One-shot Centre-filled Chocolate Deposition Process
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Solution Overview
Problem
Traditional methods for producing centre-filled chocolate products are inefficient, requiring multiple steps and being limited in producing smaller products due to the need for moulds, which restricts flexibility and increases costs.
Innovation Solution
A one-shot process where chocolate shell and centre-fill materials are co-deposited onto a planar surface, with controlled temperature and density matching, and subjected to vibration before cooling, allowing for the production of varied shapes and sizes without the need for moulds, using a nozzle arrangement with concentric nozzles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional shell moulding is used to produce centre-filled chocolate products, then the products can be manufactured with hollow shells and fillings, but the process requires multiple steps and is time-consuming
Solution Approach 1:
The patent combines the shell deposition and filling operations into a single simultaneous deposition step. The concentric nozzles allow chocolate shell material and centre-fill material to be deposited together in one action, eliminating the separate steps of shell preparation, inversion, and filling required in traditional shell moulding
Solution Approach 2:
The deposition system is segmented into concentric nozzles with separate channels for shell material and centre-fill material. This segmentation allows independent control of each material stream while achieving simultaneous deposition, simplifying the overall process compared to traditional multi-step methods
2Adaptability or versatility
If moulds are used to confine the precursor during deposition, then the product shape is controlled, but the apparatus cannot easily produce products of different sizes and shapes
Solution Approach 1:
The planar surface serves as a universal deposition substrate that can accommodate precursors of various sizes and shapes. The same apparatus configuration can produce different product variations by simply changing the deposition pattern or surface template, eliminating the need for multiple specialised moulds
Solution Approach 2:
Instead of confining the precursor within mould walls during deposition, the patent inverts the approach by depositing the precursor onto a planar surface where it spreads freely. The product shape is defined by the deposition process and surface characteristics rather than mould constraints, enabling greater flexibility
3Manufacturing precision
If the precursor is vibrated before cooling, then the surface area increases and product consistency improves, but the centre-fill material may leak
Solution Approach 1:
The patent carefully controls the vibration parameters (amplitude, frequency, duration) to achieve sufficient precursor spreading and surface area increase while remaining below the threshold that would cause centre-fill leakage. This optimised parameter selection resolves the contradiction between improving uniformity and preventing leakage
Solution Approach 2:
The centre-fill material formulation is locally optimised with specific viscosity and density characteristics that match the shell material. This local property adjustment ensures the centre-fill remains stable during vibration while still allowing precursor spreading, preventing leakage while maintaining product consistency
4Stability of the object's composition
If the centre-fill material density differs significantly from the chocolate shell material density, then the materials can be distinguished, but the centre-fill may settle or separate during deposition
Solution Approach 1:
The patent optimises the density difference between centre-fill and shell materials to fall within a specific range (±15%). This parameter control ensures sufficient material distinction for identification while preventing excessive density-driven separation or settling during the simultaneous deposition process, maintaining both composition stability and deposition uniformity
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 process simplifies the production of centre-filled chocolate products, reduces costs by eliminating the need for moulds, and enables the creation of uniform, consistent products of different sizes and shapes, while preventing leakage through the use of additives like microcrystalline cellulose and carrageenan.
Implementation Method 1
the precursor is subject to vibration before cooling. The vibration causes the precursor to spread out on the substantially planar surface and thereby increase its surface area
Implementation Method 2
the precursor is cooled to set the chocolate shell material and form the centre-filled chocolate product
Data Source
Figure 1~2
AI summary
A process for the preparation of centre-filled chocolate products and one-shot deposited centre-filled chocolate products. In particular, a one-shot process for the preparation of a centre-filled chocolate product (10; 20) comprising a chocolate shell (12; 22) and a centre-fill (14), wherein a chocolate shell material and a centre-fill material are at least partially co- deposited at respective deposition temperatures onto a substantially planar surface to form a precursor; and the precursor is cooled to set the chocolate shell material and form the centre-filled chocolate product, wherein the precursor is subject to vibration before cooling. The centre-filled chocolate products may be generally disc-shaped and/or may have a mass of less than 3.5g. The centre- fill material may comprise microcrystalline cellulose, invert sugar or carageenan.