Chocolate Tempering Machine Dynamic Thermal Control
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Solution Overview
Problem
Existing continuous tempering processes for chocolate require excessive energy and result in suboptimal quality when the chocolate mass flow rate is reduced below 50% of the maximum capacity, leading to prolonged crystallization times and energy wastage due to unnecessary tempering and de-crystallization of excess chocolate.
Innovation Solution
A tempering process and machine that adjust the thermal exchange fluid temperatures and stages dynamically based on the chocolate mass flow rate, allowing for optimized crystallization at lower flow rates by maintaining the chocolate temperature closer to the pre-treatment level in the first stage and reducing the cooling step to a single stage, thereby minimizing energy usage and waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the chocolate mass flow rate is reduced below 50% of maximum capacity in known tempering processes, then the forming process requirements are met for certain products, but the chocolate remains in cooling stages for excessive time leading to suboptimal crystallization and quality
Solution Approach 1:
The patent implements dynamic adjustment of thermal exchange fluid temperatures based on the actual chocolate mass flow rate. The control unit continuously monitors flow rate and modifies the temperature profiles in pre-treatment, cooling, and heating stages accordingly. This dynamic adaptation allows the system to maintain optimal crystallization conditions regardless of whether the flow rate is at maximum capacity or reduced to meet specific forming process requirements.
2Productivity
If known tempering processes operate at reduced flow rates to match forming process requirements, then product formation is enabled, but excessive energy is consumed and surplus tempered chocolate must undergo energy-consuming de-crystallization
Solution Approach 1:
The patent changes the operational parameters of the thermal exchange system based on the actual chocolate flow rate. By adjusting the temperature parameters of the thermal exchange fluid in each stage according to real-time flow rate measurements, the system optimizes energy consumption. The control unit modifies heating and cooling intensities to match the actual processing needs, eliminating waste of energy on treating excess chocolate that isn't required by the forming process.
3Productivity
If the chocolate mass flow rate is reduced to match forming process requirements, then the forming process can proceed, but the entire amount of unused tempered chocolate requires high energy consuming de-crystallization before returning to the tank
Solution Approach 1:
The patent implements a feedback control system where the actual chocolate mass flow rate is continuously measured and used to adjust the tempering process parameters. The control unit receives flow rate information and dynamically modifies the thermal exchange fluid temperatures in response. This closed-loop feedback ensures that the tempering process is optimized for the actual processing requirements, preventing the waste of energy on treating and de-crystallizing excess chocolate that isn't needed by the forming 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
The process achieves good tempering quality with reduced energy consumption and minimal waste by adjusting the tempering stages and thermal fluid temperatures according to the flow rate, ensuring optimal crystallization even at low flow rates, and utilizing a single cooling and heating system to maximize energy efficiency.
Implementation Method 1
a tempering column (2) extending along a vertical axis (A) and having a lower inlet (3)... which are put in communication with the previous chamber (13) and/or with the successive chamber (13) by passages (14)... The column (2) comprises three sections or tempering stages (17, 18, 19)... The stages 20, 17, 18, 19 comprise respective chambers 21, 22, 23, 24, which are arranged axially between the chambers 13, are isolated from the path L and are connected to respective circuits 25, 26, 27, 28 for receiving a thermal exchange fluid
Implementation Method 2
the thermal exchange in the stages 17, 18, 19 is adjusted by the unit 31 in response to a variation of the flow rate Q
Implementation Method 3
The pipe 5 is provided with a pump 7, which feeds a chocolate mass flow from the tank 6 to the inlet 3 with a flow rate Q which can be adjusted
Implementation Method 4
a tempering process is required, which is carried out so as to form, in the chocolate, appropriate crystals that lead to obtain the desired quality
Implementation Method 5
the chocolate is cooled in the first stage up to a temperature of about 32-37 °C and in the second stage up to a temperature of about 25-30 °C. Finally, in the third stage the chocolate mass flow is heated so as to make the temperature rise by 0.5-3 °C, for melting again unstable crystals
Data Source
Figure 1
Figure 2
AI summary
According to the process for the continuous tempering, the chocolate mass flows with a variable flow rate (Q) along a given path (L) and is subjected to thermal exchange in three stages (17,18,19) arranged immediately one after the other; the chocolate is cooled starting from an input temperature (T1), for forming a plurality of crystals in the chocolate, and is then heated for melting again a part of the crystals; the thermal exchange in at least one of the stages (17,18,19) is adjusted for varying at least one temperature of the chocolate mass flow in response to a variation of the flow rate (Q).