AU2917802A

AU2917802A - Apparatus and method for shaping compositions

Info

Publication number: AU2917802A
Application number: AU29178/02A
Authority: AU
Original assignee: Mars UK Ltd
Current assignee: Wrigley Candy UK
Priority date: 2001-07-13
Filing date: 2002-03-27
Publication date: 2003-01-16
Also published as: ZA200302781B; GB0117175D0; WO2003005833A1

Description

P/00/011 28/5/91 Regulation 3.2(2)

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION STANDARD PATENT Application Number: Lodged: Invention Title: APPARATUS AND METHOD FOR SHAPING COMPOSITIONS The following statement is a full description of this invention, including the best method of performing it known to us APPARATUS AND METHOD FOR SHAPING COMPOSITIONS The present invention relates to apparatus for shaping compositions into slabs and/or ropes which may be used particularly, but not exclusively, in the manufacture of confectionery. Compositions which may be shaped into ropes according to the present invention include aerated nougat, fondant, caramel, coconut compositions and compositions incorporating inclusions, e.g. nuts. In particular, compositions of sensitive material may be used in the present invention.

In the context of the present application, the term "rope" is intended to represent a continuous length of material of no particular cross-sectional shape. Once formed, these ropes may be immediately passed to a cutter where the rope is cut g into shorter lengths or the rope may be subjected to further treatment before cutting. A number of processes for forming ropes of material are known.

o• DE 3004022 discloses apparatus in which two grooved rolls are arranged such o that the projections in one roll engage in the grooves of the other. This arrangement of rolls allows the formation of a number of adjacent material 20 strings or ropes from the sheet of material supplied to the rolls. Adjacent ropes will, of course, be on different rolls. The lateral limiting faces of the groove and projection form the interacting shearing faces which divide the material into the ropes. One problem with this apparatus is that the material cost of each grooved roll is very high and therefore if strings of a different width are required, two new rolls with the new dimensions have to be manufactured. It is also a very time consuming process to replace the two grooved rolls, which consequently means that a change of the width of the rope requires a long down time period during which no product is produced. This is inefficient.

Another system for the production of ropes of material is by the use of a comb type insert placed in the gap between two rolls as set out in, for example, GB 1600464. Relative to the cost of each of the rolls, the cost of such an insert is small and it is therefore possible to have a number of inserts available of different channel widths which can be readily changed in just a few minutes.

The inserts of GB 1600464 have regularly spaced teeth leading to grooves of identical width. If a different width rope is required, a new comb has to be inserted and once again all the products produced by this comb will be of identical width. When different spacings have been tried within the same comb, the product produced has been irregular and of a low quality. It is therefore only possible to make strips of one width at a time using the comb of GB 1600464.

ooooo An object of the present invention is to provide apparatus which can be used to S"simultaneously produce ropes and/or slabs of at least two different widths and/or 15 heights, or a range of shaped profiles. A further object is to provide apparatus S-which can be used for materials of a sensitive nature which may not normally be suitable for extrusion.

According to the present invention, there is provided apparatus for shaping 20 compositions into ropes or slabs of at least two different widths and/or heights or at least two different shaped profiles simultaneously.

According to a first embodiment of the present invention, there is provided apparatus for shaping compositions into ropes of at least two different widths and/or heights simultaneously, the apparatus comprising two moving surfaces separated by a gap and an insert which extends into the gap and is configured to conform closely to the contours of the two moving surfaces and has at least two grooves of different width and/or height running in the direction of one of the 3 moving surfaces.

According to a second embodiment of the present invention, there is provided apparatus for shaping compositions into ropes of at least two different shaped profiles simultaneously, the apparatus comprising two moving surfaces separated by a gap and an insert which extends into the gap and is configured to conform closely to the contours of the two moving surfaces and has at least two grooves of different shaped profile running in the direction of one of the moving surfaces.

Preferably the grooves in the inserts are of dimensions such that the sum of the cross-sectional area of the grooves over a critical distance is substantially equal.

S"The use of such apparatus allows the simultaneous production of ropes of 15 different widths and/or heights or different shaped profiles. It has been found S that the substantial equality of the sum of the cross-sectional areas of the grooves of different widths and/or heights or shaped profile over the critical distance avoids the problems of inconsistent density and structure in the rope.

S".i 20 Maintaining the equality of the sum of the cross-sectional areas over the critical distance between the grooves of different width and/or height or shaped profile means that the composition can flow smoothly through the system as the pressure distribution across the width of the comb remains constant. In the prior art insert varying the width of the grooves resulted in an uneven pressure drop across the width of the comb. Consequently, the feed material did not flow smoothly and the ropes of material produced were uneven in character and did not have the properties required for use in the confectionery industry.

4 A particular benefit of the application of the technology of the present invention is that it can be used for materials of a sensitive nature, for example nougat and caramel. These materials may generally be subject to a loss of aeration, breakage of inclusions, oiling out of caramel etc. if subjected to the heavy manipulation and shearing of the prior art processes.

Using the apparatus of the present invention, it is possible to simultaneously produce ropes of different height and/or width or shaped profile simply and cheaply. This flexibility in manufacture of ropes of different dimensions simultaneously provides a lean manufacturing solution to a need to produce nl ropes of dimension xi, y, and n 2 ropes of dimension x 2 Y2. Simply changing the insert to one in which the ratio n 1 /n 2 is different can allow simultaneous production of the required numbers of ropes of each dimension. Similarly, if S"changes in either the shape of the profdiles of the ropes or the ratio between two 15 different shapes are required, the insert can be changed to the suitable one.

Preferably, the critical distance over which the sum of the cross-sectional areas of the grooves is substantially equal is the sum of the widths of the widest tooth and the widest groove in the insert.

Advantageously, the two moving surfaces are two rolls such as those used in one example of the systems currently employed for the production of ropes. By using the insert of the first and second embodiments of the present invention in the gap between the rolls to generate the ropes, there is no need for the inclusion of slitters and dividers. This results in a considerable saving in capital costs as well as introducing considerably more flexibility to the system. Instead of having to change both the slitters and dividers each time ropes of different dimensions are required it is now only necessary to choose the appropriate insert with the desired combination of widths of rope. This insert is then positioned to extend into the gap between the two rolls. Changing the insert takes only a few minutes and thereby minimises the time when the system is shut down.

In addition, the use of the insert to produce ropes of different widths and/or heights on the moving surfaces reduces the cooling duty on the production line when compared to the duty required when the sheet of material produced in the prior art system is cooled before being passed to the slitters and dividers.

Further, slitters and dividers only work effectively within a narrow temperature range. The use of the insert in the first and second embodiments of the present invention therefore also results in lower running costs as well as lower capital Scosts.

Preferably the two moving surfaces comprise two rolls with smooth surfaces.

15 These are cheaper to produce than rolls with grooved surfaces and can also be used with a number of different inserts. Alternatively, one or more of the moving surfaces may be a roll and the other may be a moving belt again separated from the roll by a small gap. In both cases, the material is drawn through the insert by the movement of the two surfaces, which effectively acts as S- 20 a low pressure extruder.

According to a third embodiment of the present invention, there is provided apparatus for shaping composition into slabs of at least two different heights simultaneously, the apparatus comprising two generally cylindrical stepped rolls moveable relative to each other such that there are at least two different spacings between the rolls at all times.

Preferably the rolls are moveable relative to each other both in the direction of the axes of rotation of the rolls and in the perpendicular direction in the plane of the two rotation axes.

Optionally the rolls are moveable relative to each other while the system is rnmning without having to shut down the line.

The apparatus of the third embodiment does require the use of slitters and dividers to split the slabs of confectionery of two or more different heights into ropes of a defined width or widths.

According to a fourth embodiment of the present invention, there is provided apparatus for shaping compositions into ropes of at least two different widths simultaneously, the apparatus comprising means for producing a slab of the composition and variable slitting means which can be independently moved 15 relative to each other to split the slab into ropes of at least two different widths simultaneously and associated dividing means.

*o Preferably the dividing means comprise multi polycords of a suitable material such as plastic.

According to a fifth embodiment of the present invention, there is provided apparatus for shaping compositions into ropes of at least two different widths and/or heights simultaneously, the apparatus comprising two generally cylindrical stepped rolls moveable relative to each other such that there are at least two different spacings between the rolls at all times, and variable slitting means which can be independently moved relative to each other to split the slab of at least two different heights into ropes of at least two different widths simultaneously, and dividing means associated with the slitting means.

I

7 Preferably control means are present to control the movement of both the stepped rolls and the slitting means and associated dividing means. Optionally the slitting means and associated dividing means are controlled such that each different height has a corresponding different width. Ropes of height ha will therefore always be of width wa and ropes of height hb will always be of width wb etc.

Other preferred features and advantages will be apparent from the following specific description of two of the embodiments of the present invention as shown in the accompanying figures in which: Figure la is a schematic representation of one configuration of apparatus for shaping ropes according to the first embodiment of the present invention; SFigure lb is a schematic representation of a second configuration of S 15 apparatus for shaping ropes according to the first embodiment of the present invention; Figure 2 shows in a schematic form, a plan view from the front of one embodiment of an insert as used in the first embodiment of the present invention; 20 Figure 3a shows in a schematic form, a side view of one embodiment of an insert as used in the first embodiment of the present invention with detail of the narrower grooves; Figure 3b shows in a schematic form, a side view of one embodiment of an insert as used in the first embodiment of the present invention with detail of the wider grooves; Figure 4 shows in a schematic form, a plan view from above of one embodiment of an insert as used in the first embodiment of the present invention; 8 Figure 5 shows, in schematic form, two stepped rolls which may be used in the third and fifth embodiments of the present invention.

Figure la shows one embodiment of the first embodiment of the present invention in which the two moving surfaces are both rolls 2, 4. In this schematic representation, the rolls have been shown to be identical in size although they may, of course, be of different sizes. The surfaces of the two rolls 2, 4 are smooth and the rolls rotate about their respective axes 1 and 3. There is a gap between the two rolls 2, 4 into which an insert 20 extends. This insert is shown more clearly in the later figures, but in general comprises a number of teeth which at one end extend into the gap and at the other end lead to a number of grooves on one side of the insert. In accordance with this embodiment of the 4444 present invention, there are at least two different widths and/or heights of grooves in the insert to produce ropes of different dimensions.

The rolls 2, 4 are supplied with a suitable composition 8, for example, molten caramel, nougat, fondant, coconut, by means of a hopper unit 9. The invention is not limited to the means for supplying the composition to the apparatus and any suitable means for producing a regular supply of composition on the surface of the rolls 2, 4 before passing through the insert 20 may be used.

The position of hopper 8 over roll 4 may be varied, and the hopper 8 may be positioned at any point on the roll. Advantages of this variability'include a further degree of control over the temperature of the composition as it passes through the insert 20. The longer the residence time on the roll, the greater the degree of cooling. The temperature of the composition as it passes through the insert affects the quality of the ropes formed. By the time the composition passes through the insert 20, it should have cooled to a sufficient degree to be in a 9 plasticised form whereby it is able to retain its configuration once it has passed through the insert.

The apparatus of this embodiment of the present invention is also capable of handling deformable materials, e.g. aerated materials, which can be described as substantially elastic in form. These materials may require compensation in the size of the apertures (grooves) in the insert to deliver a rope of specific final dimension. As the rope of deformable material leaves the groove it may expand slightly and this expansion may be compensated for in the calculation of the 10 dimensions of the insert.

Another advantage of the variable position of the hopper is that the amount of composition entering the gap may be more easily controlled.

15 The insert 20 is configured such that its surfaces conform closely to the surfaces of the rolls 2, 4. The gaps visible in figures la and lb are for clarity of the separate parts. The composition 8 is therefore forced to pass through the grooves *o .o on one side of the insert 20 and is accordingly formed into ropes 10 of material.

The material is guided into the grooves of the insert 20 by means of the teeth 20 which extend into the gap between the rolls.

The ropes 10 of material are removed from the surface 5 of the roll 2 by means of a doctor blade 6. Since the surface 5 of the roll 2 is smooth and does not have grooves running around its circumference, the doctor blade 6 may be a simple blade which is not castellated in contrast to the blade or blades required in some of the systems of the prior art when grooved rolls are used. The ropes 10 of material are then conveyed away by means of a belt 7 for further processing.

I

In an alternative arrangement of this embodiment shown in figure lb, the hopper 9 is positioned over both rolls 2, 4. The composition 8 is thus applied to both rolls and forms a pool 12 directly above the insert 20. Again, since the insert is configured such that its surfaces conform closely to the surfaces of the rolls, the composition is forced to pass through the grooves of the insert Referring to Figures 2, 3a, 3b and 4, one embodiment of an insert of the first embodiment of the present invention is shown in greater detail. The insert comprises a number of teeth 30, 40 which extend down the length of the insert as protrusions 31, 41. The width of the teeth 30, 40 and corresponding protrusions 31, 41 may be the same along the length of the insert 20 or may vary in dimension as shown in these figures. In between the protrusions 31, 41 lie grooves 35, 45 of width w. The insert 20 shown is constructed to include at least S. two different widths w although there may be more than two different dimensions.

a.i As can be seen from Figures 3a and 3b, the depth h of the grooves also varies along the length of the insert. Figure 3a shows, in dotted lines, the contour of the groove 35 which corresponds to the narrower groove of width wl. The depth of 20 groove 35 is hl. Figure 3b shows, in dotted lines, the contour of the groove which is the wider groove of width w 2 The depth of groove 45 is h 2 As set out above, an important feature of this embodiment of the present invention is the fact that the sum of the cross-sectional areas of the grooves in the insert 20 over a critical length z is the same to ensure even flow of the material through the insert. The critical length z is the width of the widest tooth plus the width of the widest groove as shown in figure 2. Of course, if there are more than two different widths in the insert 20 care must be taken to define the critical length z in terms of the widest tooth and associated gap. Therefore, in the case of rectangular shaped grooves, the different dimensions of the grooves in the insert are related by the equation:

Z

Zw 1 k =Zw,h, (1) 0 0 The even flow of material through the insert 20 along the whole of its length ensures that even ropes of regular density are formed. Ropes of two different dimensions, both in height and in width, are formed which are then passed on for further treatment as appropriate. As indicated above, the insert 20 may be constructed to include more than two different dimensions.

Referring to figure 2 it will be noted that the thinner, shallower grooves are 9.

longer than the thicker, deeper grooves 45. The points of the teeth 30, 40 are all at the same height, but the top 32, 42 of the smooth surface adjacent to the .i second roll is higher for the grooves 35 than for the grooves 45. The same principle applies if there are more than two different sizes of groove. The narrower and shallower the groove, the higher up the insert the top of the smooth surface lies. This arrangement assists in the even distribution of material into the ~different sizes of groove and helps to ensure even quality ropes are obtained.

As can be seen particularly from Figures 3 and 4 the grooves are only present on one side of the insert 20. The other side is smooth and conforms exactly to one of the moving surfaces, for example, the surface of roll 4 in Figure 1. In operation, there is no gap between the moving surface and the smooth surface of the insert. All the material passing between the moving surfaces and entering the insert 20 is therefore forced through the grooves 35, 45 to form ropes of varying dimensions. The second roll 4 may therefore be considered to be a drive roll which serves to provide the insert with a regular flow of composition which may I 12 be in the form of a sheet.

The grooves shown in the figures are generally rectangular in shape. However, it is clearly possible to form other shapes of groove which will accordingly simultaneously produce ropes of a different shape according to the second embodiment of the present invention. For example, the profile of the rope may be semicircular or triangular in cross section. As stated above equation only applies in the case when the grooves are rectangular in cross section, but the principle of equal cross sectional area over a critical length z will still apply for grooves of a different shape.

The main portion of the inserts 20 as shown in figures 3a and 3b may be made of any suitable material such as plastics or metal and are considerably cheaper to S"produce than the chilled rolls 2, 4. This portion of the insert 20 may be fixed to a 15 base (not shown) for helping to position the insert between the rolls 2, 4. It is possible to attach some form of temperature control to the insert. However sufficient control can normally be obtained through varying the conditions of the two rolls 2, 4 or the position of the hopper 9 over the roll(s). The insert 20 is also considerably quicker to change than the rolls 2, 4. Therefore, alternative inserts 20 using grooves of different widths or shapes may also be used. In particular, inserts with three or more different widths and/or depths across its length may be used. In general, the inserts may be positioned between the rolls by means of pneumatics or any other suitable means.

It will be appreciated that similar inserts will be used in the second embodiment of the present invention where two or more different shaped profiles of rope are produced simultaneously. Naturally the cross section of the groove will be different, but the same operational principles apply. Primary amongst these is the sum of the cross sectional area of the grooves over a critical distance being substantially equal. As indicated above, equation only applies to the situation were the cross section of the groove is rectangular. Similar equations will apply for different cross sections.

Referring to Figure 5, a schematic representation of the two stepped rolls which may be used in the third and fifth embodiments of the present invention is shown. The view is essentially a plan view from above with the gaps between the rolls exaggerated for clarity. Two stepped rolls 60, 70 rotate about their respective axes 61, 71. Roll 70 is fixed, but roll 60 is moveable laterally with respect to roll 70 in the direction of arrow A. The steps s 6 $70 for each roll will :o.be different to ensure that, at all times, there will be at least two differently sized S"gaps, gi, between the rolls. In the arrangement shown in Figure 5 there are three S"differently sized gaps g 1 g2 and g3 which will result in three different thicknesses in the slab passing out from these rolls. It will be appreciated that by moving roll 60 to the right such that the two steps lined up, only two differently sized gaps would be present. Similarly, by moving the roll 60 laterally in the direction of arrow A, the ratio between the quantity of material of each thickness will be varied.

Preferably roll 60 is also moveable in the direction of arrow B, perpendicular to the axis of rotation 61 and in the plane of the two axes 61, 71. Movements in this direction enable the values of gi, g 2 and g3 to be varied as well as the iatio of the amount of each thickness produced, which is controlled by movement in the direction of arrow A. This means that the system has almost universal variability of the height ratio and any combination of slab thicknesses can be produced.

Movement of just one of the rolls is relatively simple and quick and can be achieved without the need to shut down the complete system to remove and 14 replace a complete roll. As indicated previously, these rolls are often chilled, and complete removal and change is a time consuming operation. The composition may be applied to the rolls by either of the means shown in Figures 1 and la or by any suitable means.

As indicated above, the apparatus of these embodiments requires the use of slitters and dividers to cut and divide the slabs of composition into ropes of the required width. Preferably the slitters are independently variably operated such that the different widths of rope can be produced and that the widths may be readily changed to react to changes in demand. Preferably, the system is controlled such that each thickness of slab has its own corresponding width.

Therefore, when the stepped roll 60 is moved either laterally or in the direction of arrow B, a corresponding change in the slitters and associated dividers is *initiated. This apparatus therefore produces ropes of material of at least two 15 different heights and/or widths simultaneously.

o t.*

Claims

1. Apparatus for shaping compositions into ropes or slabs of at least two different widths and/or heights or at least two different shaped profiles simultaneously.

2. Apparatus as claimed in claim 1 for shaping compositions into ropes of at least two different widths and/or heights simultaneously, the apparatus comprising two moving surfaces separated by a gap and an insert which extends into the gap and is configured to conform closely to the contours of the two moving surfaces and has at least two grooves of different width and/or height running in the direction of one of the moving surfaces. 15

3. Apparatus as claimed in claim 1 for shaping compositions into ropes of at e least two different shaped profiles simultaneously, the apparatus comprising two moving surfaces separated by a gap and an insert which extends into the gap and is configured to conform closely to the contours of the two moving surfaces and has at least two grooves of different 20 shaped profile running in the direction of one of the moving surfaces

4. Apparatus as claimed in claim 2 or claim 3, in which the grooves are of dimensions such that the sum of the cross-sectional area of tfie grooves over a critical distance is substantially equal.

Apparatus as claimed in any one of claims 2 to 4, in which the insert includes teeth which project into the gap between the two moving surfaces and which direct the composition into the grooves.

6. Apparatus as claimed in any one of claims 2 to 5, in which the critical distance is the sum of the widths of the widest tooth and the widest groove.

7. Apparatus as claimed in any one of claims 2 to 6, in which the narrower grooves are longer than the wider grooves.

8. Apparatus as claimed in any one of claims 2 to 7, in which the two 10 moving surfaces are two rolls.

9. Apparatus as claimed in claim 8, in which the surfaces of the two rolls are smooth. 15

10. Apparatus as claimed in any one of claims 2 to 8, in which one of the two moving surfaces is a roll and the other is a belt.

S11. Apparatus as claimed in any one of claims 2 to 10, in which the moving surfaces are heated or cooled.

12. Apparatus as claimed in any one of claims 2 to 11, in which the insert is manufactured of material which facilitates easy formation and removal of the ropes of composition.

13. Apparatus as claimed in any one of claims 2 to 12, further comprising a hopper to distribute composition onto one or both of the moving surfaces.

14. Apparatus as claimed in claim 13, in which the position of the hopper in 17 relation to the moving surfaces is variable.

Apparatus as claimed in claim 14, in which movement of the hopper relative to the moving surfaces is used to control the temperature of the composition.

16. Apparatus as claimed in claim 1 for shaping compositions into slabs of at least two different heights simultaneously, the apparatus comprising two generally cylindrical stepped rolls moveable relative to each other such that there are at least two different spacings between the rolls at all times.

17. Apparatus as claimed in claim 16, in which one roll is moveable relative to the other in the direction of the axes of rotation. *.i 15

18. Apparatus as claimed in claim 16 or claim 17, in which one roll is e*g moveable relative to the other in the direction perpendicular to the axis of rotation in the plane of the two axes of rotation.

19. Apparatus as claimed in claim 1 for shaping compositions into ropes of at 20 least two different widths simultaneously, the apparatus comprising means for producing a slab of the composition and variable slitting means which can be independently moved relative to each other to split the slab into ropes of at least two different widths simultaneously, and 'associated dividing means.

Apparatus as claimed in claim 19, in which the dividing means comprise polycords of a plastic material. 18

21. Apparatus as claimed in claim 1 for shaping compositions into ropes of at least two different widths and/or heights simultaneously, the apparatus comprising two generally cylindrical stepped rolls moveable relative to each other such that there are at least two different spacings between the rolls at all times, and variable slitting means which can be independently moved relative to each other to split the slab of at least two different heights into ropes of at least two different widths simultaneously, and dividing means associated with the slitting means.

22. Apparatus as claimed in claim 21, in which the stepped rolls and slitting means and associated dividing means are controlled by central control means. 0000*0 000*

23. Apparatus as claimed in claim 21 or claim 22, in which the slitting means and associated dividing means are controlled such that each different *90height has a corresponding different width. *0*t

24. Apparatus constructed and arranged substantially as herein specifically described with respect to and shown in Figs. 1 to 4 or Figure 5 of the 20 accompanying drawings.

A method of shaping compositions into ropes or slabs of at least two different widths and/or heights or at least two different shaped profiles simultaneously, the method comprising feeding a composition in a fluid form to the apparatus as claimed in any preceding claim and passing the composition through the apparatus to form the different height and/or width product. 19

26. A method as claimed in claim 25, in which the apparatus is that claimed in any one of claims 2 to 15, and in which the composition is fed to at least one of the moving surfaces from where it is forced through the grooves in the insert to form the ropes of different profiles or dimensions.

27. Use of apparatus as claimed in any one of claims 1 to 24 to simultaneously produce ropes or slabs of at least two different heights and/or widths or of different shaped profiles. DATED this 27th day of March 2002. MARS UK LIMITED 290 BURWOOD ROAD HAWTHORN. VIC. 3122. o d: WATERMARK PATENT TRADEMARK ATTORNEYS 290 BURWOOD ROAD HAWTHORN. VIC. 3122. 0 0 0