Chocolate Shell Deposition Using Restriction Element and Vibration
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Solution Overview
Problem
Current shell moulding methods for centre-filled confectionery products face issues such as mould fouling, inconsistent shell formation, and increased energy costs due to the 'backing off' process, which involves applying a chocolate backing layer that can lead to mould abrasion, chocolate residue, and energy inefficiencies, especially when dealing with low-viscosity centre fills.
Innovation Solution
An apparatus and method utilizing a depositor with a restriction element featuring apertures that match the mould opening dimensions to control the flow of chocolate, allowing for precise deposition of a continuous chocolate layer to form the shell and base of confectionery items, including centre-filled chocolate products, while minimizing waste and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If overfilling method is used to back chocolate products, then all voids are filled and mass is evenly distributed, but mould fouling occurs, scraping is required, and energy costs increase due to re-tempering
Solution Approach 1:
The patent extracts the harmful reflow and scraping steps from the backing process. By using a vibratory table to distribute chocolate mass without overfilling, the method eliminates mould fouling and the need for scraping, while still achieving even distribution of chocolate across the mould surface.
Solution Approach 2:
The patent applies mechanical vibration through a vibratory table to distribute the chocolate mass evenly across the mould surface. This vibration-based distribution method replaces the need for scraping arrangements and eliminates mould fouling while maintaining uniform chocolate coverage.
2Manufacturing precision
If scraping arrangement is used to remove excess chocolate, then even distribution is achieved, but mould abrasion occurs and plastics debris may be scraped into chocolate
Solution Approach 1:
The patent replaces the mechanical scraping action with vibratory motion. The vibratory table causes the chocolate mass to naturally distribute itself through vibration, eliminating the need for scraping arrangements that cause mould abrasion and potential contamination with plastics debris.
Solution Approach 2:
The patent substitutes the mechanical scraping system with a vibratory distribution system. Instead of using scrapers to remove excess chocolate, the vibratory table uses oscillatory motion to achieve even distribution, eliminating mould damage and contamination risks.
3Loss of substance
If reflow method is used to recycle chocolate, then chocolate is reused, but energy costs increase due to re-tempering and re-processing
Solution Approach 1:
The patent extracts the reflow and re-tempering steps from the process by using a vibratory distribution method that works with the chocolate mass as deposited. This eliminates the need to collect, re-melt, and re-temper excess chocolate, significantly reducing energy consumption while still allowing for effective chocolate utilization.
4Manufacturing precision
If vibration method is used to distribute chocolate mass, then even distribution is achieved for small surfaces, but it is not suitable for larger flat surfaces and areas with corners
Solution Approach 1:
The patent enhances the vibratory distribution system by making it adjustable and adaptable. The vibratory table can be adjusted in intensity and duration, and can accommodate different mould configurations including large flat surfaces and pieces with corners, extending the applicability of vibration-based distribution beyond small concentrated surfaces.
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 solution enables accurate dosing and application of chocolate layers, reducing mess and scraping, minimizing production line downtime, and allowing for the production of multicoloured or multi-flavour chocolate products with improved shell consistency and reduced energy costs.
Implementation Method 1
distributing the mass evenly by vibrating the mould in an x/y movement
Data Source
Figure 1
Figure 2~3
Figure 4A~4B
AI summary
An apparatus for producing a moulded food item comprises: a depositor for depositing a flowable food mass to a one or more moulds, wherein a mould has a opening of pre-determined dimensions; and a restriction element forming one or more apertures which restrict the flow of the food mass from the depositor to substantially the same dimensions as the mould opening. Preferably, the depositor comprises a spray or curtain nozzle. The restriction element may comprise a planar stencil with a plurality of openings. Alternatively, the restriction element may be cylinder with a plurality of apertures capable of being in rotatable registration with a plurality of mould openings. The apparatus may be used to deposit the shell of centre-filled chocolates.