Frozen Confectionery Coating With Horizontal Particle Application
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Solution Overview
Problem
Existing industrial methods for decorating frozen confectionery with particles fail to replicate the artisanal appearance and suffer from limitations in particle choice and visibility, as well as significant waste generation.
Innovation Solution
An apparatus and method involving a coating station, particle dispensing station, conveyor with gripping means, heating station, and optional coating removal means to apply particles while controlling coating solidification, allowing for better particle adherence and reduced waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If particles are suspended in liquid coating material during dipping, then coating and particles adhere to the surface, but particles are covered with coating so that details of their shape and color are masked
Solution Approach 1:
The process is segmented into two distinct stages: first applying a base coating layer that provides adherence, then applying particles, and finally adding a clear top coating layer that protects and enhances particle visibility. This segmentation allows each layer to serve its specific function without compromising the others.
Solution Approach 2:
Different regions of the coating system are given different properties: the base coating layer has high adhesion properties for particle attachment, while the top clear coating layer has high transparency and protective properties. This local differentiation of material properties resolves the contradiction between adherence and visibility.
2Reliability
If particles are applied while coating is still liquid, then particles adhere well to the coating, but coating drip and loose particles remain on the tray creating waste
Solution Approach 1:
The harmful element of uncontrolled coating drip is extracted and removed from the process by using a raised tray design that collects and contains the drip, preventing it from mixing with particles and creating waste. The drip is separated and can be recovered or disposed of cleanly.
Solution Approach 2:
The raised tray acts as an intermediary structure between the coating application process and the final product. It provides a controlled environment where coating drip can be contained and managed, preventing waste while maintaining particle adherence properties.
3Reliability
If frozen confectionery bars are manually dipped and decorated, then artisanal individualized products are created with good particle adherence, but the process cannot be replicated in industrial manufacturing
Solution Approach 1:
The system is designed to automatically perform the functions previously requiring manual operation. The conveyor belt automatically transports bars through the coating and particle application stations, and the raised tray design automatically contains drip without manual intervention, enabling industrial-scale production while maintaining artisanal quality.
Solution Approach 2:
The process parameters are optimized for industrial automation: coating viscosity, dip speed, particle application rate, and tray height are all controlled within specific ranges that ensure consistent particle adherence while enabling automated operation at industrial production speeds.
4Adaptability or versatility
If heavy particles are used in suspended coating, then variety of particles can be used, but heavy particles fall off from the vertical surface
Solution Approach 1:
Particles are applied to the coating surface while it is still liquid and the bar is in a horizontal or near-horizontal position, allowing heavy particles to be properly embedded before gravity can cause them to fall. The coating is then allowed to solidify, locking the particles in place.
Solution Approach 2:
The process dynamically adjusts the bar orientation and coating state: bars are positioned horizontally during particle application to prevent gravity-induced particle loss, then repositioned vertically after coating solidification. This dynamic adjustment of process conditions allows use of heavy particles that would otherwise fall off vertical surfaces.
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 and method produce industrially manufactured frozen confectionery with an artisanal appearance, minimizing waste and improving particle adherence by controlling coating solidification and excess removal.
Implementation Method 1
heating the upper surface of the confection prior to moving the confectionery past the particle dispensing station
Implementation Method 2
Immediately after coating, particles are sprinkled onto the coating, while the coating is still liquid. After a few seconds, the coating solidifies, and the embedded particles become fixed in place.
Data Source
AI summary
The invention relates to an apparatus for decorating frozen confectionery (1) on sticks, the apparatus comprising: a coating station (4) for applying coating material onto the frozen confectionery (1), a particle dispensing station (7) for applying particles onto the coated frozen confectionery, a conveyor (3) for moving the frozen confectionery past the coating station and the particle dispensing station, the conveyor (3) comprising gripping means (2) arranged on the conveyor (3) and having a product attached position and an opened position for gripping and releasing the stick of the frozen confectionery (1), and the conveyor (3) comprising guides for moving the gripping means with the frozen confectionery between a vertical position and a horizontal position, and wherein the apparatus further comprises a heating station (11) installed at a position between the coating station (4) and the particle dispensing station (7), and wherein the gripping means (2) are arranged to hold the frozen confectionery in the horizontal position when passing the heating station (11) and the particle dispensing station (7), and optionally coating removal means (6) for removing coating material on one side of the frozen confectionery, which coating removal means (6) are at a position after the coating station (4) in the direction of the movement of the conveyor (3) and before the particle dispensing station. The invention also relates to a method for manufacturing decorated frozen confectionery on sticks making use of the apparatus.