Confectionery Moulding Machine with Sequential Forming and Cutting
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Solution Overview
Problem
Industrial machinery struggles to correctly enclose soft outer portions of confectionery products with fillings of different densities or properties, leading to filling loss and inconsistent product quality, making it difficult to produce high-quality, homogenous, and cost-effective confectionery products with soft shells and fillings.
Innovation Solution
A machine with a moulding station featuring movable half-moulds that apply sequential forming and cutting pressures to a precursor, ensuring the filling is retained within the product, using a combination of rotary and chain-type processing to achieve precise control over the moulding and cutting of confectionery products with soft outer and inner components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional industrial moulding systems are used to enclose filling in soft outer portions, then productivity is improved, but filling loss occurs and product quality becomes inconsistent
Solution Approach 1:
The patent applies preliminary action by performing a first forming operation before the final moulding. The precursor is pre-shaped with the filling already positioned inside, so that when the half-moulds close in the second operation, the filling is already contained and cannot escape. This resolves the filling loss problem while maintaining high productivity through automated continuous processing.
Solution Approach 2:
The moulding process is segmented into two distinct operations: first forming (pre-shaping the precursor with filling) and second moulding (final shaping and closing). This segmentation allows the filling to be secured in place during the first operation, preventing loss during the closing phase of the second operation, while still achieving industrial-level productivity.
2Productivity
If conventional industrial machinery is used to close soft outer portions with different density fillings, then productivity is improved, but manufacturing precision deteriorates due to uncontrollable filling quantity
Solution Approach 1:
The precursor is pre-formed with the exact required quantity of filling already positioned inside before the final moulding operation. This preliminary action ensures precise filling quantity control because the filling amount is determined during the first forming operation when the precursor structure is created, not during the high-speed closing operation. This resolves the contradiction by decoupling filling quantity control from the productivity-critical closing operation.
3Manufacturing precision
If craft type production is used to avoid filling loss, then manufacturing precision is improved, but productivity decreases and costs increase
Solution Approach 1:
The patent adopts the precision advantage of craft production (secure filling containment) by using preliminary forming to position filling inside the precursor, but achieves industrial productivity through automated continuous processing. The two-operation moulding system is fully automated, allowing high-volume production while maintaining precise filling control, thus resolving the contradiction between manufacturing precision and productivity.
Solution Approach 2:
By segmenting the process into pre-forming (precision filling placement) and final moulding (high-speed production), the patent achieves both craft-level filling containment and industrial-level productivity. The segmentation allows each operation to be optimized for its specific function while working together in an automated continuous process.
4Device complexity
If single-stage moulding is used, then device complexity is reduced, but manufacturing precision deteriorates due to inability to retain filling during closing
Solution Approach 1:
The patent uses preliminary forming to create a precursor with filling already inside before the final moulding operation. This preliminary action ensures that when the half-moulds close in the second operation, the filling is already contained and cannot escape, achieving precise filling retention. The two-stage approach increases device complexity slightly but is necessary to achieve the required manufacturing precision for filling retention.
Data Source
Figure 1
Figure 2~3
AI summary
The present invention relates to a machine (1) for producing food products (11, 11', 11 ") comprising a supporting structure (2), a loading portion of a precursor (10) of the food products (11) and a moulding station (4) of the food products (11, 11', 11"). The moulding station (4) comprises a first (142') and a second (142") plurality of half-moulds opposite each other and movable in succession between a first rest position, in which at least one of the first (142') and second (142") pluralities of half-moulds is not in contact with the precursor (10), and a preforming position, in which the half-moulds (142', 142") are positioned opposite each other to exert a first forming pressure on the precursor (10), and between a second rest position, in which at least one of the first (142') and second (142") pluralities of half-moulds is not in contact with the precursor (10), and a forming position, in which the half-moulds (142', 142") are positioned opposite each other to exert a second forming and cutting pressure on the precursor (10) for producing the food products (11, 11 ', 11"). In a further aspect thereof, the present invention relates to a method for producing food products (11, 11', 11") using at least two half-moulds (142', 142") opposite each other and movable, acting on a precursor (10) of the food products (11, 11 ', 11"). The method comprises the following steps: adjusting the preforming distance to which to move, and/or the preforming pressure to apply to, the half-moulds (142', 142") for movement to the preforming position; adjusting the forming distance to which to move, and/or the forming pressure to apply to, the half-moulds (142', 142") for movement to the forming position; loading the precursor (10) to be formed into the half- moulds (142', 142"); moving the half-moulds (142', 142") from a first rest position to the preforming position, and/or applying the preforming pressure to the half-moulds (142', 142"); moving the half-moulds (142', 142") from the preforming position to a second rest position, and/or releasing the preforming pressure; moving the half-moulds (142', 142") from said second rest position to the forming position, and/or applying the forming pressure to the half-moulds (142', 142"); unloading the food products (11, 11', 11") formed.