WO2009004467A1

WO2009004467A1 - Apparatus for making food items, in particular confectionery

Info

Publication number: WO2009004467A1
Application number: PCT/IB2008/001739
Authority: WO
Inventors: Erminio Diolaiti; Giuseppe Motta; Gaetano Castiglione; Leonardo Rabaglia
Original assignee: Ima Flavour SRL
Current assignee: Ima Flavour SRL
Priority date: 2007-07-04
Filing date: 2008-06-27
Publication date: 2009-01-08
Anticipated expiration: 2010-01-04
Also published as: ITBO20070458A1

Abstract

Described is an apparatus (100) for making food items (1), in particular confectionery, starting with a powdered food material (M) containing excipients, the apparatus (100) being of the type comprising at least one feed station (7) for the material (M), comprising dosing means (14) for dosing at least one dose (D) of the material (M) in a respective hole (52; 3) of a supporting structure (15; 2); and at least one station (8) for compacting the dose (D) in the hole (52; 3), comprising means (G) which generate (G) ultrasonic mechanical vibrations; the generating means (G) comprising at least one reciprocating sonotrode (5), moving away from and towards the dose (D), one operating end (51) of the sonotrode forming a curved surface with a predetermined hollow (K1) designed to operate in conjunction and interact with a hole (52) in turn consisting of a curved surface having a respective hollow (K2), the hole (52) being made in an element (15) for opposing the sonotrode (5), for ultrasonic compacting of the dose (D) and making a food item (1).

Description

Apparatus for making food items, in particular confectionery

Technical Field

The present invention relates to an apparatus for making food items, in particular in the confectionery sector.

In particular, the invention is advantageously used for making food items made with confectionery material containing saccharose, sugar or similar excipients, in particular sweetened cocoa, to obtain products such as chocolates with a soft centre, sweets, chocolate eggs, soft-centred sweets and the like, to which the following description makes explicit reference without thereby limiting the scope of the invention.

Background Art

In the confectionery sector, the production and consumption of chocolates, chocolates eggs, sweets and similar confectionery products in recent years has seen a considerable general increase, of significant commercial and economic importance, these items being very popular with consumers.

As can easily be inferred, the biggest disadvantage of such confectionery products is, naturally, is their perishability, above all at high temperatures which can cause them to rapidly melt.

In particular, the problem of the perishability of such confectionery products is very real during hot seasons, when their preservation becomes very problematic and notably hard, as is their transportation from production plants to sales sites.

Perishability during hot summer seasons is even more noticeable in confectionery products with soft centres, for example chocolates and the like containing liquid or light food/confectionery substances, such as creams or other substances, since there is the possibility of an unwanted leak of the contents from the outer casing of confectionery material melting due to the high ambient temperature.

Disclosure of the Invention Therefore, the present invention has for an aim to provide an apparatus for making food items which are free of the disadvantages in the prior art indicated above. hi particular, the present invention has for an aim to provide an apparatus able to make food items, in particular confectionery, which are easy to preserve, market and consume without problems related to melting, even and above all in high temperature environments and/or during the summer.

The invention also has for an aim to provide an apparatus for making sweetened cocoa-based confectionery products, such as chocolates, especially with a soft centre, chocolate eggs and similar products, which are easy to preserve and transport, and tend not to be perishable even in high temperature environments and/or during hot seasons.

Brief Description of the Drawings

The technical characteristics of the invention are described in the claims below and its advantages are more apparent from the detailed description which follows, with reference to the accompanying drawings which illustrate a preferred embodiment of the invention provided merely by way of example without restricting the scope of the inventive concept, and in which:

Figure 1 is a schematic view, partly in cross-section and with some parts cut away for greater clarity, of a preferred embodiment of an apparatus for making food items according to the present invention;

Figure 2 is a perspective view of the apparatus of Figure 1; Figures 3a and 3b are, respectively, a schematic front elevation view and a plan view from bottom to top, of a first embodiment of a first element of an operating unit belonging to the apparatus of Figures 1 and 2; Figure 3c is a front elevation view, partly in cross-section, of a second element operating in conjunction with the element illustrated in Figure 3a and in Figure 3b;

Figures 4a and 4b are, respectively, a schematic front elevation view and a plan view, of a second embodiment of a first element of the operating unit belonging to the apparatus of Figures 1 and 2;

Figure 4c is a front elevation view, partly in cross-section, of a second element operating in conjunction with the element illustrated in Figure 4a and in Figure 4b; Figure 5 is a perspective view of two items, which can be joined together, made using the apparatus according to the present invention;

Figures 6a and 6b are, respectively, a plan view and a perspective view of a product made using the apparatus according to the present invention and equipped with the operating unit illustrated in Figures 4a, 4b and 4c; Figures 7a and 7b are, respectively, two front views of the second element of

Figure 4c illustrated in two possible alternative embodiments.

Detailed Description of the Preferred Embodiments of the Invention

With reference to Figures 1 and 2, the numeral 100 denotes as a whole an apparatus for making food items 1, of the type comprising a plurality of operating stations arranged one after another along a production line extending in a substantially horizontal direction A.

Preferably, but without limiting the scope of the invention, the apparatus 100 is enclosed in a structure 101 (illustrated with a dashed line in Figure 2) so that it can operate in an environment with a controlled atmosphere, for example using inert gas.

The plurality of stations belonging to the apparatus 100 consists of a first operating station 6 for feeding in the direction A from a reel 2a and using a feed roller 22, a web 2 of material with a high level of thermal resistance and predetermined thickness, preferably, but without limiting the scope of the invention, made of Teflon® or the like, and having pockets or cavities 3 distributed on the web 2 one after another and having a predetermined shape C, as explained in more detail below; a second station 7 for feeding doses D of powdered food material M into the cavities 3 in the web 2; a third station 8 for compacting the doses D in the cavities 3 to form the items 1; and a fourth station 9 for ejecting (arrow F6) from the cavities 3 the items 1 obtained in this way and then collecting the items 1.

For example, the items 1 may be collected in a suitable container 13 (Figure

2) or on a conveyor (of the known type and therefore not illustrated) which carries them to a subsequent packaging station (also of the known type and not illustrated).

Again as shown in Figures 1 and 2, the station 7 comprises a unit 14 for dosing the material M in doses D into the cavities 3. The unit 14 is mounted above the web 2 moving along the direction A. Specifically, the material M fed to the station 7 is confectionery food material, comprising powdered cocoa mixed with sugar, saccharose and/or another excipient.

In particular, the above-mentioned excipient may be selected from those indicated in patent WO 98/53700, to which, for a full description, explicit reference is made, without restricting the scope of the invention.

The third station 8 for compacting the doses D comprises a unit G which generates ultrasonic energy, mounted above the web 2, in turn consisting of at least one sonotrode 5, supported in such a way that it can move with reciprocating motion (arrow F3) driven by actuator means of the known type and not illustrated, from and towards an opposing element, schematically illustrated with a block 15 in Figures 1 and 2 and positioned on the opposite side of the web 2 to the sonotrode 5. hi this way, every time a cavity 3 full of material M passes through the station 7 due to the movement of the web 2, the sonotrode 5 is moved towards the opposing element 15 so that a mechanical vibration at predetermined ultrasonic frequencies is applied to the material M in the cavity 3, said vibration able to compact the material M of the dose D.

Moreover, the opposing element 15 may also be connected to additional actuator means, of the known type and not illustrated, so that both the sonotrode 5 and the opposing element 15 can move towards each other.

It should be noticed that the ultrasonic compacting method to which explicit reference is made is of the known type and described in the above-mentioned patent WO 98/53700, and therefore it is not described in further detail.

Thanks to the action of the ultrasonic vibrations which provide optimum molecular aggregation especially of the above-mentioned excipients contained in the material M, the items 1 obtained with the apparatus 100 can be perfectly preserved and transported, and they tend not to perish even in high temperature environments.

Therefore, the items 1 obtained may be made, sold and consumed in a well- preserved state even during hot seasons, since they do not melt due to high temperatures.

As illustrated in Figures 3a and 4a, 3b and 3c and 4b, 4c, also with reference to the diagram in Figure 1, the sonotrode 5 of the unit G consists of a body 50, one operating end 51 or operating projection having a shape C, forming a curved surface with a hollow Kl facing towards the sonotrode 5, that is to say, facing upwards, forming a substantially convex profile, its dimensions and shape being substantially the same as the shape C of the cavities 3.

The end 51 is designed in such a way that when used it operates in conjunction with and perfectly couples with a respective cavity 3, pressing on the dose D contained in the cavity 3, and making contact inside a respective cavity or hole 52, having a shape C forming a curved surface with a hollow K2 facing towards the sonotrode 5, that is to say, facing upwards and forming a concave surface. The concave hole 52 is made in the upper portion of the opposing element

15, for compacting the dose D of material M and so forming the items 1. The items 1 obtained with the apparatus 100 equipped with the unit G therefore each constitute a hollow, substantially cup-shaped container, as illustrated in Figures 5 and 6a.

In particular, when the shape C of the convex end 51 of the sonotrode 5 substantially has a hemispheric shape (see Figures 3a and 3b) or that of a spherical cap, and the cavity 3 and the respective concave hole 52 of the opposing element 15 have the same substantially concave hemispheric shape (Figure 3 c) or that of a spherical cap, so as to mate perfectly with the convex end 51, the items 1 obtained with the apparatus 100 substantially have the shape of a hemispheric shell (Figure 5). Said hemispheric shells 1 may therefore be designed to be subsequently joined together in pairs, using known methods outside the scope of this invention, to form confectionery products having a substantially spherical surface, for example chocolate eggs or the like, and in which gift items made of various types of materials can be housed. Or, according to the non-limiting embodiment illustrated in Figures 4a, 4b and 4c, when the shape C of the end 51 of the sonotrode 5 is substantially a convex parallelepiped, in particular having a trapezoidal vertical cross-section (Figures 4a and 4b), and the cavity 3 and the concave hole 52 of the opposing element substantially have the shape of a parallelepiped, in particular with a trapezoidal vertical cross-section (Figure 4c), the items 1 obtained with the apparatus 100 are hollow and box-shaped (Figure 6a), in particular with a trapezoidal hollow in them.

Said box-shaped items 1 may therefore be filled with material, also confectionery or food material in general, which is creamy or liquid, then closed, for example with a flat layer of the same material M compacted by a sonotrode 5 which has a smooth, flat operating surface (that is to say, without a convex projection 51) and secured using known methods, to make confectionery products such as chocolates with soft centres or the like, as illustrated in Figure 6b.

According to an alternative embodiment not illustrated, the operating end 51 of the sonotrode, the concave hole 52 in the opposing element 15 and the cavity 3 have an oblong shape C for compacting the dose D and forming a shell-shaped product 1 which is substantially a paraboloid.

In an alternative embodiment not illustrated of the apparatus 100 unit G, the hollow Kl at the end 51 of the sonotrode 5 faces towards the opposing element 15, that is to say, it faces downwards, so as to form a substantially concave curved surface, and the hollow K2 of the hole 52 again faces towards the sonotrode 5, that is to say, upwards, forming a substantially concave curved surface for coupling with the concave end 51. In this way, the confectionery food item 1, for example a chocolate, made with the apparatus 100 by compacting the dose D of material M using a unit G formed in this way has a complete surface.

Again as illustrated in Figures 1 and 2, the apparatus 100 may also comprise, downstream of the station 6 in the direction A between the station 6 and the feed station 7, a forming station 10 for forming (for example thermoforming) the cavities 3 having the shape C in the web 2 being unwound in the direction A. The station 10 preferably comprises punch means 16 moving with reciprocating motion away from and towards a forming element 18 positioned on the opposite side of the web 2 (arrow Fl in Figure 1) and having a head 17 shaped in such a way that it creates a cavity 3 having dimensions and a shape C matching the shape C of the end 51 of the sonotrode 5 and the hole 52 in the element 15. There may also be another compression station 11 in the apparatus 100, downstream of the feed station 7, between the feed station 7 and the compacting station 8, to compress the dose D of material M using a reciprocating presser element 19 which moves away from and towards an opposing element 20 positioned on the opposite side of the web 2 and the cavity 3 (arrow F2 in figure 1).

It is important to emphasise that the items 1 described may also be obtained without using the web 2 with the cavities 3, to simplify the structure of the apparatus 100 just described, according to an alternative embodiment of the apparatus 100, not illustrated. hi said alternative embodiment the stations 6 and 10 and 11 are eliminated in the apparatus 100, and there is a special layout in which the station 7 and the station 8 substantially coincide.

The material M for forming the doses D is fed into a hole 52 made in the upper end of a piston element 53 (Figures 7a and 7b) supported by the element 15 of the unit G in such a way that it can slide, driven by suitable actuator means.

During the subsequent compacting step, said piston element 53 whose hole 52 is full of a dose D of material M, is therefore raised (arrow F4) towards the sonotrode 5, which is in turn moving towards the piston element 53, for ultrasonic compacting of the dose D, avoiding direct contact between the sonotrode 5 and the surface of the opposing element 15 which, due to the heat released, would irreparably compromise the surface structure of the opposing element 15.

In another form of said alternative embodiment of the apparatus 100, the end

51 of the sonotrode 5, whether convex or concave, is advantageously coated with a covering of material having a high level of thermal resistance and predetermined thickness, preferably but without limiting the scope of the invention, Teflon® or the like.

The invention described can be modified and adapted in several ways without thereby departing from the scope of the inventive concept. Moreover, all technical details of the invention may be substituted by technically equivalent elements.

Claims

1: An apparatus (100) for making food items (1), in particular confectionery, starting with a powdered food material (M) containing excipients, the apparatus (100) being of the type comprising at least one feed station (7) for the material (M), comprising dosing means (14) for dosing at least one dose (D) of the material (M) in a respective hole (52; 3) of a supporting structure (15; 2); and at least one station (8) for compacting the dose (D) in the hole (52; 3), comprising means (G) which generate (G) ultrasonic mechanical vibrations; the apparatus (100) being characterised in that the generating means (G) comprise at least one sonotrode (5), moving with reciprocating motion away from and towards the dose (D), one operating end (51) of the sonotrode forming a curved surface with a predetermined hollow (Kl) designed to operate in conjunction and interact with a hole (52) in turn consisting of a curved surface having a respective hollow (K2), the hole (52) being made in an element (15) for opposing the sonotrode (5), for ultrasonic compacting of the dose (D) and making a food item (1).

2. The apparatus according to claim 1, characterised in that the hollow (Kl) at the end (51) of the sonotrode (5) faces towards the sonotrode (5), forming a substantially convex curved surface; the hollow (K2) of the hole (52) in the opposing element (15) facing towards the sonotrode (5) to form a substantially concave curved surface for coupling with the convex end (51); the food item (1) having the shape of a hollow, cup-shaped container.

3. The apparatus according to claim 1, characterised in that the hollow (Kl) at the end (51) of the sonotrode (5) faces towards the opposing element (15), forming a substantially concave curved surface; the hollow (K2) of the hole (52) in the opposing element (15) facing towards the sonotrode (5) to form a substantially concave curved surface for coupling with the concave end (51); the food item (1) having a complete surface.

4. The apparatus according to any of the claims from 1 to 3, characterised in that the unit (G) opposing element (15) forms the supporting structure and the hole (52) in the structure is the hole (52), positioned on the upper part of the opposing element (15).

5. The apparatus according to any of the claims from 1 to 4, characterised in that the end (51) of the sonotrode (5) is coated with a covering material which has a high level of thermal resistance and a predetermined thickness.

6. The apparatus according to any of the claims from 1 to 5, characterised in that the concave hole (52) is made in the upper end of a reciprocating piston element (53) slidably supported by the opposing element (15).

7. The apparatus according to any of the claims from 1 to 3, characterised in that it also comprises a station (6) for feeding a web (2) of material having a high level of thermal resistance and predetermined thickness, said web (2) feed station (6) being upstream of the stations (7, 8) for feeding the material (M) and ultrasonic compacting so that it feeds the web (2) through the feed and compacting stations (7, 8); the supporting structure comprising the web (2) and the hole in the structure consisting of a cavity (3) made in the web (2).

8. The apparatus according to claim 7, characterised in that the cavity (3) has a shape (C; K2) which is the same as the shape of the concave hole (52).

9. The apparatus according to claim 8, characterised in that it also comprises punch means (16) positioned at a forming station (10) for forming at least one cavity (3) in the web (2); the forming station (10) being positioned between the web (2) feed station (6) and the material (M) feed station.

10. The apparatus according to any of the foregoing claims from 1 to 2 and from 4 to 9, characterised in that the operating end (51) of the sonotrode (5) and the concave hole (52) in the opposing element (15) are substantially hemispheric in shape for compacting the dose (D) and forming a hemispheric hollow shell-shaped item (1).

11. The apparatus according to any of the foregoing claims from 1 to 2 and from 4 to 9, characterised in that the operating end (51) of the sonotrode (5) and the concave hole (52) in the opposing element (15) are substantially oblong in shape for compacting the dose (D) and forming a hollow shell-shaped item (1) which is substantially a paraboloid.

12. The apparatus according to any of the foregoing claims from 1 to 2 and from 4 to 9, characterised in that the operating end (51) of the sonotrode (5) and the concave hole (52) in the opposing element (15) substantially have the shape of a parallelepiped for compacting the dose (D) and forming a hollow, box-shaped container item (1).

13. The apparatus according to claim 12, characterised in that the parallelepiped shape has a substantially trapezoidal vertical cross-section; the box-shaped container item (1) therefore being substantially trapezoidal.

14. The apparatus according to any of the foregoing claims from 1 to 13, characterised in that the material (M) comprises confectionery material mixed with saccharose or the like.

15. The apparatus according to any of the foregoing claims from 1 to 14, characterised in that the material (M) comprises sweetened cocoa.

16. A food item (1), in particular confectionery, obtained using the apparatus (100) according to any of the foregoing claims from 1 to 15.

17. A food product, in particular confectionery, obtained by coupling and fixing together two food items (1) made using the apparatus (100) according to claim 10 or claim 11, and claim 14 or claim 15.

18. A food product, in particular confectionery, obtained using an item (1) made using the apparatus (100) according to claim 12 or claim 13, and claim 14 or claim 15, suitably filled with material that is also confectionery material, in liquid and/or creamy form, then closed with a flat layer made of compacted material (M).