MXPA96006643A - Apparatus and method for making a frozen confection of multiple sabo - Google Patents

Abstract

The present invention relates to a method for making a frozen confection having a plurality of sections of different flavor or color, comprising: a) providing a mold b) providing a first body having fixed or protruding surfaces at its outer periphery c) inserting the first body into the mold so that the fixed or protruding surfaces are substantially in contact with the inner wall of the mold to thereby create a first space confined by the first body and the mold; liquid comprising the ingredients of a first taste or color within the mold before step (c) or after step (c), through which when the step is carried out after step (c), the first one is inserted liquid within the first space in the mold, e) freezing the first liquid to form a substantially frozen first outer layer, f) separating the first body from the mold, g) inserting a second liquid comprising the ingredients of a second flavor or color inside the mold, and h) freezing the second liquid

Description

APPARATUS AND METHOD FOR MAKING A FROZEN JUMPING OF MULTIPLE FLAVORS BACKGROUND OF THE INVENTION This invention pertains to the apparatus and methods for making frozen confections and, more particularly, to the apparatus and methods for making frozen confections having a plurality of sections of different flavors or colors. The subject matter of US Patent No. 5,374,436, which was issued on December 20, 1994 to the same inventors, is incorporated herein by reference. Apparatus for the manufacture of frozen confections generally comprises a plurality of molds fixed to a conveyor or turntable to move the molds through several process stations. These stations conventionally comprise: (a) a filling station where the molds are filled with ingredients in liquid form; (b) a bar insertion station wherein the bars are inserted into the molds; (c) a freezing station where the molds are subjected to temperatures below freezing to cause solidification of the liquid ingredients; and (d) a product separation station where the frozen confections are removed from the molds. As a final step, in some cases, frozen confections are submerged in a bath comprising the ingredients of a coating (for example chocolate). Frozen confections comprising more than one flavor or color are also known. U.S. Patent No. 2,747,525 to Lund discloses a method and apparatus for making such a product. In Lund, the molds are filled with a first ingredient in liquid form and then immersed in a saline solution that has a temperature below freezing. Before the inner core of the product is frozen, this portion is removed by suction from the mold. A second ingredient in liquid form is then injected into the mold and the mold is again immersed in the saline solution. The resulting product is a frozen confection comprising an outer layer of a flavor or color and an inner core of a second flavor or color. However, using the Lund system, the second flavor or color is not visible to the consumer, except on the basis of the product. US Patent No. 3,971,853 to Crowder describes an apparatus and method for making a frozen confection having a plurality of different flavors and colors. However, Crowder uses a complicated nozzle arrangement to fill the molds that deliver different ingredients to the molds in a semi-liquid state. Using the Crowder system, in addition, the ingredients are intermixed so that the different flavors or colors do not form different sections.

US Patent No. 1,429,405 to Carter et al., Discloses a method for making a frozen confection having a plurality of sections of different flavors or colors. In Carter, a die or punch is used to remove a portion of the frozen confection after the frozen confections are removed from the mold. The resulting cavity is then filled with an ingredient, in liquid form, having a different flavor or color and, the entire product is then subjected to further freezing. This method is unsuitable for mass production. US Patent No. 2,674,960 to DePasquale describes a method for making a frozen confection that has a plurality of different flavors or colors. Following a partial filling of a first mold with a first ingredient, a second smaller mold is inserted into the first mold to cause the first ingredient to fill the space between the two molds. The first ingredient is then frozen and the second mold is removed. The resulting cavity in the product is partially filled with a second ingredient, and the same steps are repeated using an even smaller mold. Using the DePasquale system, only the first taste or color is visible to the consumer. U.S. Patent No. 4,986,080 to Grigoli discloses an apparatus and method for making a frozen confection having a plurality of different flavors or colors. However, the Grigoli method requires substantial modifications to conventional frozen confectionery manufacturing apparatuses. Grigoli's apparatus operates on a double stage principle in which the rows of molds advance in pairs. A first filling unit fills a first row of molds although it omits the second row of molds subsequent. The ingredients inside the first row molds are then frozen and, in a first removal and insertion station, the frozen products are removed from those first molds and inserted into the molds of the second row. The second molds have a cross section such that when the frozen product is inserted into the second molds, there is space between the product and the inner walls of the second molds in at least some locations. A second ingredient in liquid form is then inserted into the second molds to fill those spaces. In a variation of this process described in the North American Patent No. 5, 343,710 for Cathenaut et al. , the second molds are partially filled with the second ingredient before the frozen products are inserted into the second molds. In any case, the second molds are transmitted to a second freezing station and then to a final separation station where the final product is separated. This double-stage method substantially complicates and increases the cost of making a frozen confection. US Patent No. 4, 188, 768 to Getman discloses an apparatus for making a frozen confection comprising an edible cone covered with paper containing ice cream. In order to prevent the cones from becoming saturated with moisture, the inside of the cones is completely covered with a liquid chocolate composition. The chocolate is mixed with compressed air and sprayed through nozzles placed on the cones. Chocolate forms a film impervious to liquid, continuous. The jam is then refrigerated to solidify the ice cream and the sprayed chocolate.

BRIEF DESCRIPTION OF THE INVENTION The present invention provides an apparatus and method for making a frozen confection having a plurality of sections of different flavors or colors, visible and distinct. The applicant's system and method uses conventional ice cream manufacturing equipment and requires only the addition of stations to this equipment. In one embodiment of the Applicant's system and method, the molds for an ice cream product are first filled with a first ingredient for a first flavor or color and are subjected to freezing in a conventional manner. However, after the outer layer of this ingredient is substantially frozen, but before complete freezing of the product core, the liquid comprising the core is separated, preferably through aspiration or similar means. Each mold is then advanced to a milling station where the milling means, such as a laser beam, a pressurized gas stream or a mechanical tool, are inserted into the core of the mold. This milling tool is programmed to remove or cut a portion of the frozen outer layer of the first ingredient according to a predetermined pattern. A plurality of milling means can be used to remove successive portions of the outer layer. In a preferred embodiment, three heated male tools are used to remove successively deeper regions in a continuous portion of the outer layer. For longitudinal, depth-carving portions of the outer layer, it has been found advantageous to use the three successive tools, instead of a single tool, since the area of the outer layer that is attached to the portion that is best preserved is better preserved. is going to be removed. Following the carving of the frozen outer layer, the molds are advanced to a second filling station where a second ingredient for a second flavor or color is inserted into the molds. The molds are moved to a bar insertion station where the bars are inserted into the molds. The frozen confections are completely frozen in a final freezing station and, in a separation station, the final products are removed from the molds.

By including additional freezing, liquid removal and intermediate clearing stations in the process, frozen confections can be made that comprise more than two sections with flavor or color. For example, instead of completely freezing the frozen confections in the second freezing station, only partial freezing can occur in this season, followed by a second removal of the non-frozen ingredients within the cores of the product. A second milling station can then carve a second pattern through the first or second frozen layers, or both. A third ingredient can then be inserted into the molds, followed by the final freeze, to create an intricate or distinct pattern of multiple flavors or colors, distinct and visible within an individual frozen confection. In an alternative embodiment, instead of partially freezing the first ingredient and separating the liquid comprising the core of this ingredient, a solid or hollow body is inserted into the mold, either before or after the insertion of the first ingredient. This body is molded to be insertable into and removable from the mold and, such that, when inserted, there is a space between the internal wall of the mold and the external surface of the body in some locations. The first ingredient, to the insertion inside the mold, occupies this space and is frozen. The body is separated from the mold, preferably by applying heat to thaw the first ingredient in the area immediately adjacent to the outer surface of the body. The heat can be applied, for example, moving the molds to a heated environment, passing an electric current through the body or inserting chemicals into the body for a heat-producing reaction to occur. In another embodiment of the Applicant's system and method, the molds for a frozen confection product are partially filled with a first ingredient for a first flavor or color. A solid or hollow tool having fixed projections to make contact with the internal surface of the mold which is then inserted into each mold, displacing the first ingredient within the passages between the projections. Alternatively, a male tool is placed in each mold before filling the mold with a first ingredient or ingredients. Each mold is then advanced to a freezing station where the first ingredient is frozen. In the alternative, the insertion of the first ingredient or ingredients within the molds occurs in a freezing station. Following the freezing of the first ingredient, each mold is advanced to a tool separation station, where the male tool is heated and removed from the mold. The second ingredient or ingredients are then added and frozen, creating a visible pattern of different flavors or colors on the external surface of the frozen confection.

In yet another embodiment, the molds are first cooled in a freezing station. The molds are then advanced to a spray station, wherein a first ingredient comprising a first flavor and / or color is sprayed in a fine mist on an external surface of the mold. In the alternative, this sprinkling occurs in a freezing station. A first freezing station can be used to spray the first ingredient or ingredients or, in the alternative, an individual freezing station can be used for both stages. The sprinkling of the first ingredient on the inner surface of the mold can be uniform or in a pattern. Additional ingredients comprising additional flavors and / or colors can also be sprayed onto the mold surface to create a more complex pattern. The molds are advanced to a dosing station where a final liquid ingredient is added to fill the mold, adding an additional color or flavor to the surface pattern. The final product is frozen and then removed from the molds. An advantage of all embodiments of the present invention is that each line of the molds attached to the conveyor or turntable of a frozen confectionery making machine produces final products during an individual cycle through the machine. This is an advantage over the double stage systems of the prior art described in US Patent Nos. 4, 986,080 and 5, 343, 710 where the final products are produced only by another line of molds that goes through a cycle through the machine. Therefore, the present system requires less floor space and fewer molds.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a functional block diagram of a frozen confection manufacturing system in accordance with the present invention. FIG. 2 shows a perspective view of a frozen confection of multiple flavors or colors made using the system of FIG. 1; FIG. 3 is a bottom view of the frozen confection of multiple flavors or colors of FIG. 2; FIG. 4 shows other frozen confections of multiple flavors or colors that can be manufactured in accordance with the present invention; FIG. 5 is a functional block diagram of an internal body insertion and removal station according to the second embodiment of the present invention; FIG. 6 is a cross section of the mold and the internal body shown in FIG. 5; FIG. 7 is a partial perspective view of a first milling tool station according to a third embodiment of the invention; FIG. 8 is a partial perspective view of a second milling tool station according to the third embodiment of the invention; FIG. 9 is a partial perspective view of a third milling tool station according to the third embodiment of the invention shown; FIG. 10 is a partial perspective view of an alternately structured cutting tool according to a variation of the third embodiment of the invention; FIG. 11 is a partial functional block diagram of the sequential milling tool stations according to the embodiments of FIGS. 7-9; FIG. 12 is a partial functional block diagram of the sequential milling tool stations according to a variation of the embodiment shown in FIG. eleven; FIG. 13 is a partial functional block diagram of a frozen confection manufacturing system using a male tool according to a fourth embodiment of the invention; FIG. 14 is a partial functional block diagram of a frozen confection manufacturing system using a male tool according to a variation of the embodiment shown in FIG. 13; Fig. 15 is a partial perspective view of a male tool and a frozen confection partially formed according to the modalities shown in FIGS. 13 and 14; Fig. 16 is a partial perspective view of another male tool according to the embodiments of FIGS. 13 and 14; FIG. 17 is a partial functional block diagram of a frozen confection manufacturing system having a spray station according to a fifth embodiment of the invention; Fig. 18 is a partial perspective view of a first ingredient spraying station having two nozzles according to the embodiment shown in FIG. 17; Fig. 19 is a partial perspective view of a first ingredient spraying station for forming a spiral pattern according to the embodiment shown in FIG. 17; and Fig. 20 is a partial perspective view of a first ingredient spraying station for forming spots according to the embodiment shown in FIG. 17 DETAILED DESCRIPTION OF THE PREFERRED MODALITIES In FIG. 1 a functional block diagram of a frozen confection manufacturing system according to the present invention is shown. The system 1 comprises a plurality of rows of mounds 9, 11, 15, 17, 19, 21, 23 and 25 fixed to a turntable 27. In the alternative, the turntable 27 may comprise an in-line conveyor. . The turntable 27 moves the rows of molds through several stations where the different stages occur in the frozen confection manufacturing process. These stations include the dosing station 101, the freezing station 103, the aspiration emptying station 105, the milling station 107, the dosing station 109, the bar insertion station 1 1 1, the freezing station 1 13 and the separation station 1 15. In the dosing station 101, the filling unit 3 inserts the first ingredients in liquid form into the molds. The molds are transported to the freezing station 103 where they enter the freezing tank 5. Alternatively, the dosing station 101 (in addition to all other intermediate stations except for the final product separation station) may be above the tank. freezing 5. This tank generally contains a saline bath whose temperature is below freezing to cause rapid freezing of the first ingredients. This freezing progresses from the internal walls of the molds inside the central nuclei of the molds. The molds are moved before the complete freezing of the central nuclei. In the vacuum extraction station 105, the vacuum unit 36 inserts the hose 38 into the molds. Following this insertion, the vacuum extraction station 36 removes the non-frozen liquid comprising the central cores of the molds. A frozen outer layer of the first ingredients remains in the molds. Preferably, this outer layer is approximately 0.158 cm thick. This thickness has been found sufficient to remain intact during subsequent milling or melting operations, while requiring, if a heated tool is used for milling, only moderate heat for carving or melting a pattern, which preserves intact the remaining outer layer . Following this separation of the unfrozen liquid, the molds are moved to the milling station 107. In the embodiment of FIG. 1, the milling station 107 comprises a nozzle 107 for directing high pressure air, or gas, preferably sterilized, on the frozen outer layer within the molds. The nozzle 29 is attached to a robot arm 34. The nozzle and the arm are controlled by a control system 31. In the alternative, the nozzle 29 can be replaced by a laser beam or a mechanical cutting tool. The control system 31 is programmed to insert the nozzle 29 into the molds, activate the pressurized gas at appropriate times and move the nozzle 29 in a predetermined pattern to remove portions of the frozen outer layer of the first ingredient. The programming for such robot activation and movement is well known in the art. In this case, the nozzle 29 is programmed to remove the adjacent wing sections from the frozen outer layer 32 of the molds. Upon completion of this removal, the nozzle control system 31 causes the arm 34 and the nozzle 29 to exit the molds. The molds are moved to the dosing station 109.

In the dosing station 109, the filling unit 33 inserts the second ingredients, different in color and / or flavor to those of the first ingredients, into the same molds as in the dosing station 101. Those second ingredients fill the cores and wing sections of the molds and surround the portions of the frozen outer layers of the first ingredients that remain in the molds. The molds are then moved to the rod insertion station 111. At the rod insertion station 111, the bar insertion unit 31 is inserted into each of the molds one of the plastic or conventional bars 37. The molds are then moved to the freezing station 113. In a process similar to that of the freezing station 103, the freezing station 113 contains a freezing tank 7 with a saline solution maintained at a temperature below freezing. The molds inside the freezing tank 7 remain surrounded by the saline solution until all the ingredients inside the molds are completely frozen. A freezing tank, similar to freezing tanks 5 and 7, can, in the alternative, be extended from the dosing station 101 through all, or substantially all, intermediate stations to the separation station 115. Finally, the jam Frozen two flavors 43 is separated from the molds in the separation station 115. The separation unit 41 holds the bars inside the frozen confections from the molds. In order to facilitate this process, the frozen ingredients inside the molds can be slightly thawed, through the use of hot water or other means, before separating the product. The frozen confection of two flavors 43 is shown in greater detail in Figs. 1 and 3. As shown in these figures, the frozen confection 43 comprises different visible sections each comprising a different flavor and / or color. The outer main section 47 consists of the ingredients that enter the molds in the dosage section 101, and the wing sections 45 and the inner core 48 consist of the ingredients that enter the molds in the dosing station 109. As can be seen in FIG. explained earlier, when the second ingredients enter the molds, they fill the wing sections 32 and the core of the molds. FIG. 4 shows examples of the other frozen flavors of two flavors that can be made using the system and method of the invention. The manufacture of these frozen confections requires only the use of different molds in the system 1 and reprogramming the nozzle control system 31. The frozen confections of two flavors 51 and 57 comprise, respectively, first sections 53 and 59 and second sections. 55 and 61. The ingredients comprise sections 53 and 59 enter the molds in the dosage section 101 and, the ingredients comprising the sections 55 and 61 enter the molds in the dosing station 109. The ingredients comprising the second sections of the frozen confections, for example, sections 55 and 61 of the frozen confections 51 and 57, respectively, include the first ingredients removed at the milling station 107 that melt into the core of the molds. If those portions removed are of small volume, they have a negligible effect on the flavor and / or color of the second ingredients. However, if desired, a second aspiration station may be inserted into the system 1 after the first milling station to remove those first molten ingredients. Also, by including within the system 1 additional freezing, liquid separation and intermediate milling stations, frozen confections comprising more than two sections with flavor or color can be manufactured. For example, instead of completely freezing the frozen confections in the freezing station 113, only partial freezing may occur in this season, followed by the removal of the non-frozen second ingredients. A second milling station may then be used to carve a second pattern within the first or second frozen layers, or both, to create an intricate pattern of visible sections, different flavors or colors within a single frozen confection. In FIGS. 5 and 6 a second embodiment of the present invention is shown. In this modality, instead of partially freezing the first ingredients in the freezing station 103 and removing the non-frozen liquid comprising the core cores of the molds in the aspiration emptying station 105, the system 1 incorporates the body insertion / removal station 21 1. This station may be part of the freezing station 103. According to this second embodiment, the internal body control system 201 inserts an internal body 207 into the mold 205 using a robotic arm 203. The molds are only partially filled with the first ingredients in the dosing station 101 so that this insertion does not cause spillage of the first ingredients from the molds but causes those ingredients to occupy the space 209 between the internal wall of the mold 205 and the external surface of the inner body . In the alternative, the molds can be filled with the first ingredients after the inner body is inserted into the mold. The molds are then subjected to freezing temperatures to freeze the first ingredients and, following this freezing, the internal body control system 201 separates the internal body 207 from the mold. This separation can be facilitated by the application of heat from an electrical circuit (not shown), inside the inner body 207 and activated by the internal body control system 201. This heat causes thawing of the first ingredients in the area immediately adjacent to the external surface of the inner body 207. In the alternative, the heat can be applied directly to the molds or chemical substances can be inserted into the internal body 207 to cause a reaction that generates heat. Following the removal of the internal body 207, the molds can be moved to the carving station 107 where a pattern is carved on the first frozen ingredients in the same manner as described above. Other embodiments of the present invention are shown in FIGS. 7- 12. For example, milling station 107 (FIG.!) May comprise one or more milling tool stations, such as station 310 (FIG ./), each having a heated milling tool 320, for stirring a predetermined portion of the frozen outer layer 322 of the frozen confection. The tool 320 is maintained at a temperature above the melting point of the first ingredient, preferably at 65.5 ° C before the tool is inserted into the mold. In a preferred embodiment, the tool is heated using an electric bar heater with a thermostat. Alternatively, the tool can be heated by a pair of radiant heaters placed on either side of the tool when the tool is retracted from the mold. In yet another embodiment, steam or hot water can be circulated through the passages in the tool. The tool 320 is mounted on a support 325 such as a robotic arm. The external surfaces 321 of the tool 320 touch, or arrive within close proximity to, the inner wall 305 of the mold 306. By doing so, the portions of the outer layer 322 close to the outer surfaces. 321 of the tool are removed as the tool is inserted into the mold. The release slots 359 on the external surfaces 321 allow the molten product to exit the casting region. The tool 320 has two diametrically opposed tapered outer surfaces 321 for removing portions of the outer layer that extend from the top of the mold. The surfaces 321 are positioned to simultaneously touch or, in close proximity of, the upper internal surface 305 of the mold when the tool is inserted into the mold. The tool 320 may comprise any external configuration to produce any desired pattern on the external surface of the frozen confection. FIGS. 8 and 9 show longitudinal openings that are formed progressively from the top of the outer layer 322 by a series of tools similar to those shown in Fig. 7. Initially, an upper portion of the opening 350 having a lower edge 351 is formed using a tool 320 (FIG.7). As shown in FIG. 8, a mid-level portion of the opening 350 having a lower edge 352 is then formed using a second tool 341. A lower portion of the opening 350 is formed as shown in FIG. 9 using the tool 342, in a conventional staggered frozen confection making machine, the tool lines, such as tools 320, 341 and 342, can be sequentially located along the conveyor so that the outer layers within Each line of molds are removed in stages and all the tools are operated simultaneously. On the other hand, the three tools 320, 341 and 342 can be combined in a single tool, for example, by structuring an individual tool extending the length of the mold. However, it has been found that, for a typical product of 15.24 - 22.86 cm in length, it is not practical to form a full length opening inside the outer layer of the frozen confection using an individual entry with a longitudinal tool without destroying the other portions of the outer layer. By using successive applications of one or more heated tools to form the stepped opening limited to 5.08 cm in length, the outer layer can be accurately carved and portions of the outer layer between intact intact openings. As shown in FIG. 11, the three heated tools 320, 341 and 342 may comprise sequential milling stations 360, 361 and 362, replacing the individual milling station 107 of FIG. 1. The tool 320 removes the frozen confection from the upper 5.08 cm of the outer layer, the tool 341 removes the frozen confection from the average 5.08 cm and the tool 342 removes the frozen confection from the lower 5.08 cm of the outer layer. The tools can be heated up to the correct temperature between cycles or can be maintained thermostatically within an operating temperature range. The molten material comprising the removed portions of the outer layer is collected in the core of the mold. In a preferred embodiment, after the milling process, the first melt is removed by vacuum in a single suction station 363. In FIG. 12 shows an alternative embodiment, wherein the vacuum stations 371, 373 and 375 are positioned after the heated tool stations 370, 372 and 374 to remove the molten material after each milling step. This arrangement opposes the refreezing of the first product in the core of the mold during subsequent milling operations. Alternatively, evacuation by suction after the milling step can be completely elminated. In that case, the molten liquid is left on top of the frozen confection to provide a superior color. Also, all the milling stations may be located within a freezing tank in order to further maintain the integrity of the outer layer 322 during the formation of the openings.

An alternative configuration for the heated cutting tool is shown in FIG. 10. One or more outer surfaces 343, 344 of the heated tool 345 are placed within a shell smaller than the inside of the mold. The tool is laterally moved after it is placed in the mold, separately bringing each of the outer surfaces 343, 344 into contact, or in close proximity with, the internal wall 305 of the mold, thereby removing portions of the layer. frozen external 322 of the product. The openings, such as the opening 346, can thus be formed in the outer layer 322. Like the tool 330, the tool 45 can be maintained above the melting point of the first ingredient with a heating means. After completion of the milling operation, the molds are moved to the dosing station 109 (FIG.1) for the addition of the second product. The dosing station 109 may be located either within a freezing tank (not shown) or before the freezing tank 7 (FIG. 7). the addition of the second product within a freezing tank ensures the additional rigidity of the external shell and reduces the mixing of the first and second products. While those and subsequent processes are described as having discrete freezing tanks, machines that have a continuous saline bath or saline spray throughout the system, such as the "Vitaline ®" machine, can be used.

Preferably, the spraying of saline can be deactivated when freezing is not desired. In another embodiment of the invention shown in FIGS. 13-16, a male tool is inserted into the mold before the first ingredient is frozen in the mold. The first ingredient can be inserted into the mold either before or after the insertion of the male tool. FIG. 13 is a schematic representation of the first stations of a process according to this modality. In the dosing station 401, a filling unit 423 inserts a first ingredient in liquid form into the mold. The mold is only partially filled. The molds are then transported to the tool insertion station 402, where the male tool 429 is inserted into the mold using the robot arm 434. The male tool has a geometry such that, in this insertion, the external surfaces of the tool male make contact with the internal surfaces of the mold. For example, the male tool 390 shown in FIG. 15 has surfaces 396 that contact the inner surface 392 of the mold 393 when the tool is inserted into the mold. As the male tool is inserted into the mold, the first liquid ingredient is restricted to mold portions 397 not occupied by the male tool. 390. Relatively few or no first ingredients remain at the interfaces between the external surfaces 396 of the male tool and the internal surfaces of the mold 392. Returning to FIG. 13, the mold, together with the male tool 429 and the first ingredient, are transported to a freezing station 403, where the first ingredient is frozen in the freezer tank 430. The mold is then transported to a waste removal station. tool 404. The tool can be heated in this station by chemical means, driving electricity through the mold, and / or using an external electric heater. The heat can also be applied by raising the ambient temperature surrounding the molds; for example, using hot water. The tool is heated sufficiently to heat any first frozen ingredient to its surface, but not so much as to significantly thaw the first remaining ingredient in the mold. The male tool 429 is then removed using for example, a robot arm 431 similar to arm 434. The first frozen ingredient remains in the mold, forming a pattern on the internal surface of the mold. The mold is then transported to a dosing station 405 where additional ingredients, different in flavor and / or color of the first ingredient, are added to the mold. Additional ingredients fill sections 398 (FIG.15) within the mold left by the male tool. Additional ingredients are preferably added into the freezer tank 435 so that the additional ingredients freeze quickly and remain relatively separated from the first ingredient. When using a male tool such as the tool 390 (FIG.15), a continuous single passage remains after the removal of the tool. Therefore, only the individual metering device 433 is used, to add an additional individual ingredient to fill that passage. In an alternative embodiment, a male tool 440 (FIG.16), which has multiple male elements 441, is used. Each element has an external surface 442 for contact with the internal wall of the mold. Each male element 441 leaves a separate longitudinal section in the first frozen ingredient after the tool is removed. In that case, the dispensing device 433 (FIG.13) may comprise multiple filling elements for introducing a plurality of ingredients, each having a different flavor and / or color, within the plurality of passages 441. After leaving the dosing device 433, the mold continues through a manufacturing system such as that of FIG. 1, being transported through a bar insert station, a freezing station and a product separation station. In an alternative embodiment of the invention shown in FIG. 14, the male tool 429 is first placed in the mold in a tool insertion station 410. The external surfaces of the male tool make contact with the internal surface of the mold. The surfaces of the tool and the internal surface of the mold form one or more sections within the mold, preferably, a freezing tank 415 in the tool insertion station freezes the mold, causing the tool to adhere to the internal surface of the mold as the surface condensation freezes, sealing the contact surfaces. The mold, together with the male tool, is then transferred to the dosing station 41 1, where a first ingredient is inserted in liquid form into the mold, filling the sections. If a male tool is used, such as the tool 390 (FIG.15), the multiple sections 397 formed by the male tool and the internal wall of the mold are distinct and separate. Therefore, each section can be filled with a different ingredient that has a different color and / or taste. In yet another embodiment, the multiple ingredients can be vertically layered within each section by alternate filling and freezing steps. In other words, one or more sections may be partially filled with ingredient, which is frozen, partially filled with a second ingredient, which is frozen, etc. The mold, the male tool and the ingredients thereof are then transferred to a freezing station 412, where the ingredients are frozen and, to a tool removal station 413, where the freezing is stopped and the male tool 429 is heated and removed as explained before. The mold, which contains the first frozen ingredients forming a pattern on the internal surface of the mold, is transferred to a second dosing station 414 where an additional ingredient is added to fill the mold. Alternatively, multiple ingredients can also be added in this station in layers, as explained above, or to separately fill separate, multiple separate sections within the mold (if such exists as a result of the structure of the male tool). One embodiment of the invention that uses a spray nozzle to apply one or more first ingredients is shown in FIG. 17. A reusable mold is first frozen to a temperature below the freezing point of the first ingredients (below about 0 ° C) in the freezing station 450 inside the freezer tank 460. In a preferred embodiment, the mold is frozen to about -28.8 ° C to about -17.7 ° C using a saline solution at -40 ° C. The mold then advances to a sprinkler station 451, which is also preferably inside the freezer tank 460. In the sprinkler station 451, a nozzle head 461 is manipulated, for example, by a robot arm 462, to direct a fine mist of liquid or semi-frozen ingredient on an internal wall of the mold. The nozzle can be moved into the mold, close to the area of the inner wall to be sprayed. Alternatively, the nozzle can be maintained on the mold, directing the spray down on the inner walls. The flow of the ingredient and the robot arm are controlled by the 463 controller. The sprayed ingredient is frozen in place without any significant operation. By manipulating the robot arm 462 and controlling the spray, patterns can be formed on the inner wall of the mold. By controlling the spray time, the thickness of the outer layer can also be controlled. FIG. 18 shows a nozzle 461 having two holes 465, 466. By moving the nozzle head axially downward (or upwardly) within the mold during the spray operation, two axial strips 467, 468 of the first ingredient are formed on the inner wall of the mold. Alternatively, different ingredients having different colors and / or flavors are sprayed through each orifice, forming bands of different colors. In addition, a plurality of nozzles may be used to cover entire areas of the mold with the same or different colors and / or flavors. FIG. 19 shows a helical band 470 of a first ingredient formed by rotation and moving the nozzle head 469. FIG. 20 shows a dot pattern formed by rotation and translation of the nozzle head 471 while an ingredient is sprayed intermittently. Other patterns and nozzle configurations will be apparent to those skilled in the art.

If a frozen confection making machine is used that freezes from the bottom, it is preferred to start the spraying operation at the bottom of the mold and move the injector upwards. This method also avoids scratching. On the other hand, if a frozen confectionery machine is used which freezes from the top of the molds downwards, it is preferred that the nozzle starts at the top of the mold and operates downwards. Returning to FIG. 17, after the first ingredient is applied to the inner wall of the mold, the mold is advanced to a freezing station 452, where the pattern is further frozen on the inner wall. The mold is advanced to a dosing station 453, where a second ingredient is added by a filling unit 464. Preferably, this dosing also occurs within a freezing tank in order to ensure the integrity of the first frozen ingredient pattern. Also, alternatively, for this dosage, multiple additional ingredients may be layered as described above. The first ingredient remains frozen towards the inner wall of the mold, forming a pattern having a backing formed by the second ingredient. After adding the second or additional ingredients, the mold is advanced through the bar insertion stations as described with reference to FIG. 1 . The mold can be heated slightly in order to facilitate the removal of the frozen confection.

Although particular embodiments of the present invention have been shown and described, a variety of embodiments can be constructed that incorporate the teachings of the present invention in a simple manner by those skilled in the art. For example, depending on the construction of the high pressure gas nozzle or other milling tool and the particular portions of the first frozen ingredients which are desired to be removed (such as along the upper portions of the mold only), the Insertion of the nozzle inside the mold itself may not be necessary.

Claims (79)

1. CLAIMS 1 . A method for making a frozen confection having a plurality of sections of different flavor or color, comprising: (a) creating in a mold a first frozen outer layer comprising a first ingredient of a first flavor or color; (b) removing a first portion of said first outer layer with a first heated male tool; (c) inserting a second liquid comprising ingredients of a second flavor or color into said mold; and (d) freezing said second liquid. The method of claim 1, wherein the step of creating the first frozen outer layer comprises: (a) inserting a first liquid comprising said first ingredient into the mold; (b) partially freezing said first liquid so that the first liquid comprises the first frozen outer layer and a substantially internal first core; (c) separating from said mold the liquid comprising the first internal core. 3. The method of claim 1, wherein the step of creating the first frozen outer layer comprises: (a) partially filling said mold with a first liquid comprising the first ingredient; (b) inserting a body into the mold so that the first liquid forms an outer layer between the body and the mold; (c) freezing the first liquid to create the first frozen outer layer; and (d) separating the body from the mold. The method of claim 1, wherein the step of creating the first frozen outer layer will comprise) inserting a body into the mold so that there is a gap between the body and the mold; (b) filling said space with a first liquid comprising the first ingredient; (c) freezing the first liquid to form the first frozen outer layer; and (d) separating the body from the mold. The method of claim 1, further comprising the step of heating the male tool to about 65.5 ° C prior to removal of the first portion of the first outer layer. The method of claim 1, further comprising the step of heating the male tool with radiant heaters prior to removal of the first portion of the first outer layer. 7. The method of claim 1, further comprising the step of heating the male tool using an electric heater. 8. The method of claim 1, further comprising the step of circulating heated water through said heated tool. The method of claim 1, wherein the removal step comprises inserting said tool down into the mold until the outer surface of the tool is substantially coextensive with the internal surface of the mold. 10. The method of claim 1, further comprising the step of separating from said mold a liquid comprising the first portion in liquid form prior to the insertion of the second liquid. The method of claim 1, wherein the removal step with a second heated male tool of a second portion of the first outer layer, prior to the insertion of the second liquid. The method of claim 12, further comprising the step of removing with a third heated male tool a third portion of the first outer layer, prior to the insertion of the second liquid. The method of claim 12, wherein the first, second and third portions of said first outer layer are, respectively, portions of the upper section, the middle section and the lower section of the outer layer. The method of claim 12, further comprising the step of removing from said mold a liquid comprising the first, second and third portions in liquid form, after said removal of the third portion of the first outer layer. The method of claim 12, wherein the first, second and third tools are the same tool. The method of claim 12, further comprising the steps of separating from the mold a liquid comprising the first portion in liquid form before the removal of the second portion; separating from the mold a liquid comprising the second portion in liquid form before the removal of the third portion; and separating from the mold a liquid comprising the third portion in liquid form after the removal of said third portion. The method of claim 1, further comprising: (a) partially freezing the second liquid so that the second liquid comprises a substantially frozen second outer layer and a substantially liquid second inner core; (b) separating from the mold the liquid comprising the second inner core; (c) removing with a second heated male tool a first portion of the second outer layer; (d) inserting a third liquid comprising the ingredients of a third flavor or color within the mold; and (e) freeze the third liquid. 18. The method of claim 1, wherein the step of removing a portion of said first outer layer with a first male tool further comprising spacing the tool down into the mold and moving the tool laterally into the mold. The method of claim 1, further comprising the step of placing the mold in a freezing section prior to the insertion of the second liquid. 20. A system for making a frozen confection having a plurality of sections of different flavor or color, comprising: (a) means for creating in a mold a first frozen outer layer comprising a first ingredient of the first flavor or color; (b) a first heated male tool; (c) means for removing with the first heated male tool a first portion of the first outer layer; (d) means for inserting a second liquid comprising the ingredients of a second, flavor or color within the mold; and (e) means for freezing the second liquid. The system of claim 20, wherein the means for creating the first frozen outer layer comprises: (a) means for inserting a first liquid comprising the first ingredient into the mold; (b) means for partially freezing the first liquid so that the first liquid comprises the first frozen outer layer and a first substantially liquid internal core; (c) means for separating the liquid comprising the first inner core from the mold. The system of claim 20, wherein the means for creating the first frozen outer layer comprises: (a) means for partially freezing the mold with the first liquid comprising the first ingredient; (b) means for inserting a body into the mold so that the first liquid is located between the body and said mold; (c) means for freezing the first liquid; and (d) means for separating the body from the mold. The system of claim 20, wherein the means for creating the first frozen outer layer comprises: (a) means for inserting a body into the mold such that there is a gap between the body and the mold; (b) means for filling said space with a first liquid comprising said first ingredient; (c) means for freezing the first liquid to form the first frozen outer layer; and (d) means for separating the body from the mold. The system of claim 20, wherein the means for removal comprises means for inserting the tool down into the mold until the outer surface of the tool is substantially coextensive with the internal surface of the mold. 25. The system of claim 20, further comprising means for separating from the mold a liquid comprising the first portion in liquid form. 26. The system of claim 20, further comprising a second heated male tool and means for removing with said second heated male tool a second portion of the first outer layer. The system of claim 26, further comprising a third heated male tool and means for removing with said third heated male tool a third portion of the first outer layer. The system of claim 27, wherein the first, second and third portions of the first outer layer are, respectively, portions of the upper section, the middle section and the lower section of the outer layer. 29. The system of claim 27, further comprising means for separating from the mold a liquid comprising the first, second and third portions in liquid form. 30. The system of claim 27, wherein the first, second and third tools are the same tool. 31 The system of claim 27, further comprising means for separating from the mold a liquid comprising the first portion in liquid form prior to removal of the second portion of the first outer layer; means for separating from the mold a liquid comprising the second portion in liquid form prior to removal of the third portion of the first outer layer; and means for separating from the mold a liquid comprising said third portion in liquid form after removal of the third portion of the first outer layer. 32. The system of claim 20, further comprising: (a) means for creating in said mold a second frozen outer layer comprising the ingredients of the second flavor; (b) a second heated male tool; (c) means for removing with the second heated male tool a first portion of the second outer layer; (d) means for inserting a third liquid comprising the ingredients of a third color or flavor within the mold; and (e) means for freezing the third liquid. 33 *. The system of claim 20, wherein the means for removal comprise means for spacing the first tool down into the mold and moving the first tool laterally into the mold. 34. The system of claim 20, further comprising means for subjecting the first outer layer to a temperature below 0 ° C during the insertion of the second liquid. 35. The system of claim 20, wherein the removal means comprise a robot arm. 36. The system of claim 20, further comprising radiant heaters for heating the male tool before removal of the first portion. 37. The system of claim 20, further comprising an electric heater for heating the male tool. 38. The system of claim 20, further comprising means for circulating heated water through the male tool. 39. A method for making a frozen confection having a plurality of sections of different flavor or color, comprising: (a) inserting a first liquid comprising the ingredients of a first flavor or color within the mold; (b) providing a first body having fixed surfaces on its outer periphery; (c) inserting the first body into the mold so that the fixed surfaces are substantially in contact with the internal wall of the mold; (d) freezing the first liquid to form a substantially frozen first outer layer surrounding the fixed surfaces; (e) separating the first body from the mold; (f) inserting a second liquid comprising the ingredients of a second flavor or color within the mold; and (g) freezing the second liquid. 40. The method of claim 39, further comprising the steps of: (a) inserting a third liquid comprising comprising the ingredients of a third flavor or color within the mold on top of the first frozen layer; (b) Freeze the third liquid. 41. The method of claim 39, further comprising the steps of: (a) inserting a third liquid comprising the ingredients of a third flavor or color into the mold on top of the second frozen ingredients; (b) Freeze the third liquid. 42. The method of claim 39, wherein the step of providing the first body includes providing said first body with a plurality of male elements to form a plurality of longitudinal passages within the first frozen outer layer and the step of inserting said second one. liquid includes inserting the second liquid into a first of those passages and, further comprising the steps: (a) inserting a third liquid comprising the ingredients of a third flavor or color within a second of those passages; and (b) freezing the third liquid. 43. The method of claim 39, further comprising the step of heating the first body before separating the first body from the mold. 44. A system for making a frozen confection having a plurality of sections of different flavor or color, comprising: (a) means for inserting a first liquid into the mold; (b) a body having surfaces fixed at its outer periphery; (c) means for inserting the first body into the mold so that said fixed surfaces are substantially in contact with the inner wall; (d) means for freezing the first liquid to form a substantially frozen first outer layer surrounding said fixed surfaces; (e) means for separating the body from the mold; (f) means for inserting a second liquid into the mold; and (g) means for freezing the second liquid. 45. The system of claim 44, further comprising means for cooling the body and the mold to 0 ° C before inserting the first liquid. 46. The system of claim 44, wherein the system further comprises a heater for heating said body. 47. The system of claim 46, wherein the heater is an electric heater. 48. The system of claim 46, wherein the heater is a chemical heater. 49. A method for making a frozen confection having a plurality of different flavor or color sections, comprising: (a) providing a body having fixed projections on its outer periphery; (b) inserting the first body in the mold so that the fixed projections are in contact with the internal surface of the mold and create a first space joined by said first body, the projections and said mold; (c) inserting a first liquid comprising the ingredients of a first flavor or color within the first space; (d) freezing the first liquid so that the first liquid comprises a first substantially frozen outer layer; (e) separating the first body from the mold; (f) inserting a second liquid comprising the ingredients of a second flavor or color within the mold; and (g) freezing the second liquid. 50. The method of claim 49, wherein the step of inserting the fixed body into the mold includes creating a second space joined by the fixed projections, the body and the internal surface, said second space being substantially independent of the first space and comprising further the steps of inserting a third liquid comprising the ingredients of a third flavor or color within the second space; and freeze the third liquid. 51. A method for making a frozen confection having a plurality of sections of different flavor or color, comprising: (a) creating in a mold a first frozen outer layer comprising a first ingredient of a first flavor or color; (b) removing a portion of the first outer layer with a pressurized gas stream; (c) inserting a second liquid comprising the ingredients of a second flavor or color within the mold; and (d) freezing the second liquid. 52. The method of claim 51, wherein the gas is air. 53. The method of claim 51, further comprising the step of sterilizing said gas. 54. The method of claim 51, wherein the step of creating the first frozen outer layer comprises: (a) inserting a first liquid comprising said first ingredient into the mold; (b) partially freezing the first liquid so that the first liquid comprises the first frozen outer layer and a first substantially liquid inner core; (c) separating from the mold the liquid comprising the first internal core. 55. The method of claim 51, wherein the step of creating the first frozen outer layer comprises: (a) partially filling the mold with a first liquid comprising the first ingredient; (b) inserting a body into the mold so that the first liquid forms an outer layer between the body and the mold; (c) freezing the first liquid to create the first frozen outer layer; and (d) separating the body from the mold. 56. The method of claim 51, wherein the step of creating the first frozen outer layer comprises: (a) inserting a body into the mold so that there is a gap between the body and the mold; (b) filling the space with the first liquid comprising the first ingredient; (c) freezing the first ingredient to form the first frozen outer layer; and (d) separating the body from the mold. 57. The method of claim 51, further comprising the step of separating from the mold a liquid comprising the portion of the first outer layer in liquid form, before inserting the second liquid. 58. The method of claim 51, further comprising: (a) partially freezing the second liquid so that the second liquid comprises a second substantially frozen external layer and a second substantially liquid internal core; (b) separating from the mold the liquid comprising the second inner core; (c) removing a first portion of the second outer layer with a pressurized gas stream; (d) inserting a third liquid comprising the ingredients of a third flavor or color within the mold; and (e) freeze the third liquid. 59. The method of claim 51, further comprising the step of placing the mold in a freezing section before inserting the second liquid. 60. A system for making a frozen confection having a plurality of sections of different flavor or color, comprising: (a) means for creating in a mold a first frozen outer layer comprising a first ingredient of a first flavor or color; (b) means for providing a pressurized gas stream; (c) means for removing a first portion of the first outer layer with the pressurized gas stream; (d) means for inserting a second liquid comprising the ingredients of a second flavor or color within the mold; and (e) means for freezing the second liquid. 61. The system of claim 60, wherein the means for creating the first frozen outer layer comprises: (a) means for inserting a first liquid comprising the first ingredient into the mold; (b) means for partially freezing the first liquid so that the first liquid comprises the first frozen outer layer and a first substantially liquid inner core; (c) means for separating from the mold the liquid comprising the first internal core. 62. The system of claim 60, wherein the means for creating the first frozen outer layer comprises: (a) means for partially filling the mold with a first liquid comprising the first ingredient; (b) means for inserting a body into the mold so that the first liquid forms an outer layer between the body and the mold; (c) means for freezing the outer layer; and (d) means for separating the body from the outer layer. 63. The system of claim 60, wherein the means for creating a first frozen outer layer comprises: (a) means for inserting a body into the mold such that there is a gap between the body and the mold; (b) means for filling that space with a first liquid comprising the first ingredient; (c) means for freezing the first liquid to create the first frozen outer layer; and (d) means for separating the body from the mold. 64. The system of claim 60, further comprising a controller for manipulating the gas stream. 65. The system of claim 60, wherein the removal means comprises a pressurized gas nozzle to create the gas stream, a gas valve to regulate the gas stream, a robot arm for manipulating the nozzle and a controller for control the robot arm and the valve. 66. The system of claim 60, further comprising means for separating from the mold a liquid comprising a portion of said first layer in liquid form. 67. The system of claim 60, further comprising: (a) means for creating in the mold a second frozen outer layer comprising the second ingredients; (b) means for providing a second pressurized gas stream; (c) means for removing with the second pressurized gas stream a first portion of the second frozen outer layer; (d) means for inserting a third liquid comprising the ingredients of the third flavor or color within the mold; and (e) means for freezing the third liquid. 68. The system of claim 60, further comprising a freezing section for subjecting said first outer layer to a temperature below 0 ° C during the insertion of the second one. 69. A method for making a frozen confection having a plurality of different flavor or color sections, comprising: (a) spraying a first liquid comprising the ingredients of a first flavor or color onto an inner wall of the mold; (b) freezing the first liquid so that the first liquid comprises a first substantially frozen outer layer; (c) inserting a second liquid comprising the ingredients of a second flavor or color within the mold; (d) freezing the second liquid to form a confection with a plurality of flavored or colored sections; and (e) stirring the frozen confection from the mold; 70. The method of claim 69 wherein the step of spraying the first liquid on the inner wall of the mold further comprises forming a pattern of areas on said inner wall covered by the first liquid and areas on the inner wall not covered by the first liquid. 72. The method of claim 69, further comprising the step of cooling the mold below 0 ° C prior to spraying. 72. The method of claim 69, wherein the spraying step of the first liquid comprises inserting a spray nozzle into the mold and spraying the liquid through the nozzle onto the inner wall. 73. The method of claim 69, further comprising the steps of spraying a third liquid onto selected portions of the inner wall and freezing said third liquid so that the third liquid comprises a second substantially frozen outer layer. 74. The method of claim 73, wherein the first and third liquids are sprayed substantially at the same time. 75. A system for making a frozen confection having a plurality of sections of different flavor or color, comprising: (a) a reusable mold; (b) means for spraying a first liquid onto selected portions of an internal wall of the mold; (c) means for directing the nozzle; (d) means for controlling the spraying of the first liquid; (e) means for inserting a second liquid into the mold; Y (f) means for freezing the first and second liquids. 76. The system of claim 75, wherein the means for spraying comprises a plurality of orifices. 77. The system of claim 75, further comprising second means for spraying a third liquid onto selected portions of the internal wall of the mold. 78. The system of claim 75, wherein the means for directing the nozzle comprises means for inserting said nozzle into the mold. 79. A system as in claim 75, further comprising means for cooling the reusable mold below 0 ° C before spraying.