Dual Layer Frozen Confection Viscosity Control
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Solution Overview
Problem
Manufacturing frozen confectionery products with multiple layers of chocolate and sauce poses challenges in achieving a desired shape and aesthetically appealing appearance, especially when larger amounts are used, as high temperatures can cause melting, texture changes, and uneven layer distribution, leading to distorted presentation and sensorial issues.
Innovation Solution
A method involving controlled thickness and viscosity of chocolate, sauce, and ice cream layers, with specific viscosities (1.5-1.7 Pa.s for sauce and 1.0-1.4 Pa.s for chocolate) and thicknesses (0.5-3.0 mm), along with rapid crystallization and proper heat transfer, to maintain texture and appearance, using a dosing nozzle for simultaneous application of layers in a helical pattern.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If larger amounts of chocolate and sauce are used to create premium products, then the product quality and premiumness are improved, but the heat transfer to frozen confection increases causing local melting and texture degradation
Solution Approach 1:
The patent introduces an intermediate frozen confection layer between the hot chocolate/sauce and the ice cream core. This intermediate layer acts as a thermal buffer, absorbing heat from the chocolate and sauce while protecting the ice cream from direct heat shock, thus preventing local melting and texture degradation while allowing larger amounts of premium ingredients to be used.
Solution Approach 2:
The patent applies preliminary freezing to the chocolate and sauce layers before final assembly, or uses pre-cooled chocolate and sauce formulations. This preliminary action reduces the initial temperature of the chocolate and sauce, thereby reducing the heat transfer to the frozen confection and preventing excessive melting while maintaining the desired premium quantity.
2Reliability
If hot chocolate and sauce are added to frozen confection, then the chocolate and sauce solidify through heat transfer, but the frozen confection experiences heat shock resulting in larger ice crystals and coarse texture
Solution Approach 1:
The frozen confection layer serves as an intermediary thermal buffer that mediates between the hot chocolate/sauce and the ice cream. It absorbs the heat necessary for chocolate and sauce solidification while limiting the heat transfer to the ice cream, thus preventing heat shock and maintaining fine ice crystal structure and smooth texture.
Solution Approach 2:
The patent modifies the parameters of the frozen confection layer, specifically its thickness and thermal properties, to optimize its heat absorption capacity. By changing these parameters, the system achieves reliable chocolate and sauce solidification while maintaining ice cream texture stability, preventing the formation of large ice crystals.
3Quantity of substance
If too much sauce or chocolate is applied at the outer parts of the product, then the product has sufficient filling, but the sauce or chocolate runs down along the outer surface and into packaging material distorting presentation
Solution Approach 1:
The patent applies different viscosity characteristics to different layers: the sauce and chocolate layers are formulated with higher viscosity than conventional formulations. This local quality change in viscosity prevents the sauce and chocolate from running down the outer surface while maintaining adequate quantity, thus preserving layer definition and aesthetic presentation.
Solution Approach 2:
The patent changes the viscosity parameter of the sauce and chocolate formulations to a higher range. This parameter change allows larger amounts of sauce and chocolate to be used without running, maintaining both sufficient filling and proper layer shape definition, preventing distortion of presentation.
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
Results in a product with well-defined, aesthetically appealing layers and a smooth texture, preventing heat shock and ensuring the chocolate and sauce layers maintain their shape and desired consistency, while maintaining the quality of the ice cream.
Implementation Method 1
the heat transfer to the frozen confection is necessary to solidify the chocolate and sauce and cool down the additions
Implementation Method 2
the frozen confection layer has a thickness of between 3.0 and 7.0 mm... preventing heat shock of the ice cream
Implementation Method 3
a rapid crystallization of the chocolate layer is needed in order to keep the general aspect of the decoration, if the chocolate does not crystalize quickly it will not keep the desired shape
Implementation Method 4
the frozen confection , sauce and chocolate layers form substantially helical layers... the heat transfer to the frozen confection is necessary to solidify the chocolate and sauce
Data Source
Figure 1~3
Figure 4
AI summary
The present invention relates to a layered frozen confectionery product comprising at least one a layer of frozen confection, at least one layer of chocolate and at least one layer of sauce. The sauce in the sauce layer has a viscosity of between 1.2 and 1.7 Pa.s at a temperature below +47°C and is present in the frozen confectionery at a thickness of 0.5 to 3.0 mm. The chocolate in the chocolate layer has a viscosity of between 1.0 and 1.4 Pa.s at a temperature of +45°C and is present in the frozen confectionery at a thickness of 0.5 to 3.0 mm, and the frozen confection layer has a thickness of between 3.0 and 7.0 mm and an overrun between 80 and 200 and is positioned between the chocolate and sauce layer. The invention also relates to a method for making such a product.