Automated manufacturing process for molded confections

Abstract

An automated process for manufacturing molded confections featuring a three-dimensional mold stack process that is compact, non-starch, and steam-less. The process steps include selecting mold sets for a desired production sequence; loading them onto the system; performing a mold release application; in parallel, preparing and pumping the ingredients; depositing ingredients into the mold sets and transferring them to a temperature and humidity controlled forming room; inverting the mold sets; de-molding candy pieces/product with a rotating brush mechanism from the mold sets and transferring the product to a belt conveyor; inverting and returning the mold sets to a mold release or a new mold insertion step; sending the product to a transfer and collection conveyor; sending the product to a temperature and humidity controlled curing room; surging and then sending the product to a package and label machine; and finally sending the packaged product for shipping/distribution.

Claims

1. A unique automated manufacturing process for a three-dimensional 3-D molded gel confection product is comprised of: Zone A Preparing and changing-out the mold or mold sets, which have an aperture(s)/port and which determine the product types; Zone B Preparing a group of ingredients for the 3-D molded gel confection product, comprised of mixing and pumping the ingredients; Zone C Producing, without additional heat or a use of starch, the 3-D molded gel confection product; and Zone D Finishing the 3-D molded gel confection product, comprised of preparing and packing-out the confection product wherein the automated manufacturing process for a three-dimensional 3-D molded gel confection product can be adapted to a space saving footprint; wherein the space saving footprint can be used for initial volumes in introductory markets; and wherein the space saving footprint without huge steam, vacuum and compressed air is less costly for the initial capital investment since the assets are less costly.

2. The process in claim 1 wherein the Zone A is further comprised of: Step 1: selecting a mold (35) or mold sets, with an aperture(s)/port (66), for a desired production sequence; Step 2: loading (36) the selected mold or mold sets onto an assembly system and thereby establishing a mold housing assembly (37) made of the mold or mold sets; and Step 3: transferring the mold housing assembly steps (34) and sequential steps with the mold housing assembly.

3. The process in claim 2 wherein the Zone B is further comprised of: Step 4: preparing the ingredients (41) which are mixed and stored; and Step 5: pumping the ingredient by a pump (42).

4. The process in claim 3 wherein the Zone C is further comprised of: Step 6: performing an application of a mold release material (38) which includes a starch-less means for releasing (39), the means located inside an unheated enclosure of an HVAC ventilation system (40), the HVAC system having temperature and humidity control features; Step 7: depositing (43) the ingredients into the apertures/port (66) of the molds or mold sets; Step 8: transferring the mold housing assembly to an unheated forming room (44); Step 9: inverting (45) the mold housing assembly; Step 10: Clearing and de-molding step (47) with a brush paddle mechanism (48) that removes the 3-D molded gel confection product and a quantity of molded gel confection drops (46) to a transfer belt conveyor; and Step 11: re-inverting the mold housing assembly (45A) and the mold housing assembly returns for re-use to load (36) or directly to the application of the mold release material (38).

5. The process in claim 4 wherein the means for releasing (39) is selected from the group consisting of a spray, a mist, and a liquid applicator.

6. The process in claim 4 wherein the ventilation system (40) is further comprised of an enclosure and a duct fan.

7. The process in claim 4 wherein the forming room (44) has temperature and humidity control.

8. The process in claim 4 wherein the inverting (45) mold housing assembly is selected from a group consisting of a conveyor, a walking beam, and a pick and place system.

9. The process in claim 4 wherein the mechanism for the clearing and de-molding step (47) with mechanism (48) is selected from the group consisting of a rotating brush and a rotating spatula.

10. The process in claim 4 wherein the Zone D is further comprised of: Step 12: sending the 3-D molded gel confection product to a transfer (49); Step 13: transferring the 3-D molded gel confection product to a temperature and humidity controlled curing room (50); Step 14: transferring the 3-D molded gel confection product to a means for surging the 3-D molded gel confection product (51); Step 15: packaging and labeling (52) the 3-D molded gel confection product; and Step 16 transferring the labelled package to a box, and pallet and label (53) the box for shipping and distribution.

11. The process in claim 10 wherein the curing room (50) has temperature and humidity control for a set of cooling trays in a surge system.

12. A unique automated manufacturing process for a three dimensional 3-D molded gel confection product is comprised of: Step 1: selecting a mold (35) or mold sets, with an aperture(s)/port (66), for a desired production sequence; Step 2: loading (36) the selected mold or mold sets onto an assembly system and thereby establishing a mold housing assembly (37) made of the mold or mold sets; Step 3: transferring the mold housing assembly steps (34) and taking sequential steps with the mold housing assembly; Step 4: performing an application of a mold release material (38) which includes a means for releasing (39), the means located inside an enclosure of a ventilation system (40); Step 5: preparing the ingredients (41) which are mixed and stored as a mixture of ingredients; Step 6: pumping the mixture of ingredients by a pump (42); Step 7: depositing (43) the mixture of ingredients into the apertures/port (66) of the starch-less mold(s); Step 8: transferring the mold housing assembly to an unheated forming room (44); Step 9: inverting (45) the mold housing assembly; Step 10: Clearing and de-molding step (47) with mechanism (48) that removes the mixture of ingredients as the 3-D molded gel confection product and a quantity of molded gel confection drops (46) to a transfer belt conveyor; Step 11: re-inverting the mold housing assembly (45A) and returning the mold housing assembly for re-use to load (36) or directly to the application of the mold release material (38); Step 12: sending the 3-D molded gel confection product to a transfer (49); Step 13: transferring the 3-D molded gel confection product to a curing room (50) which has a temperature and humidity control system for a set of cooling trays in a surge system; Step 14: transferring the 3-D molded gel confection product to a means for surging the 3-D molded gel confection product (51); Step 15: packaging and labeling (52) the 3-D molded gel confection product; and Step 16 transferring the labelled package to a box, and pallet and label (53) the box for shipping and distribution. wherein the automated manufacturing process for a three-dimensional 3-D molded gel confection product can be adapted to a space saving footprint; wherein the space saving footprint can be used for initial volumes in introductory markets; and wherein the space saving footprint without huge steam, vacuum and compressed air is less costly for the initial capital investment since the assets are less costly.

13. The process in claim 12 wherein the release means (39) is selected from the group consisting of a spray, a mist, and a liquid applicator.

14. The process in claim 12 wherein the ventilation system (40) is further comprised of an enclosure and a duct fan.

15. The process in claim 12 wherein the ingredients are selected from a group consisting of Sucrose, Gelatin, Corn Syrup, Flavors and colors, fructose, dextrose, artificial/low-calorie sweetener, rice syrup, pectin, modified starch, dextrin, fruit pulp/juice, dairy ingredients including milk and whey, egg white, nut/nut paste, fat/oil, vitamins/ and nutraceuticals.

16. The process in claim 12 wherein the forming room (44) has temperature and humidity control.

17. The process in claim 12 wherein the inverting (45) mold assembly is selected from a group consisting of a conveyor, a walking beam, and a pick and place system.

18. The process in claim 12 wherein the collection means (49) is selected from a group consisting of conveyors and vibrating tables.

19. The process in claim 12 wherein the curing room (50) has temperature and humidity control for a set of cooling trays in a surge system.

20. The process in claim 12 wherein the mechanism for the Clearing and de-molding step (47) with mechanism (48) is selected from the group consisting of a rotating brush and a rotating spatula.

Description

DESCRIPTION OF THE DRAWINGSFIGURES

[0019] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate an embodiment of the unique automated manufacturing process for molded confections that is preferred. The drawings together with the summary description given above and a detailed description given below serve to explain the principles of the unique automated manufacturing process for molded confections. It is understood, however, that the unique automated manufacturing process for molded confections is not limited to only the precise arrangements and instrumentalities shown.

[0020] FIG. 1 is a sketch of the unique automated manufacturing process for molded confections.

[0021] FIG. 2 is a sketch of the unique molded confections process without forming and curing rooms shown.

[0022] FIG. 3 is a sketch of the unique mold system that is utilized for the process shown.

[0023] FIG. 4 is a process flow chart of the automated molded confections process.

[0024] FIGS. 5 A and 5 B is a sketch of the mold clearing/de-molding mechanism (rotating brushes) process in the automated molded confections process and a comparison of candy piece detail possible with the brush.

[0025] FIG. 6 is a reference sketch of a non automated, traditional starch (Mogul) candy process.

[0026] FIG. 7 A is a layout of the old steam and starch system (traditional starch (Mogul) candy process) and FIG. 7 B is a layout of the new automated manufacturing process for molded confections without steam or starch with a significantly reduced floor space.

DESCRIPTION OF THE DRAWINGSREFERENCE NUMERALS

[0027] The following list refers to the drawing reference numbers.

TABLE-US-00002 Ref # Description Zone A Mold preparation - repair, change out of product types, etc. Zone B Ingredient preparation, mix and pump Zone C Production of main 3-D confection product Zone D Finish product, prepare and pack-out 30 Unique automated process for making starch-less molded confections 30A Unique process 30 without forming and curing rooms 31 Unique flowchart 31 of automated process 33 Ingredients 33 - Sucrose, Gelatin, Corn Syrup, Flavors and colors 33A Means 33A to transfer to mix tank 41 34 Transfer steps 34 - various A through G 35 Select mold 35 36 Load mold 36 onto mold housing assembly 35 37 Mold housing assembly 37 38 Mold release application 38 39 Release means 39 (applied by spray, mist, liquid, etc.) 40 Ventilation system 40 (enclosure and duct fan) 41 Ingredients mix and store 41 42 Ingredients pump 42 43 Deposit ingredients 43 into molds 44 Forming room 44 (Heating, Ventilation and air condition system [HVAC system] with: temperature and humidity control) 45 Invert mold assembly 45 [conveyor, walking beam, pick and place etc. presented as examples and not as limitations] 45A Invert mold assembly 45A - return for re-use to load 36 or direct to mold release application 38 46 Drop candy 46 to transfer conveyor belt or equal 47 De-mold and Clear 47 mold cavities 48 Clearing/de-molding mechanism 48 (rotating brushes, spatula or the like) 49 Transfer and collection means 49 (conveyors, vibrating tables, etc.) 50 Curing room 50 (Heating, Ventilation and air condition system [HVAC system]with: temperature and humidity control) 51 Transfer and surge means 51 (conveyors, etc.) 52 Package and label 52 53 Box, Pallet and label 53 60 Prepare mold 60 61 Mold housing 61 62 Retaining plate 62 63 Clean pins 63 64 Ring 64 65 Mold castings 62 (3-D, various formation) 66 Depositing port 66 67 Casting aperture 67 68 3D recess 68 (figures or characters or shapes of the ultimate desired molded confections) 70 Compounding 70 gumming ingredients 71 Sucrose 71 72 Glucose 72 73 Corn syrup 73 74 Flavors 74 80 Traditional (Mogul) non-automated gummy manufacturing process 80 81 Stacker 81 82 Depositor 82 84 Printer table 84 85 Starch bank machine 85 86 Rotary brush 86 87 Rotary Sieve 87 88 Stacker filled 88 with cooler trays 89 89 Trays 89 90 Final product 90 91 Package and skid to suit 91 95 Floorplan 95 of unique automated process 30 98 Floorplan 98 of mogul process 80 100 Compounding/Jellifying 100 101 Starch 101 102 Rework 102 103 Sugar/Glucose add conveyor 103 104 Batch Cookers 104 105 Unaerated mass equipment 105 106 Dosing 106 or Dynamic Mixers 107 108 Mogul hoppers/trays 108 109 Cooling rooms 109 110 Steam equipment 110 111 Vacuum machines 111 112 Compressors 112 for compressed air 115 typical rounded feature candy 115 117 rounded and blurred features 117 120 more intricate featured candy 120 122 intricate and angular features 122

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT

[0028] The present development is a unique automated manufacturing process for molded confections. This invention relates to a Special automated manufacturing process for manufacturing molded confections. Traditionally processes for manufacturing sweets, including those known as molded confectionssweets, including but not limited to those known as gummy snacks (hereinafter the term gummy or gelatin snacks or candies) or lollipops or jelly beans, or the like, are known in the food industry; however, none of the existing procedures allow for the production of three-dimensional molded confections in a compact, non-starch and automated fashion. Likewise, the majority of the conventional processes use starch beds as molds that are stamped to form cavities with the shapes of the gummy snacks that are desired; nevertheless, these shapes are not perfect because the material used does not allow any detail in the formation of the cavities. This new process eliminates the starch and inconsistencies to provide a controllable and repeatable process for providing the three dimensional (3-D) candies. Therefore, there is a need to develop an efficient technology to produce three dimensional (3-D) molded confections that eliminates the disadvantages of the known starch and labor intensive processes and furthermore makes it possible to obtain three-dimensional (3-D) molded confections in a total cost efficient basis.

[0029] The advantages for the unique automated manufacturing process for molded confections are listed above in the introduction. Succinctly the benefits are that the device: [0030] A. Reduced direct labor. [0031] B. Starch-less mold process. [0032] C. Tooling investment cost compared to other starch-less molding moguls is more competitive. The use of separate forming room and curing room allows for less molds needed for the entire process. [0033] D. Other process improvements: Type of molds and rotating brush mold removing mechanism allows for better formation of product, repeatable process, unique shapes, 3-D shapes, multi-color and flavors molded simultaneously, (inject different mold ports or different molds with different colors/flavors) so there is an automatics mix at packaging. [0034] E. Multiple colors/no mixing is all in the set-up of depositors. [0035] F. Reduce overall processing time by reducing holding time for candy curing and thus overall in-process inventory. [0036] G. Cleanliness. [0037] H. Reduced total costs. [0038] I. Reduced significantly the processing floor space.

[0039] The preferred embodiment of the unique automated manufacturing process for molded confections is comprised of: (1)transfer steps and various sequential steps between the distinct steps, (2) select the mold or mold sets for the desired production sequence, (3) load the selected molds onto the assembly system and thereby establish a mold housing assembly made of the several molds, (4) then perform a mold release application which includes a release means inside a ventilation system; (5) meanwhile or in a parallel manner, prepare the ingredients (Sucrose, Gelatin, Corn Syrup, Flavors and colors. Other ingredients such as fructose, dextrose, artificial/low-calorie sweetener, rice syrup, pectin, modified starch, dextrin, fruit pulp/juice, dairy ingredients including milk and whey, egg white, nut/nut paste, fat/oil, vitamins/Non-Provisional nutraceuticals, etc. which may be included or substituted.) which are mixed and stored; (6) pump the ingredients by a pump; (7) deposit ingredients into the mold; (8) transfer the mold assembles to a forming room; (9) invert mold assembly; (10) Clearing/de-molding; (11) next Re-invert mold assembly and mold assembly returns for re-use to load or direct to mold release application; (12) then send molded confections product to a transfer and collection means; (13) next send the collected molded confections product to a curing room; (14) next transfer to a surge means; (15) next send to a package and label; and finally (16) send to a box, pallet and label for shipping and distribution. These various steps can be simplified as four (4) distinct zones: Zone AMold preparationrepair, change out of product types, etc.; Zone BIngredient preparation, mix and pump; Zone CProduction of main 3-D confection product; and Zone DFinish product, prepare and pack-out.

[0040] There are shown in FIGS. 1-6 a complete description and operative embodiment of the unique automated manufacturing process for molded confections. In the drawings and illustrations, one notes well that the FIGS. 1-6 demonstrate the unique configuration and use of this process. The various example uses are in the operation and use section, below.

[0041] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate an embodiment of the unique automated manufacturing process for molded confections that is preferred. The drawings together with the summary description given above and a detailed description given below serve to explain the principles of the unique automated manufacturing process for molded confections. It is understood, however, that the process is not limited to only the precise arrangements and instrumentalities shown. Other examples of molded confections automated processes and uses are still understood by one skilled in the art of molded confections producing processes to be within the scope and spirit shown here.

[0042] FIG. 1 is a sketch of the unique automated manufacturing process for molded confections. These various steps can be simplified as four (4) distinct zones: Zone AMold preparationrepair, change out of product types, etc.; Zone BIngredient preparation, mix and pump; Zone CProduction of main 3-D confection product; and Zone DFinish product, prepare and pack-out. Shown and demonstrated are the unique automated process 30 for making starch-less molded confections including the (1) transfer steps 34 and various sequential steps between the distinct steps, (2) select the mold 35 or mold sets for the desired production sequence, (3) load 36 the selected molds onto the assembly system and thereby establish a mold housing assembly 37 made of the several molds, (4) then perform a mold release 38 application which includes a release means 39 (applied by spray, mist, liquid, etc.) inside a ventilation system 40 (enclosure and duct fan); (5) meanwhile or in a parallel manner, prepare the ingredients (Sucrose, Gelatin, Corn Syrup, Flavors and colors. Other ingredients such as fructose, dextrose, artificial/low-calorie sweetener, rice syrup, pectin, modified starch, dextrin, fruit pulp/juice, dairy ingredients including milk and whey, egg white, nut/nut paste, fat/oil, vitamins/nutraceuticals, etc. which may be included or substituted.) which are mixed and stored; (6) pump the ingredient by a pump 42; (7) deposit 43 ingredients into the mold apertures 66; (8) transfer the mold assembles to a forming room 44 (Heating, Ventilation and air condition system [HVAC system] with temperature and humidity control); (9) invert 45 mold assembly [conveyor, walking beam, pick and place etc. presented as examples and not as limitations]; (10) Clearing/de-molding step 47 with mechanism 48 (rotating brushes, spatula or the like) that removes the product and the molded confection drops 46 to a transfer belt conveyor or equal; (11) next Re-invert mold assembly 45Amold assembly returns for re-use to load 36 or direct to mold release application 38; (12) then send molded confections product to a transfer and collection means 49 (conveyors, vibrating tables, etc.); (13) next send the collected molded confections product to a curing room 50 (Heating, Ventilation and air condition system [HVAC system] with: temperature and humidity control); (14) next transfer to a surge means 51 (conveyors, etc.); (15) next to a package and label 52; and finally (16) to a Box, Pallet and label 53 for shipping and distribution.

[0043] FIG. 2 is a sketch of the unique molded confections process without forming and curing rooms shown. These various steps can be simplified as four (4) distinct zones: Zone AMold preparationrepair, change out of product types, etc.; Zone BIngredient preparation, mix and pump; Zone CProduction of main 3-D confection product; and Zone DFinish product, prepare and pack-out. Shown and demonstrated are the unique automated process 30 for making starch-less molded confections including the (1) transfer steps 34 and various sequential steps, (2) select the or a mold 35 or mold sets for the desired production sequence, (3) load 36 the selected molds onto the assembly system and thereby establish a mold housing assembly 37 made of the several molds, (4) then perform a mold release 38 application which includes a release means 39 (applied by spray, mist, liquid, etc.) inside a ventilation system 40 (enclosure and duct fan); (5) meanwhile or in a parallel manner, prepare the ingredients (Sucrose, Gelatin, Corn Syrup, Flavors and colors) which are mixed and stored 41; (6) pump the ingredient by a pump 42; (7) deposit 43 ingredients into the mold apertures 66; (8) transfer the mold assembles to a forming room 44 (HVAC system with temperature and humidity control); (9) invert 45 mold assembly; and (10) drop 46 candy to a transfer belt conveyor or equal. Note the forming, curing and pack out are not shown in this view.

[0044] FIG. 3 is a sketch of the unique mold system 60 that is utilized for the process shown. Demonstrated here are the prepare mold 60, mold housing 61, retaining plate 62, clevis pins 63, ring 64, mold castings 65 (3-D, various formation), depositing port 66, casting aperture 67, and three dimensional (3-D) recess 68.

[0045] FIG. 4 is a process flow chart of the automated gelatin candy process. Shown as a flow chart are the similar steps from FIG. 1. These various steps can be simplified as four (4) distinct zones: Zone AMold preparationrepair, change out of product types, etc.; Zone BIngredient preparation, mix and pump; Zone CProduction of main 3-D confection product; and Zone DFinish product, prepare and pack-out. Shown and demonstrated are the unique automated process 30 for making starch-less molded confections including the (1)transfer steps 34 and various sequential steps, (2) select the or a mold 35 or mold sets for the desired production sequence, (3) load 36 the selected molds onto the assembly system and thereby establish a mold housing assembly 37 made of the several molds, (4) then perform a mold release 38 application which includes a release means 39 (applied by spray, mist, liquid, etc.) inside a ventilation system 40 (enclosure and duct fan); (5) meanwhile or in a parallel manner, prepare the ingredients (Sucrose, Gelatin, Corn Syrup, Flavors and colors) which are mixed and stored 41; (6) pump the ingredient by a pump 42; (7) deposit 43 ingredients into the mold apertures 66; (8) transfer the mold assembles to a forming room 44 (HVAC system with temperature and humidity control); (9) invert 45 mold assembly [conveyor, walking beam, pick and place etc. presented as examples and not as limitations]; (10) Clearing/de-molding step 47 with mechanism 48 (rotating brushes, spatula or the like) that removes the product and the molded confection drops 46 to a transfer belt conveyor or equal; (11) next Re-invert mold assembly 45Amold assembly returns for re-use to load 36 or direct to mold release application 38; (12) then send molded confections product to a transfer and collection means 49 (conveyors, vibrating tables, etc.); (13) next send the collected molded confections product to a curing room 50 (HVAC system with temperature and humidity control); (14) next transfer to a surge means 51 (conveyors, etc.); (15) next to a package and label 52; and finally (16) to a Box, Pallet and label 53 for shipping and distribution.

[0046] FIGS. 5 A and 5 B is a sketch of the mold clearing/de-molding mechanism (rotating brushes) process in the automated molded confections process and a comparison of candy piece detail possible with the brush. Here is shown the molds 60 with the housing 61 and casting 65, along with the de-molding or clearing mechanism 48brush, spatula, etc. Once the molded confection is removed from the cavities, the mold assembly is re-inverted 45A and returned for re-use to load 36 or direct to mold release application 38. FIG. 5 B is a comparison of candy piece detail possible with the brush. A typical rounded feature candy 115 made in the traditional Mogul machine with starch, steam and harsh demolding methods and stiff brushes. The features are rounded and blurred 117 with little detail possible. The more intricate featured candy 120 is from the new Chan designed process with soft rotating brushes. This allows for more intricate and angular features 122 which can then be detailed later with the colored printing.

[0047] FIG. 6 is a reference sketch of a non automated, traditional starch candy process 80. Gummy candy is manufactured in a machine called a Mogul. Cooled trays of gummy candy are inverted in the starch buck. This candy is ready for packaging. The trays are then filled with starch to keep the candy from sticking and sent to the printer table, which imprints a pattern into the starch. The depositor fills the trays with the hot candy mixture, and the trays are sent back to the stacker to cool for 24 hours. Then the machine can start the process again. Shown are the Compounding gumming ingredients 70 (including but not limited to sucrose 71, glucose 72, corn syrup 73, and flavors 74), traditional non-automated gummy manufacturing (Mogul) process 80; a stacker 81, a depositor 82, a printer table 83, a starch bank machine 85, a rotary brush 86, a rotary Sieve 87, a stacker filled with cooler trays 88, a set of cooling trays 89, a final product 90, and means to package and skid to suit 91. This process typically consists of: [0048] A. The manufacture of gummy candy begins with compounding. Factory workers, known as compounders, follow instructions outlined in the recipes and physically pour the appropriate amount of gummy raw materials into the main mixing tanks. These tanks, which are equipped with mixing, heating, and cooling capabilities, are quite large. Depending on the size of the batch, gummy candy compounding can take from one to three hours. When the batch is complete, it is sent to the Quality Control (QC) laboratory to make sure that it meets the required specifications. [0049] B. After the gummy candy is compounded and passes QC testing, it is either pumped or transferred to a starch molding machine known as a Mogul. This machine can automatically perform the multiple tasks involved in making gummy candy. It is called a starch molding machine because starch is a main component. In this machine, starch has three primary purposes. First, it prevents the candy from sticking to the candy molds, which allows for easy removal and handling. Second, it holds the gummy candy in place during the drying, cooling, and setting processes. Finally, it absorbs moisture from the candies, giving them the proper texture. [0050] C. Making gummy candy in a Mogul is a continuous process. At the start of the machine, trays that contain previously filled, cooled, and formed gummy candy are stacked. The trays are then removed from the stack one-by-one and wove along a conveyor belt into the next section of the machine, known as the starch buck. [0051] D. As they enter the starch buck, the trays are inverted and the gummy candy falls out into a vibrating metal screen known as a sieve. The vibrating action of the sieve, in concert with oscillating brushes, removes all of the excess starch that adheres to the gummy candy. These pieces then move along a conveyor belt to trays, where they are manually transferred to other machines by which they can be decorated further and placed into appropriate packaging. A more recent advance, called the pneumatic starch buck, further automates this step. In this device, a tightly fitting cover is placed over the filled trays. When it is inverted, the candies adhere to the cover and remain in their ordered position. The excess starch is then removed by fast-rotating compressed-air jets. The candy can then be conveyed for further processing. [0052] E. The starch that is removed from the gummy candy is reused in the process, but first it must be cleaned, dried, and otherwise reconditioned. Candy particles are first removed by passing the starch through a metal screen known as a sieve. It is then conveyed to a recirculating starch conditioning system. As it enters this machine, it is dried by being passed through hot, moving air. After drying, the starch is cooled by cool air jets and conveyed back out to the Mogul to be reused in the starch molding process. [0053] F. The starch returns from the drier via a conveyor belt to the Mogul, where it is filled into the empty trays and leveled. These were the same trays that were inverted and emptied in step two. These starch-filled trays then move to a printer table. Here, a board that has the inverse of the mold printed on it presses the starch down so the mold has an indent in it. From here, the trays are moved to the depositors. [0054] G. The gummy candy, compounded in step 1, is transferred to the depositors. This is the part of the mogul that has a filling nozzle and can deliver the exact amount of candy needed into the trays as they pass under it. The depositor section of the mogul can contain 30 or more depositors, depending on how many imprints there are on the trays. In more modern depositors, the color, flavor, and acids can be added to the gummy base right in the depositor. This allows different colors and flavors to be made simultaneously, speeding up the process. [0055] H. The filled trays are moved along to a stacking machine and then sent to a cooling room, where they stay until they are appropriately cooled and formed. This part of the process can take over 24 hours. After this happens, the trays are moved back to the Mogul, and the process starts all over again.

[0056] FIG. 7 A is a layout of the old steam and starch system (traditional starch (Mogul) candy process) and FIG. 7 B is a layout of the new automated manufacturing process for molded confections without steam or starch with a significantly reduced floor space. In all of the old, traditional processes (as just described in FIG. 6) they used vast amounts of steam, vacuum, and compressed air. This alone drove the size of the footprint or floor space up in size. Also, they used starch in the process to coat the molds and then to condition and re-use the starch when possible. Finally they inverted the trays and used stiff brushes, vibration, and compressed air to clear the candy pieces from the molds. This meant delicate features and more detail to the candy was avoided since the means of clearing the molds damaged such fine details. The resultant footprint was large as compared to the new unique automated process 30 for making starch-less molded confections described herein by Chan. The relative size was 2400-3000 square meters for a single mogul starch molding line. This requires 3-4 times more space than the new unique automated process 30 by Chan. Shown here is a typical floorplan 98 of mogul process 80. It includes: a compounding/Jellifying 100 machine, starch handling equipment 101, rework equipment 102, sugar/glucose equipment and conveyor 103, batch cookers 104, unaerated mass equipment 105, dosing 106 and/or dynamic mixers 107, Mogul hoppers/trays 108, cooling rooms 109 steam equipment 110, vacuum machines 111, and compressors 112 for compressed air.

[0057] FIG. 7 B is a layout of the new automated manufacturing process 30 for molded confections without steam or starch and with a significantly reduced floor space. This process has steam-less forming rooms 44 and conditioning rooms 50 unlike the traditional mogul lines. Steam or high pressure, extreme hot water is only used in the compounding and mixing of the materials for the candy. This can be accomplished by very small/condensed steam generators. Likewise, there is an absence of vacuum and compressed air required. This results in a footprint shown with less than 600 square meters (i.e. actually 588 SMspace saving footprint) for production. Office and finished goods add to that depending on desired finished goods inventory. Shown in the Floorplan 95 of unique automated process 30 are: forming room 44 (Heating, Ventilation and air condition system [HVAC system] with: temperature and humidity control), ingredients mix and store 41, ingredients pump 42, package and label 52, box, pallet and label 53, deposit ingredients 43 into molds, curing room 50 (Heating, Ventilation and air condition system [HVAC system] with: temperature and humidity control), final product 90, and rework 102. The new automated manufacturing process 30 for molded confections without steam or starch and with a significantly reduced floor space provides several significant business advantages: (1) The smaller modules (space saving footprint) can be used for initial volumes in introductory markets. Then additional modules can be easily added for growing demand in the market; (2) The smaller module (space saving footprint) without huge steam, vacuum and compressed air is less costly for the initial capital investment since the assets are less costly; and (3) the module concept can be placed close to the market served so that finished goods cost less to be shipped and changes in specific type of candy desired can be focused on the desires of the immediate market served.

[0058] The details mentioned here are exemplary and not limiting. Other specific components and manners specific to describing a unique automated manufacturing process for molded confections may be added as a person having ordinary skill in the field of molded confections processes and manufacturing methods and their uses well appreciates.

Operation of the Preferred Embodiment

[0059] The unique automated manufacturing process for molded confections has been described in the above embodiment. The manner of how the process operates is evident from the descriptions above. One notes well that the description above is incorporated as describing the operation. These various steps can be simplified as four (4) distinct zones: Zone AMold preparationrepair, change out of product types, etc.; Zone BIngredient preparation, mix and pump; Zone CProduction of main 3-D confection product; and Zone DFinish product, prepare and pack-out. The basic process steps are: (1) select the mold 35 or mold sets for the desired production sequence; (2)transfer steps 34 and various sequential steps; (3) load 36 the selected molds onto the assembly system and thereby establish a mold housing assembly 37 made of the several molds, (4) then perform a mold release 38 application which includes a release means 39 (applied by spray, mist, liquid, etc.) inside a ventilation system 40 (enclosure and duct fan); (5) (5) meanwhile or in a parallel manner, prepare the ingredients (Sucrose, Gelatin, Corn Syrup, Flavors and colors. Other ingredients such as fructose, dextrose, artificial/low-calorie sweetener, rice syrup, pectin, modified starch, dextrin, fruit pulp/juice, dairy ingredients including milk and whey, egg white, nut/nut paste, fat/oil, vitamins/nutraceuticals, etc. which may be included or substituted.) which are mixed and stored; (6) pump the ingredient by a pump 42; (7) deposit 43 ingredients into the mold apertures 66; (8) transfer the mold assembles to a forming room 44 (HVAC system with temperature and humidity control); (9) invert 45 mold assembly [conveyor, walking beam, pick and place etc. presented as examples and not as limitations]; (10) Clearing/de-molding step 47 with mechanism 48 (rotating brushes, spatula or the like) that removes the product and the molded confection drops 46 to a transfer belt conveyor or equal; (11) next Re-invert mold assembly 45Amold assembly returns for re-use to load 36 or direct to mold release application 38; (12) then send molded confections product to a transfer and collection means 49 (conveyors, vibrating tables, etc.); (13) then send the collected molded confection product to a curing room 50 (HVAC system with temperature and humidity control); (14) next transfer to a surge means 51 (conveyors, etc.); (15) next to a package and label 52; and finally (16) to a Box, Pallet and label 53 for shipping and distribution.

[0060] With this description it is to be understood that the unique automated manufacturing process for molded confections is not to be limited to only the disclosed embodiment of product. The features of the unique automated manufacturing process for molded confections are intended to cover various modifications and equivalent arrangements of the production process included within the spirit and scope of the description.

[0061] It will be understood that each of the elements described above may also find a useful application in other types of methods differing from the type described above. While certain novel features of this invention have been shown and described and are pointed out in the annexed claims, it is not intended to be limited to the details above, since it will be understood that various omissions, modifications, substitutions and changes in the forms and details of the device illustrated and in its operation can be made by those skilled in the art without departing in any way from the spirit of the present invention. Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.

[0062] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which these inventions belong. Although any methods and materials similar or equivalent to those described herein can also be used in the practice or testing of the present inventions, the preferred methods and materials are now described. All patents and publications mentioned herein, including those cited in the Background of the application, are hereby incorporated by reference to disclose and described the methods and/or materials in connection with which the publications are cited.

[0063] The publications discussed herein are provided solely for their disclosure prior to the filing date of the present application. Nothing herein is to be construed as an admission that the present inventions are not entitled to antedate such publication by virtue of prior invention. Further, the dates of publication provided may be different from the actual publication dates which may need to be independently confirmed.

[0064] Other embodiments of the invention are possible. Although the description above contains much specificity, these should not be construed as limiting the scope of the invention, but as merely providing illustrations of some of the presently preferred embodiments of this invention. It is also contemplated that various combinations or sub-combinations of the specific features and aspects of the embodiments may be made and still fall within the scope of the inventions. It should be understood that various features and aspects of the disclosed embodiments can be combined with or substituted for one another in order to form varying modes of the disclosed inventions. Thus, it is intended that the scope of at least some of the present inventions herein disclosed should not be limited by the particular disclosed embodiments described above.

[0065] Thus the scope of this invention should be determined by the appended claims and their legal equivalents. Therefore, it will be appreciated that the scope of the present invention fully encompasses other embodiments which may become obvious to those skilled in the art, and that the scope of the present invention is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean one and only one unless explicitly so stated, but rather one or more. All structural, chemical, and functional equivalents to the elements of the above-described preferred embodiment that are known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the present claims. Moreover, it is not necessary for a device or method to address each and every problem sought to be solved by the present invention, for it to be encompassed by the present claims. Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims.

[0066] The terms recited in the claims should be given their ordinary and customary meaning as determined by reference to relevant entries (e.g., definition of plane as a carpenter's tool would not be relevant to the use of the term plane when used to refer to an airplane, etc.) in dictionaries (e.g., widely used general reference dictionaries and/or relevant technical dictionaries), commonly understood meanings by those in the art, etc., with the understanding that the broadest meaning imparted by any one or combination of these sources should be given to the claim terms (e.g., two or more relevant dictionary entries should be combined to provide the broadest meaning of the combination of entries, etc.) subject only to the following exceptions: (a) if a term is used herein in a manner more expansive than its ordinary and customary meaning, the term should be given its ordinary and customary meaning plus the additional expansive meaning, or (b) if a term has been explicitly defined to have a different meaning by reciting the term followed by the phrase as used herein shall mean or similar language (e.g., herein this term means, as defined herein, for the purposes of this disclosure [the term] shall mean, etc.). References to specific examples, use of i.e., use of the word invention, etc., are not meant to invoke exception (b) or otherwise restrict the scope of the recited claim terms. Other than situations where exception (b) applies, nothing contained herein should be considered a disclaimer or disavowal of claim scope. Accordingly, the subject matter recited in the claims is not coextensive with and should not be interpreted to be coextensive with any particular embodiment, feature, or combination of features shown herein. This is true even if only a single embodiment of the particular feature or combination of features is illustrated and described herein. Thus, the appended claims should be read to be given their broadest interpretation in view of the prior art and the ordinary meaning of the claim terms.

[0067] As used herein, spatial or directional terms, such as left, right, front, back, and the like, relate to the subject matter as it is shown in the drawing FIGS. However, it is to be understood that the subject matter described herein may assume various alternative orientations and, accordingly, such terms are not to be considered as limiting. Furthermore, as used herein (i.e., in the claims and the specification), articles such as the, a, and an can connote the singular or plural. Also, as used herein, the word or when used without a preceding either (or other similar language indicating that or is unequivocally meant to be exclusivee.g., only one of x or y, etc.) shall be interpreted to be inclusive (e.g., x or y means one or both x or y). Likewise, as used herein, the term and/or shall also be interpreted to be inclusive (e.g., x and/or y means one or both x or y). In situations where and/or or or are used as a conjunction for a group of three or more items, the group should be interpreted to include one item alone, all of the items together, or any combination or number of the items. Moreover, terms used in the specification and claims such as have, having, include, and including should be construed to be synonymous with the terms comprise and comprising.

[0068] Unless otherwise indicated, all numbers or expressions, such as those expressing dimensions, physical characteristics, etc. used in the specification (other than the claims) are understood as modified in all instances by the term approximately. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the claims, each numerical parameter recited in the specification or claims which is modified by the term approximately should at least be construed in light of the number of recited significant digits and by applying ordinary rounding techniques.