A PROCESS FOR FILLING A RECEPTICLE WITH FROZEN CONFECTION

Abstract

The invention relates to a process for the preparation of a frozen confection product comprising the steps of: a. rotating a receptacle about a substantially vertical axis and depositing a continuous stream of one or more frozen confections into the receptacle; b. depositing into the receptacle a batch of solid inclusions independently from the continuous stream of frozen confection of step a.; and c. cooling the product of step b. to 5 C. or lower; wherein, the duration of steps a. to b. is 2.0 seconds or less.

Claims

1. A process for the preparation of a frozen confection product comprising the steps of: a. Rotating a receptacle about a substantially vertical axis and depositing a continuous stream of one or more frozen confections into the receptacle; b. Depositing into the receptacle a batch of solid inclusions delivered as a particulate material into the receptacle independently from the continuous stream of frozen confection of step a.; and c. Cooling the product of step b. to 5 C. or lower; wherein, the duration of steps a. to b. is 2.0 seconds or less.

2. A process according to claim 1, wherein step b. occurs during step a.

3. A process according to claim 1, wherein the batch of solid inclusions is delivered to the receptacle by conveyor belt and chute.

4. A process according to claim 1, wherein the batch of solid inclusions are deposited under gravity.

5. A process according to claim 1, wherein the batch of solid inclusions of step b. are cooled or frozen.

6. A process according to claim 1, wherein the batch of solid inclusions have an average hydraulic diameter of from 2 mm to 25 mm.

7. A process according to claim 1, wherein the receptacle is sealed after step c.

8. A process according to claim 1, wherein the receptacle is rotated from 3 to 30 times during steps a. and b.

9. A process according to claim 1, wherein the process is a continuous process wherein at least 30 receptacles are dosed per minute.

10. A process according to claim 1, wherein 95% or greater of the batch of solid inclusions are deposited in substantially the centre of the receptacle comprising the frozen confection.

11. A process according to claim 1, wherein 95% or greater of the batch of solid inclusions are deposited between the centre and the edge of the receptacle comprising the frozen confection.

12. A process according to claim 1, wherein 95% or greater of the batch of solid inclusions are deposited substantially at the edge of the receptacle comprising the frozen confection.

13. A process according to claim 1, wherein 90% or greater of the frozen confection products have a percentage deviation by weight from the mean weight of the batch of solid inclusions of frozen confection products of from 0% to 10%.

14. A product obtainable by the process of claim 1.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0069] The invention will now be illustrated, by way of example, with reference to the following figures in which:

[0070] FIG. 1 is a schematic representation of an apparatus according to the invention for carrying out the process of the present invention.

[0071] FIG. 2a is a view of a receptacle filled with ice cream and solid inclusions according to the process which has been cut in half to show the internal structure of the product.

[0072] FIG. 2b is a plan view of the receptacle shown in FIG. 2a before it has been cut in half.

[0073] FIG. 3a is a view of a receptacle filled with ice cream and solid inclusions according to the process which has been cut to show the internal structure of the product.

[0074] FIG. 3b is a plan view of the receptacle shown in FIG. 3a before it has been cut in half.

[0075] In FIG. 1 is shown a filling station 10 with a receptacle delivery station 12 and a lid placement station 14.

[0076] Receptacle delivery station 12 comprises receptacles 16 are to be deposited onto a receptacle conveyor 18. The conveyor 18 is actuated by drive shafts 20, 22.

[0077] At the filling station 10 there is provided a frozen confection dispenser 24 which may comprise one, two, three or more frozen confection delivery channels, however only one such channel is shown in the figure.

[0078] Also present at the filling station 10 is a solid inclusion dispenser 26. The solid inclusion dispenser comprises a multi-head weigher 28, a dosing belt 30 and a chute 32. Multi-head weigher 28 is fed by two linear conveyors 36, 38.

[0079] The filling station 14 also comprises a receptacle rotator 40.

[0080] The lid placement station 14 comprises an automatic lid placement device 34.

[0081] In use, receptacles 16 are fed sequentially from receptacle delivery station 12 onto conveyor 18. Conveyor 18 is driven by drive shafts 20, 22 to take the receptacles 16 towards the filling station 10.

[0082] Once at the filling station the receptacle is placed on the receptacle rotator 40. Frozen confection is then dispensed into the open top of receptacle 16 from frozen confection dispenser 24. Multiple streams of frozen confection could be delivered, providing different varieties of frozen confection. The receptacle rotator 40 rotates the receptacle 16 whilst the frozen confection is being deposited into the receptacle 16. In this example the receptacle 16 rotates 7 times in the time taken to fill the receptacle with frozen confection and solid inclusions.

[0083] At the same time as the frozen confection is being deposited, solid inclusions are also deposited into the open top of the receptacle 16 from solid inclusion dispenser 26. Multi-head weigher 28 delivers a very accurate dose of solid inclusions onto dosing belt 30. The solid inclusions are then conveyed towards the receptacle 16 and are deposited under gravity through chute 32 and into the receptacle 16 as it is being rotated. As all of the solid inclusions deposited by the multi-head weigher 28 enter the receptacle 16 an accurate dosing of solid particulate material is ensured. Additionally, as the solid inclusions have not been exposed to any form of shear and only gently handled, there are very little, if any, breakages.

[0084] Once the receptacle 16 has been suitably filled it is then transferred to the lid placement station 14 by conveyor 18. Once at the lid placement station a lid is placed onto the receptacle and it exits the apparatus. The receptacle is then cooled. The receptacle is cooled in an apparatus such as a freezer with a typical temperature of about 18 C. The temperature may vary from between 30 C. and 10 C., depending on the type of apparatus and its environment; i.e. whether it is in an industrial, commercial or domestic environment. The receptacle and contents may be stored.

[0085] The process as described may be repeated in order to achieve a rate of from 20 to 80, a rate of from 30 to 60 receptacles per minute filled according to the process of the invention.

[0086] FIGS. 2a and 2b show a frozen confection product 100 made according to the apparatus and process of the present invention. The frozen confection product 100 comprises a receptacle 102 containing an ice cream outer region 104 and an inner core of solid inclusions 106. The product was manufactured by simultaneously depositing the ice cream 104 and solid inclusions 106. The ice cream 104 was deposited near the side wall of the open top of the receptacle 102 and the solid inclusions 106 were deposited near the middle of the open top. FIGS. 2a and 2b demonstrate that the majority of solid inclusions are positioned substantially about the vertical axis located in the centre of the receptacle. At least 80%, at least 90%, at least 95% of the solid inclusions are positioned substantially about the vertical axis located in the centre of the receptacle.

[0087] FIGS. 3a and 3b show a frozen confection product 200 made according to the apparatus and process of the present invention. The frozen confection product 200 comprises a receptacle 202 containing a blend of two ice creams 204, 205 and solid inclusions 206. The product was manufactured by simultaneously depositing the ice cream 204, 205 and solid inclusions 206. The ice cream 204, 205 was fed near the side of the open top of the receptacle 202 and the solid inclusions 206 were deposited between the middle of the open top and the side of the receptacle to create the result shown. FIGS. 3a and 3b demonstrate an even distribution of solid inclusions throughout the frozen confection within the receptacle. At least 80%, at least 90%, at least 95% of the solid inclusions were distributed evenly throughout the frozen confection within the receptacle.

[0088] Alternatively, if the chute 32 is positioned towards the side wall of the receptacle 16; i.e. the solid inclusions are delivered to the receptacle towards the side wall of the receptacle, at least 80%, at least 90%, at least 95% of the solid inclusions are positioned substantially towards the side wall of the receptacle 16.

[0089] The phrase product obtainable by is intended to include, but is not limited to products obtained by the process of the invention.

[0090] General Experimental Method:

[0091] Solid particulate inclusions are dosed at a specified weight and deposited under gravity through a chute into the receptacle as it is being rotated. The average hydraulic diameter, average weight and deviation in average weight of the batch of solid inclusions dosed was calculated for each run.

Example 1

[0092] Solid inclusions were cookie pieces (target weight: 10 g; average hydraulic diameter: 12 mm).

Example 2

[0093] Solid inclusions were crumble pieces (target weight: 17 g; average hydraulic diameter: 2 mm).

Example 3

[0094] Solid inclusions were cookie pieces (target weight: 10 g; average hydraulic diameter: 12 mm). The receptacles were dosed at a rate of 30 receptacles per minute.

Example 4

[0095] Solid inclusions were crumble pieces (target weight: 5 g; average hydraulic diameter: 2 mm). The receptacles were dosed at a rate of 30 receptacles per minute.

Example 5

[0096] Solid inclusions were cookie pieces (target weight: 10 g; average hydraulic diameter: 12 mm) and crumble pieces (target weight: 5 g; average hydraulic diameter: 2 mm). The receptacles were dosed at a rate of 30 receptacles per minute.

Example 6

[0097] Solid inclusions were cookie pieces (target weight: 10 g; average hydraulic diameter: 12 mm) and crumble pieces (target weight: 5 g; average hydraulic diameter: 2 mm). The receptacles were dosed at a rate of 50 receptacles per minute.

TABLE-US-00001 TABLE 1 Deviation in weight of batches of solid inclusions per receptacle from the average weight of the batch of solid inclusions per receptacle. Solid Inclusions Cookies and Receptacles Cookies Crumble Crumble filled per Av. Dev. Av. Dev. Av. Dev. Ex. minute (g) (g) (g) (g) (g) (g) 1 9.92 0.37 2 17.4 0.48 3 30 10.0 0.21 4 30 4.77 0.25 5 30 14.8 0.32 6 50 14.62 0.33

[0098] The number of receptacles filled per minute was not measured for Examples 1 and 2; Examples 3, 4 and 5 were filled at a rate of 30 receptacles per minute and Example 4 were filled at a rate of 50 receptacles per minute.

[0099] Example 1 shows that the deviation in weight of the batch of solid inclusions from the average weight of the batch of inclusions is 0.37 g. The solid inclusions are cookies and have an average weight of 9.92 g per receptacle. The weight percent deviation of the solid inclusions from the average weight of the inclusions per frozen confection is 3.7 wt %.

[0100] Example 2 shows that the deviation in weight of the batch of solid inclusions from the average weight of the batch of inclusions is 0.48 g. The solid inclusions are crumble and have an average weight of 17.4 g per receptacle. The weight percent deviation of the solid inclusions from the average weight of the inclusions per frozen confection is 2.8 wt %.

[0101] Example 3 shows that the deviation in weight of the batch of solid inclusions from the average weight of the batch of inclusions is 0.21 g. The solid inclusions are cookies and have an average weight of 10.0 g per receptacle. The weight percent deviation of the solid inclusions from the average weight of the inclusions per frozen confection is 2.1 wt %.

[0102] Example 4 shows that the deviation in weight of the batch of solid inclusions from the average weight of the batch of inclusions is 0.25 g. The solid inclusions are crumble and have an average weight of 4.77 g per receptacle. The weight percent deviation of the solid inclusions from the average weight of the inclusions per frozen confection is 2.2 wt %.

[0103] Example 5 shows that the deviation in weight of the batch of solid inclusions from the average weight of the batch of inclusions is 0.32 g. The solid inclusions are both cookies and crumble and have an average weight of 14.8 g per receptacle. The weight percent deviation of the inclusions from the average weight of the solid inclusions per frozen confection is 2.2 wt %.

[0104] Example 6 shows that the deviation in weight of the batch of solid inclusions from the average weight of the batch of inclusions is 0.33 g. The solid inclusions are both cookies and crumble and have an average weight of 14.62 g per receptacle. The weight percent deviation of the solid inclusions from the average weight of the inclusions per frozen confection is 2.3 wt %.

[0105] All examples demonstrate the high accuracy of dosing the solid inclusions per receptacle.

[0106] Example 5 illustrates that the at a fill rate of 30 receptacles per minute; i.e. filling the receptacles of a continuous production process in 2 seconds or less, a weight percent deviation of the solid inclusions from the average weight of the inclusions per frozen confection product is 2.2 wt %.

[0107] Example 6 illustrates that the at a fill rate of 50 receptacles per minute; i.e. filling the receptacles of a continuous process in 1.2 seconds or less, a weight percent deviation of the solid inclusions from the average weight of the solid inclusions per frozen confection product is 2.3 wt %.

[0108] Examples 5 and 6 demonstrate that the process of the present invention is both accurate with regard to the dosing of the receptacle with solid inclusions and capable of accuracy of dosing at high speed of the continuous process.