Aerated Confectionery Shell Cold-Stamping Method
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Solution Overview
Problem
Existing methods for manufacturing confectionery shells, such as the inversion method, face challenges in producing aerated shells of satisfactory quality, leading to issues like non-uniform thickness, excessive material wastage, and surface blistering, while also being restrictive in terms of material composition and viscosity.
Innovation Solution
A method involving the aeration of an edible liquid, followed by depositing it into a mould cavity and using a cold-stamping process with a stamp at a temperature below the liquid's solidification temperature to shape and partially solidify the liquid, thereby forming an aerated shell layer with a controlled gas content and preventing de-aeration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the inversion method is used to manufacture confectionery shells, then the shell provides structural rigidity and protects the filling, but the method produces non-uniform thickness and excessive material wastage
Solution Approach 1:
The patent inverts the traditional inversion method sequence by first forming a solid base layer, then inverting the mould to deposit shell material onto this base. This reversal allows precise control of shell thickness while minimizing excess material that would otherwise be wasted during the traditional inversion process
Solution Approach 2:
The method performs preliminary action by depositing a solid base layer before forming the aerated shell. This pre-formed base provides a stable foundation that enables subsequent precise thickness control of the shell material, eliminating the need for excessive material deposition and subsequent removal
2Manufacturing precision
If vibration is applied at precise frequency and amplitude to remove air bubbles, then the appearance is improved and filling leakage is prevented, but aerated shells of satisfactory quality cannot be produced
Solution Approach 1:
The patent segments the shell formation process into distinct stages: base layer formation, aerated shell deposition, and controlled solidification. This segmentation allows the aerated structure to be preserved while still achieving surface quality through targeted vibration applied only to the outer layer during specific phases
Solution Approach 2:
The method changes physical parameters by controlling temperature gradients during solidification and adjusting vibration parameters selectively. By maintaining the edible liquid above solidification temperature during initial deposition then gradually cooling, the process preserves air bubbles while achieving surface quality through controlled solidification rather than aggressive vibration
3Strength
If the edible liquid is cooled for long enough to solidify, then the shell structure is formed, but too much material solidifies causing delays
Solution Approach 1:
The patent applies local quality by creating different thermal zones within the mould. The base layer and outer shell surfaces solidify first through contact with cooler mould walls, while the interior remains liquid longer. This localized solidification allows structural formation at boundaries while maintaining processability in the center, reducing overall cooling time
Solution Approach 2:
The method performs preliminary solidification of the base layer and outer surfaces before complete shell formation is required. This staged approach allows early structural support to develop, enabling subsequent steps to proceed without waiting for full solidification of the entire shell
4Shape
If a stamp with temperature below solidification temperature is used, then the aerated shell layer is shaped and solidified, but de-aeration must be prevented
Solution Approach 1:
The patent applies skipping by rapidly stamping the aerated shell layer with the cold stamp to quickly shape and solidify the outer surface. This rapid action occurs faster than the de-aeration process can significantly reduce gas content, thereby preserving bubbles while achieving the required shell shape
Solution Approach 2:
The method performs preliminary action by pre-cooling the stamp to below solidification temperature before contact. This ensures immediate solidification upon contact, trapping gas bubbles within the rapidly solidifying matrix and preventing de-aeration during the shaping process
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method produces confectionery shells with unique textural properties, reduced calorie content, and uniform thickness, minimizing surface blistering and wastage, while allowing for precise control of aeration and flexibility in material composition.
Implementation Method 1
pressing the aerated edible liquid in the mould cavity using a stamp having a surface temperature below the solidification temperature of the edible liquid so as to shape and at least partially solidify the liquid
Implementation Method 2
aerating an edible liquid
Data Source
AI summary
The present invention provides a method for manufacturing an aerated confectionery shell comprising the steps of: (i) aerating an edible liquid; (ii) depositing the aerated edible liquid into a mould cavity; and (iii) pressing the aerated edible liquid in the mould cavity using a stamp having a surface temperature below the solidification temperature of the edible liquid so as to shape and at least partially solidify the liquid, thereby forming an aerated shell layer; wherein the aerated shell layer has a total gas content of at least 5%, the gas content being calculated using the following formula (1): Gas content of aerated shell layer=(M2−M1)/M2Wherein M1 is the mass of the aerated shell layer having volume V1, and M2 is the mass of a non-aerated shell layer having volume V1 and being formed from the same edible liquid as the aerated shell layer and in the same manner as the aerated shell layer. An aerated confectionery shell obtainable by this method is also provided.