Ultrasonic In-Line Measurement for Chocolate Demolding Optimization
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Solution Overview
Problem
The chocolate industry lacks an effective in-line method to measure the solidification and mold wall detachment behavior of confectionery/chocolate products, leading to lengthy setup times, product rejects, and inconsistent quality due to empirical determination of demolding times, which are influenced by various parameters.
Innovation Solution
An in-line measuring device using ultrasonic sensors with a transmitter and receiver pair attached to the mold wall, measuring amplitude damping and phase shift to determine the optimal demolding time, ensuring a homogeneous and shiny product surface by monitoring the solidification and detachment processes in real-time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If empirical trial and error method is used to determine demolding time, then setup time is lengthy and product rejects increase, but no in-line measurement capability is available
Solution Approach 1:
The patent replaces mechanical/empirical trial-and-error methods with ultrasonic measurement technology. Ultrasonic sensors detect the detachment of chocolate from mold walls by measuring acoustic impedance changes, providing precise real-time demolding time data without manual intervention or lengthy setup periods.
Solution Approach 2:
The measurement system uses the chocolate product itself as the measurement object, detecting its own detachment behavior from the mold walls through ultrasonic wave transmission. The product's physical state changes during cooling and solidification are directly measured, eliminating the need for external calibration or reference standards.
2Measurement precision
If pressure sensors are used to detect detachment, then detachment time at specific locations is determined, but sensor material differs from mold material affecting representativeness
Solution Approach 1:
The patent introduces ultrasonic waves as an intermediary measurement medium that transmits through the mold walls and chocolate product. This allows detection of detachment at multiple locations simultaneously without direct sensor contact with the chocolate, ensuring the measurement reflects actual mold-chocolate interface behavior rather than sensor-material specific effects.
Solution Approach 2:
The measurement system extracts the detection function from physical contact sensors and implements it through ultrasonic wave transmission. The ultrasonic sensors are mounted on the mold walls rather than embedded in the chocolate, separating the measurement mechanism from the product while maintaining accurate detachment detection through acoustic impedance changes at the interface.
3Adaptability or versatility
If ultrasonic Doppler and pressure measurement are coupled, then in-line measurement of rheological properties is enabled, but device complexity increases
Solution Approach 1:
The patent extracts and applies only the essential ultrasonic transmission and reception components needed for detachment detection. While acknowledging the versatility of coupled ultrasonic Doppler and pressure measurement systems, this implementation focuses on the core ultrasonic amplitude and time-of-flight measurement capabilities required for demolding time determination, simplifying the overall system architecture.
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 solution allows for precise optimization of the cooling process, reducing defective production, improving product quality consistency, extending mold service life, and reducing costs by determining the exact demolding time and adjusting cooling parameters, resulting in a significant reduction in adhesion and surface defects.
Implementation Method 1
ultrasonic sensors (transmitter and receiver)
Implementation Method 2
The transmitted ultrasonic waves propagate in the casting mold material and the mass that may have been poured in
Implementation Method 3
which are detected by the receiver (2) and from which the amplitude damping and the phase shift are determined
Implementation Method 4
the ultrasonic reflection behavior on materials with different densities or different sound speeds is used to detect material defects
Implementation Method 5
The onset of solidification crystallization of the fat component, which usually forms the continuous, initially fluid suspension phase, results in a volume contraction
Implementation Method 6
results in a volume contraction, the extent of which depends on the fat content (i), fat type/fat mixture (ii) and the type and degree of any pre-crystallization (iii)
Data Source
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AI summary
The invention relates to a method and an apparatus for detecting the solidification behaviour of pourable and setting masses or masses to be solidified, in particular chocolates, and the release behaviour thereof from boundary walls which touch these masses, in particular moulds. Solutions are provided with regard to how the mould removal time and the product surface quality can be optimized taking into account the process variables such as cooling temperature, cooling rate and belt speed.