Chocolate Mould Tempering with U-Shaped Trays
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Solution Overview
Problem
Existing chocolate production plants face challenges in achieving uniform preheating and cooling of moulds, particularly in border areas, leading to potential deformation and inefficiencies in chocolate solidification.
Innovation Solution
The use of individual, U-shaped trays with slots in a processing station allows for point or linear contact with the moulds, enabling uniform exposure to a tempering medium for heating or cooling, ensuring even temperature distribution across the entire mould surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conveyor belt is used to transport moulds through preheating or cooling cells, then continuous production is enabled, but uniform temperature distribution across the mould surface is difficult to achieve
Solution Approach 1:
The mould surface is segmented into multiple zones (center and border areas) that receive different tempering medium flow rates. The tempering medium distribution system is divided into separate controllable zones that can be independently regulated to achieve uniform temperature across the entire mould surface while maintaining continuous production through the conveyor belt system.
Solution Approach 2:
Different regions of the mould receive different qualities of tempering treatment. Border areas receive higher flow rates of tempering medium compared to center areas, creating local quality variations in temperature control that compensate for the inherent cooling/heating differences in various mould regions, thereby achieving overall uniformity.
2Temperature
If spiral conveyors are used for tempering moulds, then heating or cooling can be achieved, but the design becomes complex and expensive
Solution Approach 1:
The complex spiral conveyor design is replaced by extracting only the essential function of tempering moulds while removing the cumbersome spiral structure. A simpler conveyor belt system is used, supplemented by a targeted tempering medium distribution system that directs heated or cooled medium directly to the mould surfaces through nozzles or channels, achieving the same tempering effect with much reduced mechanical complexity.
Solution Approach 2:
The mechanical spiral conveyor system is replaced by a combination of a simple linear conveyor belt and a tempering medium delivery system. Instead of relying on complex mechanical spiral structures to achieve both transport and tempering, the solution substitutes the mechanical complexity with a fluid-based tempering medium distribution system that delivers heated or cooled medium directly to the moulds.
3Extent of automation
If hydraulic or pneumatic robots are used to handle moulds, then automation is achieved, but hygienic requirements are not met and speed/accuracy are poor
Solution Approach 1:
Instead of using complex hydraulic or pneumatic robots that pose hygienic risks and performance limitations, the invention employs simpler, easily cleanable robotic handling systems or even manual handling where appropriate. The focus shifts to using disposable or easily sanitized components in the tempering medium delivery system, such as single-use nozzle attachments or easily cleaned channels, ensuring hygienic compliance without sacrificing automation.
Solution Approach 2:
The system is designed to be easily maintainable and cleanable by operators without requiring complex disassembly or specialized service. The tempering medium delivery components are designed for simple removal and cleaning, and the robotic handling system uses materials and designs that meet hygienic requirements while maintaining automated operation.
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 approach ensures uniform and efficient tempering of moulds, preventing deformation and enhancing the quality of chocolate production by maintaining consistent heating or cooling conditions throughout the mould.
Implementation Method 1
a tempering medium is guided in the trays... ensures uniform exposure to a tempering medium for heating or cooling
Implementation Method 2
slots in the wall below and/or above the trays for dispensing a tempering medium... a tempering medium is guided in the trays
Implementation Method 3
enabling uniform exposure to a tempering medium for heating or cooling, ensuring even temperature distribution across the entire mould surface
Data Source
AI summary
In an plant for producing foodstuff, in particular a chocolate article, in at least one mould (1) which can be tempered in at least one processing station (3, 8, 9) before and/or after the foodstuff is filled in, wherein the mould (1) being taken over in or at the processing station (3, 8, 9) by a robot (4) and being deposited for tempering, individual, separate trays (5) for the moulds (1) are provided in the processing station (3, 8, 9).