Chocolate Tempering Apparatus with Integrated Plate Heat Exchanger
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing tempering apparatuses for chocolate and creme masses are high, heavy, and inefficient, leading to the formation of unstable crystals, reduced capacity, high energy consumption, and difficulties in handling and installation, especially when tempering high-fat content materials.
Innovation Solution
A compact tempering apparatus with a cooling stage arranged in a plate heat exchanger having parallel channels, eliminating the need for a separate reheating stage by ensuring only stable βV-crystals are formed, reducing height and weight, and optimizing energy use through counter-flow or co-current flow configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by stationary object
If traditional separate cooling and crystallization stages are used, then effective heat exchange is achieved, but the apparatus becomes high and heavy
Solution Approach 1:
The patent combines the cooling stage and crystallization stage into a single integrated chamber where both functions occur simultaneously. The chamber serves dual purposes: cooling the chocolate mass while also facilitating crystal formation, thereby eliminating the need for separate stages and reducing overall apparatus height.
Solution Approach 2:
The single chamber is designed to perform multiple functions - both cooling and crystallization - making it a multi-functional unit. This universal chamber handles different process stages within one structure, improving space utilization and reducing the vertical footprint of the apparatus.
2Use of energy by stationary object
If cold surface temperatures are used in cooling stage, then heat exchange effectiveness is improved, but unstable crystals are formed simultaneously
Solution Approach 1:
The patent applies different temperature conditions to different zones within the same chamber. The cooling function operates at lower temperatures for heat exchange effectiveness, while the crystallization zone maintains conditions favorable for stable crystal formation. This localized temperature control allows both functions to coexist without compromising crystal stability.
Solution Approach 2:
The chamber is designed to preliminary cool the mass in a controlled manner before crystal formation begins. This preliminary cooling action prepares the mass for subsequent crystallization without causing premature or unstable crystal formation, ensuring that stable crystals develop in the intended crystallization zone.
3Adaptability or versatility
If high-fat content materials are tempered, then product versatility is improved, but unstable crystal formation increases
Solution Approach 1:
The patent uses localized temperature control within different zones of the chamber to address the specific crystallization needs of high-fat materials. The crystallization zone provides optimized conditions that promote stable crystal formation even in high-fat content materials, while the cooling zone handles the thermal management separately.
Solution Approach 2:
The patent adjusts temperature parameters within the crystallization zone to optimize crystal formation for high-fat materials. By controlling the temperature profile and maintaining it within specific ranges, the system promotes stable crystal formation regardless of the fat content level in the material being processed.
4Manufacturing precision
If separate cooling and crystallization chambers are used, then process control is improved, but device complexity increases
Solution Approach 1:
The patent merges the cooling and crystallization chambers into one integrated unit, simplifying the overall device structure. While the functions are combined, the chamber is designed with internal zones that maintain functional separation, allowing good process control without the complexity of multiple separate chambers.
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 apparatus achieves efficient tempering with reduced dimensions and weight, minimizing unstable crystal formation, increasing capacity, and lowering energy consumption while maintaining consistent chocolate quality and ease of handling.
Implementation Method 1
The cooling stage is arranged in a heat exchanger having a row of parallel plates arranged in a stack sealed at their edges providing intermediary, neighbouring channels each having an inlet and an outlet
Implementation Method 2
optimizing energy use through counter-flow or co-current flow configurations
Implementation Method 3
For the continuous tempering to be performed, it is decisive, that whether the fat phase constitutes of genuine cocoa butter or substitutes, the fat phase must be capable of crystallizing into stable crystal types, such as the βV-crystals developing in genuine cocoa butter
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Apparatus (1) for continuous tempering of a fat-containing, crystallisable mass such as chocolate mass or creme mass, comprising a column (2) of mass chambers (4) and intermediary water chambers (5) arranged in stacked elements (3). A central drive shaft (7) is in engagement with mixing elements (10) arranged in the mass chambers (4). The crystallisation stage is arranged in the column (2). A cooling stage is arranged in a heat exchanger (11) having parallel plates (12) arranged in a stack (13) sealed at their edges (14) providing intermediary, neighbouring channels (16, 17). Every second channel (16) in the row is connected with a common first inlet (18) and a common first outlet (19) for the flow of mass there through. Each of the intermittent, neighbouring channels (17) are connected with a common second inlet (20) and a common second outlet (21) for the flow of water medium there through. The building height, weight and centre of gravity of the apparatus are reduced severely in comparison with the prior art columns comprising cooling stage, crystallisation stage and re-heating stage.