U.S. patent application number 09/757281 was filed with the patent office on 2002-10-03 for shelf-stable cookie dough confection, product, packaging apparatus and process.
This patent application is currently assigned to Wm. Wrigley Jr. Company.. Invention is credited to Corriveau, Christine L., Guydan, Timothy J., McHale, Michael P., Milosch, Gregory J., Nichtula, George M., Ream, Ronald L..
Application Number | 20020142081 09/757281 |
Document ID | / |
Family ID | 26774879 |
Filed Date | 2002-10-03 |
United States Patent
Application |
20020142081 |
Kind Code |
A1 |
Ream, Ronald L. ; et
al. |
October 3, 2002 |
Shelf-stable cookie dough confection, product, packaging apparatus
and process
Abstract
An apparatus for metering and dispensing a compressible
confection comprises: at least one metering pump having an intake
port and a discharge port; at least one internal bottom shutoff
nozzle; at least one product line interconnecting the metering pump
and the internal bottom shutoff nozzle; and a control mechanism for
cyclically operating the at least one metering pump and operating
the at least one internal bottom shutoff nozzle in synchronization
with the metering pump such that generally constant pressure is
maintained between the metering pump and the internal bottom
shutoff nozzle.
Inventors: |
Ream, Ronald L.; (Plano,
IL) ; Corriveau, Christine L.; (Orland Park, IL)
; Milosch, Gregory J.; (Oswego, IL) ; Guydan,
Timothy J.; (Naperville, IL) ; McHale, Michael
P.; (Aurora, IL) ; Nichtula, George M.;
(Yorkville, IL) |
Correspondence
Address: |
BRINKS HOFER GILSON & LIONE
P.O. BOX 10395
CHICAGO
IL
60610
US
|
Assignee: |
Wm. Wrigley Jr. Company.
|
Family ID: |
26774879 |
Appl. No.: |
09/757281 |
Filed: |
January 8, 2001 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
09757281 |
Jan 8, 2001 |
|
|
|
09314715 |
May 19, 1999 |
|
|
|
6193105 |
|
|
|
|
60086561 |
May 21, 1998 |
|
|
|
Current U.S.
Class: |
426/396 ;
426/564; 426/660 |
Current CPC
Class: |
A21C 11/00 20130101 |
Class at
Publication: |
426/396 ;
426/660; 426/564 |
International
Class: |
A23G 003/00; B65B
055/00 |
Claims
What is claimed is:
1. A shelf-stable confection having a taste and a texture of raw
cookie dough.
2. The confection of claim 1 having a water activity (A.sub.w)
level of 0.6 or less.
3. The confection of claim 1 comprising between about 10 and about
45 weight percent of an aerated fat.
4. The confection of claim 1 comprising between about 0.5 and about
10 weight percent of a food grade glycerine.
5. The confection of claim 4 wherein the glycerine has a percent
solids level of between about 96 and about 99 percent solids.
6. The confection of claim 1 comprising between about 0.1 and about
2 weight percent of a food grade emulsifier.
7. The confection of claim 6 wherein the emulsifier is selected
from the group consisting of mono- and di-glycerides and propylene
glycol.
8. The confection of claim 1 comprising a fat and a food grade
antioxidant at a level of about 0.02 percent by weight of the
fat.
9. The confection of claim 1 comprising between about 0.05 and
about 3.5 weight percent of a flavoring.
10. The confection of claim 1 comprising between about 5 and about
30 weight percent of a food grade starch.
11. The confection of claim 1 comprising between about 5 and about
30 weight percent corn syrup solids.
12. The confection of claim 1 comprising between about 5 and about
45 weight percent sugar.
13. The confection of claim 11 wherein the sugar is selected from
the group consisting of brown sugar, brown sugar powder, granular
sugar, powder sugar and mixtures thereof.
14. The confection of claim 12 comprising between about 5 and about
30 weight percent brown sugar powder.
15. The confection of claim 12 comprising between about 5 and about
30 weight percent granular sugar.
16. The confection of claim 12 comprising between about 5 and about
30 weight percent powder sugar.
17. The confection of claim 1 comprising a flavored chip content of
between about 0.1 and about 20 weight percent.
18. The confection of claim 17 wherein the flavored chips are
fat-based.
19. The confection of claim 18 wherein the flavored chips are
coated.
20. The confection of claim 17 wherein the flavored chips are
chocolate flavored.
21. The confection of claim 1 comprising between about 0.5 and
about 4 weight percent of a cellulose-based gum.
22. The confection of claim 21 wherein the cellulose based gum
comprises hydroxypropyl methylcellulose.
23. The confection of claim 1 comprising between about 0.1 and
about 4 weight percent of a food grade salt.
24. The confection of claim 1 comprising: a) between about 10 and
about 45 weight percent of an aerated fat; b) between about 0.5 and
about 10 weight percent of a food grade glycerine; c) between about
5 and about 30 weight percent of a food grade starch; and d)
between about 5 and about 45 weight percent sugar.
25. The confection of claim 1 having a water activity (A.sub.w)
level of 0.6 or less and comprising: a) about 28 weight percent of
an aerated fat, b) about 1 weight percent of a food grade
glycerine, c) about 0.5 weight percent of a food grade emulsifier,
d) about 0.25 weight percent flavor, e) about 0.0056 weight percent
of a food grade antioxidant, f) about 14.75 weight percent of a
food grade starch, g) about 13 weight percent brown sugar powder,
h) about 12.64 weight percent granular sugar, i) about 10 weight
percent corn syrup solids, j) about 9.0 weight percent powder
sugar, k) about 7.75 weight percent chocolate chips, l) about 2
weight percent cellulose-based gum and m) about 1.1 weight percent
of a food grade salt.
26. The confection of claim 1 wherein the confection is chocolate
chip cookie dough flavor.
27. The confection of claim 1 wherein the confection is peanut
butter cookie dough flavor.
28. The confection of claim 1 wherein the confection is sugar
cookie dough flavor.
29. The confection of claim 1 wherein the confection is chocolate
cream sandwich cookie flavor.
30. The confection of claim 1 wherein the confection is cookie and
cream flavor.
31. The confection of claim 1 wherein the confection is chocolate
mint chip flavor.
32. The confection of claim 1 wherein the confection is brownie
flavor.
33. A product comprising the confection of claim 1 in a
package.
34. The product of claim 33 wherein the package is resistant to
oxygen and moisture.
35. The product of claim 34 wherein the package comprises a
multi-layer laminate of polystyrene, ethylvinyl alcohol and
polyethylene.
36. The product of claim 33 wherein the package comprises a
cup.
37. The product of claim 36 wherein the package further comprises a
lid.
38. The product of claim 37 wherein the lid comprises a multi-layer
laminate of clay-coated paper, foil and a sealant layer, the
sealant layer comprising high density polyethylene, ethyl acrylic
acid and surlyn polymer.
39. The product of claim 33 wherein the package contains an eating
implement.
40. The product of claim 39 wherein the package comprises a
sanitary disk placed between the confection and the eating
implement.
41. The product of claim 40 wherein the sanitary disk comprises a
foam material; the foam material being impervious to fat.
42. The product of claim 39 wherein the eating implement is choke
resistant.
43. The product of claim 42 wherein the eating implement is a
spoon.
44. The product of claim 43 wherein the spoon has a 21/2 inch
length.
45. An apparatus for metering and dispensing a compressible
confection comprising: a) at least one metering pump; the metering
pump comprising an intake port and a discharge port; b) at least
one internal bottom shutoff nozzle; c) at least one product line
interconnecting the metering pump and the internal bottom shutoff
nozzle; and d) a control mechanism for cyclically operating the at
least one metering pump and operating and the at least one internal
bottom shutoff nozzle in synchronization with the metering pump
such that generally constant pressure is maintained between the
metering pump and the internal bottom shutoff nozzle.
46. The apparatus of claim 45 comprising at least one pulse
regulator attached to the intake port of the metering pump.
47. The apparatus of claim 46 wherein the pulse regulator is
sanitary.
48. The apparatus of claim 45 comprising a diving mechanism for
lowering and elevating the at least one internal bottom shutoff
nozzle, the control mechanism is capable of operating the diving
mechanism in synchronization with the metering pump.
49. The apparatus of claim 48 comprising a bracket for supporting
the at least one internal bottom shutoff nozzle and interconnecting
the diving mechanism and the at least one internal bottom shutoff
nozzle.
50. The apparatus of claim 48 wherein the diving mechanism
comprises at least one air cylinder.
51. The apparatus of claim 45 wherein the control mechanism
comprises a clutch breaking system.
52. The apparatus of claim 45 wherein the metering pump comprises a
lobe-type positive displacement pump.
53. The apparatus of claim 52 wherein the lobe-type positive
displacement pump has a maximum flow rate of 2.8 GPM at 20 PSI.
54. The apparatus of claim 45 comprising a motor to drive the
metering pump.
55. The apparatus of claim 45 wherein the internal bottom shutoff
nozzle comprises a nozzle tip collar for holding a cup in place as
the cup is filled with the compressible confection.
56. The apparatus of claim 55 wherein the nozzle tip collar
comprises a collar and at least one spring.
57. The apparatus of claim 45 wherein the internal bottom shutoff
nozzle has an outlet with an inner diameter of about 1 inch.
58. The apparatus of claim 45 wherein the product line is
sanitary.
59. The apparatus of claim 58 wherein the product line is
flexible.
60. The apparatus of claim 59 wherein the product line is stainless
steel braided pipe.
61. The apparatus of claim 45 comprising multiple metering
pumps.
62. The apparatus of claim 61 comprising multiple internal bottom
shutoff nozzles.
63. The apparatus of claim 61 comprising multiple product
lines.
64. The apparatus of claim 45 wherein the control mechanism is
capable of cyclically operating multiple metering pumps and
operating multiple internal bottom shutoff nozzles in
synchronization with the multiple metering pumps.
65. The apparatus of claim 45 comprising multiple pulse
regulators.
66. The apparatus of claim 63 further comprising a manifold
comprising at least one inlet port and multiple outlet ports, the
manifold interconnecting the multiple outlet ports to the multiple
product lines.
67. The apparatus of claim 66 wherein the manifold comprises
multiple ball valves wherein each ball valve is attached to at
least one outlet port of the manifold.
68. The apparatus of claim 67 wherein the multiple product lines
interconnect the ball valves and the intake ports of the multiple
metering pumps.
69. The apparatus of claim 66 comprising a supplemental surge
accumulator.
70. The apparatus of claim 69 wherein the supplemental surge
accumulator is attached adjacent the manifold inlet port for
additional surge protection from air pockets in the compressible
confection.
71. An apparatus for metering and dispensing a compressible
confection comprising: a) at least one electrically operated rotary
metering pump comprising: i) an intake port, ii) a discharge port,
and iii) a chain drive; b) at least one pneumatically operated
internal bottom shutoff nozzle controlled by at least one first
electrical solenoid and supported by a bracket; c) at least one
nozzle tip collar comprising a collar and at least one spring for
holding a cup in place as the cup is filled with the compressible
confection dispensed from the internal bottom shutoff nozzle; d) a
diving mechanism comprising at least one pneumatically operated air
cylinder controlled by at least one second electrical solenoid and
attached to the bracket for lowering and elevating the at least one
pneumatically operated internal bottom shutoff nozzle; e) a product
line interconnecting the electrically operated rotary metering pump
and the pneumatically operated internal bottom shutoff nozzle; f) a
control mechanism for cyclically operating the at least one
electrically operated rotary metering pump and operating the at
least one pneumatically operated internal bottom shutoff nozzle in
synchronization with the rotary metering pump such that constant
pressure is maintained between the electrically operated rotary
metering pump and the pneumatically operated internal bottom
shutoff nozzle, the control mechanism being capable of operating
the diving mechanism in synchronization with the electrically
operated rotary metering pump; g) a drive shaft comprising at least
one sprocket engaging the chain drive of the electrically operated
rotary metering pump; and h) a motor driving the drive shaft.
72. The apparatus of claim 71 comprising at least one pulse
regulator attached to the intake port of the rotary metering
pump.
73. The apparatus of claim 71 wherein the pulse regulator is
sanitary.
74. The apparatus of claim 71 wherein the control mechanism
comprises: a) a signal generating device controlled by a packaging
conveyor; and b) an electrically operated clutch breaking system
comprising a clutch break engaging the drive shaft.
75. The apparatus of claim 74 wherein the control mechanism is
capable of simultaneously sending a signal to at least one first
electrical solenoid, at least one second electrical solenoid and
the clutch breaking system.
76. The apparatus of claim 75 wherein the first electrical solenoid
is capable of receiving the signal and opening the internal bottom
shutoff nozzle.
77. The apparatus of claim 76 wherein the second electrical
solenoid is capable of receiving the signal and lowering the at
least one internal bottom shutoff nozzle to a fully lowered
position.
78. The apparatus of claim 77 wherein the clutch breaking system is
capable of receiving the signal and starting the rotary metering
pump.
79. The apparatus of claim 78 wherein the clutch break is capable
of disengaging the drive shaft to start the rotary metering
pump.
80. The apparatus of claim 78 wherein the diving mechanism is
capable of gradually elevating the at least one internal bottom
shutoff nozzle as the rotary metering pump operates.
81. The apparatus of claim 75 wherein the first electrical solenoid
is capable of receiving the signal and closing the internal bottom
shutoff nozzle.
82. The apparatus of claim 81 wherein the second electrical
solenoid is capable of receiving the signal and elevating the
internal bottom shutoff nozzle to a fully upright position.
83. The apparatus of claim 81 wherein the clutch breaking system is
capable of receiving the signal and stopping the rotary metering
pump.
84. The apparatus of claim 82 wherein the clutch break is capable
of engaging the drive shaft to stop the rotary metering pump.
85. The apparatus of claim 71 wherein the rotary metering pump
comprises a lobe-type positive displacement pump.
86. An apparatus for metering and dispensing a compressible
confection comprising: a) a pneumatically operated displacement
drum pump which comprises a ram and a relief spout and is
controlled by a third electrical solenoid; b) a manifold which
comprises: i) at least one inlet port, ii) multiple outlet ports,
iii) multiple ball valves wherein each ball valve is attached to at
least one outlet port, and iv) a supplemental surge accumulator for
additional surge protection from air pockets in the compressible
confection; c) a product line connected at one end to the
displacement drum pump and at the other end to the at least one
manifold inlet port; d) an accumulator attached to the product line
between the displacement drum pump and the manifold; e) multiple
lobe-type positive displacement pumps each comprising an intake
port and a discharge port, the pumps being driven by a motor
driving a drive shaft having multiple sprockets thereon and chain
drives between the drive shaft sprockets and the pumps; f) multiple
sanitary pulse regulators wherein each sanitary pulse regulator is
attached to the intake port of at least one lobe-type positive
displacement pump; g) multiple first flex-lines wherein each first
flex-line is connected at one end to one of said ball valves and at
the other end to one of said pump intake ports; h) multiple
pneumatically operated internal bottom shutoff nozzles; i) multiple
nozzle-tip collars wherein each nozzle-tip collar comprises a
collar and at least one spring mounted to the collar for holding a
cup in place as the cup is filled with the compressible confection,
the nozzle tip collar being attached to the pneumatically operated
internal bottom shutoff nozzle; j) multiple first electrical
solenoids wherein each first electrical solenoid controls at least
one pneumatically operated internal bottom shutoff nozzle; k) a
bracket for supporting and spacing the multiple pneumatically
operated internal bottom shutoff nozzles; l) a diving mechanism for
lowering and elevating the multiple internal bottom shutoff nozzles
comprising at least one pneumatically operated air cylinder
controlled by at least one second electrical solenoid and is
attached beneath the bracket; m) multiple second flex-lines wherein
each second flex-line is connected at one end to one of said pump
discharge ports and at the other end to one of said internal bottom
shutoff nozzles; and n) a control mechanism for synchronously
operating the displacement drum pump, the multiple lobe-type
positive displacement pumps and the multiple internal bottom
shutoff nozzles such that generally constant pressure is maintained
between each multiple lobe-type positive displacement pump and
shutoff nozzle, the control mechanism also being capable of
operating the diving mechanism in synchronization with they rotary
metering pump.
87. The apparatus of claim 86 wherein the control mechanism
comprises: a) a signal generating device controlled by a packaging
conveyor; and b) an electrically operated clutch breaking system
comprising a clutch break engaging the drive shaft.
88. The apparatus of claim 87 wherein the control mechanism is
capable of simultaneously sending a signal to the first electrical
solenoids, the second electrical solenoids, the third electrical
solenoid and the clutch breaking system.
89. The apparatus of claim 88 wherein the first electrical solenoid
is capable of receiving the signal and opening the internal bottom
shutoff nozzle.
90. The apparatus of claim 89 wherein the second electrical
solenoid is capable of receiving the signal and lowering the at
least one internal bottom shutoff nozzle to a fully lowered
position.
91. The apparatus of claim 90 wherein third electrical solenoid is
capable of receiving the signal and starting the pneumatically
operated displacement drum pump.
92. The apparatus of claim 91 wherein the clutch breaking system is
capable of receiving the signal and starting the rotary metering
pump.
93. The apparatus of claim 92 wherein the clutch break is capable
of disengaging the drive shaft to start the rotary metering
pump.
94. The apparatus of claim 93 wherein the diving mechanism is
capable of gradually elevating the at least one internal bottom
shutoff nozzle as the rotary metering pump operates.
95. The apparatus of claim 88 wherein the first electrical solenoid
is capable of receiving the signal and closing the internal bottom
shutoff nozzle.
96. The apparatus of claim 95 wherein the second electrical
solenoid is capable of receiving the signal and elevating the
internal bottom shutoff nozzle to a fully upright position.
97. The apparatus of claim 96 wherein the third electrical solenoid
is capable of receiving the signal and stopping the pneumatically
operated displacement drum pump.
98. The apparatus of claim 97 wherein the clutch breaking system is
capable of receiving the signal and stopping the rotary metering
pump.
99. The apparatus of claim 98 wherein the clutch break is capable
of engaging the drive shaft to stop the rotary metering pump.
100. The apparatus of claim 86 wherein the product line comprises 1
inch stainless steel pipe.
101. The apparatus of claim 86 wherein the manifold comprises 4
inch stainless steel pipe.
102. The apparatus of claim 86 wherein the first and second
flex-lines comprise 1 inch stainless steel braided pipe.
103. The apparatus of claim 86 wherein the internal bottom shutoff
nozzles comprise a 1 inch inner diameter outlet.
104. The apparatus of claim 86 wherein each of the lobe-type
positive displacement pumps has a maximum output rate of 2.8 GPM at
20 PSI.
105. The apparatus of claim 86 wherein the motor comprises an
electrical motor.
106. A process for packaging the product of claim 1 comprising the
steps of: a) loading at least one empty cup onto a packaging
conveyor; b) conveying the at least one empty cup to a filling
station; c) filling the at least one empty cup with the product of
claim 1 to form at least one filled cup; d) conveying the filled
cup to a lid placement station; e) placing a lid on top of the
filled cup; f) conveying the filled cup to a lid sealing station;
and g) sealing the lid to the filled cup to form a packaged
product.
107. The process of claim 106 further comprising between steps c)
and d) the steps of: a) conveying the filled cup to a disk insert
station; and b) inserting a disk.
108. The process of claim 107 further comprising the step of
tapping the disk to settle the product of claim 1 within the filled
cup.
109. The process of claim 106 further comprising before steps d,
the steps of: a) conveying the filled cup to an eating implement
placement station; and b) placing an eating implement in the filled
cup.
110. The process of claim 106 further comprising the steps of: a)
conveying the packaged product to a packaged product removal
station; and b) removing the packaged product from the packaging
conveyor.
111. The process of claim 106 wherein the filling is performed
using a lobe-type positive displacement pump feeding product to an
internal bottom shutoff nozzle.
112. The process of claim 109 wherein the lid placement is
performed by a pick and place machine inserting and tapping the
disk.
113. The process of claim 106 wherein the lids are heat sealed at
the lid sealing station.
114. The process of claim 106 wherein the packaging conveyor
comprises at least one nesting tray; the nesting tray having an
aperture into which the cup is loaded.
115. The process of claim 114 wherein the packaging conveyor
comprises multiple nesting trays.
116. The process of claim 115 wherein the nesting tray comprises
multiple apertures into which multiple cups are loaded.
117. The process of claim 116 wherein the multiple apertures
comprise a configuration having two rows of three apertures.
118. The process of claim 106 wherein the packaging conveyer
comprises a first magazine and a second magazine.
119. The process of claim 118 wherein the first magazine hold the
cups to be loaded onto the packaging conveyor.
120. The process of claim 119 wherein the second magazine hold the
lids to be placed on top of the filled cup.
121. The process of claim 120 wherein the packaging conveyor
comprises a blister pack machine.
122. The process of claim 106 wherein the packaging conveyor
operates intermittently.
123. The process of claim 122 wherein the packaging conveyor
operates in synchronization with the apparatus of claim 45.
124. The process of claim 123 wherein the packaging conveyor
conveys for about 1 second and stops for about 3 seconds.
125. The process of claim 124 wherein the apparatus of claim 45
fills at least one empty cup at the cup filling station within
about 3 seconds.
Description
[0001] This application claims the benefit of the filing date under
35 U.S.C. .sctn. 119(e) of U.S. Provisional Application No.
60/086,561, filed May 21, 1998 which is hereby incorporated by
reference.
BACKGROUND OF THE INVENTION
[0002] The present invention is directed to a shelf-stable cookie
dough confection, a product comprising the shelf-stable cookie
dough confection packaged in a sanitary package, an apparatus for
metering and dispensing a compressible confection, and a process
for packaging the compressible confection.
[0003] Traditionally, raw cookie dough was merely the intermediate
product of the desired product, the baked cookie. Cookies were
either made at home, or were baked and packaged for distribution.
In recent years, raw cookie dough has been packaged and distributed
as such, to be formed into cookies and baked at home. The cookie
itself has somewhat bowed in popularity to the rich, sweet and
creamy texture of conventional raw cookie dough. Conventional raw
cookie dough and products containing raw cookie dough, such as
cookie dough ice-cream, have become increasingly popular.
Typically, these products include real eggs and flour. To decrease
the danger in eating these products, egg substitutes often replace
eggs. However, even with the omission of real eggs, a danger
remains under moist conditions as the flour and the proteins
therein provide a harbor for bacteria. To prevent microbial growth,
conventional raw cookie dough and products containing raw cookie
dough require refrigeration and, as such, are not shelf-stable. A
shelf-stable cookie dough would therefore be of great
importance.
[0004] Conventional raw cookie-dough has traditionally been
packaged in what is known in the art as a chub-pack. The chub-pack,
typically, comprises a thin plastic casing in the form of a tube
encasing the cookie dough. Each end of the plastic casing is
clinched with a metal band. Despite the bands, when not
refrigerated the fat in the product can wick out of the clinched
ends, resulting in exposure to air, moisture and contamination. A
shelf-stable cookie dough product comprising a shelf-stable cookie
dough confection packaged in a sanitary package would therefore be
a great improvement.
[0005] Once a shelf-stable cookie dough confection was invented in
accordance with the present invention, it was found to be
compressible. In packaging processes, a compressible confection
exhibits compression and relaxation phenomena. More specifically,
the compression and relaxation phenomena occur when a compressible
confection is initially forced to move through a process line. For
example, because air cells are incorporated in an aerated fat used
in the confection, the material initially does not move when
pressure is applied. In fact, movement only occurs once the
confection builds up a head pressure sufficient to overcome the
flexing, or compressing, air cells. This is known as the
compression phenomenon. Once the confection is moving, the majority
of the pressure is stored in the furthest back portion of the
confection in the line where pressure originated. Upon relieving
the pressure to stop the flow, the partially compressed confection
returns to its original form and the confection springs forward to
equalize the pressure. This is known as the relaxation phenomenon.
Thus, if the product is packaged using an intermittent flow system
and a finite number of units per minute to fill the packaged
product, the confection will not fill on immediate command due to
the compression phenomenon, nor will the flow of the confection
shut off on immediate command due to the relaxation phenomenon.
These phenomena lead to inconsistent flow, or weight control, of
the compressible confection in the final packaged product. Thus, a
compressible confection requires unconventional pumping equipment
for even flow, or weight control, of the final product. An
apparatus and process for metering and dispensing a compressible
confection capable of overcoming the compression and relaxation
phenomena would be a significant contribution to the art of
confection packaging.
SUMMARY OF THE INVENTION
[0006] As noted above, a confection has been invented which has a
taste and texture of raw cookie dough, but which is shelf-stable.
In one aspect, the present invention is such a shelf-stable
confection itself
[0007] In another aspect, the invention is a product comprising a
shelf-stable confection having the taste and texture of raw cookie
dough in a package, preferably a sanitary package of an individual
portion of the confection.
[0008] In yet another aspect, the invention is an apparatus for
metering and dispensing a compressible confection comprising at
least one metering pump, the metering pump comprising an intake
port and a discharge port, at least one internal bottom shutoff
nozzle, at least one product line interconnecting the metering pump
and the internal bottom shutoff nozzle, and a control mechanism for
cyclically operating the at least one metering pump and operating
the at least one internal bottom shutoff nozzle in synchronization
with the metering pump such that generally constant pressure is
maintained between the metering pump and the internal bottom
shutoff nozzle.
[0009] In a further aspect, the invention is a process for
packaging a shelf-stable confection having the taste and texture of
raw cookie dough comprising the steps of loading at least one empty
cup onto a packaging conveyor, conveying the at least one empty cup
to a filling station, filling the at least one empty cup with the
confection to form at least one filled cup, conveying the filled
cup to a lid placement station, placing a lid on top of the filled
cup, conveying the filled cup to a lid sealing station, and sealing
the lid to the filled cup to form a packaged product.
[0010] The shelf-stable cookie dough confection itself confers an
improvement over the prior art in that it requires no
refrigeration. In addition, the shelf-stable cookie dough product
satisfies a need unmet by the prior art for a sanitary package
containing a shelf-stable cookie dough confection that protects the
confection from exposure to air, moisture and contamination at room
temperature. Yet another improvement over the prior art conferred
by the present invention is an apparatus and process for metering
and dispensing a compressible confection which is capable of
overcoming the compression and relaxation phenomena exhibited in
conventional processes for packaging compressible confections.
These and other advantages of the invention, as well as the
invention itself, will be best understood in view of the attached
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a block diagram of the process of packaging the
shelf-stable cookie dough confection of the present invention.
[0012] FIG. 2 is a side elevational view of the apparatus for
metering and dispensing the shelf-stable cookie dough confection
located parallel to the filling station used with the packaging
conveyor identified in FIG. 1.
[0013] FIG. 3 is an exploded view of a preferred shelf-stable
cookie dough confection product produced by the process of FIG.
1.
[0014] FIG. 4 is a perspective view of the shelf-stable cookie
dough confection product of FIG. 3.
[0015] FIG. 5 is a side elevational view of the displacement drum
pump depicted in FIG. 2.
[0016] FIG. 6 is a top plan view of the displacement drum pump of
FIG. 5.
[0017] FIG. 7 is a side elevational view of the apparatus for
metering and dispensing the shelf-stable cookie dough confection
depicted in FIG. 2.
[0018] FIG. 8 is a top plan view of the apparatus for metering and
dispensing the shelf-stable cookie dough confection of FIG. 7.
[0019] FIG. 9 is a side elevational view of the packaging conveyor
depicted in FIG. 2.
[0020] FIG. 10 is a top plan view of the packaging conveyor of FIG.
9.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] The present invention includes aspects drawn to a
shelf-stable cookie dough product 20, as depicted in FIGS. 3 and 4,
an apparatus for metering and dispensing a compressible confection
22, as depicted in FIGS. 1, 2, 5, 6, 7, 8, 9 and 10, and a process
of packaging the compressible confection 10 as depicted in FIG.
1.
[0022] The shelf-stable cookie dough product 20 includes a
shelf-stable cookie dough confection 22. The shelf-stable cookie
dough confection 22 has a taste and texture of raw cookie dough.
The confection can be made using an aerated fat, a food grade
glycerine, a food grade starch and sugar.
[0023] The taste and texture of the confection is selected from,
but not limited to, the group consisting of chocolate chip cookie
dough flavor, peanut butter cookie dough flavor, chocolate peanut
butter cookie dough flavor, sugar cookie dough flavor, chocolate
cream sandwich cookie flavor, cookie and cream flavor, chocolate
mint chip flavor and chocolate brownie flavor.
[0024] The aerated fat provides a light, fluffy, or doughy, texture
to the confection. The aerated fat is selected from the group
consisting of, but is not limited to, shortening-type fats. The
preferred confection has an aerated fat composition between about
10 and 45 weight percent.
[0025] The food grade glycerine provides plasticity to the
confection. Preferably, the glycerine has a percent solids level of
between about 96 to about 99 percent solids. The preferred
composition comprises between about 0.5 and about 10 weight percent
of a food grade glycerine having a solids level of about 96 weight
percent solids.
[0026] The food grade starch acts both as a drying agent and a
bulking agent. As a desiccant, starch provides additional moisture
protection. As a bulking agent, starch eliminates the need to use
flour, a bulking agent used in conventional cookie dough
confections. Flour, and the proteins found therein, typically
provide a harbor for bacteria. Thus, the use of starch as a bulking
agent and the attendant reduced risk of bacterial contamination
confers an advantage to the relevant art. The preferred composition
comprises between about 5 and about 30 weight percent of a food
grade starch.
[0027] The sugar is selected from the group consisting of brown
sugar, brown sugar powder, granular sugar, powder sugar and
mixtures thereof. The preferred composition comprises between about
5 and about 45 weight percent sugar. More preferably, the
confection comprise between about 5 and about 30 weight percent
brown sugar powder, between about 5 and about 30 weight percent
granular sugar, and between about 5 and about 30 weight percent
powder sugar.
[0028] The preferred confection includes a food grade emulsifier.
The emulsifier acts as a binding agent and is added in either a dry
or a melted form. As a binding agent, the food grade emulsifier
brings together the fat portions of the confection with any
available moisture and provides stability to the overall
confection. More specifically, the food grade emulsifier provides a
dough-like texture and prevents the confection from crumbling and
falling apart over time. Preferably the food grade emulsifier is
selected from a group consisting of mono- and di-glycerides and
propylene glycol. Most preferably the food grade emulsifier is
MIVATEX 3-50. The preferred composition comprises between about 0.1
and 2 weight percent of a food grade emulsifier.
[0029] The preferred confection includes a food grade antioxidant.
The antioxidant is added to prevent oxidative rancidity and to
improve the shelf life. Typically, a shelf life of about nine to 12
months can be achieved. The antioxidant is added in compliance of
governmental regulations as a percentage of the fat. The preferred
composition comprises a food grade antioxidant at a level of about
0.02 percent by weight of the fat.
[0030] The preferred confection includes corn syrup solids. The
preferred composition comprises between about 5 and about 30 weight
percent corn syrup solids.
[0031] The preferred confection includes a flavoring. The flavoring
is selected from, but not limited to, the group consisting of
vanilla, almond, peanut butter, chocolate, mint and combinations
thereof The preferred composition comprises between about 0.05 and
about 3.5 weight percent of a flavoring.
[0032] The preferred confection includes a flavored chip. The
flavored chip is selected from, but not limited to, the group
consisting of chocolate, peanut butter, mint, chocolate cookie,
vanilla cookie, mint cookie, and brownie. Preferably, the flavored
chips are fat-based. Most preferably, the fat-based flavored chips
are coated. The coating prevents the fat-based flavored chips from
dissolving in the confection. The preferred composition comprises a
flavored chip content of between about 0.1 and about 20 weight
percent.
[0033] The preferred confection includes a stabilizer such as a
cellulose-based gum. The stabilizer is added to create a creamy,
doughy texture. Most preferably, the cellulose-based gum comprises
hydroxypropyl methylcellulose. The preferred composition comprises
between about 0.5 and about 4 weight percent of a cellulose-based
gum.
[0034] The preferred confection includes a food grade salt. The
preferred composition comprises between about 0.1 and 4 weight
percent of a food grade salt.
[0035] The confection of the present invention is virtually
moisture-free. As such, microbial growth is inhibited. The
preferred confection has a water activity (A.sub.w) level of 0.6 or
less.
[0036] An example of a cookie dough confection of the preferred
invention has a water activity (A.sub.w) level of 0.6 or less and
comprises about 28 weight percent of an aerated fat, about 1 weight
percent of a food grade glycerine, about 0.5 weight percent of a
food grade emulsifier, about 0.25 weight percent flavoring, about
0.0056 weight percent of a food grade antioxidant, about 14.75
weight percent of a food grade starch, about 13 weight percent
brown sugar powder, about 12.64 weight percent granular sugar,
about 10 weight percent corn syrup solids, about 9.0 weight percent
powder sugar, about 7.75 weight percent chocolate flavored chips,
and about 2 weight percent cellulose-based gum.
[0037] FIGS. 3 and 4 illustrate another aspect of the invention.
The shelf-stable cookie dough confection product 20 comprises a
shelf-stable cookie dough confection 22 in a package, preferably a
sanitary package of an individual portion of the confection. The
sanitary package provides a barrier to oxygen and moisture and
preferably includes a cup 24, a sanitary disk 26, an eating
implement 28, and a lid 30.
[0038] Most preferably the cup 24 comprises a multi-layer laminate
of polystyrene, ethylvinyl alcohol and polyethylene. The eating
implement 28 is choke resistant and is preferably a spoon. Most
preferably the spoon has a 21/2 inch length. The ideal length of
21/2 inches makes the spoon small enough to fit within the cup but
large enough to avoid the danger of becoming lodged in the throat
of a small child. Thus, the incorporation of an eating element 28
within the packaging of the shelf-stable cookie dough confection
product 20 represents a unique aspect of the present invention.
[0039] The sanitary disk 26 is placed between the shelf-stable
cookie dough confection 22 and the eating implement 28. Most
preferably the sanitary disk 26 is impervious to fat and comprises
a foam material.
[0040] The lid 30 preferably comprises a multi-layer laminate of
clay-coated paper, foil and a sealant layer. Preferably, the
sealant layer (not shown) comprises high density polyethylene,
ethyl acrylic acid and surlyn polymer.
[0041] FIGS. 2, 5, 6, 7, 8, 9, and 10 depict yet another aspect of
the present invention. The apparatus for metering and dispensing a
compressible confection 50 comprises at least one metering pump 52,
at least one internal bottom shutoff nozzle 54, at least one
product line 56 interconnecting the metering pump 52 and the
internal bottom shutoff nozzle 54, a diving mechanism 40 for
lowering and elevating the internal bottom shutoff nozzle 54, and a
control mechanism (not shown) for cyclically operating the metering
pump 52 and operating the internal bottom shutoff nozzle 54 and the
diving mechanism 40 in synchronization with the metering pump 52.
By operating the internal bottom shutoff nozzle 54 in
synchronization with the metering pump 52, generally constant
pressure is maintained between the metering pump 52 and the
internal bottom shutoff nozzle 54. Ultimately, the compression and
relaxation phenomenon of the compressible confection is minimized
by maintaining a generally constant pressure between the metering
pump 52 and the internal bottom shutoff nozzle 54 and a more even
flow, or the weight control, of the final product is achieved.
[0042] Preferably the apparatus for metering and dispensing the
compressible confection 50 includes a displacement drum pump 70 for
transporting the compressible confection from a 55 gallon drum 72.
The product line 56 interconnects the displacement pump 70 and the
metering pump 52.
[0043] Most preferably, the apparatus comprises a manifold 80,
multiple metering pumps 52, multiple internal bottom shutoff
nozzles 54, a bracket 42 for supporting and spacing the multiple
internal bottom shutoff nozzles 54, and multiple product lines 56
interconnecting the multiple metering pumps 52 and the multiple
internal bottom shutoff nozzles 54. The manifold 80 interconnects
the multiple metering pumps 52 and the displacement drum pump
70.
[0044] The metering pumps 52 of the present invention are rotary
metering pumps. The rotary metering pumps 52 meter as well as
transport the compressible confection to be dispensed. The rotary
metering pumps 52 are electrically operated and comprise an intake
port 58 and a discharge port 60. Preferably a sanitary pulse
regulator 62 is attached to the intake port 58 of each rotary
metering pump 52. By protecting against air pockets in the
compressible confection, the pulse regulator 62 enhances the
metering capability of the pump 52. Generally, the selection of
lobe-type positive displacement pumps 52 achieves greater metering
precision. Most preferably the lobe-type positive displacement pump
is a Tri-Clover.RTM. PR3 Series Positive Rotary Pump having an
intake and discharge port size of about 1 inch and having a maximum
flow rate of about 2.8 GPM at 20 PSI. The PR3 pumps 52 are driven
by a motor 98 driving a drive shaft 96 having multiple sprockets 97
thereon and chain drives 99 between the drive shaft sprockets 97
and the PR3 pumps 52.
[0045] The internal bottom shutoff nozzle 54 of the present
invention are pneumatically operated and controlled by at least one
electrical solenoid (not shown). The pneumatically operated
internal bottom shutoff nozzles 54 prevent the confection from
flowing out of the bottom of the nozzle as the confection relaxes.
Most preferably the pneumatically operated internal bottom shutoff
nozzles 54 are KALISH brand Kalishtronic Giant Internal Bottom
Shutoff Nozzles comprising a nozzle size of about 11/2 inches and
an outlet having an inner diameter of about 1 inch. The
Kalishtronic Giant Internal Bottom Shutoff Nozzles generally
deliver a precise amount of the confection. By preference, a
nozzle-tip collar 46 is attached to each internal bottom shutoff
nozzle 54 for holding a cup 24 in place as the cup 24 is filled
with a compressible confection 22. Most preferably, the nozzle-tip
collar 46 comprises a collar and at least one spring attached to
the collar.
[0046] The product line 56 interconnecting the metering pump 52 and
the internal bottom shutoff nozzle 54 is sanitary and flexible.
Preferably, the product line 56 interconnecting the metering pump
52 and the internal bottom shutoff nozzle 54 comprises 1 inch,
stainless steel braided pipe. Also by preference, the apparatus of
the present invention comprises an accumulator 74 for surge
protection from air pockets in the compressible confection 22. The
accumulator 74 is attached to the product line 56 between the
displacement drum pump 70 and the manifold 80. Most preferably, the
product line 56 interconnecting the displacement drum pump 70 and
the manifold 80 comprises 11/2 inch, stainless steel braided
pipe.
[0047] The manifold 80 comprises at least one inlet port 82 and
preferably two inlet ports, multiple outlet ports 84 and multiple
ball valves 86. Each ball valve 86 is attached to at least one
outlet port 84. The output rate of product in finite number of
units per minute can be adjusted by opening and closing the ball
valves 86 and thereby operating either a single pump, product line,
and shutoff nozzle or multiple metering pumps, product lines, and
shutoff nozzles. Preferably, the manifold 80 includes a
supplemental surge accumulator (not shown) for additional surge
protection from air pockets in the compressible confection 22. The
supplemental surge accumulator (not shown) is attached at the top
of the manifold 80.
[0048] The displacement drum pump 70 is pneumatically operated,
controlled by an electrical solenoid (not shown), and comprises a
ram 76 and a relief spout (not shown). Most preferably the
pneumatically operated displacement drum pump 70 is a Graco.RTM.
King Pump with priming piston, Model 207-568 Series D, and
comprises a Graco.RTM. 55 Gallon Ram, Model 207-279, and a
Graco.RTM. King Air Motor, Model 207-647 Series L.
[0049] The diving mechanism 40 for lowering and elevating the
multiple shutoff nozzles 54 comprises at least one pneumatically
operated air cylinder 44 controlled by at least one electrical
solenoid (not shown). By lowering and elevating the shutoff nozzles
54, the diving mechanism 40 facilitates the dispensing of the
compressible confection 22. Preferably the diving mechanism 40
comprises multiple air cylinders 44 controlled by multiple
electrical solenoids (not shown) wherein each air cylinder 44 is
controlled by a separate electrical solenoid (not shown). Most
preferably, the diving mechanism 40 is attached to the bracket 42
for supporting and spacing the internal bottom shutoff nozzles
54.
[0050] Preferably the control mechanism (not shown) is capable of
cyclically operating the metering pumps 52 and operating the
shutoff nozzles 54, the diving mechanism 40 and the displacement
drum pump 70 in synchronization with the metering pumps 52. By
preference, the control mechanism (not shown) comprises a signal
generating device (not shown) controlled by a packaging conveyor 90
and an electrically operated clutch breaking system 92 comprising a
clutch break 94 engaging the drive shaft 96. The clutch breaking
system 92 accommodates the intermittent operation of the packaging
conveyor 90 and enables the motor 98 driving the metering pumps 52
to run continuously.
[0051] Most preferably, the control mechanism (not shown) is
capable of simultaneously sending a signal to the electrical
solenoids controlling the bottom shutoff nozzles 54, air cylinder
44 and displacement drum pump 70, as well as to the clutch breaking
system 92. Upon receiving a signal from the packaging conveyor 90,
the first electrical solenoids open the internal bottom shutoff
nozzles 54, the second electrical solenoids cause the air cylinder
44 to lower the internal bottom shutoff nozzles 54 to a fully
lowered position, and the third electrical solenoid starts the
displacement drum pump 70. Meanwhile, the clutch break 94
disengages the drive shaft 96 to start the metering pumps. As the
metering pumps 52 operate, the diving mechanism 40 gradually
elevates the internal bottom shutoff nozzles 54. Similarly, upon
receiving a signal from the packaging conveyor 90, the first
electrical solenoids close the internal bottom shutoff nozzles 54,
the second electrical solenoids cause the air cylinder 44 to
elevate the internal bottom shutoff nozzles 54 to a fully elevated
position, the third electrical solenoid stops the displacement drum
pump 70. Also, the clutch break 94 engages the drive shaft 96 to
stop the metering pumps 52.
[0052] FIGS. 1, 9 and 10 depict a further aspect of the present
invention. The invention is a process for packaging a shelf-stable
cookie dough confection comprising the steps of loading an empty
cup 24 onto a packaging conveyor 90, conveying the empty cup 24 to
a filling station 120, filling the empty cup 24 with the
shelf-stable cookie dough confection 22 to form a filled cup,
conveying the filled cup to a lid placement station 150, placing a
lid 30 on top of the filled cup, conveying the filled cup to a lid
sealing station 160, and sealing the lid to the filled cup to form
a packaged product 20.
[0053] Preferably, the filling is performed using a lobe-type
positive displacement pump 52 feeding the confection to an internal
bottom shutoff nozzle 54. Also by preference, the process includes
the steps of conveying the filled cup to a disk insert station 130
and inserting a disk 26 before the filled cup is conveyed to the
lid placement station 150. The disk is tapped to settle the
shelf-stable cookie dough confection 22 within the filled cup. By
preference a pick and place machine (not shown) is used to insert
and tap the disk 26. Next, the filled cup is conveyed to an eating
implement placement station 140 and an eating implement 28 is
placed in the filled cup. After the lid 30 is sealed to the filled
cup, the process includes the steps of conveying the packaged
product 20 to a packaged product removal station 170 and removing
the packaged product 20 from the packaging conveyor 90.
[0054] Most preferably the packaging conveyor 90 of the present
invention is an Alloyd brand Blister Pack Machine, Model 18SC1216
Carousel and comprises a cup loading station 100, nesting trays
114, a filling station 120, a disk insert station 130, an spoon
placement station 140, a lid placement station 150, a lid sealing
station 160, and a packaged product removal station 170.
[0055] More specifically, the cup loading station 100 comprises a
first magazine 112, or cup feeder magazine, (FIG. 10), an
adjustable cup suction assembly (not shown) to pull the cups from
the cup feeder magazine 112 and place them on the nesting trays
114. The cup feeder magazine 112 and the adjustable cup suction
assembly are mounted on the packaging conveyor 90 at the cup
loading station 100.
[0056] In the preferred invention the packaging conveyor comprises
multiple nesting trays 114. The nesting tray 114 comprises an
aperture into which the cup is loaded. Preferably each nesting tray
comprises multiple apertures into which multiple cups are loaded.
Most preferably the multiple apertures comprise a configuration
having two rows of three apertures.
[0057] In the preferred invention the filling station 120 comprises
the apparatus for metering and dispensing a compressible confection
50. The disk insert station 130 preferably includes a pick and
place machine (not shown). Also by preference, a spoon 28 is
manually placed in the filled cup at the spoon placement station
140.
[0058] In the preferred invention the lid placement station 150
comprises a second magazine 152, or lid feeder magazine, an
adjustable lid suction assembly (not shown) to pull the lids from
the lid feeder magazine 152 and place them on the filled cups. The
lid feeder magazine 152 and the adjustable lid suction assembly are
mounted on the packaging conveyor 90 at the lid placement station
150.
[0059] In the preferred invention the lid sealing station 160
comprises a heat plate (not shown) and a pressure anvil (not shown)
for heat sealing the lid 30 to the filled cup. Preferably, the
packaged product removal station 170 comprises an adjustable eject
station assembly (not shown) to lift the sealed packages off of the
nesting trays 114 and place them onto the discharge chute (not
shown) to exit away from the packaging conveyor 90.
[0060] In the process of the preferred invention, the packaging
conveyor 90 operates intermittently and in synchronization with the
apparatus for metering and dispensing a compressible confection 50.
Most preferably, the packaging conveyor 90 conveys for about 1
second and stops for about 3 seconds. Meanwhile, the apparatus for
metering and dispensing a compressible confection 50 fills at least
one empty cup at the cup filling station within about 3
seconds.
[0061] It should be appreciated that the compositions, apparatus
and methods of the present invention are capable of being
incorporated in the form of a variety of embodiments, only a few of
which have been illustrated and described above. The invention may
be embodied in other forms without departing from it spirit or
essential characteristics. It will be appreciated that the addition
of some other ingredients, process steps, materials or components
not specifically included may have an adverse impact on the present
invention. The best mode of the invention may therefore exclude
ingredients, process steps, materials or components other than
those listed above for inclusion or use in the invention. However,
the described embodiments are to be considered in all respects only
as illustrative and not restrictive, and the scope of the invention
is, therefore, indicated by the appended claims rather than by the
foregoing description. All changes that come within the meaning and
range of equivalency of the claims are to be embraced within their
scope.
* * * * *