SYSTEM FOR PRODUCING CHOCOLATE-BASED ARTICLES IN SOLIDIFYING FORM

Abstract

A system for producing chocolate-based articles in solidifying form includes at least a first conveyor belt and a loading section for loading mould trays onto the at least first conveyor belt, which is arranged for transporting the mould trays through a cooling chamber along a first cooling path. The cooling chamber is arranged for solidifying the chocolate mass under predetermined conditions before the mould trays are collected. An air circulation device is arranged between the top load carrying side of the at least first conveyor belt and a bottom side of the mould trays such that cooling air can circulate along the bottom side of the mould trays

Claims

1. A system for producing chocolate-based articles in solidifying form, the system comprising: a transportation system including at least a first conveyor belt; a loading section for loading mould trays filled with chocolate mass in liquid form onto a top load carrying side of the at least first conveyor belt at an entry point of the transportation system; a cooling chamber arranged for circulating cooling air for solidifying the chocolate mass under predetermined conditions before the mould trays are collected at a collecting section positioned at an exit point of the transportation system, wherein the at least first conveyor belt is arranged for transporting the mould trays through the cooling chamber along a first cooling path; and air circulation means arranged between the top load carrying side of the at least first conveyor belt and a bottom side of the mould trays such that cooling air can circulate along the bottom side (108) of the mould trays.

2. The system according to claim 1, wherein the at least first conveyor belt is a continuous flat conveyor belt.

3. The system according to claim 1, wherein the at least first conveyor belt includes overlapping sheets of material arranged in such a way so as to provide a continuous flat surface.

4. The system according to claim 1, wherein the at least first conveyor belt is made of a durable material.

5. The system according to claim 4, wherein the at least first conveyor belt is made of a polymer-based material.

6. The system according to claim 5, wherein the at least first conveyor belt is made of plastic.

7. The system according to claim 1, wherein the at least first conveyor belt is made of a metal alloy.

8. The system according to claim 1, wherein the air circulation means includes support members spaced apart from one another.

9. The system according to claim 8, wherein the support members are part of the mould trays and extend outwardly from the bottom side of the mould trays.

10. The system according to claim 9, wherein the support members are arranged on the periphery of the bottom side of the mould trays.

11. The system according claim 8, wherein the support members are formed integrally with the mould trays.

12. The system according to claim 8, wherein the support members are part of the conveyor belt and extend outwardly from the top load carrying side of the conveyor belt.

13. The system according to claim 12, wherein the support members are formed integrally with the belt of the conveyor.

14. The system according to claim 8, wherein the support members are arranged on a support body which is separate from the mould trays and the conveyor belt.

15. The system of claim 14, wherein the support body is arranged to be coupled to the bottom side of the mould trays in between the mould trays and the conveyor belt such that cooling air can circulate along the bottom side of the mould trays when the mould trays are positioned on the top load carrying side of the conveyor belt with the mould tray in between the mould tray and the conveyor belt.

16. The system of claim 15, wherein the support body is made of the same material as the mould trays.

17. The system of claim 1, wherein the mould trays are made of a polymer-based material.

18. The system of claim 17, wherein the mould trays are made of plastic.

19. The system according to claim 1, wherein the mould trays are made of a metal alloy.

20. The system according to claim 1, wherein the transportation system further comprises at least a second conveyor belt.

21. The system of claim 20, wherein the second conveyor belt is positioned below the at least first conveyor belt.

22. The system of claim 21, wherein the at least second conveyor belt is arranged for carrying the mould trays through the cooling chamber along a second cooling path.

23. The system of claim 22, wherein the transport direction in which the mould trays are carried along the second cooling path is opposite to that of the first cooling path.

24. The system according to claim 20, wherein a lift system is provided for transferring the mould trays from the at least first conveyor belt to the at least second conveyor belt.

25. The system according to claim 1, wherein the loading section and collecting section of the system are located on the same side.

26. The system according to claim 1, wherein the system is dimensioned such that it fits in an intermodal container.

27. A method for producing chocolate-based articles in solidifying form using the system according to claim 1, the method comprising the steps of: loading mould trays at a loading section filled with chocolate mass in liquid form onto a top load carrying side of at least a first conveyor belt at an entry point of a transportation system; transporting the mould trays by means of the at least first conveyor belt through a cooling chamber along a first cooling path, the cooling chamber being arranged for circulating cooling air for solidifying the chocolate mass under predetermined conditions; collecting the mould trays at a collecting section positioned at an exit point of the transportation system; providing air circulation means arranged between the top load carrying side of the at least first conveyor belt and a bottom side of the mould trays such that cooling air can circulate along the bottom side of the mould trays.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The invention will be further elucidated by means of the following description and the appended figures.

[0025] FIG. 1 shows a cross-sectional view of a system for producing chocolate-based articles in solidifying form according to an embodiment of the present invention.

[0026] FIGS. 2 to 4 show perspective views of different embodiments of the bottom side of the mould tray having support members arranged in a variety of patterns according to embodiments of the present invention.

[0027] FIG. 5 shows a cross-sectional view of the system for producing chocolate-based articles in solidifying form according to second embodiments of the present invention.

[0028] FIG. 6 shows a cross-sectional view of the system for producing chocolate-based articles in solidifying form according to third embodiments of the present invention.

[0029] FIGS. 7 and 8 show examples of the support body according to third embodiment of the present invention and how it can be used together with the mould tray.

[0030] FIGS. 9 and 10 shows cross-sectional views of the system for producing chocolate-based articles in solidifying form according to further embodiments.

MODES FOR CARRYING OUT THE INVENTION

[0031] The present invention will be described with respect to particular embodiments and with reference to certain drawings but the invention is not limited thereto but only by the claims. The drawings described are only schematic and are non-limiting. In the drawings, the size of some of the elements may be exaggerated and not drawn on scale for illustrative purposes. The dimensions and the relative dimensions do not necessarily correspond to actual reductions to practice of the invention.

[0032] Furthermore, the terms first, second, third and the like in the description and in the claims, are used for distinguishing between similar elements and not necessarily for describing a sequential or chronological order. The terms are interchangeable under appropriate circumstances and the embodiments of the invention can operate in other sequences than described or illustrated herein.

[0033] Moreover, the terms top, bottom, over, under and the like in the description and the claims are used for descriptive purposes and not necessarily for describing relative positions. The terms so used are interchangeable under appropriate circumstances and the embodiments of the invention described herein can operate in other orientations than described or illustrated herein.

[0034] The term comprising, used in the claims, should not be interpreted as being restricted to the means listed thereafter; it does not exclude other elements or steps. It needs to be interpreted as specifying the presence of the stated features, integers, steps or components as referred to, but does not preclude the presence or addition of one or more other features, integers, steps or components, or groups thereof. Thus, the scope of the expression a device comprising means A and B should not be limited to devices consisting only of components A and B. It means that with respect to the present invention, the only relevant components of the device are A and B.

[0035] The term chocolate-based articles refers to chocolate products that are stable at ambient temperatures and may take the form of solid pieces of chlorate, such as chocolate bars, or other products incorporating chocolate as a component, for example for coating other food products, such as nuts, fruits and the like.

[0036] The term chocolate-based articles in solidifying form refers to melted chocolate which has been cooled to produce a solid chocolate wherein at least a portion, preferably a substantial part, of the fat of the chocolate is in solid state.

[0037] FIG. 1 shows a system 100 for producing chocolate-based articles in solidifying form according to an embodiment of the present invention. The system 100 may comprise a loading section 106 for loading mould trays 102 filled with chocolate mass 811 in liquid form onto a top load carrying side 104 of at least a first conveyor belt 101, which at least first conveyor belt 101 may be part of a transportation system. The at least first conveyor belt 101 may be arranged to transport the mould trays 102 through a cooling chamber 103, which may be arranged for circulating cooling air for solidifying the chocolate mass 811 under predetermined conditions before the mould trays 102 are collected at a collecting section 107 positioned at an exit point of the transportation system. As previously discussed, the temperature and humidity of the cooling chamber may play an important role in the appearance and texture of the final chocolate-based article. For this reason, the cooling chamber 103 may comprise a number of cooling zones (not shown) in order to prevent sudden changes of temperature and humidity. According to embodiments of the present invention, the system of FIG. 1 may further be provided with air circulation means 105, which may be arranged between the top load carrying side 104 of the at least first conveyor belt 101 and a bottom side 108 of the mould trays 102. The air circulation means 105 are provided such that the cooling air provided by the cooling chamber 103 can circulate along the bottom side of mould trays 108 in order to make more sure that the lower part of the chocolate mass 811 in the mould trays solidifies at a same rate, preferably substantially same rate, as the upper part of the chocolate mass 811 which is exposed to the cooling air. Moreover, the provision of air circulation means between the top load carrying side 104 of the at least first conveyor belt 101 and the bottom side 108 of the mould tray ensures that the chocolate mass 811 can be solidify more uniformly irrespective of the type of the conveyor belt used. This may have as an advantage that a conveyor belt having a more stable top load carrying side 104 may be used, such as for example a flat continuous conveyor belt type, which may ensure that the dislocation of the liquid chocolate mass 811 during transportation is eliminated or at least minimised. Therefore, the provision of a stable top load carrying side in combination with the air circulation means 105 may contribute to the liquid chocolate mass being uniformly solidified in the mould trays 102 while ensuring the smooth transportation of the mould trays through the cooling chamber.

[0038] The cooling chamber 103 is for example provided for circulating cooling air by a ventilation system, for example provided with at least one ventilator in the system 100, the ventilator for example being provided with a cooling unit at the air intake of the at least one ventilator so that air sucked into the ventilator is first cooled by the cooling unit. Although the ventilating system is not shown in the figures, the ventilation system is provided for providing and circulating cooled air through the cooling chamber 103.

[0039] According to an embodiment of the present invention, the air circulation means may be provided on the mould trays 102, as shown in FIG. 1. The air circulation means 105 may comprise a number of support members, such as legs or fins, extending outwardly from the bottom side 108 of the mould tray 102 and spaced apart from one another, as shown in FIGS. 2 to 4. The support members 105 may be arranged in a variety of patterns in order to maximise the circulation of cooling air along the bottom side 108 of the mould trays 102. For example, the support members 105 may be arranged only at specific location on the periphery of the bottom side 108 of the mould trays 102, as shown in FIG. 2. The configuration of the support member 105 shown in FIG. 2 may have as an advantage that a larger portion of the bottom side 108 of the mould trays 102 remains exposed to the cooling air, which may contribute to the faster and uniform solidification of the chocolate mass 811 in the mould trays. In another example, the support members 105 may be arranged in a matrix-like configuration on the bottom side 108 of the mould trays as shown in FIG. 3. This configuration of the support members 105 shown in FIG. 3 may enable for a larger number of support members to be used, which may enable heavier mould trays to be supported on the top load carrying side of the at least first conveyor belt 101. Furthermore, a matrix-like configuration for supporting standard mould trays be allow for the support members to be designed with smaller dimensions since the weight of the mould trays 102 may be spread more evenly across a larger number of support members. FIG. 4 presents a further example of the support members 105, wherein each support member extends continuously in a predetermined direction along the bottom side 108 of the mould trays 102. The provision of a space between the support members 105 enables the formation of air passageways, which allow the cooling air to circulate along the bottom side 108 of the mould trays 102 irrespectively of the type of conveyor belt used, thereby ensuring that the liquid chocolate mass 811 solidifies uniformly in the mould trays 102.

[0040] According to embodiments of the present invention, the support members 105 may be integrally formed with mould trays 102 in a single piece made of the same material. For example, the mould trays 102 can be made from a polymer-based material such as plastic, which is less expensive and easier to produce than metal. The mould trays can also be made from a metal-alloy such as aluminium, which although usually more expensive than plastic, would enable for the faster cooling and thus faster solidification of the liquid chocolate mass 811 in the mould trays 102 due to their larger thermal conductivity. Alternatively, the support members 105 may also be provided as separate elements arranged to be attached to the bottom side 108 of the mould trays 102 by fixing means such as glue or screws. Furthermore, the support member 105, may be made from a different material than the mould trays, for example the mould trays may be made from aluminium, while the support members may be made from plastic, and visa versa. Although not explicitly mentioned, It should be noted that any other combination of a materials known to the skilled person in art would also be allowable.

[0041] FIG. 5 shows a system 500 for producing chocolate-based articles in solidifying form according to embodiments of the present invention. The system 500 is largely the same with the system 100 presented in FIG. 1, with the exception that the air circulation means 505 in this case are provided on the at least first conveyor belt 501 rather than on the mould trays 102. The air circulation means 505 may comprise, as previously discussed with reference to the system 100 of FIG. 1, support members, in the form of support legs or fins that are spaced apart from one another so as to form air passageways allowing the cooling air to circulate in the bottom side 108 of the mould trays 502. In the system 500 of FIG. 2, the support members may be arranged to extend outwardly from the top load carrying side 504 of the at least first conveyor belt 501. The provision of the support members 505 on the conveyor belt may offer a more cost effective and simpler approach to realising the system of the present invention since it allows for the use of existing conveyor belts by replacing the chains or rollers with a suitable continuous and substantially flat belt having support member on the top load carrying side. As previously discussed, the support members may be arranged on the top load carrying side 504 of the at least first conveyor belt 501 in a variety of patterns similar to those shown in FIGS. 2 to 4. Furthermore, the support member may be integrally formed with the belt of the at least first conveyor 501 in a single piece made from the same material. Alternatively, and similar to the previous embodiments, the support members 505 may be separately provided and arranged to be attached to the conveyor belt by fixing means such as glue or screws.

[0042] The at least first conveyor belt 101, 501 may comprise overlapping sheets of material arranged in such a way so that a continuous substantially flat surface is provided. The at least first conveyor belt 101, 501 can be made from a durable material which may be polymer or metal-based such as plastic or aluminium. Furthermore, the support members 505 may be made from a material different from that of the conveyor belt 501. For example, the support members 505 may be made form a polymer-based material while the conveyor belt is made of metal-based material.

[0043] FIG. 6 shows a system according to a further embodiment of the present invention. In this case, the air circulation means 605 are provided on a support body 609 which is independent from the mould trays 502 and may further be separate from the at least first conveyor belt 101. The support body 609 may be arranged to cooperate with the bottom side 608 mould trays 502 such that the mould trays can be securely positioned on the support body 609. More specifically, the support body 609 may be arranged to be coupled to the bottom side 608 of the mould trays 502 such that cooling air can circulate along the bottom side 608 of the mould trays 502 when the mould trays 502 are positioned on the top load carrying side 604 of the conveyor belt 501. The use of a separate support body 509 for providing the air circulation means 505, may enhance the stability of the mould trays 502 on the at least first conveyor belt 501 during transportation. Furthermore, the support body 509 may be designed such that it offers a stable support surface for the mould trays 502 during transportation, irrespective of the type of the conveyor belt used, thereby offering a cost effective solution by enabling the use of existing conveyor belts.

[0044] According to an embodiment of the present invention the support body 609 may comprise a hollow frame 612 attached to a support surface 610. The hollow frame may be dimensioned such that it securely fits on the bottom side of the mould trays 502 while ensuring that a gap remains between the support surface 610 and the bottom side 608 of the mould trays 502 to allow for the circulation of cooling air along the bottom side 608 of the mould trays.

[0045] According to a further embodiment of the present invention, the support body 609 may comprise support member 605 extending outwardly from the support surface 610, as shown in FIG. 7. The height of the support members 605 may be smaller than the overall height of the support body, such that when a mould tray is positioned on top of the support member the frame 612 may be arranged to prevent the mould tray 502 from being displaced during transportation, as shown in FIG. 8. In other embodiments the support body 609 may be dimensioned such that more than one mould tray 502 can be supported. The support members 605 may integrally formed with the support body 609 as a single piece made from the same material. For example the support body 609 can be made from polymer or metal based materials such as plastic or aluminium.

[0046] According to an embodiment of the present invention the support members 605 arranged on the support body 609 can be provided separately from the support body 609. For example, the support members may be glued or screwed into the desired positions on the support surface 610 of the support body 609. Furthermore, the support members 605 can be made from a different material to that of the support body 609. For example, the support member 605 can be made from a vibration absorbent material arranged to provide dampening of the vibrations caused during transportation in addition to effectively supporting the mould trays 502 on the top load carrying side 504 of the at least first conveyor belt 501. For example, the support member 605 can be made from a polymer-based elastomeric material having elastic properties such as rubber.

[0047] According to embodiments of the present invention, the system 900 for producing chocolate-based articles in solidifying form may further comprise at least a second conveyor belt 901, as shown in FIG. 9. For simplicity, the system 900 will be explained herein with references to the system 100 shown in FIG. 1. However, it should be noted that the system 900 may be equally combined with any of the embodiments of the present invention, examples of which are shown in FIGS. 1 to 8. According to one embodiment of the present invention, the at least second conveyor belt 901 of the system 900 may be positioned below the at least first conveyor belt 101. Depending on the configuration of the system 900, the at least second conveyor belt 901 may be alternatively positioned above the at least first conveyor belt 101. The at least second conveyor belt 901 may be arranged for carrying the mould trays 102 through the cooling chamber 903 along a second cooling path. The transport direction in which the mould trays 102 are carried along the second cooling path may be opposite that of the first cooling path. By arranging the at least second conveyor belt 901 to carry the mould trays 102 in the opposite direction of that of the at least first conveyor belt 101 allows for the total dimensions of the system 900 to be significantly recued. This is because the total transport distance that the mould trays 102 need to travel in the cooling chamber 903 can be split between the at least first and at least second conveyor belts 101, 901, which are positioned opposite one another. By significantly reducing the dimensions of the system, it may be possible to dimension the system 900 such that it fits in an intermodal container, such that it can be transported in a pre-assembled state in another part of the world and immediately deployed for production without the need for special engineering support.

[0048] According to embodiments of the present invention, the mould trays 102 may be transported between the different levels defined by the position of the at least first and at least second conveyor belts 101, 901 by means of a lift system 911. The lift system 911 may be positioned inside the cooling chamber 903 and may comprise a platform 918 for supporting the mould trays 102 and an arm lever 914 arranged for moving the platform between the different levels at predetermined time intervals. The lift system 911 may be for example a vertical reciprocal conveyor belt or other types of lift systems known in the art. Furthermore, the system 900 may allow for the loading section 106 and the collecting section to be positioned at the same side of the system 900. This may configuration may contribute in reducing operating cost of the system 900 since only a single operator, human or robot, can be sufficient to operate both the loading and collecting of the mould trays 102.

[0049] According to an embodiment of the present invention, the system 900 may further comprise at least a third conveyor belt 921, as shown in FIG. 10. The at least third conveyor belt may be used for making chocolate-based articles that do not require mould trays, such as individual chocolate pieces deposited directly on the third conveyor belt 921. The system 900 may comprise a chocolate dispensing machine 922 for dispensing chocolate in liquid form directly on the at least third conveyor belt 921. The liquid chocolate may be deposited in the form of continuous strips or droplets. The liquid chocolate may be transported through the cooling chamber where it solidifies before being collected at a collecting section 907. By positioning at least a third conveyor belt 921 in combination with the at least first 101 and at least second conveyor belts 901, different types of chocolate-based articles can be made at the same time or independently from each other on different moments.

[0050] According to an embodiment of the present invention a method is providing for producing the chocolate-based articles using the system according to embodiments of the present invention. The method may comprise the step of loading mould trays 102, 502 at a loading section 106 filled with chocolate mass 811 in liquid form onto a top load 104, 504, 604 carrying side of at least a first conveyor belt 101, 501 at an entry point of a transportation system. Once loaded, the mould trays 102, 502 are then transported by means of the at least first conveyor belt 101, 501 through a cooling chamber 103, 903 along a first cooling path, the cooling chamber 103, 903 being arranged for circulating cooling air for solidifying the chocolate mass 811 under predetermined conditions. After the chocolate-based articles are solidified the mould trays 102, 502 are collected at a collecting section 107, which is positioned an exit point of the transportation system. The method further comprises the step of providing prior or together with the loading step air circulation means 105, 505, 605 arranged between the top load carrying side 104, 504, 604 of the at least first conveyor belt 101, 501 and a bottom side 108 of the mould trays such that cooling air can circulate along the bottom side 108 of the mould trays 102, 502.