IE78840B1 - A process and apparatus for producing chocolate coated sweets - Google Patents

Abstract

A filling mixture for chocolate coated sweets is prepared by mixing selected ingredient materials at a mixing station (10) to form a mixture which is then cooked (12). Chocolate pieces are cooled in cooler (14). A preset quantity of the cooled chocolate pieces is added to the cooked mixture and is mixed with the cooked mixture in a mixer (16) melting the chocolate pieces which cool the mixture rapidly and evenly to a temperature of about 30 C. The mixture is then delivered to a filling machine (20). Open chocolate casings are prepared (18) by moulding the casings, and the casings are delivered upwardly open through the filling machine (20) to deposit filling mixture in each casing. Downstream of the filling machine (20) the casings are passed through a molten chocolate pouring station (22) in which molten chocolate is poured into each casing opening to seal the filling mixture within each casing thus forming a chocolate coated sweet.

Description

A process and apparatus for producing chocolate coated sweets v This invention relates to a process and apparatus for producing chocolate coated sweets. * According to the invention there is provided a process for producing chocolate coated sweets, comprising the steps: mixing preset quantities of a number of selected ingredient materials to form a mixture of uniform consistency; boiling the mixture to cook the mixture; cooling one or more additional ingredient materials to a preset desirable temperature; adding a preset quantity of the cooled ingredient material to the cooked mixture; mixing the cooled ingredient material with the cooked mixture to cool the mixture evenly and rapidly to form a filling mixture at a desired temperature; delivering the filling mixture to a filling machine; preparing a plurality of chocolate casings, each casing having a hollow internal cavity for reception of filling mixture and a filling opening extending through a sidewall of the casing to the cavity; orienting each casing such that the filling opening of the casing is facing upwardly; * supporting each casing in an upwardly open position; delivering each casing through the filling machine t while maintaining the casing in the upwardly open position; 'j, positioning each casing in the filling machine with the 5 filling opening of the casing located directly beneath a filling mixture dispenser of the filling machine; discharging a measured quantity of the filling mixture from the filling mixture dispenser when a casing is located beneath the dispenser; depositing a measured quantity of filling mixture through the filling opening into the cavity within the casing; delivering each casing to a sealing station; delivering each casing through the sealing station, maintaining the casing in the upwardly open position as it passes through the sealing station; depositing molten chocolate in the opening of each casing at the sealing station; setting the chocolate to seal the filling mixture within the casing thus forming a chocolate coated sweet; and delivering the sweets to a packing station and packaging the sweets .

In one embodiment of the invention the cooled ingredient material includes pieces of solid material of a pre3 desired size having a melting point below the temperature of the cooked mixture, and the process includes the steps: cooling the pieces of solid material to a temperature in the range 16°C - 18°C; weighing a pre-desired quantity of the cooled ingredient material dependent on the nature, quantity and temperature of the cooked mixture; adding the pieces of cooled ingredient material to the cooked mixture; mixing the pieces of cooled ingredient material with the cooked mixture, evenly distributing the pieces of cooled ingredient material throughout the cooked mixture; melting the pieces of cooled ingredient material in the cooked mixture thus absorbing heat from the cooked mixture; mixing the molten ingredient material with the cooked mixture further absorbing heat from the cooked mixture to form a filling mixture of uniform consistency at a uniform pre-desired temperature.

Preferably the cooled ingredient material comprises chocolate pieces having a size in the range 5-10 grams.

In another embodiment the chocolate casings are prepared by: preparing mould trays, each tray having a number of spaced-apart casing moulds, each mould having a charging opening at a top surface of the tray; delivering the trays to a tray feeder; orienting each tray such that each casing mould is upwardly open; arranging the trays edge to edge; pushing the trays outwardly from the tray feeder along a conveying track in a continuous stream; conveying the trays along the track to a chocolate pouring station; passing each tray in turn under a chocolate pouring spout; pouring molten chocolate from the spout onto a top surface of each tray as the tray passes beneath the chocolate pouring spout; filling each mould in the tray with molten chocolate; delivering excess molten chocolate onto each tray to overflow the tray; passing the tray under a wiper downstream of the pouring spout, engaging the top surface of the tray with the wiper; directing excess molten chocolate from the top surface of the tray rearwardly onto a top surface of the following upstream tray; delivering each tray to a first vibrator immediately downstream of the wiper; vibrating each tray to remove any air entrained with the molten chocolate in each mould; filling spaces left in each mould by evacuated air with molten chocolate; setting a thin wall of chocolate adjacent an inner surface of each mould to form a casing; inverting each tray; discharging molten chocolate from each mould leaving the casing in each mould; delivering each tray to a second vibrator, maintaining the tray in an inverted orientation as it passes through the second vibrator; and vibrating the tray in a controlled manner to assist in removing molten chocolate from each mould.

In a preferred embodiment the process includes the step of regulating the vibration of each inverted tray in the second vibrator by vibrating each tray in the second vibrator at a preselected vibration intensity for a preset duration dependent on the nature of the chocolate being moulded to form the casings, for controlling the final wall thickness of the chocolate casing retained in each mould to within preset desirable limits.

In a further embodiment the process includes the step of: collecting the excess molten chocolate discharged from each inverted tray; delivering the molten chocolate to a collecting tank; maintaining the chocolate in a molten state in the collecting tank within a preset desirable temperature range; periodically recirculating molten chocolate from the collecting tank to a mixing tank at the chocolate pouring station; mixing the molten chocolate in the mixing tank to keep the chocolate evenly mixed at a uniform temperature; maintaining the temperature of the chocolate in the mixing tank at a temperature in the range 35°C to 37°C, most preferably at 36°C; discharging molten chocolate from the mixing tank through a cooler; cooling the molten chocolate to a temperature in the range 27°C to 28°C; heating molten chocolate discharged from the cooler to a temperature in the range 29°C to 30°C in a heater downstream of the cooler; and delivering molten chocolate from the heater to the chocolate pouring spout.

In another embodiment the process includes the steps of: periodically pumping a batch of molten chocolate from the collecting tank to the mixing tank at the chocolate pouring station by means of a chocolate recirculating pump mounted in a molten chocolate transfer pipeline extending between the collecting tank and the mixing tank; operating the pump to draw molten chocolate through a filter at an outlet of the collecting tank for delivery of the batch of molten chocolate to the mixing tank.

In another embodiment the process further includes the step of briefly operating the pump in reverse after transferring each batch of molten chocolate from the collecting tank to the mixing tank for delivering molten chocolate from the molten chocolate transfer pipeline back through the filter and into the collecting tank for cleaning the filter.

In a further embodiment the chocolate casings are prepared by: preparing each part of a two part mould assembly comprising a top mould part and a complementary bottom mould part, each mould part having a number of spacedapart hemi-spherical mould cups such that when the mould parts are joined a number of spaced-apart spherical moulds are formed by associated overlying mould cups on the top mould part and the bottom mould part; supporting the bottom mould part with each mould cup being maintained in an upwardly open position; delivering the bottom mould part to a chocolate pouring station; positioning each mould cup beneath a molten chocolate dispenser at the chocolate pouring station; dispensing a preset amount of molten chocolate from the molten chocolate dispenser into each mould cup in the bottom mould part; removing the bottom mould part from the chocolate pouring station; overlying the top mould part in mating relationship with the bottom mould part; clamping the mould parts together, sealing each spherical mould; mounting each mould assembly on a universal rotator of a mould spinning device and detachably securing the mould assembly on the rotator; rotating each mould assembly multi-directionally in a controlled manner to urge the molten chocolate in each spherical mould of the mould assembly outwardly against an inner side wall of each spherical mould to coat the inner side wall with molten chocolate; setting the chocolate against the inner side wall in each spherical mould to form a thin walled spherical casing in each mould; removing each mould assembly from the mould spinning device; unclamping the mould parts of each mould assembly; supporting the mould parts together in a horizontal position with the top mould part uppermost; punching a filling opening in a top of each spherical casing; and removing the top mould part from each mould assembly leaving each bottom mould part carrying a plurality of the spherical casings.

In another embodiment after sealing each casing the process further includes the steps of: delivering the sealed casings to a heater; indirectly heating an outer surface of each filled casing in a controlled manner to soften but not melt an outer surface layer of the casing; prior to cooling of the outer surface layer coating an outer surface of each casing with molten chocolate thus forming a chocolate coated sweet; optionally decorating an exterior of each sweet casing; and delivering each sweet through a cooling tunnel for fully setting the chocolate in each casing prior to delivering the sweets to the packing station for packaging the sweets .

In another aspect the invention provides a process for producing chocolate coated sweets, comprising the steps: preparing mould trays, each tray having a number of spaced-apart casing moulds, each mould having a charging opening at a top surface of the tray; delivering the trays to a tray feeder; orienting each tray such that each casing mould is upwardly open; arranging the trays edge to edge; pushing the trays outwardly from the tray feeder along a conveying track in a continuous stream; conveying the trays along the track to a chocolate pouring station; passing each tray in turn under a chocolate pouring spout; pouring molten chocolate from the spout onto a top surface of each tray as the tray passes beneath the chocolate pouring spout; filling each mould in the tray with molten chocolate; J delivering excess molten chocolate onto each tray to overflow the tray; passing the tray under a wiper downstream of the pouring spout, engaging the top surface of the tray with the wiper; directing excess molten chocolate from the top surface of the tray rearwardly onto a top surface of the following upstream tray; delivering each tray to a first vibrator immediately downstream of the wiper; vibrating each tray to remove any air entrained with the molten chocolate in each mould; filling spaces left in each mould by evacuated air with molten chocolate; setting a thin wall of chocolate adjacent an inner surface of each mould to form a casing; inverting each tray; discharging molten chocolate from each mould leaving the casing in each mould; delivering each tray to a second vibrator, maintaining the tray in an inverted orientation as it passes through the second vibrator; vibrating the tray in a controlled manner to assist in removing molten chocolate from each mould inverting the tray; preparing a filling mixture and delivering the filling mixture to a filling machine; orienting each casing such that a filling opening of the casing is facing upwardly; supporting each casing in an upwardly open position; delivering each casing through the filling machine while maintaining the casing in the upwardly open position; positioning each casing in the filling machine with the filling opening of the casing located directly beneath a filling mixture dispenser of the filling machine; discharging a measured quantity of the filling mixture from the filling mixture dispenser when a casing is located beneath the dispenser; depositing a measured quantity of filling mixture through the filling opening into the cavity within the casing; delivering each casing to a sealing station; delivering each casing through the sealing station, maintaining the casing in the upwardly open position as it passes through the sealing station; depositing molten chocolate in the opening of each casing at the sealing station; setting the chocolate to seal the filling mixture within the casing thus forming a chocolate coated sweet; and delivering the sweets to a packing station and packaging the sweets .

In another aspect the invention provides a process for producing chocolate coated sweets, comprising the steps: preparing each part of a two part mould assembly comprising a top mould part and a complementary bottom mould part, each mould part having a number of spacedapart hemi-spherical mould cups such that when the mould parts are joined a number of spaced-apart spherical moulds are formed by associated overlying mould cups on the top mould part and the bottom mould part; supporting the bottom mould part with each mould cup being maintained in an upwardly open position; delivering the bottom mould part to a chocolate pouring station; positioning each mould cup beneath a molten chocolate dispenser at the chocolate pouring station; dispensing a preset amount of molten chocolate from the molten chocolate dispenser into each mould cup in the bottom mould part; removing the bottom mould part from the chocolate pouring station; overlying the top mould part in mating relationship with the bottom mould part; clamping the mould parts together, sealing each spherical mould; mounting each mould assembly on a universal rotator of a mould spinning device and detachably securing the mould assembly on the rotator; rotating each mould assembly multi-directionally in a controlled manner to urge the molten chocolate in each spherical mould of the mould assembly outwardly against an inner side wall of each spherical mould to coat the inner side wall with molten chocolate; setting the chocolate against the inner side wall in each spherical mould to form a thin walled spherical casing in each mould; removing each mould assembly from the mould spinning device; unclamping the mould parts of each mould assembly; supporting the mould parts together in a horizontal position with the top mould part uppermost; punching a filling opening in a top of each spherical casing; removing the top mould part from each mould assembly leaving each bottom mould part carrying a plurality of the spherical casings; preparing a filling mixture and delivering the filling mixture to a filling machine; orienting each casing such that a filling opening of the casing is facing upwardly; supporting each casing in an upwardly open position; delivering each casing through the filling machine while maintaining the casing in the upwardly open position; positioning each casing in the filling machine with the filling opening of the casing located directly beneath a filling mixture dispenser of the filling machine; discharging a measured quantity of the filling mixture from the filling mixture dispenser when a casing is located beneath the dispenser; depositing a measured quantity of filling mixture through the filling opening into the cavity within the casing; delivering each casing to a sealing station; delivering each casing through the sealing station, maintaining the casing in the upwardly open position as it passes through the sealing station; depositing molten chocolate in the opening of each casing at the sealing station; setting the chocolate to seal the filling mixture within the casing thus forming a chocolate coated sweet; and delivering the sweets to a packing station and packaging the sweets .

In another aspect the invention provides apparatus for carrying out the process as will be hereinafter described.

The invention will be more clearly understood by the following description of some embodiments thereof, given by way of example only, with reference to the accompanying drawings, in which; Fig. 1 is a schematic illustration of a process for producing chocolate coated sweets according to the invention; Fig. 2 is a schematic illustration of another process for producing chocolate coated sweets according to the invention; Fig. 3 is a schematic illustration of apparatus used for producing chocolate coated sweets according to the process of Fig. 2; Fig. 4 is a perspective view of apparatus used in the process; Fig. 5 is a side elevational view of the apparatus shown in Fig. 4; Fig. 6 is a plan view of the apparatus shown in Fig. 4; Fig. 7 is a perspective view of a mould tray used in the process; and Fig. 8 is a schematic illustration of another process for producing chocolate coated sweets according to the invention.

Referring initially to Fig. 1, a process for producing chocolate coated sweets according to the invention will be described. At a mixing station 10 preset quantities of a number of selected ingredient materials are mixed to form a mixture of uniform consistency and the mixture is boiled at a cooker 12 to cook the mixture.

Chocolate pieces, preferably of size 5-10 grams, are cooled to a temperature of 16°C in a cooler 14. A preset quantity of the cooled chocolate pieces is added to the cooked mixture and is mixed with the cooked mixture in a mixer 16 melting the chocolate pieces which cool the mixture evenly and rapidly to a temperature of approximately 30°C. Thereafter the mixture can be delivered to a filling machine 20.

Open chocolate casings are prepared (18) and the casings are delivered, upwardly open, through the filling machine 20. As the casings pass through the filling machine 20 a measured quantity of the filling mixture is deposited in each casing.

Each filled casing is then delivered through a chocolate pouring station 22. As the casings travel through the pouring station 22 molten chocolate is poured into each casing opening to seal the filling mixture within each casing thus forming a chocolate coated sweet. The sweets are then packaged.

Referring now to Figs. 2 to 7, there is illustrated another process for producing chocolate coated sweets. A number of trays 30 (Fig. 7) each having a number of spaced-apart casing moulds 47 are prepared. Each mould 47 has a charging opening 48 at the top surface 49 of the tray 30. A number of the trays 30 are delivered to a tray feeder 33 and each tray 30 is oriented such that each casing mould 47 is upwardly open. Trays 30 are advanced along the track 31 by the tray feeder 33 which pushes the trays 30 end to end along the track 31 to a chocolate pouring station 32. The trays 30 may be preheated if desired. Each tray 30 passes end to end under a chocolate pouring spout 35 at the chocolate pouring station 32. Molten chocolate 36 is poured from the spout 35 onto a top of each tray 30 such that it fills the casing moulds 47 and overflows each tray 30, the overflow chocolate being caught in a sump 37 for recycling through a tempering device 38 before return to the pouring spout 35. Downstream of the pouring station 32 are a number of overhead wipers 40 comprising pivotally mounted flaps 41 which engage a top surface 49 of each tray 30 as it passes beneath the wipers 40. Excess chocolate is thus scraped from a top of each tray 30 and is directed rearwardly onto the following upstream tray 30 (see Fig. 6). A pair of spaced-apart guide flaps 45 are mounted on each side of the track 31 extending rearwardly from the wipers 40 to the filling station 32. A lower edge of these flaps 45 engage with a top surface of each tray 30 as it passes through the pouring station 32 so that the overspill chocolate directed rearwardly from the wipers 40 is directed back along the following trays 30 to fill these trays 30 as they advance along the track 31. Openings 46 at a lower end of each guide 45 allow overspill of excess molten chocolate to the sump 37.

Downstream of the wipers 40 a vibrator (not shown) engages an underside of each tray 30 to vibrate the tray 30 to ensure the chocolate settles properly in each mould, removing any entrained air. A thin wall of chocolate is allowed to set adjacent an inner wall of each mould 47 to form a casing.

Each tray 30 is then delivered to an inverter 50 which turns over each tray 30 to remove excess chocolate leaving a thin walled casing of chocolate formed on a side wall of each mould. The excess chocolate drops into a collecting tank 52.

A second vibrator (not shown) downstream of the inverter 50 is mounted above the track 31 and engages a bottom side of each tray 30 to vibrate the tray to assist removal of excess chocolate. Advantageously the intensity and duration of the vibration can be varied to control the thickness of the chocolate casing retained in each mould and also to allow for different chocolate compositions.

Molten chocolate is periodically pumped from the collecting tank 52 back to a mixing tank of the tempering device 38 by means of a recirculating pump 55 which draws molten chocolate from the collecting tank 52 through a filter 56 at an outlet of the collecting tank 52. After each pumping operation, the pump 55 is briefly operated in reverse to pump molten chocolate back through the filter 56 to clear the filter 56. Molten chocolate in the mixing tank is maintained at a temperature in the range 35°C to 37°C and most preferably at 36°C. Molten chocolate from the mixing tank is passed through a cooler to cool the chocolate to 27°C-28°C and it is then subsequently heated by passing it through a heater downstream of the cooler to heat the molten chocolate to a temperature of 29°C-30°C prior to delivery of the molten chocolate to the chocolate pouring spout 35.

As chocolate is used up additional chocolate can be added to the collecting tank 52 to replenish the chocolate supply.

Preset quantities of a number of selected ingredient materials are mixed to form a filling mixture of uniform consistency and this filling mixture is then delivered to a filling station 60. At the filling station 60, as previously described, the casings are delivered upwardly open through the filling station 60 having a measured quantity of the filling mixture deposited in each casing as it passes through the filling station 60.

Then the trays 30 carrying the filled casings are passed back through the chocolate pouring station 32 in which molten chocolate is poured into each casing opening to seal the filling mixture within each casing. Downstream of the wipers 40 when the chocolate has set the sweets are removed from the trays 30 and then packaged.

Referring now to Fig. 8, another process for producing chocolate coated sweets is illustrated. In this case, the process is for producing truffles having a generally spherical chocolate casing. Each casing is formed by a two-part mould assembly each part having a number of spaced-apart hemi-spherical mould cups so that when the mould parts are joined they form a number of spherical moulds. A bottom half of the mould is delivered to a chocolate pouring station 80 in which a preset quantity of molten chocolate is poured into each hemi-spherical mould cup. A top half of the mould is then overlain on the bottom half of the mould to define a plurality of spherical moulds each containing a molten chocolate charge and the mould halves are clamped together.

The mould is mounted on a rotator 82 which rotates, the mould multi-directionally to urge the chocolate in each mould outwardly against a side wall of the mould to form a spherical chocolate casing within each mould.

A filling hole is punched in a top of each casing. The mould is then removed from the rotator 82 and split to remove the top part of the mould leaving a number of spherical casings sitting in the bottom part of the mould.

Preset quantities of a number of selected ingredient materials are mixed to form a filling mixture of uniform consistency which is delivered to a filling machine 90. Each mould part carrying the casings is delivered through the filling machine 90 in which a measured quantity of the filling mixture is deposited into each casing.

Each filled casing is then delivered through a chocolate pouring station which pours molten chocolate into each casing opening to seal the filling mixture within the casing thus forming a chocolate coated sweet.

After sealing of the casings the sweets are removed from the mould and each sweet is delivered through a heater 92 which gently raises the temperature of an outer surface of each casing above ambient temperature. Then the casings are enrobed with an outer chocolate coating by passing each casing under a stream of molten chocolate. An outer surface of the casing may optionally be decorated prior to delivering each sweet through a cooling tunnel. Sweets discharged from the cooling tunnel are then delivered to a packing station.

Claims (29)

1. A process for producing chocolate coated sweets, comprising the steps: mixing preset quantities of a number of selected ingredient materials to form a mixture of uniform consistency; boiling the mixture to cook the mixture; cooling one or more additional ingredient materials to a preset desirable temperature; adding a preset quantity of the cooled ingredient material to the cooked mixture; mixing the cooled ingredient material with the cooked mixture to cool the mixture evenly and rapidly to form a filling mixture at a desired temperature; delivering the filling mixture to a filling machine; preparing a plurality of chocolate casings, each casing having a hollow internal cavity for reception of filling mixture and a filling opening extending through a sidewall of the casing to the cavity; orienting each casing such that the filling opening of the casing is facing upwardly; supporting each casing in an upwardly open position; delivering each casing through the filling machine while maintaining the casing in the upwardly open position; positioning each casing in the filling machine with the filling opening of the casing located directly beneath a filling mixture dispenser of the filling machine; discharging a measured quantity of the filling mixture from the filling mixture dispenser when a casing is located beneath the dispenser; depositing a measured quantity of filling mixture through the filling opening into the cavity within the casing; delivering each casing to a sealing station; delivering each casing through the sealing station, maintaining the casing in the upwardly open position as it passes through the sealing station; depositing molten chocolate in the opening of each casing at the sealing station; setting the chocolate to seal the filling mixture within the casing thus forming a chocolate coated sweet; and delivering the sweets to a packing station and packaging the sweets .

2. A process as claimed in claim 1 wherein the cooled ingredient material includes pieces of solid material of a pre-desired size having a melting point below the temperature of the cooked mixture, and the 5 process includes the steps: cooling the pieces of solid material to a temperature in the range 16°C - 18°C; weighing a pre-desired quantity of the cooled ingredient material dependent on the nature, 10 quantity and temperature of the cooked mixture; adding the pieces of cooled ingredient material to the cooked mixture; mixing the pieces of cooled ingredient material with the cooked mixture, evenly distributing the 15 pieces of cooled ingredient material throughout the cooked mixture; melting the pieces of cooled ingredient material in the cooked mixture thus absorbing heat from the cooked mixture; 20 mixing the molten ingredient material with the cooked mixture further absorbing heat from the cooked mixture to form a filling mixture of uniform consistency at a uniform pre-desired temperature. A process as claimed in claim 1 or claim 2 wherein the cooled ingredient material comprises chocolate pieces having a size in the range 5-10 grams.

3. 4. A process as claimed in any preceding claim wherein the chocolate casings are prepared by: preparing mould trays, each tray having a number of spaced-apart casing moulds, each mould having a charging opening at a top surface of the tray; delivering the trays to a tray feeder; orienting each tray such that each casing mould is upwardly open; arranging the trays edge to edge; pushing the trays outwardly from the tray feeder along a conveying track in a continuous stream; conveying the trays along the track to a chocolate pouring station; passing each tray in turn under a chocolate pouring spout; pouring molten chocolate from the spout onto a top surface of each tray as the tray passes beneath the chocolate pouring spout; filling each mould in the tray with molten chocolate; delivering excess molten chocolate onto each tray to overflow the tray; passing the tray under a wiper downstream of the pouring spout, engaging the top surface of the tray with the wiper; directing excess molten chocolate from the top surface of the tray rearwardly onto a top surface of the following upstream tray; delivering each tray to a first vibrator immediately downstream of the wiper; vibrating each tray to remove any air entrained with the molten chocolate in each mould; filling spaces left in each mould by evacuated air with molten chocolate; setting a thin wall of chocolate adjacent an inner surface of each mould to form a casing; inverting each tray; discharging molten chocolate from each mould leaving the casing in each mould; delivering each tray to a second vibrator, maintaining the tray in an inverted orientation as it passes through the second vibrator; and vibrating the tray in a controlled manner to assist in removing molten chocolate from each mould.

4. 5. A process as claimed in claim 4 including the step of regulating the vibration of each inverted tray in the second vibrator by vibrating each tray in the second vibrator at a preselected vibration intensity for a preset duration dependent on the nature of the chocolate being moulded to form the casings, for controlling the final wall thickness of the chocolate casing retained in each mould to within preset desirable limits.

5. 6. A process as claimed in claim 4 or claim 5 including the step of: collecting the excess molten chocolate discharged from each inverted tray; delivering the molten chocolate to a collecting tank; maintaining the chocolate in a molten state in the collecting tank within a preset desirable temperature range; periodically recirculating molten chocolate from che collecting tank to a mixing tank at the chocolate oourina station; mixing the molten chocolate in the mixing tank to keep the chocolate evenly mixed at a uniform temperature; maintaining the temperature of the chocolate in the mixing tank at a temperature in the range 35°C to 37°C, most preferably at 36°C; discharging molten chocolate from the mixing tank through a cooler; cooling the molten chocolate to a temperature in the range 27°C to 28°C; heating molten chocolate discharged from the cooler to a temperature in the range 29°C to 30°C in a heater downstream of the cooler; and delivering molten chocolate from the heater to the chocolate pouring spout.

6. 7. A process as claimed in claim 6 including the steps of : periodically pumping a batch of molten chocolate from the collecting tank to the mixing tank at the chocolate pouring station by means of a chocolate recirculating pump mounted in a molten chocolate transfer pipeline extending between the collecting tank and the mixing tank; operating the pump to draw molten chocolate through a filter at an outlet of the collecting tank for delivery of the batch of molten chocolate to the mixing tank.

7. 8. A process as claimed in claim 7 further including the step of briefly operating the pump in reverse after transferring each batch of molten chocolate from the collecting tank to the mixing tank for delivering molten chocolate from the molten chocolate transfer pipeline back through the filter and into the collecting tank for cleaning the filter.

8. 9. A process as claimed in any of claims 1 to 3 wherein the chocolate casings are prepared by: preparing each part of a two part mould assembly comprising a top mould part and a complementary bottom mould part, each mould part having a number of spaced-apart hemi-spherical mould cups such that when the mould parts are joined a number of spaced-apart spherical moulds are formed by associated overlying mould cups on the top mould part and the bottom mould part; supporting the bottom mould part with each mould cup being maintained in an upwardly open position; delivering the bottom mould part to a chocolate pouring station; positioning each mould cup beneath a molten chocolate dispenser at the chocolate pouring station; dispensing a preset amount of molten chocolate from the molten chocolate dispenser into each mould cup in the bottom mould part; removing the bottom mould part from the chocolate pouring station; overlying the top mould part in mating relationship with the bottom mould part; clamping the mould parts together, sealing each spherical mould; mounting each mould assembly on a universal rotator of a mould spinning device and detachably securing the mould assembly on the rotator; rotating each mould assembly multi-directionally in a controlled manner to urge the molten chocolate in each spherical mould of the mould assembly outwardly against an inner side wall of each spherical mould to coat the inner side wall with molten chocolate; setting the chocolate against the inner side wall in each spherical mould to form a thin walled spherical casing in each mould; removing each mould assembly from the mould spinning device; unclamping the mould parts assembly; of each mould supporting horizontal uppermost; punching spherical the mould parts position with the a filling opening casing; and together in a top mould part in a top of each removing the top mould part from each mould assembly leaving each bottom mould part carrying a plurality of the spherical casings.

9. 10. A process as claimed in claim 9 wherein after sealing each casing the process further includes the steps of: delivering the sealed casings to a heater; indirectly heating an outer surface of each filled casing in a controlled manner to soften but not melt an outer surface layer of the casing; prior to cooling of the outer surface layer coating an outer surface of each casing with molten chocolate thus forming a chocolate coated sweet; optionally decorating an exterior of each sweet casing; and delivering each sweet through a cooling tunnel for fully setting the chocolate in each casing prior to delivering the sweets to the packing station for packaging the sweets.

10. 11. A process for producing chocolate coated sweets substantially as hereinbefore described with reference to the accompanying drawings.

11. 12. Chocolate coated sweets whenever produced by the process as claimed in any preceding claim.

12. 13. A process for producing chocolate coated sweets, comprising the steps: preparing mould trays , each tray having a number of spaced-apart casing moulds, each mould having a charging opening at a top surface of the tray; delivering the trays to a tray feeder; orienting each tray such that each casing mould is upwardly open; arranging the trays edge to edge; pushing the trays outwardly from the tray feeder along a conveying track in a continuous stream; conveying the trays along the track to a chocolate pouring station; passing each tray in turn under a chocolate pouring spout; pouring molten chocolate from the spout onto a top surface of each tray as the tray passes beneath the chocolate pouring spout; filling each mould in the tray with molten chocolate; delivering excess molten chocolate onto each tray to overflow the tray; passing the tray under a wiper downstream of the pouring spout, engaging the top surface of the tray with the wiper; directing excess molten chocolate from the top surface of the tray rearwardly onto a top surface of the following upstream tray; delivering each tray to a first vibrator immediately downstream of the wiper; vibrating each tray to remove any air entrained with the molten chocolate in each mould; filling spaces left in each mould by evacuated air with molten chocolate; setting a thin wall of chocolate adjacent an inner surface of each mould to form a casing; inverting each tray; discharging molten chocolate from each mould leaving the casing in each mould; delivering each tray to a second vibrator, maintaining the tray in an inverted orientation as it passes through the second vibrator; vibrating the tray in a controlled manner to assist in removing molten chocolate from each mould inverting the tray; preparing a filling mixture and delivering the filling mixture to a filling machine; orienting each casing such that a filling opening of the casing is facing upwardly; supporting each casing in an upwardly open position; delivering each casing through the filling machine while maintaining the casing in the upwardly open position; positioning each casing in the filling machine with the filling opening of the casing located directly beneath a filling mixture dispenser of the filling machine; discharging a measured quantity of the filling mixture from the filling mixture dispenser when a casing is located beneath the dispenser; depositing a measured quantity of filling mixture through the filling opening into the cavity within the casing; delivering each casing to a sealing station; delivering each casing through the sealing station, maintaining the casing in the upwardly open position as it passes through the sealing station; depositing molten chocolate in the opening of each casing at the sealing station; setting the chocolate to seal the filling mixture within the casing thus forming a chocolate coated sweet; and delivering the sweets to a packing station and packaging the sweets .

13. 14. A process as claimed in claim 13 wherein the filling mixture is prepared by: mixing preset quantities of a number of selected ingredient materials to form a mixture of uniform consistency; boiling the mixture to cook the mixture; cooling one or more additional ingredient materials to a preset desirable temperature; adding a preset quantity of the cooled ingredient material to the cooked mixture; and mixing the cooled ingredient material with the cooked mixture to cool the mixture evenly and rapidly to form a filling mixture at a desired temperature.

14. 15. A process as claimed in claim 14 wherein the cooled ingredient material includes pieces of solid material of a pre-desired size having a melting point below the temperature of the cooked mixture, and the process includes the steps: cooling the pieces of solid material to a temperature in the range 16°C - 18°C; weighing a pre-desired quantity of the cooled ingredient material dependent on the nature, quantity and temperature of the cooked mixture; adding the pieces of cooled ingredient material to the cooked mixture; mixing the pieces of cooled ingredient material with the cooked mixture, evenly distributing the pieces of cooled ingredient material throughout the cooked mixture; melting the pieces of cooled ingredient material in the cooked mixture thus absorbing heat from the cooked mixture; mixing the molten ingredient material with the cooked mixture further absorbing heat from the cooked mixture to form a filling mixture of uniform consistency at a uniform pre-desired 5 temperature.

15. 16. A process as claimed in claim 14 or claim 15 wherein the cooled ingredient material comprises chocolate pieces having a size in the range 5-10 grams.

16. 17. A process as claimed in any of claims 13 to 16 10 including the step of regulating the vibration of each inverted tray in the second vibrator by vibrating each tray in the second vibrator at a preselected vibration intensity for a preset duration dependent on the nature of the chocolate being 15 moulded to form the casings, for controlling the final wall thickness of the chocolate casing retained in each mould to within preset desirable limits.

17. 18. A process as claimed in any of claims 13 to 17 including the step of: 20 collecting the excess molten chocolate discharged from each inverted tray; delivering the molten chocolate to a collecting tank; maintaining the chocolate in a molten state in 25 the collecting tank within a preset desirable temperature range; periodically recirculating molten chocolate from the collecting tank to a mixing tank at the chocolate pouring station; mixing the molten chocolate in the mixing tank to keep the chocolate evenly mixed at a uniform temperature; maintaining the temperature of the chocolate in the mixing tank at a temperature in the range 35°C to 37°C, most preferably at 36°C; discharging molten chocolate from the mixing tank through a cooler; cooling the molten chocolate to a temperature in the range 27°C to 28°C; heating molten chocolate discharged from the cooler to a temperature in the range 29°C to 30°C in a heater downstream of the cooler; and delivering molten chocolate from the heater to the chocolate pouring spout.

18. 19. A process as claimed in claim 18 including the steps of: periodically pumping a batch of molten chocolate from the collecting tank to the mixing tank at the chocolate pouring station by means of a chocolate recirculating pump mounted in a molten chocolate transfer pipeline extending between the collecting tank and the mixing tank; operating the pump to draw molten chocolate through a filter at an outlet of the collecting tank for delivery of the batch of molten chocolate to the mixing tank.

19. 20. A process as claimed in claim 19 further including the step of briefly operating the pump in reverse after transferring each batch of molten chocolate from the collecting tank to the mixing tank for delivering molten chocolate from the molten chocolate transfer pipeline back through the filter and into the collecting tank for cleaning the filter.

20. 21. A process for producing chocolate coated sweets as claimed in any of claims 13 to 20 substantially as hereinbefore described with reference to the accompanying drawings .

21. 22. Chocolate coated sweets whenever produced by the process as claimed in any of claims 13 to 21.

22. 23. A process for producing chocolate coated sweets, comprising the steps: preparing each part of a two part mould assembly comprising a top mould part and a complementary bottom mould part, each mould part having a number of spaced-apart hemi-spherical mould cups such that when the mould parts are joined a number of spaced-apart spherical moulds are formed by associated overlying mould cups on the top mould part and the bottom mould part; supporting the bottom mould part with each mould cup being maintained in an upwardly open position; delivering the bottom mould part to a chocolate pouring station; positioning each mould cup beneath a molten chocolate dispenser at the chocolate pouring station; dispensing a preset amount of molten chocolate from the molten chocolate dispenser into each mould cup in the bottom mould part; removing the bottom mould part from the chocolate pouring station; overlying the top mould part in mating relationship with the bottom mould part; clamping the mould parts together, sealing each spherical mould; mounting each mould assembly on a universal rotator of a mould spinning device and detachably securing the mould assembly on the rotator; rotating each mould assembly multi-directionally in a controlled manner to urge the molten chocolate in each spherical mould of the mould assembly outwardly against an inner side wall of each spherical mould to coat the inner side wall with molten chocolate; setting the chocolate against the inner side wall in each spherical mould to form a thin walled spherical casing in each mould; removing each mould assembly from the mould spinning device; unclamping assembly; the mould parts of each mould supporting the mould parts together in a horizontal position with the top mould part uppermost; punching a filling opening in a top of each spherical casing; removing the top mould part from each mould assembly leaving each bottom mould part carrying 10 a plurality of the spherical casings; preparing a filling mixture and delivering the filling mixture to a filling machine; orienting each casing such that a filling opening of the casing is facing upwardly; 15 supporting each casing in an upwardly open position; delivering each casing through the filling machine while maintaining the casing in the upwardly open position; 20 positioning each casing in the filling machine with the filling opening of the casing located directly beneath a filling mixture dispenser of the filling machine; discharging a measured quantity of the filling. 25 mixture from the filling mixture dispenser when a casing is located beneath the dispenser; depositing a measured quantity of filling mixture through the filling opening into the cavity within the casing; delivering each casing to a sealing station; 5 delivering each casing through the sealing station, maintaining the casing in the upwardly open position as it passes through the sealing station; depositing molten chocolate in the opening of 10 each casing at the sealing station; setting the chocolate to seal the filling mixture within the casing thus forming a chocolate coated sweet; and delivering the sweets to a packing station and 15 packaging the sweets.

23. 24. A process as claimed in claim 23 wherein the filling mixture is prepared by: mixing preset quantities of a number of selected ingredient materials to form a mixture of 20 uniform consistency; boiling the mixture to cook the mixture; cooling one or more additional ingredient materials to a preset desirable temperature; adding a preset quantity of the cooled 25 ingredient material to the cooked mixture; mixing the cooled ingredient material with the cooked mixture to cool the mixture evenly and rapidly to form a filling mixture at a desired temperature.

24. 25. A process as claimed in claim 24 wherein the cooled ingredient material including pieces of solid material of a pre-desired size having a melting point below the temperature of the cooked mixture, and the process includes the steps: cooling the pieces of solid material to a temperature in the range 16°C - 18°C; weighing a pre-desired quantity of the cooled ingredient material dependent on the nature, quantity and temperature of the cooked mixture; adding the pieces of cooled ingredient material to the cooked mixture; mixing the pieces of cooled ingredient material with the cooked mixture, evenly distributing the pieces of cooled ingredient material throughout the cooked mixture; melting the pieces of cooled ingredient material in the cooked mixture thus absorbing heat from the cooked mixture; mixing the molten ingredient material with the cooked mixture further absorbing heat from the cooked mixture to form a filling mixture of uniform consistency at a uniform pre-desired temperature.

25. 26. A process as claimed in claim 24 or claim 25 wherein the cooled ingredient material comprises chocolate pieces having a size in the range 5-10 grams.

26. 27. A process as claimed in any of claims 23 to 26 5 wherein after sealing each casing the process further includes the steps of: delivering the sealed casings to a heater; indirectly heating an outer surface of each filled casing in a controlled manner to soften 10 but not melt an outer surface layer of the casing; prior to cooling of the outer surface layer coating an outer surface of each casing with molten chocolate thus forming a chocolate coated 15 sweet; optionally decorating an exterior of each sweet casing; and delivering each sweet through a cooling tunnel for fully setting the chocolate in each casing 20 prior to delivering the sweets to the packing station for packaging the sweets.

27. 28. A process for producing chocolate coated sweets as claimed in any of claims 23 to 27 substantially as hereinbefore described with reference to the 25 accompanying drawings.

28.

29. Chocolate coated sweets whenever produced by the process as claimed in any of claims 23 to 28.