping and packaging steps.
[0057] Figure 2 shows a subsequent processing step of coating, where the sequence of dimensionally similar sticked frozen confections 24 approach a bath 26 containing the first coating liquid 28. As they approach, the carriages 14 descend vertically due to the arrangement of the frame 16, so that each sticked frozen confection 24 descends into the first coating liquid 28.
[0058] Figure 3 shows a second coating step where the sequence of dimensionally similar sticked frozen confections 24 approach another bath 30 containing a second coating liquid 32, which in this case is a chocolate coating. In this case the carriages 14 are rotated about a horizontal axis to raise each sticked frozen confection 24 above the height of the bath 30. Each carriage 14 is then rotated again in the opposite sense, in order to dip the frozen confection 24 into the second coating liquid 32. The carriages 14 are then once more rotated the allow the coated aerated frozen confections 34 to pass over the side of the bath 30. This is followed by a further and final rotation of the carriages 14 to return the coated sticked frozen confections 34 to a vertical position. As the aerated frozen confection is at the low temperature of -10°C to -19°C the chocolate coating quickly solidifies without the need for additional cooling being applied.
[0059] It may also be seen that two additional lines of dimensionally similar sticked frozen confections 24 supported in free space by its respective supporting carriage 14 are provided. This merely increases the production rate of the frozen confections 24.
[0060] Figure 4 shows a further processing step, where three conveyor belts 36, 38, 40 are provided. Each of the three lines of dimensionally similar sticked frozen confections 34 supported in free space are rotated to a horizontal orientation by rotation of their respective carriage 14, as the conveyor belts 36, 38, 40 are approached. The carriages 14 are then arranged to let go of the stick 18 in a coordinated timing to result in a sequence of sticked and coated frozen confections 34 lying on the conveyor belt surface 36, 38, 40. These can then pass to a wrapping machine and can be subsequently boxed by known means. Figure 5 shows another apparatus for carrying out the process of the present invention. Shown is a nozzle 50 through which can flow a continuous stream of extruded aerated frozen confection. Above the nozzle 50 is a plurality of equally spaced apart supporting carriages 54 arranged to move in the horizontal extrusion direction and at essentially the same speed as the extrusion speed. Each carriage 54 grips a grippable length of a stick 58. Each carriage is shaped to snugly fit within the thread of a scroll 60.
[0061] The nozzle 50 comprises an elongate slit 62 aligned in the extrusion direction. The nozzle has also been surrounded by a water jacket 66 which warms the extruded frozen confection.
[0062] In operation of the apparatus, the scrolls rotate along their horizontal axis, which causes the carriages 54 to move horizontally (from left to right in the figure). A guideway (not shown) additionally causes them to descend vertically so as to insert the sticks 58 into the elongate slit 62 when frozen confection is being extruded.
[0063] The horizontal velocity of the carriages 54 is essentially the same as the extrusion speed, and so the sticks 58 are inserted with no relative horizontal movement between the sticks 58 and the extruded aerated frozen confection.
[0064] It can be seen that the thread of the scroll 60 increases in region 61, which provides the effect that the spacing of the carriages is increased, at the point of exit from the nozzle 50 so as to separate the produced individual aerated frozen confections after cutting.
[0065] Figure 6 shows a preferred type of subsequent processing step of coating the dimensionally similar sticked aerated frozen confections, once produced. The sequence of dimensionally similar sticked frozen confections 24 approach a bath 26 containing the first coating liquid 28. As they approach, the carriages 14 descend vertically, so that each sticked frozen confection 24 descends into the first coating liquid 28. In this embodiment however, the bath 26 rotates in a counter-clockwise manner (as viewed from above) at a speed that matches the speed of movement of the frozen confections 24, so that when they are in the coating liquid 28 there is no relative lateral movement between the frozen confections 24 and the coating liquid 28. Figure 7 shows a preferred type of further processing step, where a conveyor belt 36 is provided. The line of dimensionally similar sticked frozen confections 34 supported in free space are rotated to a horizontal orientation by rotation of their respective carriage 14, as the conveyor belt 36 is approached. The carriages 14 are then arranged to let go of the stick 18 in a coordinated timing to result in a sequence of sticked and coated frozen confections 34 lying on the conveyor belt surface 36. These can then pass to a wrapping machine and can be subsequently boxed by known means. In this preferred embodiment, the speed of the conveyor belt matches that of the speed of movement of the frozen confections 24, so that when they are deposited thereon there is no relative lateral movement between the frozen confections 24 and the conveyor belt 36.
Claims
Claims1. A process for the manufacture of a plurality of dimensionally similar sticked aerated frozen confections, the process comprising the steps ofi) preparing a source of aerated frozen confectionii) extruding a continuous flow of the aerated frozen confection in at least one screw extruder, such that a continuous stream of extruded aerated frozen confection leaves the screw extruder via a nozzle in an extrusion direction and at an extrusion speed,iii) sequentially inserting a plurality of grippable sticks into the continuous stream of extruded aerated frozen confection at equally spaced intervals, and such that a grippable length of each grippable stick protrudes from the aerated frozen confection,iv) sequentially cutting through the continuous stream of extruded aerated frozen confection at locations between two adjacent inserted sticks, to produce a continuous sequence of dimensionally similar sticked frozen confections,wherein during or before the cutting, each grippable length of stick is gripped by one of a plurality of spaced apart supporting carriages, such that each dimensionally similar sticked frozen confection is supported in free space during cutting and is subsequently conveyed by its respective supporting carriage to at least one subsequent processing step.
2. A process according to any one of the preceding claims, wherein the extruded aerated frozen confection is at a temperature of from -10°C to -19°C.
3. A process according to claim 1 or claim 2, wherein the extrusion direction is a horizontal direction and the sticks are inserted in a direction that is within a vertical plane.
4. A process according to any one of the preceding claims, wherein the nozzle comprises an elongate slit aligned in the extrusion direction exposing an elongatestrip of extruded aerated frozen confection, the grippable sticks being inserted into the elongate strip of extruded aerated frozen confection.
5. A process according to any one of the preceding claims, wherein the extrusion speed is greater than 5cm / s, preferably from 5 to 20cm / s, more preferably from 8 to 15 cm / s.
6. A process according to any one of the preceding claims, wherein the velocity of the sticks during insertion have a component of velocity perpendicular to the extrusion direction and a component of velocity parallel to the extrusion direction.
7. A process according to claim 6, wherein the component of velocity parallel to the extrusion direction is substantially the same as the extrusion speed.
8. A process according to any one of the preceding claims, wherein the plurality of supporting carriages are adapted to have a variable separation between adjacent carriages.
9. A process according to claim 8, wherein the spacing between adjacent supporting carriages increases during the cutting.
10. A process according to any one of the preceding claims, wherein the plurality of spaced apart supporting carriages are mounted on an endless track.
11. A process according to any one of the preceding claims, wherein the plurality of supporting carriages are adapted such that each gripped stick is rotatable relative to the carriage, preferably wherein the axis of rotation is perpendicular to the track.
12. A process according to any one of the preceding claims, wherein each carriage is located within the rotating thread of a threaded scroll, and the spacings of the threads governs the spacings of the carriages.
13. A process according to any one of the preceding claims, wherein each dimensionally similar sticked frozen confection is supported in free space as it isconveyed by its respective supporting carriage to and through a dipping stage, and / or to a packaging stage.
14. A process according to claim 13, wherein each dimensionally similar sticked frozen confection is supported in free space as it is conveyed by its respective supporting carriage to and through a dipping stage, and wherein, during the dipping, there is no lateral movement between the frozen confection and the coating liquid.
15. A process according to any one of the preceding claims, wherein each dimensionally similar sticked aerated frozen confection proceeds through at least one subsequent processing step without any additional cooling applied.
16. A process according to any one of the preceding claims, wherein the process comprises sequentially cutting through the continuous stream of extruded aerated frozen confection in a horizontal cutting direction, the extrusion direction being horizontal and perpendicular to the cutting direction.