DEPOSITING METHOD AND DEPOSITOR PLATE

Abstract

A method and apparatus for producing confectionery products, preferably shells for chocolate products. The invention comprises depositing one or more inclusions into a mould cavity and depositing a food product into the mould cavity through a depositor plate comprising a plurality of nozzles.

Claims

1. A method of producing a confectionery product containing externally visible inclusions, the method comprising: depositing one or more inclusions into a mould cavity; and depositing a food product into the mould cavity through a depositor plate, the depositor plate comprising a plurality of nozzles configured to direct at least a portion of the food product towards a wall of the mould cavity.

2. The method of claim 1, wherein the plurality of nozzles comprises: a first nozzle group configured to direct a first volume of the food product towards a central portion of the mould cavity; and a second nozzle group configured to direct a second volume of the food product towards the wall of the mould cavity.

3. The methods of claim 2, wherein nozzles of the second nozzle group are arranged in a circumferential arrangement with respect to the first nozzle group.

4. The method of claim 2, wherein nozzles in the second nozzle group are angled with respect to the axis of nozzles in the first nozzle group.

5. The method of claim 1, wherein the depositor plate comprises additional nozzle groups for depositing the food product into additional mould cavities.

6. The method of claim 1, comprising: the additional step of inserting a stamp into the mould cavity to press the food product towards the wall of the mould cavity to form a shell for a confectionery material; wherein a first portion of the stamp has a shape generally complementary to a shape of the mould cavity and penetrates the mould cavity such that a distance between a central region of an outer surface of the first portion of the stamp and an inner surface of the mould cavity is greater than a diameter of the one or more inclusions; and wherein a second portion of the stamp does not penetrate the mould cavity.

7. The method of claim 6, wherein the second portion of the stamp additionally comprises a chamfer located proximate the first portion.

8. The method of claim 6, wherein the second portion of the stamp abuts a rim of the mould cavity.

9. The method of claim 1, wherein depositing one or more inclusions into a mould cavity comprises depositing one or more inclusions into a mould cavity through an inclusion depositor, wherein the inclusion depositor comprises: an upper plate comprising one or more holes; a lower plate comprising one or more, the intermediate plate positioned proximate to the mould cavity during deposition of the one or more inclusions; an intermediate plate comprising one or more holes, the intermediate plate positioned between the upper plate and the lower plate; the intermediate plate is slideable between a first position, in which the one or more holes of the intermediate plate are aligned with the one or more holes of the upper plate, and a second position, in which the one or more holes of the intermediate plate are aligned with the one or more holes of the lower plate; and during deposition of the one or more inclusions into the mould cavity, the one or more inclusions sequentially pass through the upper plate, the intermediate plate and the lower plate.

10. The method of claim 9, wherein the one or more holes of the lower plate of the inclusion depositor have a diameter that is greater than a diameter of the one or more holes of the upper plate of the inclusion depositor, and wherein the one or more holes of the intermediate plate have a conical shape, and the one or more holes of the intermediate plate having a smallest diameter equal to the diameter of the one or more holes of the upper plate, and the one or more holes of the intermediate plate having a largest diameter equal to the one or more holes of the lower plate.

11. The method of claim 9, wherein the one or more holes of the upper plate are laterally offset from the one or more holes of the lower plate.

12. The method of claim 1, further comprising the additional step of vibrating the mould cavity after depositing the food product into the mould cavity.

13. (canceled)

14. An inclusion depositor for depositing inclusions into mould cavities, the inclusion depositor comprising: an upper plate comprising one or more holes; a lower plate comprising one or more, the intermediate plate positioned proximate to the mould cavity during deposition of the one or more inclusions; an intermediate plate comprising one or more holes, the intermediate plate positioned between the upper plate and the lower plate; and wherein the intermediate plate is slideable between a first position, in which the one or more holes of the intermediate plate are aligned with the one or more holes of the upper plate, and a second position, in which the one or more holes of the intermediate plate are aligned with the one or more holes of the lower plate.

15. A depositor plate for use in producing shells for confectionery products containing externally visible inclusions, the depositor plate comprising: a plurality of nozzles configured to direct at least a portion of a food product towards a wall of a mould cavity.

16-19. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0083] Embodiments of the invention will now be described, by way of example only, with reference to the following figures.

[0084] In accordance with one (or more) embodiments of the present invention, the Figures show the following:

[0085] FIGS. 1A-C show a traditional method for producing chocolate shells for confectionery products;

[0086] FIG. 2A shows a cross-sectional view of an inclusion depositor with an intermediate in a first position according to an example of the disclosure;

[0087] FIG. 2B shows a cross-sectional view of an inclusion depositor with an intermediate in a second position according to an example of the disclosure;

[0088] FIG. 3A shows a depositor plate for depositing a food product into a mould cavity;

[0089] FIG. 3B shows the depositor plate shown in FIG. 3A from an alternative angle;

[0090] FIG. 4A shows a close-up view of the depositor plate shown in FIGS. 3A and 3B;

[0091] FIG. 4B shows a cross-sectional view of the depositor plate shown in FIG. 4A;

[0092] FIG. 5 shows a depositor plate and mould cavity for deposition of a food product;

[0093] FIG. 6A shows a stamp and mould cavity for shaping deposited chocolate;

[0094] FIG. 6B shows the stamp of FIG. 6B when inserted into the mould cavity;

[0095] FIG. 6C shows a shell for a confectionery product in a mould cavity after the stamp has been removed from the mould cavity;

[0096] FIG. 7 shows a flow diagram of the steps of a method for producing shells for confectionery products;

[0097] FIG. 8 shows a flow diagram for producing filled confectionery products, continuing from the flow diagram shown in FIG. 7;

[0098] FIGS. 9A-9D show inventive example confectionery products produced according to example techniques described herein;

[0099] FIGS. 10A and 10B show a depositor plate for backing off a confectionery product.

[0100] FIGS. 11A and 11B show a side-by-side comparison of comparative examples using a ‘single-shot’ deposition technique and the inventive examples of the present application.

[0101] Any reference to prior art documents in this specification is not to be considered an admission that such prior art is widely known or forms part of the common general knowledge in the field.

[0102] As used in this specification, the words “comprises”, “comprising”, and similar words, are not to be interpreted in an exclusive or exhaustive sense. In other words, they are intended to mean “including, but not limited to”.

DETAILED DESCRIPTION

[0103] As discussed above, the present invention relates to providing a food product, preferably a confectionery product, preferably a chocolate-product, comprising visible inclusions.

[0104] In a preferred embodiment, the invention provides a method of producing a shell for a confectionery product, a tablet of a confectionery product (e.g. a bar of chocolate) or a confectionery product piece (e.g. a bon bon). Each of the above may be filled with a filling or not filled. Although the preferred examples below are described in reference to a confectionery shell, the embodiment may be applicable to producing a tablet or a confectionery piece, where appropriate. However, the most preferred embodiment of the present invention relates to preparing a shell for a confectionery product.

[0105] As used herein the term ‘inclusion’ denotes an edible body and/or particle of distinct composition which is embedded (or capable of being embedded) wholly or partially in a food composition. Inclusions are often used to provide contrasting texture, hardness, visual appearance and/or flavour to the material in which they are embedded thus a unique eating and sensory experience to the consumer consuming the product. Typically, more than one inclusion will be incorporated in single portion of the food composition that comprises inclusions. It can be desirable in many products for inclusions to be dispersed as evenly as possible within the product (or within a sub-set of the product such as in a layer or filling thereof) so each mouthful of the product provides a consistent eating experience.

[0106] Conveniently, the inclusions comprise any of the following non-limiting list (more conveniently selected from the group consisting of): [0107] fruits or fruit pieces which may comprise: hard fruits (e.g. seeds, nuts such as hazelnuts, almonds, brazil nuts, cashew nuts, peanuts, pecans and/or similar); soft fruits (e.g. raisins, cranberries, blueberries, blackcurrant, apples, pear, orange, apricot and/or similar); and/or freeze-dried fruit pieces, candied fruit and/or alcohol-soaked fruit, preferred soft fruits are dried fruits; [0108] crispy inclusions (e.g. caramel, coffee, biscuits, wafer, etc.); [0109] herbs (for example chives, dill, coriander, parsley); [0110] cereals (for example puffed rice, puffed wheat, extruded cereal pieces); [0111] chocolate or choco-material (for example chocolate vermicelli, chocolate shapes); [0112] sugar confectionery (for example cinder toffee pieces, toffee, fudge, caramel, fondant pieces, jelly pieces; [0113] marshmallow, sugar-panned centres such as those available commercially from Nestle under the trade mark mini SMARTIES®); and/or [0114] any suitable mixtures and/or combinations thereof.

[0115] Preferred inclusions have an average size from 1 to 50 mm, from 2 to 40 mm, from 3 to 25 mm or from 5 to 10 mm or from 2 to 6 mm.

[0116] In a further example, the product produced according to the method and apparatus described herein comprises inclusions with an average diameter greater than 2 mm, for example inclusions, which are retained by a sieve with a 2 mm opening. The inclusions may have a diameter ranging from 2 mm to 22.6 mm, for example inclusions, which pass through a sieve with an opening of 22.6 mm but are retained by a sieve with a 2 mm opening. The inclusions may have a diameter ranging from 2.83 mm to 11.2 mm, for example inclusions, which pass through a sieve with an opening of 11.2 mm but are retained by a sieve with a 2.83 mm opening.

[0117] As mentioned above, the term “visible inclusions”, e.g. fruits, nuts, dried fruit etc., means that the preferably particulate inclusions are visible at an external surface of the product, i.e. that at least a portion of the fruits or fruit pieces facing to an external surface of the chocolate product is not covered with material, preferably chocolate material, but is visible for a consumer. The inclusions are preferably visible on the profiled side of the chocolate product which is opposed to the flat bottom side.

[0118] Within the context of the present invention, the term “profiled side” of the product indicates the side, aspect or surface which is opposed to the bottom side and which is shaped by moulding in the moulds according to the present invention. For the sake of clarity, the profiled side of the product corresponds to that side, aspect or surface of the product which, during the moulding process, is in contact with the mould surface.

[0119] Preferably, the product comprises between 25 and 100% surface area coverage, for example, between 30 and 95%, between 40 and 90%, or between 50% and 80% visible inclusions with respect to the profiled side surface of the product.

[0120] FIGS. 1A to 10 illustrate an example of a traditional method for producing chocolate shells for confectionery products. First, as shown in FIG. 1A, chocolate 101 is deposited into a mould cavity 102. After the chocolate 101 has been deposited, a stamp 103 is inserted into the mould cavity 102 to shape the chocolate into a shell 104, as shown in FIG. 1B. Then, as demonstrated in FIG. 10, the stamp 103 is removed, after which the chocolate shell 104 may be filled with a filling before the product is ‘backed-off’ by depositing a thin layer of chocolate on top of the filling to seal the filling within the chocolate to produce a filled confectionery product. The finished product can then be removed from the mould cavity 102 for packing and subsequent distribution.

[0121] Such a method is commonly referred to as ‘cold-forming’ or ‘cold-stamping’. These operations can be carried out on large single or multiple rows of mould cavities simultaneously to facilitate mass production of confectionery products.

[0122] These traditional methods are, however, unsuitable for producing shells for confectionery products containing inclusions that are visible externally (i.e. not entirely covered in a layer of chocolate). Whilst it is accepted that it is known in the art to use such methods to produce chocolate shells where inclusions are contained within the shell, the prior art methods do not offer the requisite control of the process steps in order to produce a product with visible inclusions that are securely attached to the shell and in a manner that is industrially feasible.

[0123] According to an example teaching of the disclosure, in order to produce such shells inclusions are initially deposited in a mould cavity.

[0124] FIG. 2A illustrates a cross-sectional view of an inclusion depositor 200, which may be used for depositing inclusions 201 into a mould according to an example teaching of the disclosure. The depositor includes an upper plate 210, which includes one or more holes 211 through which the inclusions 201 can pass, and a lower plate 230, which includes one or more holes 231 through which the inclusions can pass. The depositor also includes an intermediate plate 220 disposed between the upper plate 210 and the lower plate 230, the intermediate plate 220 comprising one or more holes 221.

[0125] As shown, the holes of the upper plate 210 and lower plate 230 may not be aligned with each other (i.e. may be laterally offset) such that inclusions 201 cannot fall directly through both sets of holes.

[0126] In the present example, each of the holes in the upper plate 210, intermediate plate 220 and lower plate 230 correspond to a particular mould cavity for a confectionery product. However, each of the upper plate 210, intermediate plate 220 and lower plate 230 could include multiple holes per mould cavity.

[0127] In this example, the diameter of the holes 211 of the upper plate 210 is smaller than the diameter of the holes 231 of the lower plate 230. As shown, the holes 221 of the intermediate plate 220 may be conical with an upper diameter (proximate to the upper plate 210) equal to the diameter of the holes 211 of the upper plate 210 and a lower diameter (proximate to the lower plate 230) equal to the diameter of the holes 231 of the lower plate 230. Although not shown, chamfers (or an edge radius) may be provided on any of the holes of the upper plate 210, intermediate plate 220 and/or lower plate 230 to avoid cutting or otherwise damaging the inclusions 201 during deposition.

[0128] The intermediate plate 220 is slideable between a first position and a second position during the deposition process using an actuator 250. FIG. 2A illustrates the depositor 200 with the intermediate plate 220 in the first position. In the first position, the holes 221 of the intermediate plate 220 are aligned to the holes 211 of the upper plate 210 to allow the inclusions 201 to fall through the holes 211 of the upper plate 210 and into the holes 221 of the intermediate plate 220.

[0129] FIG. 2B illustrates the depositor 200 with the intermediate plate 220 in the second position. In this position, the holes 221 of the intermediate plate 220 are aligned to the holes 231 of the lower plate 230 to allow the inclusion to fall from the holes 221 of the intermediate plate 220, through the holes 231 of the lower plate 230, and into mould cavities.

[0130] During deposition of the inclusions 201, the intermediate plate 220 is initially in the first position. The inclusions 201 are placed on a top surface of the upper plate 210 and are contained by a rim 240 of the upper plate 210. Due to the alignment of the holes of the upper plate 210 and the intermediate plate 220, some or all of the inclusions 201 fall into the holes 221 of the intermediate plate 220.

[0131] The actuator 250 then slides the intermediate plate 220 into the second position. The inclusions 201 previously positioned in the holes 221 of the intermediate plate 220 are able to pass through the holes 231 of the lower plate 230 and fall into a mould cavity.

[0132] The actuator 250 may cause the intermediate plate 220 to move between the first and second position many times during deposition, potentially many times per second.

[0133] After the inclusions 201 have been deposited in mould cavities, chocolate is deposited in the mould cavities for producing the shells for the confectionery products. The chocolate may be deposited through a depositor plate such as that shown in FIGS. 3A and 3B.

[0134] FIG. 3A illustrates a depositor plate 300 for depositing chocolate (or any suitable food product) into multiple mould cavities. The depositor plate 300 may include a plurality of depositing sections 301, each depositing section including a plurality of nozzles 310. The depositor plate shown contains 96 depositing sections 301 and is therefore capable of depositing chocolate into up to 96 separate mould cavities. However, multiple depositing sections 301 could be used to deposit chocolate into a single mould cavity. Further, different numbers of depositing sections 301 are possible.

[0135] As shown in FIG. 3B, the depositor plate 300 includes a top surface 302 and a bottom surface 303 (no shown). The bottom surface is the surface positioned closest to the mould cavities during deposition. Furthermore, the depositing sections 301 may be recessed in the top surface 302 of the depositor plate 300, as shown.

[0136] FIG. 4A provides a close up view of a depositing section 301. The depositing section 310 shown is circular in shape, however the shape of the depositing sections 310 is dependent upon the shape of the mould cavities into which chocolate is deposited and may, therefore, be different.

[0137] The depositing section 301 includes a plurality of nozzles, in particular, the depositing section may include a first nozzle group 311 and a second nozzle group 312. The nozzles in the first nozzle group 311 are positioned in a central region of the depositing section 301. During deposition, the nozzles in the first nozzle group 311 are located directly above a central region of a mould cavity so as to deposit chocolate towards the central region of the mould cavity.

[0138] In the example of FIG. 3A, the first nozzle group 311 contains 4 nozzles and the first nozzle group 312 contains 8 nozzles, however different nozzle numbers and arrangements are possible.

[0139] The nozzles in the second nozzle group 312 are located at a periphery of the depositing section 301. As shown in FIG. 4A, the nozzles in the second nozzle group 312 may be located in a circumferential arrangement with respect to the nozzles in the first nozzle group 311.

[0140] During deposition, the nozzles in the second nozzle group 312 may be located directly above a wall of a mould cavity so as to deposit chocolate towards the wall of the mould cavity. Alternatively, the nozzles in the second nozzle group 312 may be angled with respect to the nozzles of the first nozzle group and accordingly the nozzles are not required to be located directly above the wall of the mould cavity during deposition.

[0141] FIG. 4B illustrates a cross-section the depositing section 301 of depositor plate 300 taken along line A-A shown in FIG. 4A. As shown, the axis of the nozzles in both the first nozzle group 311 and second nozzle group 312 (that is the axis of the nozzles in the direction along which the food product flows through the nozzle during deposition into the mould cavity) are perpendicular to the bottom surface 303 of the depositor plate 300.

[0142] However, the axis of one or more nozzles in either of the nozzle groups could be formed with a different angle with respect to the bottom surface 303 of the depositor plate 300. In particular, nozzles in the second nozzle group 312 may be angled with respect to the nozzles of the first nozzle group, allowing the food product to be deposited in different directions.

[0143] For example, the nozzles of the second nozzle group 312 may be angled radially outwards with respect to the perpendicular axis of the nozzles of the first nozzle group 311. The angle with respect to the perpendicular axis of the nozzles of the first nozzle group 311 could be 4-5 degrees, however other angles are possible.

[0144] Furthermore, while the axes of the nozzles are depicted as being straight, they could, for example, instead be arcuate, allowing greater precision in direction the flow of the food product during deposition.

[0145] FIG. 5 illustrates the positioning of the depositor plate 300 with respect to a mould cavity 400. The mould cavity 400 includes a central portion 401 in which inclusions 201 are generally located. The mould cavity 400 also includes a wall 402. The wall 402 of the mould cavity 400 is shown as being near-vertical in order to allow chocolate to be deposited onto the wall 402 through the depositor plate 300. However the gradient of the wall 402 could be much shallower than that shown and could be curved. The mould cavity 400 is formed out of a top surface 404 of a plate and the mould cavity 400 includes a rim 403 where the wall 402 meets the top surface 404.

[0146] During deposition, chocolate passes through the nozzles in the first nozzle group 311 of depositor plate 300 to deposit chocolate towards the central portion 401 of the mould cavity.

[0147] Furthermore, chocolate passes through the nozzles in the second nozzle group 312 of the depositor plate 300 to deposit chocolate towards the wall 402 of the mould cavity 400.

[0148] After the chocolate 101 has been deposited into the mould cavity 400, a modified stamping or ‘cold-forming’ process or is used to shape the deposited chocolate 101.

[0149] FIG. 6A illustrates a stamp 600 used in the modified stamping process. The stamp 600 includes a first portion 610 and a second portion 620, with the first portion 610 protruding from the second portion 620. The first portion 610 of the stamp is configured to penetrate the mould cavity 400 during the stamping process. The first portion 610 of the stamp 600 includes a central surface 611 corresponding to the central portion 401 of the mould cavity 400, and a side surface 612 corresponding to the wall 402 of the mould cavity 400.

[0150] In FIG. 6A, the chocolate 101 prior the stamping process is shown as extending along an entire height of the wall 402 of the mould cavity 400 to the rim 403. However, it is appreciated that the chocolate 101 is not required to extend along the entire height of the wall 402 but may instead extend only partially along the wall 402, for example 50% (or less) of the height of the wall 402.

[0151] The second portion 620 includes a surface that is generally parallel to the top surface 404 out of which the mould cavity 400 is formed during the stamping process.

[0152] The stamp 400 may also include a chamfer or edge radius 621 located between the first portion 610 and the second portion 620, however the chamfer 621 may be considered to form part of the second portion 620.

[0153] As shown in FIG. 6B, during the stamping process the stamp 600 is lowered toward the mould cavity 400 such that the first portion 610 penetrates the mould cavity 400. The stamp 600 is lowered until the second portion 620 or the chamfer 621 abuts the top surface 404 or rim 403, thereby fully inserting the stamp 600 into the mould cavity.

[0154] As shown, a distance between the central surface 611 of the first portion 610 and the central portion 401 of the mould cavity 400 is larger than the diameter of the inclusions 201, such that the inclusions 201 are not damaged when the stamp 600 is fully inserted into the mould cavity 400. Moreover, the inclusions do not pierce through the chocolate shell, which would cause a filling of a finished confectionery product to leak. Furthermore, the distance between the central surface 611 of the first portion 610 and the central portion 401 of the mould cavity 400 is larger than a distance between the side surface 612 of the first portion 610 and a wall 402 of the mould cavity 400.

[0155] The insertion of the first portion 610 of the stamp 600 into the mould cavity 400 helps to shape the chocolate 101 into a shell shape with controlled thickness.

[0156] Furthermore, at least the first portion 610 of the stamp 600 may be cooled to cause the chocolate 101 in the mould cavity 400 to at least partially solidify when in contact with the stamp 600.

[0157] As shown in FIG. 6C, the stamp 600 is then removed from the mould cavity 400 leaving an empty shell for a confectionery product in the mould cavity. The empty shell can then be filled with a suitable filling (such as jelly, chocolate, mousse, honeycomb, etc.) and a chocolate base deposited on top of the mould cavity to seal (back-off) the filling within the chocolate.

[0158] As shown, the portion of the shell proximate the rim 403 of the mould cavity may have an angled surface relative to the top surface 404 created by the chamfer 621 of the stamp 600. During any subsequent backing-off of the shell, the angled surface of the shell proximate the rim 403 provides a large surface area for improving the quality of the seal between the shell and the back-off.

[0159] FIG. 7 is a flow chart for producing shells for confectionery products containing externally visible inclusions. At step 701 inclusions 201 are deposited into a mould cavity 400. The inclusions may be deposited using the inclusions depositor shown in FIGS. 2A and 2B, however the inclusions could be deposited using alternative deposition means known in the art.

[0160] At step 702, the food product (for example chocolate) is deposited into the mould cavity 400 through a depositor plate, the depositor plate comprising a plurality of nozzles configured to direct at least a portion of the food product towards a wall of the mould cavity. The depositor plate may be the depositor plate 300 depicted in FIGS. 3A, 3B 4A and 4b, however other depositor plates including a plurality of nozzles configured to direct at least a portion of the food product towards a wall 402 of the mould cavity 400 could be used.

[0161] Optionally at step 703, the mould cavity (containing the inclusions and food product) may be vibrated. The vibration of the mould cavity helps to create a smooth shell allows for greater control of the thickness of the shell. However, the intensity and duration of vibration that is used can be reduced as compared to a situation where the depositor plate of the present invention is not used to deposit the food product into the mould cavity.

[0162] Optionally at step 704, a stamp is inserted into the mould cavity to help shape the food product into a smooth shape. Furthermore, the stamp may be the stamp 600 shown in FIGS. 6A and 6B and inserted according to the process depicted therein.

[0163] Optionally at step 705, the stamp is then removed from the mould cavity, leaving a shell for a confectionery product.

[0164] The skilled person would appreciate that any number of additional steps used in forming confectionery products and understood by the skilled reader may also be included in the production of the shell.

[0165] FIG. 8 is a flow chart for producing a confectionery product from a shell produced according to the method shown in FIG. 7. At step 801, after the stamp has been removed from the mould cavity, a second food product is deposited into the mould cavity. The second food product can be deposited into the shell using known means.

[0166] At step 802, a third food product is deposited onto the mould cavity through a second depositor plate comprising a plurality of nozzles to seal the second food product within the first and third food products. The third food product may be the same as the first food product.

[0167] The second depositor plate may be a depositor plate as shown in FIGS. 3A, 3B, 4A and 4B. Alternatively, the second depositor plate could be a different depositor plate comprising a plurality of nozzles configured to direct the third food product onto the mould cavity. The plurality of nozzles helps to prevent the third food product from mixing with the second food product.

[0168] The cross-sectional area over which the third food product is deposited through the second depositor plate is preferably smaller than a cross-sectional area of the mould cavity at the rim of the mould cavity. This helps to seal the confectionery product, while preventing spillage of the third food product outside of the mould cavity, causing wastage of (potentially expensive) ingredients. As an example, the confectionery product may have a circular cross-sectional shape, with a diameter of 31 mm, while the second depositor plate only deposits the third food product over 22.34 mm. Furthermore, if the shell includes an angled surface proximate the rim, as shown in FIG. 6C, it is not necessary to deposit the food product across the entire width of the shell in order to effectively seal the second food product within the first and third food products.

[0169] As described herein the method and apparatus described may also be used to make other consumable products such as savoury foods where it is desirable to provide visible inclusions around the surface of the product in an efficient and economical way.

[0170] The invention is further described with reference to the following examples. It will be appreciated that the invention as claimed is not intended to be limited in any way by these examples. It will be further recognised that the skilled reader will understand from the teaching herein that integers and features of different embodiments may be used in any suitable and advantageous combination.

EXAMPLES

[0171] The following products were made using the method and apparatus of the present invention. The values given in the table relates to the percentage (%) amounts by weight of each component.

TABLE-US-00001 % visibility - Example Filling Shell Back Inclusion surface area Product description 1 41.30 38.76 13.95 6 61 Dark chocolate shell and back, caramel filling and 2-4 mm almond pieces, 13.0 g 2 33.91 40.24 20.79 5.06 67 Milk chocolate shell and back, dark chocolate emulsion filling and Cocoa Nibs 2-5 mm, 12.55 g 3 31.89 40.64 23.15 4.32 49 Milk chocolate shell and back, hazelnut paste and hazelnut pieces, 12.63 g 4 40.78 40.87 17.06 1.29 48 Dark chocolate shell and back, oil in water raspberry emulsion and freeze dried raspberry pieces 0-6 mm, 11.86 g

[0172] Examples 1-4 are shown in FIGS. 9A-9D respectively.

[0173] The inclusions were deposited in the moulds using an inclusion depositor as shown in the figures. The deposition conical orifices in the sliding plate have 11 m holes in the upper surface and 14 mm holes in the lower surface and deposit between 0.16 g (Example 4) and 1.16 g (Example 4).

[0174] The ingredients are dosed over 300 ms using an arm that travels forwards and backwards to push the ingredients into the holes of the depositor. The number of times that the arm goes forward and backwards per depositing cycle is 3 for Examples 1 and 3, 2 for Example 2 and 1 for Example 4. The sliding plate then deposits the inclusions.

[0175] Subsequently liquid chocolate at 29° C. is deposited using the depositor plate displayed in FIGS. 3A, 3B, 4A, and 4B. The depositor section 301 has a diameter of 22.34 mm and the mould cavity a diameter of 31 mm.

[0176] The second outer nozzle arrangement covers 7.5% of the surface area of the mould cavity opening and 13.6% of the surface area of the portion of the depositor plate for that mould cavity. The first inner nozzle arrangement covers 3.7% of the surface area of the mould cavity opening and 6.8% of the surface area of the portion of the depositor plate for that mould cavity, The centres of the second and first nozzle groups are separated by 50% of the radius of the depositing section.

[0177] The shells are cold-stamped using a stamp at a temperature of −16 to −17° C. for a time of 1200 ms or 1400 ms (Example 3). The stamp is fully inserted into the mould leaving a shell thickness of 4 mm on the profile surface and a wall thickness of 2 mm.

[0178] The filling is then deposited and the product is cooled. The products are subsequently backed off and licking rollers are used to remove excess chocolate and cooled at 14° C. The backing off is achieved using a plate as shown in in FIG. 10A and FIG. 10B, which show the same depositor plate from different angles. The components of the depositor plate in FIGS. 10A and 10B generally correspond to those of the depositor plate shown in FIGS. 3A and 3B, however the depositor plate of FIGS. 10A and 10B deposits chocolate over a smaller surface area and contains three depositing sections per recess. This ensures that the amount of chocolate wasted is minimised, i.e. chocolate is deposited on the product not on the mould.

[0179] The percentage visibility of the inclusions was assessed using an image of the product by measuring the pixel area and mapping a gate around the inclusions.

[0180] Examples 1 to 3 were repeated (Comparative Examples 1 to 3) using a ‘single-shot’ depositor.

[0181] The following differences were observed:

TABLE-US-00002 Feature Comparative Examples 1 to 3 Examples 1 to 4 Visible visibility The ingredients are gathered Consistent ingredients Inclusions at one side of the product visibility thanks to due to mould movement chocolate-shell during production depositing, and cold stamp shell forming. adherence/ Only the larger Inclusions Smaller inclusions size adhered to the shell (3-4 mm) can be (6 mm approx.). deposited and still A portion of the inclusions stick well to the shell. is loose and get lost during demoulding. Shell thickness Thicker shell needed to Thinner shell can prevent leakages. be achieved. uniformity Heterogeneous shell Uniform shell integrity/ Higher Risk of leakages due Better shell integrity leakages to ingredients “piercing” the (less leakages due to shell and allowing the ingredients “piercing” filling to go through. the shell and allowing the filling to go through) owing to cool stamp design. Filling repartition The filling repartition More consistent depends strongly on the repartition of the filling viscosity. filling/shell. Backing Flatness Uneven backing off (outside Flat and even backing off off (outside visible part) and hard to remove (inside part in contact with visible bubbles/tail as shaking cannot the filling, and outside part) be used visible part) thanks to cool core and rain plate. Flatness Sinking backing off. (inside part- cut view) integrity/ Risks of leakages when the Very small leakage risk leakages filling is tailing. with liquid filling.

[0182] A side-by-side comparison of select examples above are shown pictorially in FIG. 11A (Comparative Examples 1-3: ‘single-shot’ deposition) and FIG. 11B (Inventive Examples 1-4).

Comparative Example 4

[0183] Two prior art processes were assessed for their applicability in preparing the product of the present invention.

[0184] The process of WO2015166451 is unable to obtain the products of the present invention as the chocolate and inclusions are pre-mixed and the deposition does not allow the necessary control of the chocolate flow to afford visible conclusions. There is no information as to how to deposit the chocolate.

[0185] The process of WO2013006599 does not provide the control of the present invention in providing visible inclusions that are suitably bound to the shell. As shown in the figures and as would be provided by the vibration steps in the examples, the inclusions will be mixed into the chocolate prior to cold stamping, minimising the degree of visibility. There is no information as to how to deposit the chocolate.

[0186] Additionally, the deposition of inclusions and backing off methods of the present invention afford a greater control of both of these process steps than the methods of these documents.