Patent Application
20170049122
The present invention relates to a system for producing chocolate-based articles in solidifying form and a method of using such system.
Production of chocolate-based articles in solidifying form, such as chocolate bars, generally requires the execution of a series of processing steps under predetermined conditions to ensure that the final chocolate-based articles have a desired appearance and texture. It is well known in the art that chocolate contains solid particles dispersed throughout a fat matrix, wherein the term “fat” may include both cocoa butter and milk fat. The state of the chocolate fat can change depending on the environment temperature. For example in room temperature chocolate is in a solid state, while when heated above a certain temperature threshold point it can be melted into a molten or liquid state so that it flows as a fluid. The liquid state of the chocolate is reversible and will return back to a solid state when cooled back below the threshold temperature point.
In view of the above, a typical production method for producing chocolate-based articles in solidifying form may start by completely melting the chocolate fat to a liquid state. Once the chocolate fat has been melted the next step may involve the tempering of the chocolate, wherein small stable crystals are formed through the chocolate fat in the liquid state. The chocolate tempering step, although not always necessary, ensures that the chocolate solidifies with a desired shiny and smooth surface. After melting and tempering, the liquid chocolate may then be deposited into mould trays, which are typically cooled in a temperature and humidity-controlled environment, such as a cooling chamber. The cooling process may typically take anywhere between 10 minutes to 40 minutes depending on the type of chocolate-based articles produced. The cooling process may require that the mould trays are transported through a number of cooling zones to prevent sudden changes in temperature and humidity. It is known in the art that such changes may cause the destabilization of the chocolate butter crystals formed during the tempering process and may result in the chocolate-based article having an undesired appearance and texture.
Typically the mould trays are transported through the cooling chamber by means of a conveyor system, which transports the mould trays along the different cooling zones in the cooling chamber before they are collected at an exit point. During transportation of the mould trays along the different cooling zones, the liquid chocolate in the mould trays preferably cools uniformly throughout.
However, the uniform cooling of the liquid chocolate in the mould trays poses some difficulties since it requires that the exposed upper part of the liquid chocolate in the mould trays solidifies at the same rate as the lower part of the liquid chocolate in the mould trays. In the simplest form, a mould tray may comprise at least one cavity for receiving the liquid chocolate mass and a flat bottom side, which flat bottom side during transportation rests on the top load carrying side of the conveyor belt In the case where a flat type conveyor belt is used, the bottom side of the mould tray would not receive sufficient cooling air from the cooling chamber. As a result the bottom part of the liquid chocolate mass would cool at a different rate, for example slower, than the exposed liquid chocolate mass.
To overcome the above-mentioned problem, prior art embodiments use a chain conveyor that employs suspended chains to which the mould trays are hung so that the cooling air can circulate on the bottom side of the mould trays. However, such chain conveyor configuration has the disadvantage that it does not provide a stable flat surface for positioning the mould trays. As a result, during transportation the mould trays may be displaced or subjected to a continuous vibration which may dislocate the liquid chocolate mass in the mould trays and alter the appearance and texture of the final chocolate-based articles leading to a production yield loss. Moreover, it has been found that the suspended chains elongate under their own weight and the weight of the mould trays having an effect on the way the mould trays hang on them, possibly even jamming the chains and hindering the movement of the chains and the mould trays.
It is an aim of the present invention to provide a system for producing chocolate-based articles in solidifying form that allows the liquid chocolate mass in the mould tray to cool under conditions with improved control while maintaining smooth transportation of the mould trays through the cooling chamber.
This aim is achieved according to the invention with the system for producing chocolate-based articles in solidifying form showing the technical characteristics of the characterising part of the first claim.
More in particular according to a first aspect of the present invention a system for producing chocolate-based articles is provided. The system may comprise a transportation system having at least a first conveyor belt. The system of the present invention may further comprise a loading section positioned at an entry point of the transportation system, which may be provided for loading mould trays filled with chocolate mass in liquid form onto a top load carrying side of the at least first conveyor belt. The at least first conveyor belt may be arranged to transport the mould trays through a cooling chamber along a first cooling path, which cooling chamber may be arranged for circulating cooling air for solidifying the liquid chocolate mass under predetermined conditions before the mould trays are collected at a collecting point, which may be positioned at an exit point of the transportation system.
It has been found that providing air circulation means between the top load carrying side of the at least first conveyor belt and a bottom side of the mould trays, allows the cooling air to circulate along the bottom side of the mould trays irrespective of the type of the conveyor system employed in the transportation system. The provision of air circulating means may have as an advantage that the chain conveyor used in the prior art solutions can be replaced with a conveyor belt having a more stable surface for transporting the mould trays while improving control of the cooling conditions such that, for example, the liquid chocolate mass solidifies more uniformly in the mould trays. As a result, the problems related to the use of a chain conveyor of the prior art can be overcome.
According to embodiments of the current invention, the at least first conveyor belt may be a continuous flat type conveyor belt. The at least first conveyor belt may further comprise a plurality of overlapping sheets of material arranged in such a way so that a continuous substantially flat surface is formed for positioning the mould trays. The at least first conveyor belt may be made of a durable material, for example a polymer or metal-based material such as plastic or aluminium. The different sheets of material can provide the belt with specific properties, for example, an inner sheet may be provided for provided strength whereas a surface sheet may be provided to provide specific surface properties with respect to, for example, the mould tray positioned on top of it.
By providing a conveyor belt with a continuous substantially flat surface, the mould trays can be transported through the cooling chamber in a smooth and controlled manner. As a result, the problems related to the use of the chain conveyors used in the prior art solutions can be eliminated or at least minimised. More in particular, eliminating or minimising the external factors that may cause the dislocation of the liquid chocolate mass in the mould trays may contribute to an increase in the production yield since the number of chocolate-based articles not meeting the production specifications would be significantly reduced.
According to embodiments of the present invention, the air circulation means may comprise support members arranged to support the mould trays on the at least first conveyor belt. The support members may be provided in the form of support legs or fins spaced apart from one another and arranged such that when the mould trays are positioned on the top loading carrying side of the at least first conveyor belt the bottom side of the mould trays is elevated with respect to the top loading carrying side of the conveyor belt. The provision of a space between the support members enables the formation of air passageways, which allow the cooling air to circulate along the bottom side of the mould trays irrespectively of the type of conveyor belt used, thereby ensuring that the liquid chocolate mass solidifies uniformly in the mould trays.
According to embodiments of the current invention, the support members may be part of the mould trays arranged to extend outwardly form the bottom side of the mould trays. The support members may be arranged on the bottom side of the mould trays in a variety of patterns. For example the support legs may be arranged along the periphery of the mould trays, such that a larger portion of the bottom side of the mould trays remains exposed to the cooling air. In another example, the support legs may be arranged in a matrix pattern on the bottom side of the mould trays, which may allow the support of heavier mould trays on the top load carrying side of the at least first conveyor belt by spreading the total weight of the mould tray across a larger number of support members.
According to embodiments of the present invention, the support members may be integrally formed with the mould trays in a single piece made of the same material, for example a polymer or metal-based material such as plastic or aluminium. Alternatively, the support members may be provided separately from the mould trays and arranged to be secured on the bottom side of the mould trays by fixing means, such as glue, screws, a bayonet mount, a snap-fit connection, etc. Furthermore, the support members may be made from a different material than the mould trays, for example the mould trays may be made from a metal-alloy such as aluminium while the support member may be polymer-based. The manufacturing of the support members from a different material from the mould trays may be significantly decrease the cost of manufacturing the mould trays with the air passageways.
According to embodiments of the present invention, the support members may be part of the at least first conveyor belt. For example, the support members may be arranged to extend outwardly from the top load carrying side of the at least conveyor belt. By providing the support members on the belt, conveyor belts used in the prior art, for example in totally different applications, can be modified for use in the current invention by replacing the belt with a suitable continuous belt provided with the support members. By enabling the use of existing conveyor belt systems in the current invention the overall cost and the time required for realising the system of the present invention may be significantly reduced.
According to embodiments of the present invention, the support members may be provided in the form of a separate support body arranged to cooperate with the bottom side of the mould trays. The support body may be in the form of a frame arranged to cooperate with the bottom side of the mould trays such that cooling air can circulate along the bottom side of the mould trays when the mould trays are positioned on the top load carrying side of the at least conveyor belt, preferably with the support body arranged in between the mould tray and the conveyor belt.
The use of a support body, separate from the mould trays and the conveyor belt, may have as an advantage that it can be used together with any conveyor belt type, even existing ones, to provide a stable surface for the mould trays, even mould trays which are for example not specifically adapted at being used on a conveyor system but adapted at being used in a stationary position, for example in a fridge, during transportation. Furthermore, in order to increase the stability of the mould trays during transportation, the support body may further be provided with support members, such as support legs or fins, extending outwardly from a support surface of the support body and spaced apart from one another. The support member may be integrally formed with the support body made form the same material. For example, the support body may be made from a polymer or metal-based material such as plastic or aluminium. Alternatively, the support members may be provided as separate elements from the support body and may be arranged to be attached to the support surface of the support body by fixing means, such as glue or screws, a bayonet mount, a snap-fit connection, etc. Furthermore, the support members may be made from a material that is different from that of the support body or has different properties. For example, the support body may be made of hard plastic to provide rigidity and support to the mould trays, while the support members may be made from an elastomeric type of material, such as rubber, to provide vibration dampening.
According to embodiments of the present invention, the system for producing chocolate-based articles may further comprise at least a second conveyor belt. The at least second conveyor belt may be positioned below or above the at least first conveyor belt and arranged for carrying the mould trays through a second cooling path in, preferably through, the cooling chamber. The at least second conveyor belt may be arranged to carry the mould trays along the second cooling path in a transport direction which is opposite to that of the first cooling path. By providing at least a second conveyor belt, the total dimensions, especially along length direction, of the system for producing chocolate-based articles can be significantly reduced since the total transport distance that the mould trays need to travel in the cooling chamber can be split between the at least first and at least second conveyor belts.
The positioning of the at least second conveyor belt at an opposite side with respect to the at least first conveyor belt, above or below, may further allow for the loading section and the collecting section to be positioned at the same side of the system. This may have as an advantage that a single operator, human or robot, may used to operate both the loading and collecting of the mould trays, which would for example reduce the operating cost of such a system.
According to embodiments of the current invention, the system may be designed so that it fits in an intermodal container, for example by using the second conveyor belt for further reducing the dimensions, which would enable for the transportation of the system in a pre-assembled state in another part of the world such that it can be deployed more rapidly for production, for example reducing the need for special engineering support.
According to embodiments of the present invention, the mould trays may be transferred from the at least first conveyor belt to the at least second conveyor belt by means of a lift system. The lift system may be provided in the form of a further conveyor belt arranged to transport mould trays between different levels, for example a vertical reciprocal conveyor belt may be used.
The invention also relates to a method for producing chocolate-based articles in solidifying form using the system according to the first aspect of the present invention is provided. The method may comprise the step of loading mould trays filled with chocolate in liquid form onto a top loading load carrying side of at least a first conveyor belt at an entry point of a transportation system. Once the loading step is completed the mould trays are transported by means of the at least first conveyor belt through a cooling chamber along a first cooling path, the cooling chamber being arranged for circulating cooling air for solidifying the chocolate mass under predetermined conditions. Finally, the mould trays are collected at a collection point positioned at an exit point of the transportation system, where the solidifying chocolate-based articles may be removed from the mould trays. The method further comprises the step of providing air circulation means according to the first aspect of the present invention between the top load carrying side of the at least first conveyor belt and a bottom side of the mould trays such that cooling air can circulate along the bottom side of the mould trays.
The invention will be further elucidated by means of the following description and the appended figures.
The present invention will be described with respect to particular embodiments and with reference to certain drawings but the invention is not limited thereto but only by the claims. The drawings described are only schematic and are non-limiting. In the drawings, the size of some of the elements may be exaggerated and not drawn on scale for illustrative purposes. The dimensions and the relative dimensions do not necessarily correspond to actual reductions to practice of the invention.
Furthermore, the terms first, second, third and the like in the description and in the claims, are used for distinguishing between similar elements and not necessarily for describing a sequential or chronological order. The terms are interchangeable under appropriate circumstances and the embodiments of the invention can operate in other sequences than described or illustrated herein.
Moreover, the terms top, bottom, over, under and the like in the description and the claims are used for descriptive purposes and not necessarily for describing relative positions. The terms so used are interchangeable under appropriate circumstances and the embodiments of the invention described herein can operate in other orientations than described or illustrated herein.
The term “comprising”, used in the claims, should not be interpreted as being restricted to the means listed thereafter; it does not exclude other elements or steps. It needs to be interpreted as specifying the presence of the stated features, integers, steps or components as referred to, but does not preclude the presence or addition of one or more other features, integers, steps or components, or groups thereof. Thus, the scope of the expression “a device comprising means A and B” should not be limited to devices consisting only of components A and B. It means that with respect to the present invention, the only relevant components of the device are A and B.
The term “chocolate-based articles” refers to chocolate products that are stable at ambient temperatures and may take the form of solid pieces of chlorate, such as chocolate bars, or other products incorporating chocolate as a component, for example for coating other food products, such as nuts, fruits and the like.
The term “chocolate-based articles in solidifying form” refers to melted chocolate which has been cooled to produce a solid chocolate wherein at least a portion, preferably a substantial part, of the fat of the chocolate is in solid state.
The cooling chamber 103 is for example provided for circulating cooling air by a ventilation system, for example provided with at least one ventilator in the system 100, the ventilator for example being provided with a cooling unit at the air intake of the at least one ventilator so that air sucked into the ventilator is first cooled by the cooling unit. Although the ventilating system is not shown in the figures, the ventilation system is provided for providing and circulating cooled air through the cooling chamber 103.
According to an embodiment of the present invention, the air circulation means may be provided on the mould trays 102, as shown in
According to embodiments of the present invention, the support members 105 may be integrally formed with mould trays 102 in a single piece made of the same material. For example, the mould trays 102 can be made from a polymer-based material such as plastic, which is less expensive and easier to produce than metal. The mould trays can also be made from a metal-alloy such as aluminium, which although usually more expensive than plastic, would enable for the faster cooling and thus faster solidification of the liquid chocolate mass 811 in the mould trays 102 due to their larger thermal conductivity. Alternatively, the support members 105 may also be provided as separate elements arranged to be attached to the bottom side 108 of the mould trays 102 by fixing means such as glue or screws. Furthermore, the support member 105, may be made from a different material than the mould trays, for example the mould trays may be made from aluminium, while the support members may be made from plastic, and visa versa. Although not explicitly mentioned, It should be noted that any other combination of a materials known to the skilled person in art would also be allowable.
The at least first conveyor belt 101, 501 may comprise overlapping sheets of material arranged in such a way so that a continuous substantially flat surface is provided. The at least first conveyor belt 101, 501 can be made from a durable material which may be polymer or metal-based such as plastic or aluminium. Furthermore, the support members 505 may be made from a material different from that of the conveyor belt 501. For example, the support members 505 may be made form a polymer-based material while the conveyor belt is made of metal-based material.
According to an embodiment of the present invention the support body 609 may comprise a hollow frame 612 attached to a support surface 610. The hollow frame may be dimensioned such that it securely fits on the bottom side of the mould trays 502 while ensuring that a gap remains between the support surface 610 and the bottom side 608 of the mould trays 502 to allow for the circulation of cooling air along the bottom side 608 of the mould trays.
According to a further embodiment of the present invention, the support body 609 may comprise support member 605 extending outwardly from the support surface 610, as shown in
According to an embodiment of the present invention the support members 605 arranged on the support body 609 can be provided separately from the support body 609. For example, the support members may be glued or screwed into the desired positions on the support surface 610 of the support body 609. Furthermore, the support members 605 can be made from a different material to that of the support body 609. For example, the support member 605 can be made from a vibration absorbent material arranged to provide dampening of the vibrations caused during transportation in addition to effectively supporting the mould trays 502 on the top load carrying side 504 of the at least first conveyor belt 501. For example, the support member 605 can be made from a polymer-based elastomeric material having elastic properties such as rubber.
According to embodiments of the present invention, the system 900 for producing chocolate-based articles in solidifying form may further comprise at least a second conveyor belt 901, as shown in
According to embodiments of the present invention, the mould trays 102 may be transported between the different levels defined by the position of the at least first and at least second conveyor belts 101, 901 by means of a lift system 911. The lift system 911 may be positioned inside the cooling chamber 903 and may comprise a platform 918 for supporting the mould trays 102 and an arm lever 914 arranged for moving the platform between the different levels at predetermined time intervals. The lift system 911 may be for example a vertical reciprocal conveyor belt or other types of lift systems known in the art. Furthermore, the system 900 may allow for the loading section 106 and the collecting section to be positioned at the same side of the system 900. This may configuration may contribute in reducing operating cost of the system 900 since only a single operator, human or robot, can be sufficient to operate both the loading and collecting of the mould trays 102.
According to an embodiment of the present invention, the system 900 may further comprise at least a third conveyor belt 921, as shown in
According to an embodiment of the present invention a method is providing for producing the chocolate-based articles using the system according to embodiments of the present invention. The method may comprise the step of loading mould trays 102, 502 at a loading section 106 filled with chocolate mass 811 in liquid form onto a top load 104, 504, 604 carrying side of at least a first conveyor belt 101, 501 at an entry point of a transportation system. Once loaded, the mould trays 102, 502 are then transported by means of the at least first conveyor belt 101, 501 through a cooling chamber 103, 903 along a first cooling path, the cooling chamber 103, 903 being arranged for circulating cooling air for solidifying the chocolate mass 811 under predetermined conditions. After the chocolate-based articles are solidified the mould trays 102, 502 are collected at a collecting section 107, which is positioned an exit point of the transportation system. The method further comprises the step of providing prior or together with the loading step air circulation means 105, 505, 605 arranged between the top load carrying side 104, 504, 604 of the at least first conveyor belt 101, 501 and a bottom side 108 of the mould trays such that cooling air can circulate along the bottom side 108 of the mould trays 102, 502.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2014/053359 | 2/20/2014 | WO | 00 |
