Multiple Rope Extrusion System for Center-Filled Confectionery
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Solution Overview
Problem
Large-scale production of center-filled confectioneries faces challenges in controlling and coordinating the flow rate of center-fill material and extrudate formation, leading to improperly sealed products, material waste, and equipment downtime, with single rope extrusion systems being limited in output.
Innovation Solution
A multiple rope extrusion system with a forming device comprising rotating drums and cooperative forming members that crimp and cut extrudate to form sealed center-filled confectionery pieces, allowing for precise control of process parameters and increased output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If single rope extrusion systems are used, then device complexity is reduced, but productivity is limited
Solution Approach 1:
The patent divides the extrusion process into multiple independent rope extrusions that are processed simultaneously. The forming device is segmented into multiple forming members arranged in arrays, with each forming member processing a separate rope. This segmentation allows the system to maintain the simplicity of individual single-rope extrusion units while achieving high productivity through parallel processing of multiple ropes.
2Manufacturing precision
If flow rate control of center-fill material and extrudate is not adequately coordinated, then manufacturing precision deteriorates, but process control complexity increases
Solution Approach 1:
The patent combines the extrusion of multiple ropes and the filling of center-fill material into a single integrated forming device. The forming members simultaneously compress the extrudate and receive center-fill material deposition, ensuring coordinated flow rates without requiring complex external control systems. This merging of functions maintains manufacturing precision while avoiding excessive control system complexity.
3Loss of substance
If improper sealing occurs during piece formation, then loss of substance increases due to leakage, but manufacturing precision deteriorates
Solution Approach 1:
The forming members are designed to pre-compress and seal the extrudate before center-fill material is deposited. This preliminary sealing action prevents leakage during the filling process, reducing material waste while ensuring proper sealing quality. The forming members create a sealed cavity that contains the fill material, preventing it from leaking onto other products or equipment.
Data Source
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AI summary
The present disclosure provides an apparatus and method for the continuous production of center-filled confectionery products. The apparatus may include an extruder for forming a continuous extrudate having a plurality of center-filled confectionery ropes. The apparatus may also include a forming device for forming individual confectionery pieces, and sealed center-filled confectionery pieces in particular. The forming device provides improved coordination and control of extrudate formation and extrudate feed into the forming device. The apparatus and method of the present disclosure increases product output and reduces the amount of unacceptable product.