Method and system for molding chocolate utilizing an air knife and products made

• US 7,819,053 B2
• Filed: 04/25/2006
• Issued: 10/26/2010
• Est. Priority Date: 01/23/2006
• Status: Active Grant

• Current Assignee: Mars Incorporated
• Original Assignee: Mars Incorporated
• Inventors: Morgan, Richard A., Harvey, Robert, Floyd, Rick A., Diperna, Dominic M., Kaiser, John M., Slesser, Dale R., Parker, Robert A.
• Primary Examiner(s): Gupta; Yogendra N
• Assistant Examiner(s): Luk; Emmanuel S
• Application Number:
  US11/410,207
• Publication Number:
  US 20070172565A1
• Time in Patent Office: 1,645 Days
• Field of Search: 425/72.1, 425/445, 425/446, 425/94, 425/105, 425/106, 425/232, 425/306, 426/293, 426/305, 426/307, 426/312, 994/506, 995/17
• US Class Current: 99/450.6
• CPC Class Codes: A23G 3/007 the material being shaped at least partially in a mould, in the hollows of a surface, a drum, an endless band or by drop-by-drop casting or dispensing of the materials on a surface or an article being completed
• CPC Class Codes: A23G 3/0072 Processes for laying down the liquid, pasty or solid materials in moulds or drop-by-drop, on a surface or an article being completed, optionally with the associated heating, cooling, proportioning, cutting cast-tail, antidripping
• CPC Class Codes: A23G 7/0093 Cooling or drying A23G9/00 takes precedence

Abstract

Prior to cooling, an air knife is used to remove bubbles from confectionery-filled chocolates, preferably center-filled chocolates, deposited in a mold tray, preferably using a one-shot depositor. Using the method and apparatus, it is possible to manufacture novel confectionery products, including one-shot deposited caramel-filled dark chocolates.

Claims

1. A system for making a molded chocolate confectionery comprising a chocolate shell material and a confectionery center-fill material, comprising:

a mold tray having a plurality of cavities;

a liquid depositor adapted to deposit simultaneously a chocolate shell material and a confectionery center-fill material;

a cooling tunnel; and

an air knife positioned above the mold tray; and

a mold tray conveyor adapted to move the mold tray sequentially from the depositor, underneath the air knife and through the cooling tunnel;

wherein

each cavity in the mold tray exposes a surface of chocolate shell material to a directed stream of gas from the air knife to remove air bubbles from the confectionery as the mold tray moves underneath the air knife.

2. The system according to claim 1, wherein the air knife comprises a hollow element positioned above the mold tray, having an elongated aperture and a fan for accelerating gas through the hollow element and through the elongated aperture toward the mold tray.

3. The system according to claim 2, wherein the air knife comprises an adjustable fan producing an air velocity at the aperture in a range of about 2.5 m/s to about 50 m/s.

4. The system according to claim 1, wherein the depositor has a central conduit and one or more concentric annular conduits for co-depositing chocolate and center-fill materials.

5. The system according to claim 1, wherein the air knife is positioned on a movable mounting and the height of the air knife with respect to the mold tray is adjustable in a range of about 10 mm to about 330 mm.

6. The system according to claim 1, wherein the elongated aperture may be variably positioned to deliver a stream of gas at different angles with respect to the exposed surface of the chocolate.