Frozen Confection Coating Bubble Prevention
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Solution Overview
Problem
Unwanted bubbles form in the coating of frozen confections due to trapped gas beneath the surface, caused by surface imperfections like troughs and peaks, which are not filled by the coating before it solidifies, leading to undesirable surface imperfections.
Innovation Solution
Applying thermal energy to the surface of the frozen confection in a non-contact manner to partially melt and smooth out the surface, allowing it to refreeze before coating, ensuring the coating can fill any troughs and preventing bubble formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the coating is applied rapidly to the frozen confection, then the coating process is efficient and productive, but bubbles form in the coating due to trapped gas beneath surface imperfections
Solution Approach 1:
The surface of the frozen confection is pre-heated before coating application to melt surface imperfections such as troughs and peaks. This preliminary action creates a smooth surface that allows the coating to flow evenly without trapping gas bubbles, thereby maintaining both high productivity and high coating quality.
Solution Approach 2:
The temperature of the frozen confection surface is changed by applying heat to melt the surface layer. This parameter change transforms the surface from a rough, imperfect state to a smooth, fluid state that facilitates bubble-free coating application while maintaining rapid processing speeds.
2Stability of the object's composition
If the coating viscosity is high, then the coating structure is stable and maintains shape, but bubbles do not burst and remain trapped in the coating
Solution Approach 1:
The surface is pre-heated to melt imperfections before the high-viscosity coating is applied. This preliminary smoothing action ensures that even though the coating maintains its high viscosity for structural stability, there are no surface troughs to trap gas bubbles that would create surface defects.
3Productivity
If the coating solidifies rapidly, then the coating process is fast and productive, but bubbles are trapped before they can burst and create surface imperfections
Solution Approach 1:
The surface is pre-heated to melt imperfections before the rapid solidification process begins. This ensures that when the coating solidifies quickly to maintain high productivity, there are no pre-existing surface troughs to trap gas bubbles, thus achieving both speed and surface quality.
4Use of energy by moving object
If thermal energy is applied in contact with the frozen confection, then the heating is efficient, but the confection structure may be damaged or the process becomes complex
Solution Approach 1:
The mechanical contact heating system is replaced with a non-contact heating method (such as infrared or microwave heating). This substitution maintains heating efficiency while simplifying the device structure and avoiding the complexity of mechanical contact systems, and also prevents damage to the confection structure.
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 effectively prevents bubble formation in the coating, resulting in a smoother, higher-quality surface finish by ensuring the coating can fill surface imperfections, thereby eliminating trapped gas and subsequent bubble formation.
Implementation Method 1
imparting thermal energy to the surface of the frozen confection sufficient to cause melting of the surface
Implementation Method 2
coating the frozen confection in a liquid coating, which subsequently solidifies to provide a solid coating
Implementation Method 3
gas is entrapped beneath the surface of the liquid coating where troughs in the surface of the frozen confection existed. Furthermore, it is theorised that such trapped gas expands as it warms due to the heat transfer to the surface of the frozen confection from the applied coating
Implementation Method 4
the troughs being filled naturally by the molten frozen confection surface acting under the surface tension forces present in the molten surface
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3B
AI summary
The invention relates to a process for the manufacture of a coated frozen confection, the process comprising the steps of (a) manufacturing a frozen confection, followed by; (b) imparting thermal energy to the surface of the frozen confection, sufficient to cause at least partial melting of the surface of the frozen confection, followed by; (c) allowing the surface of the frozen confection to refreeze, followed by; (d) coating the frozen confection in a liquid coating, which subsequently solidifies to provide a solid coating.