Confectionery Rope Snap-Forming for Irregular Piece Manufacturing
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Solution Overview
Problem
Existing methods for manufacturing irregularly sized and/or shaped confectionery pieces, such as chocolate, are inefficient and costly, often resulting in waste and a lack of uniform irregularity between pieces, especially when incorporating inclusions.
Innovation Solution
A method involving the formation of a rope of confectionery material followed by external pressure application using a pin roller to snap the rope into irregularly sized and/or shaped pieces, allowing for visible inclusions and a high level of irregularity without cutting, which enhances the tactile and visual appeal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cutting methods are used to produce irregularly shaped confectionery pieces, then production efficiency is improved, but material waste increases and uniform irregularity is lost
Solution Approach 1:
The patent changes the fundamental parameter of the forming process from cutting (subtractive) to snap-forming (fracture-based). By controlling the temperature and mechanical stress parameters during snap-forming, irregularly shaped pieces are created directly from the confectionery mass without material removal, eliminating waste while maintaining high production efficiency through continuous processing
Solution Approach 2:
The patent replaces the traditional cutting mechanism (blades or knives) with a snap-forming mechanism that uses controlled mechanical stress and temperature. This substitution allows the confectionery material to fracture into irregular shapes through controlled snapping action rather than cutting, reducing material waste while maintaining productivity
2Ease of manufacture
If traditional forming methods are used, then manufacturing cost is reduced, but the ability to incorporate visible inclusions and create high irregularity is limited
Solution Approach 1:
The patent deliberately introduces asymmetry and irregularity as the desired outcome rather than attempting to create uniform pieces. The snap-forming process naturally produces asymmetric shapes with visible inclusions exposed on the surfaces, creating a consistent level of irregularity across all pieces that enhances visual appeal while maintaining cost-effectiveness
Solution Approach 2:
The patent incorporates inclusions into the confectionery mass before the snap-forming process. This preliminary action ensures that inclusions are distributed throughout the material and will be naturally exposed on the surfaces of irregularly shaped pieces during snapping, eliminating the need for additional post-processing steps to add or position inclusions
3Speed
If blade cutting is used to form irregular pieces, then production speed is maintained, but tactile sensation and natural appearance are reduced
Solution Approach 1:
The patent changes the physical parameters of the confectionery material during processing, specifically controlling temperature and moisture content to achieve optimal snap-forming characteristics. This allows the material to fracture cleanly into irregular shapes that enhance tactile sensation and natural appearance, while the continuous snap-forming process maintains high production speed comparable to cutting methods
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 method efficiently produces confectionery pieces with varied shapes and sizes, incorporating inclusions, resulting in a more natural appearance and enhanced consumer experience while minimizing waste and improving manufacturing efficiency.
Implementation Method 1
applying external pressure at multiple locations along the length of the at least one rope to substantially snap the at least one rope at multiple locations
Data Source
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AI summary
The invention provides a method of manufacturing a plurality of irregularly shaped and/or sized pieces of confectionery material comprising the steps of; a) forming at least one rope of confectionery material; b) applying external pressure at multiple locations along the length of the at least one rope to snap the at least one rope at multiple locations.