U.S. patent application number 09/774696 was filed with the patent office on 2001-11-15 for apparatus for continuously molding chocolate products.
Invention is credited to Camporini, Alfred V., Collins, Thomas M., Martin, John M., Suttle, James M., Willcocks, Neil A..
Application Number | 20010041205 09/774696 |
Document ID | / |
Family ID | 24278905 |
Filed Date | 2001-11-15 |
United States Patent
Application |
20010041205 |
Kind Code |
A1 |
Suttle, James M. ; et
al. |
November 15, 2001 |
Apparatus for continuously molding chocolate products
Abstract
Methods for continuously molding finished chocolate tablets,
pieces and the like are disclosed. Apparatus for use with the
method, comprise a chilled rotating mold having at least one recess
into which liquid chocolate is deposited. Liquid chocolate, is held
in place by a retaining/casting belt as the rotating mold turns.
The liquid chocolate cools and partially sets while in contact with
the rotating mold and retaining/casting belt, and a molded
chocolate is removed from the recess. Novel finished chocolate
molded products made by the methods and with the apparatus, having
detailed surface design and surface gloss are also disclosed.
Inventors: |
Suttle, James M.; (East
Stroudsburg, PA) ; Martin, John M.; (Glendale,
CA) ; Willcocks, Neil A.; (Flanders, NJ) ;
Camporini, Alfred V.; (Hackettstown, NJ) ; Collins,
Thomas M.; (Nazareth, PA) |
Correspondence
Address: |
FITZPATRICK CELLA HARPER & SCINTO
30 ROCKEFELLER PLAZA
NEW YORK
NY
10112
US
|
Family ID: |
24278905 |
Appl. No.: |
09/774696 |
Filed: |
February 1, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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09774696 |
Feb 1, 2001 |
|
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09570260 |
May 12, 2000 |
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Current U.S.
Class: |
426/512 ;
426/631; 426/660 |
Current CPC
Class: |
A23G 1/205 20130101;
A23G 7/02 20130101 |
Class at
Publication: |
426/512 ;
426/631; 426/660 |
International
Class: |
A23P 001/00 |
Claims
We claim:
1. A method for continuously molding finished chocolate pieces
comprising: (a) feeding liquid chocolate into a recess in a surface
of a cooled rotating mold having an interior cavity; (b) providing
a coolant having a temperature less than about 10.degree. C. to
said interior cavity to lower the temperature of said recess; (c)
containing the liquid chocolate in said recess with a continuous
retaining/casting belt that maintains the liquid chocolate in the
recess until the liquid chocolate sets or solidifies to become at
least partially solidified molded chocolate; and (d) removing said
molded chocolate from said recess onto said retaining/casting
belt.
2. The method according to claim 1, wherein a ratio of surface area
of said chocolate in contact with said cooled rotating mold to
surface area of said chocolate in contact with said
retaining/casting belt is less than about 4.5:1.
3. The method according to claim 1, wherein a sidewall of said
recess makes an angle of greater than about 7 degrees with respect
to a line perpendicular to a radial surface of said rotating
mold.
4. The method according to claim 1, wherein said liquid chocolate
is fed into said recess at a temperature between about 27.degree.
C. and about 32.degree. C.
5. The method according to claim 1, wherein said molded chocolate
is removed from said recess at an average temperature less than
about 25.degree. C.
6. The method according to claim 5, wherein said molded chocolate
is removed from said recess at an average temperature between about
15.degree. C. and about 20.degree. C.
7. The method according to claim 1, wherein said coolant provided
to said rotating mold has a temperature between about -5.degree. C.
and about 0.degree. C.
8. The method according to claim 1, wherein said coolant provided
to said rotating mold delivers a surface temperature of said recess
just before said feeding of liquid chocolate substantially
equivalent to the temperature of said coolant.
9. The method according to claim 1, wherein said step of providing
coolant to said rotating mold comprises flowing a coolant through
the cavity in said rotating mold.
10. The method according to claim 9, wherein said coolant comprises
propylene glycol.
11. The method according to claim 1, wherein said recess is between
about {fraction (1/32)} inch (0.08 cm) and about 1 inch (2.54 cm)
deep.
12. The method according to claim 5, wherein the molded chocolate
is removed from the rotary mold when the chocolate in a surface
portion of said molded chocolate is solidified while the chocolate
in an interior portion of said molded chocolate is partially
solidified.
13. The method according to claim 5, wherein said liquid chocolate
resides in said recess for between about 30 and about 45
seconds.
14. The method according to claim 1, wherein said recess is a
continuous groove, and molded chocolate is removed from said
continuous groove in the form of a continuous molded strip.
15. The method according to claim 14, further comprising the step
of cutting said continuous molded strip into discrete pieces.
16. The method of claim 1, further comprising co-depositing a
second food material into said recess at the same time that said
liquid chocolate is in said recess.
17. The method of claim 16, wherein said second food material is
chocolate.
18. The method of claim 1, wherein said recess is heated to provide
a transient temperature increase of between 5.degree. C. and
20.degree. C. in said recess prior to said step of feeding said
liquid chocolate into said recess.
19. The method of claim 1, further comprising subjecting said
molded chocolate to thermal conditioning after said step of
removing said molded chocolate from said recess.
20. The method of claim 1, wherein said step maintaining said
retaining/casting belt in contact with said molded chocolate in
said recess comprises a system of cams in contact with said
retaining/casting belt after said molded chocolate has passed a 6
o'clock position of the rotary mold, thereby increasing a force
available to remove said molded chocolate from said recess.
21. A continuously molded chocolate product produced by the method
of claim 1.
22. A continuously molded chocolate product produced by the method
of claim 1, having a shape of a continuous and precise web, between
about {fraction (1/32)} inch (0.08 cm) and 1/4 inch (0.635 cm)
thick.
23. A continuously molded chocolate product produced by the method
of claim 1, having a glossy surface.
24. A continuously molded chocolate product produced by the method
of claim 1, having a surface design imparted by a design on a
surface of the recess in the rotary mold.
25. An apparatus for continuously molding chocolate products
comprising: a hollow substantially cylindrical rotary mold having
an interior cavity and having at least one recess on a radial
surface portion of said rotary mold, said recess having an opening
and a surface area; a motor to impart rotational motion to said
substantially cylindrical rotary mold; conduits leading to and from
said interior cavity for connecting said interior cavity with a
coolant source; a feeder for depositing liquid chocolate to said
recess; a retaining/casting belt positioned to maintain said liquid
chocolate within said recess and adapted for continuous motion in
unison with said rotational motion of said rotary mold; wherein
said opening has an area and the ratio of the surface area of the
recess to the area of the opening is less than about 3:1, and
wherein a sidewall of said recess makes an angle of greater than
about 7 degrees with respect to a line perpendicular to said radial
surface of said rotary mold.
26. The apparatus of claim 25, further comprising a second cavity
proximate said retaining/casting belt, and conduits leading to and
from said second cavity to continuously circulate coolant to and
from said cavity capable of reducing the temperature of said
retaining/casting belt.
27. The apparatus of claim 25, wherein said rotary mold has a
metallic surface.
28. The apparatus of claim 25, wherein said at least one recess is
a single continuous groove.
29. The apparatus of claim 25, further comprising a system of cams
adapted to maintain said retaining/casting belt in contact with
said chocolate within said recess after said chocolate in contact
with said retaining/casting belt passes a 6 o'clock position of
said rotary mold.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to the molding of chocolate.
Specifically, the disclosed method and apparatus are directed to
the continuous molding of chocolate tablets, pieces and the like on
a rotary mold.
[0003] 2. Discussion of the Related Art
[0004] Finished chocolates having a desired three-dimensional shape
or having an image or design imprinted on a surface are
conventionally produced by molding, and are herein referred to as
"molded chocolate." The finished chocolate may be a solid block, a
hollow shell, or a shell filled with a confectionery material such
as fondant, fudge or soft caramel (Chocolate, Cocoa and
Confectionery: Science and Technology by Bernard W. Minifie, Third
Edition, page 183, herein incorporated by reference in its
entirety). Whatever the particular form of the finished chocolate,
all are characterized by attributes such as detailed finishes and
high surface gloss. Further, these finished chocolates do not
require further processing such as enrobing with chocolate, which
only provides a home-made look to a product and lacks high gloss
and fine surface detail.
[0005] Conventional molding typically employs very large numbers of
molds, usually made of polycarbonate. These polycarbonate molds are
typically flat, approximately 1 inch in height and anywhere from 1
to 2 feet long and 1 to 5 feet in width.
[0006] The equipment employed to manipulate and process these molds
is very large and among the most complex and expensive of all
confectionery production equipment. Mold changeover and mold
tooling are also expensive and often make it costly to produce a
large variety of shaped chocolate products.
[0007] In the typical conventional molding process a chocolate
mixture is initially melted at temperatures of about 45.degree. C.
and tempered by cooling with agitation to about 29.degree. C. to
30.degree. C. to produce a tempered chocolate. The tempering of the
chocolate causes a very small percentage of the fat to form seed
crystals which results in a dispersion of these seed crystals
throughout the liquid fat phase of the liquid chocolate. The liquid
tempered chocolate is then deposited into a polycarbonate mold. The
mold is shaken to remove air bubbles and to distribute the
chocolate in the mold cavity. These steps are critical to
reproducing the detail of the mold surface and to obtaining a
glossy finished product surface. Indeed, if the chocolate viscosity
is too high or has become significantly partially solidified, the
resultant finished chocolate product appearance will be poor.
Defects such as air bubbles on the surface, poor gloss and poor or
incomplete surface detail are encountered. Thus, to properly mold
finished chocolates, it is essential that the final chocolate
structure is only developed after filling the molds (i.e., the
chocolate must still be liquid when the chocolate is deposited into
the molds.)
[0008] The mold and chocolate are then cooled and the chocolate
hardened, and finally, the set, shaped chocolate is removed from
the mold. Removing the chocolate from the mold usually involves
turning the molds upside down and deforming them slightly, or
striking the mold so that the molded chocolate falls out under its
own weight.
[0009] These methods place limitations on the size, shape and
finish of the final product, and on production efficiency.
Conventional chocolate molding processes are among the slowest
confectionery production processes for the amount of equipment and
space involved. A good production rate would be about 15-20 molds
per minute, very good about 20-25 molds per minute and excellent
about 25-30 molds per minute. To achieve these high levels of
production requires great attention to the process.
[0010] Another significant limitation to the molding of finished
chocolate products is related to the size of the products. It has
long been known in the art that small molded chocolate pieces, on
the order of 0.5 grams and smaller, cannot be reliably demolded and
this has had the practical effect of limiting confectioners to
relatively larger pieces. This problem results from the ratio of
surface area in contact with the mold to the mass of the piece
being too high in these small pieces. Demolding processes
essentially rely on gravity to help remove the pieces from the
molds. This is true even in cases where molds are tapped or
hammered and in cases where flexible molds might be employed. The
smaller mass of a small chocolate piece means less gravitational
force to overcome the attractive forces holding the piece into the
mold. Thus, a process which provided for continuously molding very
small finished chocolate pieces or the like would be a highly
desirable advancement in the art.
[0011] Processes for continuously molding food products have been
disclosed in the prior art, but these processes do not provide for
the production of finished molded chocolate.
[0012] U.S. Pat. No. 4,059,378, for example, discloses a method of
continuously molding chocolate centers, hot sugar masses, fudge,
whipped or unwhipped chewing or nougat mass, candy cream and the
like which avoids the need for an extruder. These "center"
materials are not subject to the same functional requirements as
molded chocolate. There is no disclosure of feeding liquid
chocolate to the recesses on the mold, and as a practical matter
the invention is limited to center manufacture.
[0013] The methods and apparatus described in U.S. Pat. No.
4,059,378 do not provide a means to continuously set and mold
chocolate tablets, pieces, or the like because the process will not
provide an appropriate finish or texture of a finished molded
chocolate piece.
[0014] Significant functional requirements are demanded of molded
chocolate that are not required of centers. The surface of molded
chocolate must typically have detailed surface design and glossy
finish. The formation of a suitably solidified design with an
appropriately glossy finish cannot be performed in a shaping
apparatus such as described in U.S. Pat. No. 4,059,378. The
apparatus and method of U.S. Pat. No. 4,059,378 are specifically
directed towards the molding of confectionery masses, such as the
centers or nougat masses and the like specifically noted in the
patent. The apparatus and method utilize essentially set
confectionery masses, which are then formed by means of an "intake
cylinder being operable to press the mass into the molding recesses
of the molding cylinder." Clearly the masses are substantially set
or solidified, and the patent emphasizes the need for a "gentle
molding process which does not impair the original structure of the
mass."
[0015] By clear contrast, molding processes for finished molded
chocolate pieces require the use of liquid chocolate which flows
readily into mold cavities and does not have structure. It is the
ability of liquid chocolate to flow into mold cavities which
ensures good surface detail, good gloss and proper final product
texture (i.e., good "snap.")
[0016] Published U.K. Pat. Application GB 2,337,387 A describes a
method and apparatus for molding food articles. In this method,
chocolate halves simultaneously formed in two discrete rollers are
pressed together and united in the "nip" between the two rollers.
This invention is a further refinement of the long-known technique
of roll-forming centers which typically are further processed by
panning to apply chocolate coatings or hard sugar shell coatings.
The product of these mold-forming techniques does not provide the
high quality attributes of finished molded chocolate pieces. In
fact, the product of GB 2,337,387 is a sheet of chocolate articles
connected by a continuous web of chocolate which must be removed in
an abrasive process known as deflashing. The deflashing process
abrades the surface finish of the chocolate articles leaving a
rough unfinished appearance. The result is a complex feeding and
removal mechanism of uncertain utility.
[0017] Other processes describe molding of finished chocolates but
do not employ rotary techniques. For example, published
International Application WO98/30111, the entire disclosure of
which is incorporated herein by reference, describes methods for
shaping chocolate products which involve contacting a chocolate
composition with a chilled forming device. This application does
not describe continuous molding on a rotary mold.
SUMMARY OF THE INVENTION
[0018] The inventors herein have discovered a method for
continuously molding finished chocolate pieces which comprises:
[0019] (a) feeding liquid chocolate into a recess in the surface of
a cooled rotating mold having an interior cavity;
[0020] (b) providing a coolant having a temperature less than about
10.degree. C. to said interior cavity to lower the temperature of
said recess;
[0021] (c) containing the liquid chocolate in the recess with a
retaining/casting belt that maintains the liquid chocolate in the
recess until the liquid chocolate sets to become at least partially
solidified molded chocolate; and
[0022] (d) removing the molded chocolate from the recess.
[0023] The ratio of surface area of the chocolate in contact with
the cooled rotating mold to the surface area of chocolate in
contact with the retaining/casting belt is generally less than
about 4.5:1. Preferably, this ratio is less than about 3.5:1, more
preferably less than about 3:1 and most preferably less than about
2:1.
[0024] In one aspect, the method of the present invention comprises
allowing the liquid chocolate to contact a cooled recess in a
rotating mold for a period of time such that the surface of the
chocolate sets sufficiently, and the piece can be efficiently
removed from the rotating mold, while an interior portion of the
chocolate piece remains more fluid until after the chocolate piece
is removed from the rotary mold. In another aspect, the method of
the present invention provides the means for producing small
finished molded chocolate pieces in a reliable and efficient
manner. The setting of the chocolate while in contact with the
retaining/casting belt creates a strong attractive force between
the chocolate piece and the belt. As the retaining/casting belt
separates from the rotary mold, this force effectively demolds the
small piece.
[0025] An apparatus for continuously molding chocolate products
according to the invention comprises: a substantially cylindrical
rotary mold having an interior cavity and having at least one
recess on an exterior radial surface portion of the rotary mold.
The rotary mold rotates as coolant is provided to its interior
cavity maintaining the temperature on a surface of the recess to a
temperature approaching the temperature of the coolant, less than
about 10.degree. C. As the mold rotates, a feeder deposits liquid
chocolate into said recess; and a retaining/casting belt positioned
to maintain the liquid chocolate deposited in said recess moves in
unison with the rotational motion of the rotary mold. The opening
of the recess has an area, and the ratio of surface area of the
chocolate in contact with the cooled rotating mold to the surface
area of the chocolate in contact with the retaining/casting belt is
less than about 4.5:1, preferably less than 3.5:1, more preferably
less than 3:1 and most preferably less than 2:1. It is expected
that the higher ratios would require increasing the cooling time on
the rotary mold, or using lower cooling temperatures. To permit
removal of the molded chocolate from the recess, a sidewall of said
recess makes an angle of greater than about 7 degrees with respect
to a line perpendicular to the radial surface of the rotary mold.
Additionally, as the liquid chocolate solidifies in contact with
the retaining/casting belt, it is essentially cast into the surface
contours of the belt, providing a transient bonding of the
chocolate to the belt, allowing easy demolding.
BRIEF DESCRIPTION OF THE FIGURES
[0026] FIG. 1 depicts an apparatus according to an embodiment of
the invention.
[0027] FIG. 2 depicts a system of cams in cooperation with the
rotary mold and retaining/casting belt according to an embodiment
of the invention.
[0028] FIG. 3 depicts a system of cams in cooperation with the
rotary mold and retaining/casting belt according to an embodiment
of the invention in a state wherein a molded chocolate piece has
been removed from the wheel.
[0029] FIG. 4 depicts a shoe used to feed liquid chocolate into a
recess according to an embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] The term "chocolate" is intended to refer to all chocolate
or chocolate-like compositions with a fat phase or fat-like
composition. As the invention is directed in certain aspects to the
control of the characteristics of the fat or fat-like phase of the
chocolate, rather than the non-fat materials within the chocolate,
the term is intended to include all chocolate and chocolate-like
compositions. The term is intended, for example, to include
standardized and non-standardized chocolates, i.e., including
chocolates with compositions conforming to the U.S. Standards Of
Identity (SOI) and compositions not conforming to the U.S.
Standards Of Identity, respectively, including dark chocolate,
baking chocolate, milk chocolate, sweet chocolate, semi-sweet
chocolate, buttermilk chocolate, skim-milk chocolate, mixed dairy
product chocolate, low fat chocolate, white chocolate, aerated
chocolates, compound coatings, non-standardized chocolates and
chocolate-like compositions, unless specifically identified
otherwise.
[0031] In the United States, chocolate is subject to a standard of
identity established by the U.S. Food and Drug Administration (FDA)
under the Federal Food, Drug and Cosmetic Act. Definitions and
standards for the various types of chocolate are well established
in the U.S. Nonstandardized chocolates are those chocolates which
have compositions which fall outside the specified ranges of the
standardized chocolates.
[0032] Chocolates also include those containing crumb solids or
solids fully or partially made by a crumb process.
[0033] Nonstandardized chocolates result when, for example, the
nutritive carbohydrate sweetener is replaced partially or
completely; or when the cocoa butter or milkfat are replaced
partially or completely; or when components that have flavors that
imitate milk, butter or chocolate are added or other additions or
deletions in formula are made outside the FDA standards of identify
of chocolate or combinations thereof.
[0034] For use with the apparatus disclosed herein, the only
requirement of the chocolate is that it be liquid and (if the
chocolate is a tempering system) tempered as it is fed to the
rotary mold.
[0035] As shown in FIG. 1, the liquid tempered chocolate is pumped
from chocolate feed 1 into recess 3 on rotating hollow mold 5 at
the top of the rotating hollow mold 5. The mold is, generally
speaking, cylindrical. The "top" of rotary mold 5 means the top
half of the rotary mold 5. Preferably, the feed will be located at
a position between 10 o'clock and 2 o'clock with respect to the
rotary mold. Most preferably, chocolate will be fed into the recess
directly above the mold, i.e. at the 12 o'clock position, as shown
in FIG. 1. A second feeder can be provided to co-deposit materials
in the recess with the liquid chocolate.
[0036] The recess may be one continuous groove, as shown in FIG. 1,
in which case the resulting molded chocolate would be removed from
the rotary mold in one continuous strip, or discrete recesses can
be provided, resulting in discrete molded chocolate pieces.
[0037] The surface of the recess 3 is cooled, for example with a
coolant provided in the interior of rotating mold 5. In preferred
embodiments, the coolant is propylene glycol, although a commercial
coolant such as Syltherm.RTM., available from Dow Chemical, or even
a brine solution could also be used. Preferably, coolant
continuously circulates through the system. Additionally, coolant
may be provided in an area proximate the retaining/casting belt,
for example in a cavity underneath the retaining/casting belt as
further described below. If cooling through the retaining/casting
belt is desirable, the belting material can be chosen from among
materials having higher thermal conductivity.
[0038] The surface of the recess 3 and the rotating mold 5 are both
preferably made of metal to enable better heat transfer from the
liquid chocolate to the coolant. For example, mold 5 may be of
polished aluminum, nickel-plated steel, chromium-plated copper,
silver plated copper, or other material. The specific material is
not particularly limited, provided that the surface of the recess
can be maintained reliably at the desired temperature that is, at a
temperature approaching that of the coolant. Working embodiments
have used an 8 inch diameter aluminum wheel polished to an 8 micron
finish, however, the size can vary depending upon the size of
product and the rate of production required.
[0039] The surface of the recess is generally smooth, although
portions of the surface may be etched or machined to make a design
which will be impressed or raised on the finished chocolate
product. In a preferred embodiment the recess is a continuous
groove, which may have a design, and the chocolate product that is
removed from the belt is a continuous strip, which may then be cut
into discrete pieces by a guillotine cutter 9.
[0040] Liquid chocolate is fed into recess 3 at a temperature
between about 27.degree. C. and about 32.degree. C., most
preferably at about 30.degree. C. At this temperature, tempered
chocolate will have the required fluidity for chocolate
molding.
[0041] In preferred embodiments, as shown in FIG. 3, a "shoe" is
provided between the feeder and the rotary mold to facilitate the
feeding of liquid chocolate to the recess. The shoe comprises a
body 15, typically made of a metal, such as aluminum. The body is
attached to contact surface 13, which may be made of a low friction
material, for example, Teflon.RTM. (polytetrafluoroethylene). The
contact surface is in contact with the rotary mold in a sealing
relationship. In FIG. 4, the contact surface is shown separated
from the rotary mold to allow a clearer view. Liquid chocolate is
fed through sanitary fitting 17 into the recess. The use of a shoe
in this manner avoids the necessity of having to meter precise
amounts of liquid chocolate into the recesses as the rotary mold
rotates.
[0042] The chocolate cools and partially solidifies in contact with
the rotating mold. The temperature of the surface of the rotary
mold is maintained by providing a coolant to an interior cavity of
said rotary mold having a temperature between about -40.degree. C.
and about +10.degree. C., and preferably between about -20.degree.
C. and about +5.degree. C., and most preferably between about
-5.degree. C. and about 0.degree. C. Preferably, the surface of the
molded chocolate solidifies allowing the chocolate to achieve
sufficient integrity for removal from the rotary mold, while the
interior of the molded chocolate may remain more fluid.
[0043] To obtain the glossy surface that is typically demanded of a
finished molded chocolate piece, the chocolate must be liquid when
it is poured into the mold to obtain the required smooth
surface.
[0044] In some embodiments it is be desirable to perform transient
heating of the recess 3 just prior to depositing liquid chocolate
into the recess. Heating, such as with a stream of hot air, an
infra-red heater, or other means known to those of skill in the
art, is sufficient to raise the surface temperature of the recess
temporarily to about 5.degree. C., 10.degree. C., 15.degree. C. or
20.degree. C., as desired. Warming the recess in this manner can
improve surface gloss of the molded chocolate. In another
embodiment of the invention, where non-tempering chocolate is being
molded the non-tempering chocolate can be introduced at a higher
temperature to improve the gloss of the finished molded chocolate.
This also helps to maintain chocolate fluidity during the molding
process.
[0045] The time allowed for the chocolate to cool and solidify to a
point where it can be removed from the rotary mold is determined by
the size of the mold, the speed at which it turns, the volume of
chocolate in the recess, the surface temperature of the recess, and
the rate of heat transfer from the chocolate as it cools and
solidifies. Generally, between about 20 and about 60 seconds is
necessary to partially set the chocolate, preferably between about
25 and about 50 seconds, most preferably between about 30 and about
45 seconds.
[0046] Thus, the size of mold 5 is itself not particularly
critical, provided that the chocolate has sufficient time to become
sufficiently solidified. The size of the wheel and its speed of
rotation may be adjusted to provide a partially set chocolate to be
removed from the rotary mold.
[0047] As the mold rotates, the recess is partly covered with a
retaining/casting belt 7 that tracks and runs in unison with the
rotating mold 5. While the mold preferably rotates continuously in
unison with the retaining/casting belt, the mold and belt may also
rotate in a uniform interrupted manner with liquid chocolate only
being fed to the mold during the rotational period. The
retaining/casting belt acts as a containment device to retain the
liquid chocolate in the recess of the mold while it sets and casts
to the belt. The belt may be made of, for example, plastic,
fiber-plastic composite or metal. The retaining/casting belt may be
cooled by providing a continuously circulating coolant to cavity 11
below the retaining/casting belt at a portion of the belt
positioned downstream of the rotary mold. The retaining/casting
belt may also be machined or etched to provide a design on the
surface of the finished chocolate bar or piece facing the
retaining/casting belt.
[0048] Finished molded chocolate is removed from the recess 3 onto
the belt 7. The condition of the chocolate as it is removed is
important. If the chocolate has not sufficiently set, then the bar
or piece will not retain its integrity. Preferably, the chocolate
removed from the recess 3 has an average temperature of less than
about 25.degree. C., more preferably less than about 22.degree. C.
and most preferably between about 15.degree. C. and about
20.degree. C. The temper of the chocolate as well as its fat
content will determine the temperature at which the chocolate
obtains a sufficiently integral state permitting removal from the
rotary mold. In some embodiments, the retaining/casting belt is
maintained in a pressing relationship with the partially set
chocolate in the recess after the recess advances past the 6
o'clock position. The adhesion of the belt to the chocolate in the
recess as the belt pulls away from the rotary mold creates a
perpendicular force on the partially set chocolate facilitating its
removal from the recess. Any suitable means may be provided to
maintain the retaining/casting belt in contact with the rotary mold
in this fashion. A cam 19 situated under the retaining/casting belt
in the vicinity of the rotary mold, for example, may periodically
force the belt against the wheel and then release, while another
cam 21 takes up slack in the retaining/casting belt created by this
movement, as shown in FIGS. 2 and 3. A system of cams operating
with the belt in this manner keeps the belt in contact with the
chocolate past the 6 o'clock position, allowing for improved
removal of the chocolate, owing to the greater force available for
removal of the chocolate at that position.
[0049] In connection with the temperature of the molded chocolate
as it is removed from the rotary mold, by "average temperature" is
meant a temperature that would be measured by a temperature probe
if the probe were inserted into the chocolate and the chocolate
piece were allowed to equilibrate insulated from the
environment.
[0050] The recess must also be sized so that the chocolate can be
removed from the recess. As with conventional chocolate molding
techniques, a release angle of greater than about 7 degrees from
the vertical is generally provided to permit the chocolate to slide
out of the recess. More preferably, the release angle of the recess
used in connection with the rotary mold will be greater than about
8 degrees. Most preferably, the release angle will be greater than
about 10 degrees.
[0051] In some instances the product may be removed from the wheel
as a continuous web of chocolate, which may be textured. In some
preferred embodiments, a thin web produced in this manner has a
thickness on the order of {fraction (1/32)} inch (0.08 cm) up to
about 1/4 inch (0.635 cm), and has a lace-like pattern made up of
chocolate and empty spaces. Highly-designed, non-random and
readily-reproducible chocolate structures can be made according to
the invention. The artisan will appreciate that a molded chocolate
web having these characteristics cannot be molded using
conventional techniques.
[0052] Within these general parameters, the depth of the recess is
not particularly limited and is generally between about {fraction
(1/32)} inch (0.08 cm) and about 1 inch (2.54 cm). Likewise, the
width of the recess may vary widely, up to 2 inch (5.08 cm) or
more. Working embodiments have used a recess 3/8 inch (0.95 cm)
deep by 1 inch (2.54 cm) wide. One of the advantages of the
continuous molding method of the present invention is that pieces
having a greater ratio of width to thickness, and having finer
overall structural detail can be easily obtained, as compared with
the prior art.
[0053] The temperature of the recess and speed of rotation of the
rotary mold are set to obtain a partially solid (plastic) chocolate
strip exiting the bottom of the mold. The continuous strip may then
be cut into desired lengths by guillotine cutter 9, further cooled
in conventional cooling tunnels, and packaged. However, as
mentioned above, the size of the recess is not particularly limited
and instead of a continuous strip, the finished chocolate may be in
the form of discrete pieces.
[0054] Generally, an apparatus according to the invention will have
a dehumidifier proximate the wheel and retaining/casting belt to
condition the air around the molding chocolate. Cooling means
underneath the retaining/casting belt, as described above, further
set the chocolate after it is removed from the rotary mold.
[0055] Generally, in some instances, it will be necessary to
provide further thermal conditioning of the molded chocolate pieces
to ensure proper stability of the fat phase. For example, cocoa
butter based chocolate may require conditioning in a "cooling"
tunnel after demolding to allow proper crystal formation, thus
ensuring bloom stability. Such conditioning also allows any more
liquid regions in the center of a molded piece to fully and
properly solidify. Most preferred temperature conditioning
comprises cooling at between about 15.degree. C. and about
18.degree. C. for about 10 minutes.
[0056] Products made according to the methods of the present
invention, and molded using the apparatus according to the
invention, include chocolate pieces having uniform composition
throughout and made from a single deposition into a rotary mold.
Other products according to the invention are products in which
different types of chocolate (such as light and dark chocolate), or
chocolate in combination with other food materials are co-deposited
from the same or different sources into the rotary mold. Other
variations and modifications that would be apparent to one of
ordinary skill in the art are considered within the scope of the
appended claims.
EXAMPLES
[0057] The following examples are illustrative of some of the
products and methods of making the same falling within the scope of
the present invention. They are, of course, not to be considered in
any way limiting of the invention. Numerous changes and
modifications can be made with respect to the invention within the
scope of the appended claims.
Example 1
[0058] DOVE.RTM. Milk Chocolate, a commercially available milk
chocolate, was melted and tempered in a Savage Bros. Co. Batch
Tempering System. The chocolate was cooled from 45.degree. C. to
28.degree. C. to produce cocoa butter crystals of stable and
unstable polymorphs. The tempered chocolate was then warmed
slightly to 31.degree. C. to melt out the unstable crystals. The
tempered chocolate was at 31.degree. C. and had a temper level of 6
CTU (.degree. F.) and -0.5 slope as determined by Tricor
Tempermeter Model 501. The chocolate was then pumped to the rotary
molding device.
[0059] The rotary molding device consisted of an 8 inch diameter,
metallic wheel, which was cooled with coolant having a temperature
of 5.degree. C. and rotated at 0.435 rpm. A groove was cut into the
wheel with overall dimensions of 1 inch wide and 3/8 inch deep and
a wall taper of 7.degree.. The chocolate was fed into the groove
through a pipe fitted flush against the rotating wheel. The
chocolate was contained in the groove by a solid,
polyurethane-coated belt, which was wrapped against, and rotated
concurrent with, the rotating wheel from the 12 o'clock position to
the 6 o'clock position. At the 6 o'clock position, the solid
chocolate strip released from the wheel and was carried away from
the wheel on the conveyor belt. The continuous chocolate strip was
then cut into sections to form a chocolate bar. The belt carried
the chocolate bar over a platen under the conveyor belt that was
cooled to -10.degree. C. by recirculating cooling media The platen
set the bottom of the chocolate bars so they would release from the
belt. The bars were then transferred to a Sollich cooling
tunnel.
[0060] The cooling tunnel was comprised of one section with an air
temperature of 15.degree. C. The residence time in the tunnel was
10 minutes. The resultant finished chocolate bar exiting the tunnel
had a fair to good glossy, bloom stable surface.
Example 2
[0061] Chocolate comprised as set forth in Example 1 was pumped to
the molding device as comprised in Example 1 with the exception of
the groove in the wheel. In this example, a grid design was cut
into the wheel with an array spacing of 1/4 inch by 1/2 inch. The
wheel rotated at 0.9 rpm and produced a finished product which was
a precision molded regular loose mesh. The resultant finished
chocolate mesh exiting the tunnel had a fair to good glossy, bloom
stable surface.
Example 3
[0062] Chocolate comprised as set forth in Example 1 was pumped to
the molding device as comprised in Example 1 with the exception of
the groove in the wheel. In this example, the groove was cut to
overall dimensions of 2 inches wide and 1/4 inch deep with a
7.degree. wall taper. The wheel rotated at 0.9 rpm and was supplied
with coolant having a temperature of 1.degree. C. The resultant
finished chocolate exiting the tunnel had a fair to good glossy,
bloom stable surface.
Example 4
[0063] Chocolate comprised as set forth in Example 1 was pumped to
the molding device as comprised in Example 1 with the exception of
the groove in the wheel. In this example, individual cavities were
cut into the wheel to resemble an "M&M's".RTM. Brand Character.
The wheel rotated at 1.6 rpm and was supplied with coolant having a
temperature of -10.degree. C. The resultant finished chocolate
pieces exiting the tunnel had a fair to good glossy, bloom stable
surface.
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