WO2006113943A2

WO2006113943A2 - Process for shaping and decorating food products

Info

Publication number: WO2006113943A2
Application number: PCT/YU2006/000007
Authority: WO
Inventors: Slobodan Nikasinovic
Original assignee: Slobodan Nikasinovic
Priority date: 2005-04-20
Filing date: 2006-04-19
Publication date: 2006-10-26
Also published as: WO2006113943A3

Abstract

This invention relates to processes and devices for shaping and decorating of food products, in a continuous and discontinuous way, said products being converted from fluid state into solid or gelatinized state through cooling, gelatinizing, foamy gelatinizing, coagulating, then by cutting, coating and adding printed and non-printed decorating tiles and by sprinkling with edible sprinkle.

Description

UNIVERSAL DEVICE AND PROCESSES FOR FOOD PRODUCTS SHAPING AND DECORATION

Field of the invention

Inventions are related to processes and devices for shaping and decorating of food products which are converted from fluid state into solid or gelatinized state and according to international classification these are related to this filed.

Technical problem

This Patent Application solves technical problem of shaping and decorating of food products, in a continuous and discontinuous way, said products being converted from fluid state into solid or gelatinized state through cooling, gelatinizing, foamy gelatinizing, coagulating, then by cutting, coating and adding printed and non-printed decorating tiles and by sprinkling with edible sprinkle.

State of the art

It is well known that, for example, jellying and foamy jellying confections in fluid phase were molded in shallow, relief plastic molds or in forms imprinted in starch where they were maintained until solidified, after which they were coated with chocolate dressing and sprinkled with sprinkle, such as e.g. coconut flour and similar.

Disadvantages of this process are: yield is low; starch, as a medium for molds have to be dried, sterilized, maintained in continuous mode of calefaction and relative humidity, and it is susceptible to fungi contamination, and also during sprinkling, sprinkle cannot be applied in controlled manner partially, i. e. only on desired surface.

It is well known that, for example, cream cheese is shaped through cutting or individual molding into round cylindrical forms. Disadvantage of this process is low yield or fag-ends obtained during cutting into forms; also continuous production is not possible. It is known that during molding of jellying and foamy jellying confections with core and side coating and creamy cheese with core and side coating, the core must be placed at the middle of the mould individually, and than poured sideways with another mixture. Lack of such procedure is low production. All aforementioned deficiencies are eliminated with present patent application. Summary of invention

Universal device and processes for shaping and decoration of food products comprise discontinuous process - pouring of mass in fluid phase into tubular mold equipped with plastic baggy foil or into plastic baggy foil with rod-shaped insert, or endless hose-like mold for continuous process in which the mass solidifies; after hardening, the mass is taken out, cut, coated, decorated with printed or non-printed tile, sprinkled with sprinkle, refrigerated and packaged. Advantages of these processes and devices are higher productivity, better hygienic control and attractive appearance of product, and thereby higher customer preference.

Brief description of the drawings

Universal devices and processes for shaping and decoration of food products - continuous mode is accomplished by following devices which are integral part of this invention, and where figures mentioned below represent: Fig. 1. Spiral device for pouring with endless hose-like mold Fig. 2. Endless hose-like mold — cross section Fig. 3. Endless hose-like mold — top view Fig. 4. Endless hose-like mold — cross section, detail Fig. 5. Stand for endless hose-like mold Fig. 6. Device for continuous radial cutting Fig. 7. Device for continuous radial cutting - detail Fig. 8. Device for continuous radial cutting - view "A" Fig. 9. Coating device

Fig. 10. Roller with wire conveyor of coating device Fig. 11. Device for product positioning on a coating device Fig. 12. Decorative tiles printing and manufacturing device

Fig. 13. Scheme of device for decorative tiles printing and manufacturing, coating line, decorative tiles transfer, sprinkling and product refrigerating.

Fig. 14, 15, 16. Decorative tiles printing and manufacturing device - details with projections Fig.17. Printed decorative tiles turning device Fig. 18. Device for transfer and positioning of decorative tiles onto product

Fig. 19. Device for transfer and positioning of decorative tiles onto product - detail

Fig. 20. Device for transfer and positioning of decorative tiles onto product - detail

Fig. 21. Scheme of synchronization of decorative tiles transfer onto product line

Fig. 22. - Scheme of device for product sprinkling, refrigerating and sprinkle excess removal.

Universal devices and processes for shaping and decoration of food products - discontinuous mode is accomplished by following devices which are integral part of this invention, and where figures mentioned below represent: Fig. 23. Tubular mold with plastic baggy foil insert Fig. 24. Reticulate cart

Fig. 25. Device for pouring with tubular molds in reticulate cart

(tile application, sprinkling with sprinkle and packaging are performed manually, and refrigerating is performed in the open)

Universal devices and processes for shaping and decoration of foods with core and side coating - discontinuous mode is accomplished by following devices which are integral part of this invention, and where figures mentioned below represent: Fig. 26. Tubular mold with plastic baggy foil insert and rod-shaped insert Fig. 27. Tubular mold with rod-shaped insert outside the mold Fig. 28. Tubular mold with rod-shaped insert

Fig. 29. Tubular mold with solidified mass and rod-shaped insert pulled out Fig. 30. Tubular mold wherein another mass is introduced Fig. 31. Example of radially cut solidified mass and formed product

Detailed description of the invention

Universal devices and processes for shaping and decoration of food products - continuous process is accomplished by pouring the jellying or foamy jellying or coagulating food mass in fluid state, prepared by known procedures, into spiral dosimeter (2) from which it is extruded into endless hose-like mold (3) as illustrated on Fig. 1. Endless hose- like mold (3) consists of endless hose, longitudinally cut through upper part of the wall where the in-line longitudinal fastener (1) is situated as depicted on Figs. 2, 3, 4. Endless hose-like mold (3) is carried and pulled through conveyor (6) with brackets shown on Figs. 2 and 5, which restrain radial deformation of hose-like mold. Mass in hose-like mold (3) is gelatinized and solidified by passing through cooling chamber (4). At the cooling chamber (4) outlet, endless hose-like mold (3) is unlatched with opener (9), and solidified mass (11) is transferred onto cutting device depicted on Fig. 6 through roller (1) to frame with cutting wire (2), whose tread and cutting rhythm is regulated with camshaft (3). Sliced pieces (7) fall onto conveyor (4) of coating device (10) whose movement is faster than that of the conveyor (9) which carries sectioned product and endless hose-like mould (5) through cooling chamber, thereby forming enough distance between pieces of product which is required for coating.

Device for continuous cutting is shown on Fig. 7 in greater detail. Cutting wire, fastened at the lower part of the frame (1), by force of the spring (2), cuts product (3) which is continuously moving under specific, adjusted angle α so that the resultant of direction and velocity of product and cutting wire speed is vertical cutting line. Lower part of frame with wire (1) is moveable at the axis (4). Returning upwards, frame with cutting wire (1) is driven by guide (5) which separates it from magnetic couple of magnet (6) and magnet (7). When it exits from the guide (5) control zone it is detached and, attracted by magnet (7), reseated into cutting position. At that moment camshaft (8) sequence ends, and frame (9) with movable lower part of the frame with wire (1), pulled by the spring (2), again initiates cutting of the product (3), which has been moved for desired length at that time, leaving always pieces of equal, defined size. Fig. 8 illustrates cutting device — view "A" from Fig. 6. Fig. 9 depicts coating device where product pieces (1) carried by wire conveyor (12) are transferred beneath coating device (8) in which chocolate (14) melted in melting vessel (4), mixed by propeller (6) and injected by pump (5) through pipe (7), is poured over product pieces (1) which are afterwards positioned by devices (9) for positioning and from which dressing excess is removed by fan (11). The rollers (13) are used for application of dressing to the bottom side of the product. Fig. 10. depicts roller with wire conveyor - detail. Fig. 11. shows device for positioning where wire with frame (5) pulled by the springs (4) equalizes positions of sliced pieces whose longitudinal deviation on conveyor is determined by delimiters (1) along conveyor, after which magnets (3) by mutual attraction return frame with wire into original position. Fig. 12. depicts device for manufacturing of printed decorative tiles. Extrusion of edible printing masses onto conveyor (1) through screen print frame (3) with recorded motifs is achieved by use of the rubber ejector. During extrusion, conveyor 1 and screen print frame are moving together. At the end of the extrusion frame (3) is lifted and returned to original position, and printed motifs enter drying chamber (4), after which, by use of ejector, melted mass for decorative tiles is being applied over printed motifs through frame (5) for tile manufacturing. During the extrusion of decorative tile mass, frame (5) is moving together with transport conveyor (1), and then the frame is lifted and returned to original position, while motifs coated with decorative tile mass carried by conveyor enter the refrigerating chamber 6 where decorative tiles solidify and fuse with printed motifs. Conveyor (1) has smooth plastic surface and now printed and solidified tiles are easily separated from conveyor (1).

Fig. 13. represents scheme of decorative tiles transfer from transport conveyor (13) onto line for coating of piece product (14) in zone (6), with conveyors (13) and (14) having common drive and moving in the same direction at same velocity, and designations represent: motifs printing 1, motifs drying 2, decorative tiles manufacturing 3, decorative tiles cooling 4, decorative tiles turning 5, decorative tiles vacuum lifting 6, solidified mass (from hose-like mould) cutting 7, sliced product pieces coating 8, vacuum positioning of decorative tiles onto product pieces 9, sprinkling chamber 10, product cooling in order to achieve dressing solidification and fixation of sprinkles on dressing 11, excess sprinkle removal 12, packaging 15.

Fig. 14 depicts mode of movement of sieve printing frame and frame for decorative tiles manufacturing during extrusion of printing mass and decorative tiles mass, so that delimiter (4) on the conveyor pushes frame in the direction of movement and tightens spring (6). When mass extrusion is finished, the electromagnet (5) is switched on, frame is then lifted out of reach of the delimiter 4, and spring 6 returns frame into original position, after which the cycle is repeated.

Figs. 15 and 16 show frame with apertures for mass extrusion in decorative tiles manufacturing.

Fig. 17 depicts decorative tiles (4) turning from production conveyor (1) to conveyor (2) which enables turning printed motifs upward. Decorative tiles turned in such way are transferred to product pieces by use of vacuum suckers (3). Fig. 18 represent diagram of vacuum device with suckers for decorative tiles transfer from conveyor (1) to conveyor (3), where both conveyors have common drive through gear wheel (2). Spinning of screw spindle (8) is achieved through electromotor (7) and this rotation transiently moves vacuum chamber with suckers (6). When chamber stops above decorative tiles (4) suction is turned on and decorative tiles are lifted. At that moment electromotor (7) changes rotation direction which causes vacuum chamber with suckers (6) to return above coated product pieces (5) where the suction is switched off and where decorative tiles are set down on product pieces. From this point forward the cycle is repeated.

Fig. 19 represents isometric view of vacuum device with suckers for decorative tiles transfer i. e. electromotor (23), screw spindle (19) vacuum chamber (25) with suckers (12) whose pipes run and slide through plate (14) attracted by electromagnet (21) which is switched on at the moment when vacuum suckers (12) and others are above decorative tiles (1). During passage through vacuum chamber (25) recalcitrant (4) rivets at pawl (15), whereby the suction is switched on, and pawl (15) arrives at the zone of the driving chain (3) which pushes it with delimiter (4) and through cart (9) with wheels 6 the vacuum chamber follows movement of the conveyor (1). At the moment when vacuum suckers (12) and others take up decorative tiles, electromagnet (21) is switched off, and springs (22) lift chamber (25) with suckers (12) and (13). Electromotor (23) changes direction of screw spindle rotation, vacuum chamber with suckers returns to original position, recalcitrant (4) releases pawl (15) which is returned with springs (10) to original position outside the delimiter (5) zone at driving chain (3), and vacuum chamber cease longitudinal movement, while spring (18) returns chamber back, above coating conveyor which is driven through sprocket-wheel (24) and set down decorative tiles onto coated product pieces.

Fig. 20 represents device with vacuum suckers for transfer of decorative tiles - detail.

Fig. 21 represents scheme of decorative tiles transfer in five sequences from decorative tiles production conveyor (8) to coating production conveyor (9). At the sequence A decorative tiles (2) with delimiters (1) pass above coated products (3) at the coating conveyor (9), where said tiles are stopped in sequence B when products (3) arrive beneath decorative tiles and when delimiters (4) make contact with delimiters (1) in sequence C. Decorative tiles are set down on coated products (3) maintaining the concomitant movement of products and decorative tiles at that time, after which delimiters (4) and (1) are separated at the sequence D, springs (5) return delimiters (1) with empty suckers (7) back, and coated products (3) with decorative tiles (4) continue to move carried by the conveyor (9). At the sequence E empty suckers are returned at conveyor (8) into original position where they take up new decorative tiles, arrived in the meantime carried by the conveyor (9), whereby the cycle is repeated.

Fig. 22 represent device for sprinkle application. Coated product (1) with still liquid dressing and applied decorative tile from coating conveyor moves to conveyor (3) for sprinkling and enters sprinkling chamber (4) where propeller (6) and air flow from suction pipe disseminate sprinkle all over the products (1) and affix it onto liquid dressing. Sprinkle from sprinkling vessel (8) is transported by the way of spiral transporter (7) from where the part of sprinkle is transported through pipe (5) into sprinkling chamber (4), while the part of it is further transported spirally to roller with brushes (12) which deposits sprinkle at the transport conveyor (3), whereby the sprinkle application to the bottom surface of product (1) is enabled.

From sprinkling chamber (4) product (1) is transferred to cooling chamber (9) where dressing solidification and sprinkle fixation to dressing takes place, after which sprinkle excess is removed in sprinkle removal chamber (10) through air flow from propeller (11). As decorative tiles were in solid state before sprinkling, the product is sprinkled everywhere except on decorative tiles, whereby we obtained end product with sprinkle which is constituent of overall flavor, protects the products from sticking to each other during storage in warmer conditions, and it also has decorative effect, where printed motifs are clearly visible on decorative tiles. Following this, product is transferred to packaging.

Universal devices and processes for shaping and decoration of food products — discontinuous mode is achieved by processing of jellying or foamy jellying or coagulating food mass prepared according to known procedures in following device which is integral part of this invention, and where figures mentioned below represent:

Fig. 23 represents tubular mold (1) with plastic baggy foil insert (2) in which the mass, still in liquid phase is molded and left to solidify. Fig. 24 represents reticulate carts for tubular molds which consist of wire mesh (1) and (2) in which tubular molds are placed, construction (3) with wheels and stand (4) for tubular molds, all of which enable mold mobility.

Fig. 25 represents injector (1) with multiple apertures for food mass molding into tubular moulds (2) which are situated in reticulate cart (3). When the mass becomes solid, it is taken out together with plastic baggy insert from tubular mould, liberated from plastic baggy insert and cut to defined pieces; afterwards the process is the same as continuous process.

Universal devices and processes for shaping and decoration of food products with core and side coating - discontinuous mode is accomplished by following devices which are integral part of this invention, and where figures mentioned below represent: Fig. 26. represents tubular mold which consists of mold body (1), plastic baggy insert (2), and magnet (3). Mass (4) is poured into tubular mold.

Fig. 27. represents tubular mold with rod-shaped insert outside the mold where thin rubber balloon-like membrane (7), rod-shaped insert (9) with magnet (8) and magnets (10) are placed.

Fig. 28. represents tubular mold (1) with lowered rod-shaped insert (9) and balloon-like membrane (7) where magnets (3, 8, 5, and 10) serve to center the rod-shaped insert. This is where the mass is left to solidify.

Fig. 29. represents tubular mold (1) with solidified mass (4), and rod-shaped insert with balloon-like membrane is pulled out

Fig. 30. represents tubular mold (1) with plastic baggy insert (2) and already solidified mass (4) and newly poured mass (6) which is left to solidify. After solidification plastic baggy insert (2) with mass (4) and mass (6) is taken out from tubular mold, liberated from plastic baggy insert and radially cut as described in above processes. Product may, but doesn't need to undergo coating and sprinkling. Fig. 31. represents one of the examples of radially cut product.

Universal devices and processes for shaping and decoration of food products - continuous mode is accomplished by pouring jellying or foamy jellying or coagulating or fat crystallizing food masses prepared according to known procedures, still in fluid state, through spiral dosimeter (1) into opening of hose-like endless mold (3), heated up to 25- 75°C, after which the hose-like endless mold (3) is closed, and food mass together with hose-like mold passes through cooling chamber (4) where the food mass is refrigerated to 10-25⁰C for 10 to 60 minutes whereupon food mass is solidified.

At the cooling chamber outlet endless hose-like mold is opened and solidified food mass continuously arrives to cutting device where it is cut radially after which all surfaces of product pieces are coated at coating device. Concomitantly at the parallel conveyor motifs are printed; these motifs pass through drying chamber where are dried at the temperature of 20-50°C at intervals of 2 to 4 minutes, after which dried motifs are coated with greasy dressing at temperatures of 25-40°C, whose form and thickness are defined by template. Such coated printed motifs enter the cooling chamber where are refrigerated at 18- 20°C, whereby printing mass and greasy dressing unite, and where greasy dressing becomes solid forming printed decorative tiles. Such printed decorative tiles are mechanically turned over and positioned into nested conveyor, as depicted in Fig. 17, from where decorative tiles are transferred to coated pieces on coating conveyor when the dressing is still in the liquid phase. Hence the product is transferred to air flow - propeller sprinkling chamber with temperature of 20-30°C, whereby sprinkle is applied to all surfaces of product, but sticks only to liquid dressing zones on product, whereas it is not affixed to decorative tile. From there product enters the cooling chamber at the temperature of 4-20°C where the product dressing solidifies at the same time fixing the sprinkle, after which product enters the air flow - propeller sprinkle excess removal chamber at the temperature of 18-20⁰C, whereby decorative tiles remain clean with distinctly visible printed motifs.

Universal device and processes for shaping and decoration of food products - discontinuous mode is achieved by pouring jellying or foamy jellying or coagulating or fat crystallizing food masses prepared according to known procedures in tubular molds depicted in Fig. 23 with plastic baggy insert, where molded mass is left at the temperature of 18-30°C during 1-12 hours, whereby the solidification of food mass takes place, the food mass is afterwards taken out from tubular molds together with plastic baggy insert, after which it is liberated from plastic baggy insert, dusted with starch flour, and radially cut, after which the process is the same as described in continuous process according to this application. Universal devices and processes for shaping and decoration of foods with core and side coating - discontinuous mode is accomplished by pouring jellying or foamy jellying or coagulating or fat crystallizing food masses prepared according to known procedures in tubular molds depicted in Figs. 26 and 27 to volume reduced for volume of rod-shaped insert. In such molded mass the rod-shaped insert with balloon-like membrane is inserted and left there for 1-12 hours at the temperature of 1-3O⁰C, whereby molded mass solidifies, after which the rod-shaped insert with balloon-like membrane is removed, and second food mass is poured in the empty space in tubular mold, which is also left there for 1-12 hours at the temperature of 18-30°C. Upon solidification, mass is taken out from tubular mold together with plastic baggy insert, and mass is liberated from plastic baggy insert and cut radially, which represents the end of the procedure.

Claims

1. Universal devices and processes for shaping and decoration of food products - continuous mode is accomplished by molding jellying or foamy jellying or coagulating or fat crystallizing food masses prepared according to known procedures, characterized in that jellying or foamy jellying or coagulating or fat crystallizing food masses, still in fluid state, are poured through spiral dosimeter (1) Fig. (23) into opening of hose-like endless mold (3), heated up to 25-75°C after which the hose-like endless mold (3) is closed, and food mass together with hose-like mold passes through cooling chamber (4) where the food mass is refrigerated to 10-25°C for 10 to 60 minutes whereupon food mass becomes solid, and at the cooling chamber (4) outlet endless hose-like mold (3) is opened and solidified food mass continuously arrives to cutting device represented in Fig. (6) where it is cut circularly after which all surfaces of product pieces are coated at dressing device Fig. (9), whereas positioning takes place, where concomitantly, motifs are printed on printing device Fig. (12) and they pass through drying chamber where they are dried at the temperature of 20-50°C at intervals of 2 to 4 minutes, after which dried motifs are coated with greasy dressing at temperatures of 25-40°C, whose form and thickness are defined by template, where such greasy coated printed motifs enter the cooling chamber (6) where are refrigerated at 18- 2O⁰C, whereby printing mass and greasy dressing unite, and where greasy dressing becomes solid forming printed decorative tiles, where such printed decorative tiles are mechanically turned over and positioned into nested conveyor, as depicted in Fig. 17, from where decorative tiles are transferred to coated pieces on coating conveyor (12) Fig. (9) when the dressing is still in the liquid phase, hence the product is transferred to air flow - propeller sprinkling chamber (4) Fig. (22) with temperature of 20-30⁰C, whereby sprinkle is applied to all surfaces of product, but sticks only to liquid dressing zones on product, whereas it is not affixed to decorative tile, where from there product enters the cooling chamber (4) at the temperature of 4-2O⁰C where the product dressing becomes solid and at the same time affix the sprinkle, after which product enters the air flow - propeller sprinkle excess removal chamber (10) at the temperature of 18-20⁰C, whereby decorative tiles remain clear with distinctly visible printed motifs.

2. Universal device and processes for shaping and decoration of food products - discontinuous mode is achieved by molding jellying or foamy jellying or coagulating or fat crystallizing food masses prepared according to known procedures, characterized in that jellying or foamy jellying or coagulating or fat crystallizing food masses, still in fluid state, are poured in tubular molds (1) depicted in Fig. (23) with plastic baggy insert (2), where poured mass is left at the temperature of 18-3O⁰C during interval of 1-12 hours, whereby the solidification of food mass takes place, the food mass is afterwards taken out from tubular molds together with plastic baggy insert, after that is liberated from plastic baggy insert, dusted with starch flour, and radially cut, after which is followed the process as described in continuous process according to claim 1.

3. Universal devices and processes for shaping and decoration of food products with core and side coating - discontinuous mode is accomplished by molding jellying or foamy jellying or coagulating or fat crystallizing food mass prepared according to known procedures, characterized in that jellying or foamy jellying or coagulating or fat crystallizing food mass (4), still in fluid state, are poured in tubular molds Fig. (26) to volume reduced for volume of rod-shaped insert (9) Fig. (27), where in such molded food mass (4) the rod- shaped insert (9) with balloon-like membrane (7) is inserted and left there for 1-12 hours at the temperature of l-30°C, whereby poured food mass (4) solidifies, after which the rod- shaped insert (9) with balloon-like membrane (7) is removed, and in the empty space in tubular mold (6) Fig. (29) second food mass (6) Fig. (30) is poured, which is also left there for 1-12 hours at the temperature of 18-30⁰C, where after becoming solid food masses (4) and (6) are taken out from tubular mould (1) together with plastic baggy insert (2), where food masses (4) and (6) are liberated from plastic baggy insert (2) and cut radially, after which procedure is completed.

4. Universal devices and processes for shaping and decoration of food products - endless hose-like mold consists of spiral dosimeter (1) Fig. (1) for food mass and cooling chamber (4), characterized in that through cooling chamber (4) Fig. (1) passes endless hose- like mold (3) carried by conveyor (6) and rollers (5) and (12), where the level of poured mass in endless hose-like mould (3) is controlled with sensory regulator (10), where endless hose-like mould (3) at molding sites is opened by openers (13), and the outlet for solidified mass is opened by openers (9), where endless hose-like mold is supported by girders (1) Fig. (2), where the endless hose-like mold (3) Fig. (4) is opened at its upper part of the wall which can be closed and opened by linear longitudinal buckle (1) through pressing roller (2).

5. Universal devices and processes for shaping and decoration of food products - device for continuous radial cutting, characterized in that the camshaft (8) lifts frame with cutting wire (9) Fig. (7), through spring (2) for suppression of frame with cutting wire (1) in cutting direction, where the side girders of the frame with cutting wire (9) consist of two parts, so that the lower movable girder (1) can move circularly with center in axis (4) in order to follow path while returning through elastic guide (5), where at the upper part of the girder of frame with cutting wire (9) the magnet (7) is attached, which draws lower movable girder (1) with magnet (6) to original position when it leaves the zone of the delimiter (5), where the frame with cutting wire (9) rests on camshaft (8) through ball-bearing.