Modular Confectionery Cooling Line Using Robotic Handling

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Solution Overview

Problem

Traditional chocolate moulding lines are inflexible, requiring predetermined process steps and significant space for complex cooling tunnels, which are costly and difficult to maintain.

Innovation Solution

A modular, flexible production line where each process step is performed by a self-contained, movable module, replacing mechanical mould transport with robotic handling and using stationary cooling at higher temperatures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional fixed moulding lines with chain transport systems are used, then continuous mould transport and cooling is achieved, but the line becomes inflexible and requires expensive engineering modifications for future changes

Engineering Contradiction:

Improveline flexibilityVSAvoidfixed circuit design

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The production line is divided into modular, self-contained units that can be independently moved and reconfigured. Each module performs a specific process step and can be easily relocated without affecting the entire system, enabling flexible adaptation to future product changes.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system transitions from a fixed, static line configuration to a dynamic, reconfigurable arrangement where modules can be moved and repositioned as needed, allowing the production line to adapt to changing requirements without expensive engineering modifications.

Inventive Principle:

Principle #15Dynamics

2Temperature

If traditional cooling tunnels are used to continuously transport moulds for 20-30 minutes, then cooling is achieved, but a large, mechanically complex infrastructure is required

Engineering Contradiction:

Improvecooling temperatureVSAvoidcooling tunnel complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The cooling function is extracted from the continuous transport system and implemented as a stationary process. Moulds are cooled in fixed positions using simplified cooling infrastructure, eliminating the need for a large, complex cooling tunnel that must accommodate continuous movement.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The mechanical chain transport system through a complex cooling tunnel is replaced with robotic handling that moves moulds to stationary cooling positions. This substitution eliminates the mechanical complexity of the cooling tunnel while achieving the same cooling effect.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If chain driven rail dependent transportation systems are used, then continuous transport is achieved, but cleaning effort and maintenance costs increase

Engineering Contradiction:

Improvecontinuous transportVSAvoidcleaning effort

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The chain driven rail system is replaced with robotic handling mechanisms. This substitution eliminates the complex mechanical infrastructure that requires extensive cleaning and maintenance, while maintaining continuous transport capability through automated robot operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The transportation function is segmented from the fixed rail system and performed by individual robotic modules. This segmentation eliminates the continuous chain infrastructure that requires cleaning, as each robot operates independently without shared mechanical components.

Inventive Principle:

Principle #1Segmentation

4Extent of automation

If mechanised large complex systems are used, then automation is achieved, but sources of metal filings and grease are introduced

Engineering Contradiction:

Improvemechanised handlingVSAvoidmetal filings and grease

Core Design Contradiction:

Extent of automationVSObject-generated harmful factors

Solution Approach 1:

Large mechanised systems with moving parts that generate metal filings and grease are replaced with robotic handling systems. The robots perform automated handling without the mechanical friction and wear that produce contaminants, thereby eliminating sources of metal filings and grease.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 approach allows for longer cooling times at higher temperatures without complex machinery, reduces maintenance and cleaning efforts, and enhances hygiene and product quality.

Implementation Method 1

a cooling apparatus (1000) that is capable of cooling a confectionery product within a mould (1)

Methodology Applied

Scientific EffectCooling: Cooling

Data Source

PatentUS20250143343A1Modular production line and process for using it

Publication Date: 2025.05.08 BUHLER AG

AI summary

The present invention relates to the field of confectionery production, particularly to the use of a modular, flexible process and the use thereof in combination with the confectionery cooling step of the present invention.