NZ610489A - Comestible products, apparatus and methods for production thereof - Google Patents

Abstract

610489 Disclosed is an apparatus includes a die head for extruding a main comestible or edible material to form an extruded body. A plurality of nozzles is located within the die head for introducing a comestible fluid into the extruded body to form a plurality of filled capillaries. A control system is capable of selectively connecting each of the nozzles independently to different filling fluid sources or the nozzles may be arranged into two or more groups of fluidly interconnected nozzles, where each group of nozzles can each be independently switched between different fluid sources. The apparatus can be used to form products in which the fillings in the capillaries are varied or in which an image is formed in cross section. The apparatus can also be used to switch production between products having different fillings without stopping extrusion. em is capable of selectively connecting each of the nozzles independently to different filling fluid sources or the nozzles may be arranged into two or more groups of fluidly interconnected nozzles, where each group of nozzles can each be independently switched between different fluid sources. The apparatus can be used to form products in which the fillings in the capillaries are varied or in which an image is formed in cross section. The apparatus can also be used to switch production between products having different fillings without stopping extrusion.

Description

COMESTIBLE TS APPARATUS AND METHODS FOR PRODUCTION THEREOF cal Field of the Invention This invention relates to comestible products and to apparatus and methods for producing comestible products by means of ion. This invention is particularly, though not exclusively, related to comestible products comprising a ity of aries.

Background to the Invention Al and Al, both in the name of the applicant, be confectionery products comprising a plurality of capillaries together with apparatus and methods for their production. The t invention is a r development of this concept and the reader should refer to A1 and Al, the contents of which are hereby incorporated by reference in their entirety.

Briefly, WO 34973 Al and Al describe tionery products comprising an extruded body portion which has a plurality of capillaries disposed therein. The capillaries have an average width or diameter of no more than 3mm but could have an average width or diameter as small as 10mm. The extruded body is formed from a comestible, 2O confectionery material which is liquid during extrusion but which subsequently sets or solidifies. The capillaries are filled with a fluid that may be air or a liquid confectionery material. In some cases, the liquid filling material also sets or solidifies after extrusion. Several examples are described and include products in which the body portions are formed from extruded hard candy, chewing gum, or chocolate. In the examples, a variety of filling materials for the capillaries are used, including: air, liquid fondant, liquid cocoa butter, opylene glycol, Golden Syrup, and chocolate. However, the present invention is not limited to the materials used in the examples. Embodiments are also disclosed in which the product comprises first and second extruded WO 98401 portions, both having a ity of capillaries disposed therein, and wherein the capillaries in each portion are: a) discontinuous; and/or b) continuous and orientated in more than one direction.

WO 34973 Al and Al disclose methods and apparatus for ing the products. Figures 1 to 5 of the accompanying drawings show somewhat schematically the apparatus used to produce some of the examples in Al and A1. The apparatus briefly comprises an electric motor 12 which is drivingly coupled to the single screw extruder. The extruder has a barrel 28 surrounding the screw 14 which has three independently controllable temperature zones denoted T1 to T3. The barrel 28 is connected to an extrusion die 18 by means of a feed conduit 29 which also has an independently controllable temperature zone T4.

The extruder 14 is fed at one end from a hopper 16 and the molten material is extruded through an outlet aperture 20 in the die 18. Quench jets 22 are directed towards the die outlet aperture 20 so as to cool the ed material 23 and these jets are fed with compressed air 24. If desired, the area of the apparatus where the hopper 16 is coupled to the screw 14 can be cooled by means of a cooling feed 26. In use: the hopper 16, which may be heated, is filled with a confectionery material 30 (such as candy broken into pieces) for forming the body of the product. Before the material passes into the screw 14 it can be cooled by means of the cool feed 26 so as to ensure that the material is at the correct temperature for entering the screw extruder. As the screw is rotated, the material is drawn along the screw 14 inside the barrel 28 and the temperature of the zones T1—T3 adjusted so that the material is red in a molten/liquid state to the feed conduit 29. The ed material passes through the feed t 29 and its temperature adjusted again (if required) by temperature control T4 before entering the die head 18.

The die head 18 (shown in Figures 3 toS) includes an outer body 70 having an opening 74 connected by means of an inner passage or flow path to the outlet re 20. Molten material 72 for forming the body of the product enters the opening 74 from the feed conduit and passes along the flow path to exit the die through the aperture 20, the shape of which defines the outer cross sectional profile of the extrudate 23. A nozzle assembly 58 (shown on its own in Figure 3) having a number of needles or inlet nozzles 60 is located within the flow path in the outer body so that the liquid material passes over and around the nozzles. The nozzles 60 are r to hypodermic needles being hollow and having an outlet at their , downstream end. The nozzles 60 are all in fluid communication with an inlet channel 64 via a cavity in the body 62 of the nozzle assembly. The inlet channel 64 is fluidly connected with a fluid source by means of a fluid feed conduit 56 to form fluid filled capillaries within the extrudate body. In the embodiment shown in Figure l, the inlet channel is connected with a source of air at ambient pressure and ature so that the capillaries are air filled.

As shown in Figure 5, the ate 23 is cooled by means of the quench jets 22 as it is released from the die 18. A valve 32 controls the flow of compressed air to the quench jets 22 and pressure devices P1 and P2 control the pressure of the compressed air 24 before and after the valve. The compressed air line also has a temperature l T6 so as to control the temperature of the air. The quench jets were used in particular for the generation of oidage 2O material but are not essential.

Figure 2 illustrates schematically an adaptation of the apparatus shown in Figure l to introduce a liquid confectionery filling material into the capillaries rather than air. In this arrangement, the nozzles 60 are fluidly connected to a reservoir 50 containing a liquid filling material with a hydraulic head of pressure h. In one embodiment, the liquid filling material is cocoa butter and the reservoir 50 is heated so that the cocoa butter is maintained at the correct temperature so as to maintain it in a liquid state. The reservoir 50 is connected to a conduit 52 having an ion valve 54 for controlling the flow of liquid. The conduit 52 is encased in a trace heating tube 56 which ins 3O the temperature of the conduit so that the liquid remains in a liquid state during its nt Within the conduit. The conduit 52 is coupled to the inlet channel 64 of the nozzle assembly 58 which is in fluid connection with the nozzles 60 so that so that the liquid cocoa butter is fed through the s as the main material is being extruded to simultaneously fill the capillaries formed around the nozzles with cocoa butter.

W02005/056272 A1 discloses an apparatus for producing an extruded product including a plurality of capillary ls. W02008/044122 A1 discloses a related apparatus, which onally includes means for quench cooling an extrudate as it exits the die. The apparatus described in either of these documents may also be employed/adapted for use in producing a comestible product having a body with a plurality of capillaries. The contents of W02005/056272 Al and W02008/O44122 A1 are also herby incorporated by reference in their entirety.

It is an objective of the present invention to provide apparatus and methods for producing a comestible product comprising a plurality of capillaries that are more versatile than the known tus and methods.

It is a further objective of the present invention to provide apparatus and methods for ing a ible» t comprising a plurality of capillaries that enable a r range of comestible products to be produced 2O than the known apparatus and methods.

It is a further objective of the present invention to provide apparatus and methods for producing a comestible product comprising a plurality of capillaries that enable a customized comestible product to be ed in response to an input from a consumer.

It is a further objective of the present invention to provide apparatus and methods for producing a comestible t comprising a plurality of capillaries that enable a comestible product to be produced containing an image and/or text.

It is a further objective of the present invention to provide a comestible product comprising a ity of capillaries, which contains an image and/or pattern.

It is a further objective of the present invention to provide a comestible product comprising a plurality of capillaries and in which in at least one of the capillaries has portions spaced along its length which are filled with different fluids.

The ing objectives are to be read disjunctively with the ive of at least providing the public with a useful alternative.

In accordance with a first aspect of the invention, there is provided apparatus for producing a comestible t, the apparatus comprising a die head defining flow path g to a die aperture for extruding a main comestible material to form an extruded body, a plurality of nozzles within the flow path for introducing a comestible fluid into the extruded body to form a plurality of filled capillaries in the extruded body, and a control system for selectively ting at least one of the nozzles to any one of at least two fluid sources or for selectively connecting at least two different nozzles to at least one source of fluid als.

The apparatus may be configured such that the control system is able, in use, to independently connect each nozzle, or at least one of two or more groups the nozzles, with any one of at least two different sources of ible fluid. At least some of the nozzles may be fluidly interconnected to form a group and the control system may be operative to selectively connect the, or at least one, group of fluidly interconnected nozzles to any one of at least two fluid sources.

Alternatively, the control system may be ive to selectively connect all the nozzles collectively to any one of at least two fluid sources.

The control system may comprise an electronic control unit. The control system may comprise a valve arrangement operative under the control of the electronic control unit to selectively connect the at least one of the nozzles to any one of the at least two fluid sources. Where the control system is operative to selectively connect each of the nozzles independently to any one W0 2012;098401 of at least two fluid sources, each nozzle may be independently fluidly connected with a valve for selectively connecting the nozzle with any one of at least two fluid s, each valve being independently controlled by electronic control unit.

U1 The s may be arranged in a matrix.

Each of the nozzles may have a external width or diameter of 3mm or less.

The control system may comprise a CPU which may be part of a computer network. The computer network may be a wide area network, such as the internet.

The apparatus may have a delivery system for delivering a main comestible material to the die head in a molten or liquid state for extrusion through the die aperture to form the extruded body. The delivery system may comprise an extruder.

At least one of the fluid sources may comprise a source of a liquid comestible material. At least one of the fluid sources may be a source of a s comestible material such as air.

The control system may be configured so as to be e of selectively changing the fluid source to which the at least one nozzle is connected whilst the main ible material is being extruded through the die re.

In accordance with a second aspect of the invention, there is provided a s for manufacturing comestible products having an extruded body portion formed from a comestible material, the body having a plurality of filled capillaries disposed therein using the apparatus in accordance with the first aspect of the invention, the process comprising: carrying out a first production run to produce a first product, during which first production run a main comestible product is ed through the die to e an extrudate body and the control system is operative to connect the nozzles to fluid source(s) as W0 2012i098401 appropriate for the first product; subsequently carrying out a second production run to produce a second product, during which second production run a main comestible product is extruded through the die to e an extrudate body and the control system is operative to connect the s to fluid source(s) as Ur riate for the second product, wherein between production runs, different fluid source(s) are connected to the same or different nozzles and/or the same fluid source(s) are connected to different nozzles.

The process may comprise ing the same main ible material through the die head to produce the ed body in both of the first and second production runs.

Production may be switched from the first production run to the second production run Without stopping extrusion of the main comestible product.

In ance with a third aspect of the invention, there is provided a process for manufacturing comestible products having an extruded body portion formed from a comestible material, the body having a plurality of capillaries filled with a fluid disposed therein using the apparatus in accordance with the first aspect of the invention in which each nozzle is ndently connectable to any one of at least two fluid sources, the process comprising ing a main ible product through the die to produce an extrudate body and using the control system to simultaneously connect selected nozzles to at least one fluid source and the remaining nozzles to at least one other fluid source so that the fluid filled capillaries in the extrudate body define an image or pattern visible in lateral cross section of the extrudate body.

The image or pattern defined by the filled capillaries may be selected from the group ting of: text, numbers, logos, pictures, and graphical representations.

The process may comprise using the control system to change the fluid source(s) to which at least some of the nozzles are fluidly connected Whist the main comestible material is being extruded so that within each product length of extrudate, there are portions in which the fluid filled aries define ent images or patterns.

The process may comprise connecting the selected nozzles with one of a source of air and a source of the main comestible material used to form the extrudate body and connecting the remaining nozzles the other of a source of air and a source of the main comestible material used to form the ate body.

The process may comprise connecting the selected nozzles with one of a source of air and a source of a comestible liquid filling material and connecting the remaining nozzles with the other of a source of air and a source of a comestible liquid filling material.

The process may comprise connecting the selected nozzles with a source of at least one comestible liquid filling material and connecting the remaining nozzles with a source of at least one other comestible liquid filling material having a contrasting appearance. In which case: one of the comestible liquid filling materials may be the main comestible material used to form the extrudate body.

In accordance with a fourth aspect of the ion, there is provided a process for manufacturing comestible products having an extruded body portion formed from a comestible material, the body having a plurality of capillaries ed therein using the tus in accordance with the first aspect of the invention, the process sing extruding a main comestible product through the die to produce an extrudate body and using the control system to change the fluid source and or flow of fluid to which at least one of the nozzles is ted Whilst the main comestible product is being ed so that Within each product length of the extrudatc body, at least one of the capillaries is filled with a different fluid at different positions along its length and/or formed at different positions at different portions along its length.

The s may se connecting said at least one nozzle to s of fluid materials which have different flavours, colours and/or es.

Where at least some of the nozzles are fluidly interconnected and the control system is operative to selectively connect the fluidly interconnected U! nozzles collectively to any one of at least two fluid sources, the s may se using the control system to change the fluid source to which the fluidly interconnected nozzles are connected whilst the main comestible product is being extruded so that each product length of the extrudate body has at least two portions in which the capillaries are filled with different fluid materials.

Where each of the nozzles are independently table to any one of at least two fluid sources, the process may comprise introducing one fluid material through some of the nozzles and ucing at least one other fluid material through the other nozzles simultaneously so that in at least one portion l5 of each product length of the extrudate body, some of the capillaries are filed with said one fluid material and other of the capillaries are filled with said at least one other fluid material. The process may comprise varying the ratio of nozzles connected to each of said one fluid material and said at least one other fluid material over the course of extruding each product length of the extrudate body.

In accordance with a fifth aspect of the invention, there is provided a comestible product comprising an extruded body portion having a plurality of fluid filled capillaries having a width or diameter of 3mm or less, in which the capillaries define an image or pattern Visible in lateral cross section of the extrudate body.

The image defined by the fluid filled capillaries may be selected from the group consisting of: text, numbers, logos, es, graphical representations.

The capillaries may be filled with air. Alternatively: some of the capillaries may be filled with a first fluid material and other of the capillaries filled with at least one ent fluid material.

In accordance with a sixth aspect of the invention, there is provided a U] comestible product comprising an extruded body n having a plurality of fluid tilled capillaries having a width or diameter of 3mm or less, in which at least one of the capillaries is filled with different fluid materials at different positions along its length.

All the capillaries may be filled with different fluid als at different positions along their .

The different fluid materials may have differing flavours, colours and/or textures.

A ible product in accordance with either of the fifth or sixths aspects of the invention may be a confectionery product.

In accordance with a seventh aspect of the invention, there is provided an apparatus for producing a comestible product, the apparatus comprising a die head defining flow path leading to a die aperture for ing a main comestible material to form an extruded body, a plurality of nozzles within the flow path for ucing a comestible fluid into the extruded body to form a plurality of filled capillaries in the extruded body, and a control system for selectively and independently connecting each nozzle, or at least one of two or more groups the nozzles, with any one of at least two different sources of ible fluid.

Detailed Description of the Invention Specific embodiments of the t invention will now be described, by way of example only, with reference to the accompanying drawings, in which: Figure l is a schematic diagram illustrating the known apparatus used to produce Examples 1 and 2 in the experiments described in Figure 2 is a schematic diagram illustrating known apparatus used in conjunction with the apparatus shown in Figure lto provide liquid filled capillaries as described and shown in Al; Figure 3 is a perspective View of a nozzle ly forming part of a die head in the known apparatus illustrated in Figures land 2; Figure 4 is a plan View of an extrusion die head which incorporates the nozzle ly shown in Figure 3 and which forms part of the known apparatus as illustrated in Figures 1 and 2; Figure 5 is a perspective View of the ion die head of Figure 4, showing air jets used to cool the extrudate when leaving the die; Figure 6 is a schematic entation of an apparatus in ance with a first embodiment of the present invention; Figure 7 is a schematic representation of a nozzle feed arrangement for use in apparatus in accordance with the invention; Figure 8 is a front View of an extruder die head containing a matrix of inlet nozzles for use in the apparatus of Figure 6; Figure 9 is a View similar that of Figure 8, illustrating how a fluid filling material can be uced through certain of the nozzles only to create an image in a comestible product extruded through the die head; Figure 10 is a lateral cross sectional View through a confectionery product in which an image in the form of a trade mark is defined by the fluid filled capillaries; Figure 11 is a longitudinal cross sectional View through part of an extrudate body formed using apparatus in accordance with the invention, W0 20121098401 illustrating how the capillaries can be filled with different fluid als in different sections along each product length of the extrudate; and, Figure 12 is a schematic drawing illustrating how a control unit forming part of apparatus in accordance with the invention can be ted to a wide area network such as the internet.

The same nce numerals as those adopted in Alwill be used in the following description to identify the same es or features which perform substantially the same function in the apparatus in accordance with the present invention, except that the numbers will be increased by one hundred in the first embodiment and by a further one hundred in each case for each successive ment.

Figure 6 illustrates schematically an apparatus 100 for extruding a comestible product sing a plurality of capillaries in accordance with the invention.

The apparatus 100 is similar to the apparatus 10 as shown in Figures 1 to and comprises an extruder 180 having a barrel 128 and a die head 118. The die head 118 comprises an outer body 170 defining a flow path 171 g to a die aperture 120 through which a main comestible material is ed to form an extrudate body 123. The shape of the aperture 120 defines the outer cross- sectional profile of the extrudate. The apparatus also includes a first al delivery system 116 which delivers the main comestible material 130 to the extruder in a suitable condition for extrusion. This could comprise a hopper feed arrangement, for example.

The e nature of the extruder 180 and the first material ry system 116 is not an essential element of the present invention. Those skilled in the art will appreciate that a number of different extruder arrangements can be adopted for use in the apparatus of the present invention depending on the material to be extruded, including apparatus such as that described in W02005/056272 A1, WO2008/044122 Al, A1, and WO 2010/034981 Al. In general, the main comestible material will be extruded through the die head in a liquid or molten state and the material delivery system and extruder should be configured accordingly. The extruder could be a screw extruder (either single or twin screw), a ram extruder, or a pump extruder for U! example. In some ations, it may be possible to directly pump a liquid material h the die head.

A nozzle assembly 158 having a plurality of hollow s or outlet nozzles 160 is located within the die head 116 so that the main comestible material flows over and between the nozzles as its passes along the flow path and through the die aperture to produce an extrudate body comprising a plurality of capillaries corresponding substantially to the number, location and shape of the nozzles 160. Each of the nozzles 160 has an outlet at a distal, downstream end and is in fluid tion with a source of a fluid material so that a fluid can be introduced into the capillary formed in the extrudate body about each nozzle.

As so far described, the apparatus 100 is similar to the known apparatus as shown in s 1 to 5. However, in ance with one embodiment of the invention, in the apparatus 100 the nozzles 160 are each independently and selectively connectable to at least two different fluid sources 150A, 150B.

The apparatus 100 also comprises a control system, indicated generally at 182, comprising an electronic l 183 and a valve block 184 which are operative to control which of the fluid s each nozzle 160 is in fluid communication with.

One possible embodiment of a suitable nozzle feed system 185 is illustrated schematically in Figure 7. Each nozzle 160 has an internal fluid passage 186 which is fluidly connected with the valve block 184 by means of a conduit 187. The valve block 184 contains valve means operable under control the onic control 183 to selectively connect each of the ts with any one of the at least two fluid sources 150A, 150B by means of conduits 189 and 190 respectively. Figure 7 illustrates three outlet nozzles 160A, 160B, 160C each independently connected with a separate valve 188A, 1888, 188C by a respective t 187A, 187B, 187C. Each of the valves 188A, 188B, 188C can be ndently switched to connect its respective nozzle with either one U: of the two fluid sources 150A, 150B. The valves may be solenoid actuated valves operative in response to a control signal from the electronic l 183.

It will be appreciated that three nozzles and valves are shown in Figure 7 for illustrative purposes only and the number of nozzles and valves can be selected as desired for any particular application.

In the apparatus 100, each of the nozzles 160 is ndently connectible to any one of the two or more fluid sources 150A, 150B at any one time. The control system 182 is ive to selectively change the fluid source to which any one nozzle 160 is connected as desired, even whilst extrusion is in progress. This significantly increases the versatility and adaptability of the apparatus 100 when compared with the prior art.

There are a variety of methods in which the apparatus 100 as bed above can be used to produce comestible products.

In one method, an image is created in the extruded product by selectively delivering ent fluids through different nozzles 160 at the same time. Figure 8 illustrates a die head having a circular die outlet 120 with a number of outlet nozzles 160 dispersed within the area of the outlet 120.

Figure 9 illustrates how a letter “S” can be created by a selecting certain of the nozzles 160A. The letter “S” can be differentiated in the extruded product in a number of ways. In one approach, air or a contrasting liquid filling material is introduced through the ed nozzles 160A to produce capillaries filled with air or the liquid filling material and the unselected nozzles 160B are connected to a source of the main ible material used to form the body of the extrudate so that, in effect, no capillaries are formed about the unselected nozzles. in this arrangement fluid filled capillaries are only formed about the selected s 160A to define the image in an otherwise solid extrudate body.

In an alternative approach, air may be directed through the selected nozzles 160A and a liquid filling material introduced through the non-selected nozzles or Visa versa, so that the image is defined either by the air tilled capillaries or U! by the contrasting liquid al filled capillaries. In a further alternative, a first liquid filling material can be uced through the selected nozzles 160A and a second sting liquid filling material introduced through the non- ed nozzlesl6OB to define the image. Those skilled in the art will appreciate that there are a number of different ways in which an image can be produced in the extrudate body by introducing a combination of different liquid filling materials and/or air through the selected and non-selected nozzles.

Images created in this way are Viewable in cross section of the product in the manner of a stick of rock. In some products, the aries are exposed at either end of the body so that the image can be seen. In other products, the ends of the extruded body are coated or capped so that the image is only seen when the product is broken in two laterally.

A variety of types of image can be created in this way depending on the overall cross-sectional shape of the extruded product and the number and size of the nozzles. These might include: text, s, arks, and simple pictures or graphical designs. For example, where the extruded product is a large block of chocolate, it would be possible to extrude the product to have a word, such as a person’s name, running along its length.

It will be appreciated that the achievable image resolution is dependent on the number, size and proximity of the nozzles 160 used. Thus increased image resolution can be obtained by using more and smaller nozzles positioned closer together but this comes at the expense of a more complex nozzle and fluid feed arrangement. Particularly for use in producing an image in the extruded body, the nozzles 160 may be ed in matrix in which the nozzles 160 are d in rows and columns or some other pattern.

W0 2012f098401 The apparatus 100 as described above can also he used to produce a product in which the extruded image changes along the length of the product.

For example a chocolate bar might be ed in which the words “Cadbury”, “Dairy” and “Milk” ® appear sequentially along its length. To achieve this U1 effect, the control system 182 is arranged to vary the materials introduced through at least some of the nozzles 160 during the extrusion of each product length of extrudate to produce the desired images in different portions along each product length. There may be ns of the body having no image between each different image. Alternatively, the images may change substantially instantaneously or there may be a gradual blurring from one image to the next. Figure 10 illustrates schematically a lateral cross section through a chocolate bar in which the word ry” ® is defined by the capillaries.

The term “product length” is used herein to refer to a length of extrudate which forms the basis of a separate ed product. When material is extruded it generally forms a substantially continuous length of cxtrudate which is subsequently d into separate lengths. The separated s may constitute finished products or they may be subject to further treatment such as folding, shaping or coating. In some cases, the extrudate is t to further ent such as stretching before it is divided. Accordingly, the portion of an extrudate which constitutes a product length at the die head need not be the same length as the finished product itself. More than one product may be packaged er for presentation to the er. For example, where the extruded product is a chocolate bar, each bar may be packaged separately or two or more bars may be packaged together. The term extruded product in this context refers to each extruded item regardless of whether it is packaged separately or together with one or more extruded items.

In an alternative , the control system 182 is arranged to change the fluid supplied to at least some of the nozzles 160 during extrusion of each t length of extrudate, so that each product length contains portions having different s, colours and/or textures. in a simple example, each nozzle 160 is connectable any one of two - liquid filling material sources under the command of the control 182.

The control system 182 connects all the s 160 to a first liquid filling material source to enable extrusion of a first portion of a product length of the extrudate body and subsequently connects the nozzles to the second liquid filling al source to enable extrusion of a second portion of the product length of the extrudate body. This cycle is repeated so that each product length ofthe extrudate body has a first portion in which the capillaries are filled with a first liquid filling material and a second portion in which the capillaries are filled with a second liquid filling material having a different flavour, colour and/or texture to the first. One of the liquid filling materials may be the same as the material used to form the body of the extrudate so that one of the ns in effect has no capillaries. Figure ll is a longitudinal cross section through a length of extrudate l23 illustrating how a single product length X of the extrudate may contain first and second portions Y, Z in which the capillaries 194 are filled with different filling materials 196, 198.

The portions need not be totally et as there may be a gradual change in the , , and or texture along the length of the product.

For example when extruding a product length, a first liquid filling material may be introduced through all the nozzles initially and the s gradually switched to a source of a second liquid filling material having a different flavour until all the nozzles are delivering the second liquid filling material as extrusion of the product length draws to an end. This arrangement can be used to create a gradual change in flavour, colour, and/or texture over the product length.

Those skilled in the art will appreciate that the apparatus 100 can be used in many different ways to create different flavour and texture 2012/050112 combinations. For e, air may be introduced through some of the nozzles and a liquid filling material introduced through the other nozzles at the same time so that the extrudate body has a combination of air filled and liquid filled capillaries to produce different taste/texture combinations. The ratio of air U) filled to liquid filled aries can be varied and can be changed over the course of each extruded product length to alter the taste/texture. In addition or alternatively, two or more different liquid filling materials can be introduced through various nozzles at the same time to e different taste, colour and texture combinations. The ratio of the different fillings can be varied and can be changed over the course of each extruded product length so that each product length has ns with different flavours, colours and/or textures. As with the previous example, air could be introduced simultaneously through some of the nozzles.

Whilst the ability to t each nozzle 160 independently to two or more different fluid sources is advantageous in terms of overall versatility, significant advantages can still be achieved if the apparatus 100 is modified so that all nozzles 160 are fluidly interconnected and are tively connectable to any one of two or more fluid sources by the control system 182. In one embodiment, all the nozzles 160 are fluidly connected with a common inlet which is connectable with any one of two or more fluid s by means of a valve arrangement operative under control of the l unit 183. This type of arrangement is r to implement but would still allow products to be extruded having at least two portions in which the capillaries are filled with different materials. The different fluids could e air and/or different liquid filling materials for example. It would also be possible to connect the nozzles 160 with a fluid source containing the same material used to form the body of the product so that in at least one portion, the product has no capillaries. Such an arrangement could be used to form solid end cap regions having no capillaries at either end of an extruded product. This would be useful where the liquid filling material remains liquid after the product has been extruded and is retained in the product by the solid end cap regions. An alternative arrangement for g solid end cap regions is to temporarily stop the introduction liquid filling material through the nozzles and to increase the flow of the main comestible al through the die so that the capillaries are collapsed to U] produce a portion in the extrudate body having no capillaries. Further methods and apparatus for producing solid end caps are disclosed in the applicant’s co- pending UK patent application No. GB1003288, the contents of which are hereby incorporated by reference.

A r advantageous application of the apparatus 100 in accordance with the invention is to enable production to be switched between different products quickly and in some cases without stopping the extrusion process.

Thus, a first product can be produced with the nozzles 160 connected, tively or independently, to one or more fluid sources as appropriate for that product. Production can then be switched to a ent t by using the control system 182 to connect the nozzles, collectively or independently, to one or more fluid sources as appropriate for the further product. In a simple example where all the nozzles are fluidly interconnected, a first product can be ed with the nozzles 160 connected to a source of a first liquid filling al having a first flavour and production switched to a second product by connecting the nozzles with a source of a second liquid filling material having a different flavour. Where the apparatus 100 is used to extrude chocolate bars for example, production could be switched between bars having an orange flavour filling to one having a mint flavour as one example. However, it will be appreciated that where the nozzles 160 are independently table with any one of two or more fluid sources, there are a large number of possible variations that could be adopted. It should also be appreciated that in any one of the production runs, the t may be extruded to have different fillings in different portions of the body in accordance with the methods and tus described above.

W0 2012f098401 The y to switch production quickly between two or more products allows the production of products in relatively small batch runs and so opens up the possibility of producing a broader range of products than might be commercially feasible using tional apparatus.

Whilst in the preferred ment the s 160 are shown as being connectable to any one of two alternative fluid sources 150A, 1508, it will be appreciated that the number of fluid sources to which the nozzles 160 can be connected need not be limited to two. Thus by modifying the apparatus appropriately, it can be arranged that the nozzles 160 can be connected, either independently or collectively or in groups, to any one of three, four or more fluid sources to increase the versatility of the apparatus. However, this will require a more complex control and fluid connection arrangement.

The onic control l83 may comprise a CPU such as a computer.

The CPU may be operative to run a suitable re programme for determining what fluid sources the nozzles 160 are required to be connected to e a desired product and to provide an appropriate output or outputs to the valve block or to solenoid actuators associated with the valve block to effect the required connections. Alternatively, or in addition, the electronic control 183 may be operative in response to an input from an operator and/or from a further computer to connect the nozzles to a desired fluid source.

The CPU may be connected with a computer network which may be a private computer network such as an intranet or local area network (LAN) or it may be a wide area network (WAN) such as the internet. Connecting the l system 182 with a computer network enables the control system to be integrated as part of a broader production l system in a variety of ways.

For e, where the apparatus 100 is used to enable production to be switched n various products, production runs for the various products can be automatically lled in response to product orders via the computer network. The control system 182 may also be integrated with a control system for packaging of the products after extrusion to ensure the correct packaging is applied. atively, or in addition, data from the tus 100 regarding the use of various materials in the extrusion process can be fed back via the computer network to enable re-ordering of materials as they are used up.

U: The increased versatility of the apparatus 100 in accordance with the invention and the ability readily switch production from one product to another opens up the possibility of producing customised products in response to customer orders.

Customisation may take many forms. For example, a customer may specify a ular image to be contained in the product. Thus a product having a particular name or logo running through it could be ordered, for e. The customer may be offered a range of images from which a selection can be made or the er may be offered the facility to provide a graphic image which is assessed to determine if it can be reproduced to an acceptable quality in the product. Alternatively, or in addition, customisation may take the form of specifying particular s and/or flavour combinations, textures, and/ or colours. The customer may specify the desired flavour and the software programme arranged to determine which fluids need to be introduced into the capillaries to achieve the requested flavour.

Alternatively, the client may be able to select particular fluids to be introduced.

Where the nozzles, are independently connectable to any one of a number of fluid sources, the er may be able to y particular fluid combinations and the ratio between the fluids. Thus the customer could order a product having a ular flavour or a combination of flavours which may be different in different portions of the t. For example, if the product were a chocolate bar, a customer could specify that orange and lemon flavoured fillings are used and could r specify the ratio of orange to lemon to meet their own personal preferences. A customer order could be for a single product or a minimum order in excess of one product may be required.

W0 20121098401 Customer orders could be accepted in a number of different ways but it is ally preferred that er orders are taken via computer using a computer network such as the internet. The ordering software can be mmed to t the ed data for processing and delivering the order U1 and may include the facility to automatically assess graphic images to ine if they can be reproduced in a t. In one ment, the control system 182 is connected as part of the network so that once an order has been processed, the control system 182 is able automatically control the extrusion process to produce the customised product.

Figure 12 illustrates schematically connection of the control system 182 of the apparatus 100 to customer computers 200 via the internet 201. Details of the hardware and software required to achieve a suitable connection are well known and so will not be described in detail. The control system 182 itself may not be connected directly with the internet but may be connected Via a server or host computer 202. Using an internet connection, a customer can place an order for a customised t from their own computer. The order is processed and results in the control system 182 controlling the fluids supplied to the various nozzles 160 so as to produce the d product. The control system 182 may be part of a lager control system which controls other aspects of the extrusion 2O process so that customisation could also include selection of the main comestible material used to form the body of the product as well as the fluid g materials for the capillaries.

In most cases, it is expected that manufacture of customised products will be remote from the place of ordering and that products will be dispatched to the customer by post or courier. However, it is within the scope of the invention to set up local, small scale manufacturing facilities in retail areas to which a customer can gain access to place an order which can be taken away on the same day. In this case, the order may be taken by an operative who inputs the necessary instruction to the control system 182 or the customer may W0 20121098401 place an order via an in-store computer or kiosk which is networked with the control system 182, perhaps via a LAN.

Customisation is particularly ed where the nozzles 160 are each independently connectable to any one of two or more fluid sources. However, a U: more limited customisation can also be offered where the apparatus is modified so that the nozzles 160 are collectively table to different fluid sources.

It is also within the scope of the invention to have a nozzle arrangement in which the nozzles are arranged in a number of groups, wherein the s in each group are collectively connectable to different fluid s under the control of a control system but where the fluid source for each group can be changed independently from the other group or groups.

Whereas the invention has particular application in the production of confectionery products, it can also be applied by suitable tion to the cture of other comestible products including savoury products. Tests carried out suggest that any material normally solid at room temperature (commonly regarded as around 200C) yet extrudable at elevated temperature and pressure can be formed into a body having capillaries using apparatus in ance with the invention.

For use in the production of confectionery products, the main material used to e the body n may comprise any one or more of a number of materials commonly use in the production of tionery — such as candy, gum and chocolate etc. In some embodiments, the body portion is chocolate.

Suitable chocolate includes: dark, milk, white and compound chocolate. In some embodiments, the body portion is chewing gum, bubble gum or gum base. In other embodiments, the body portion is candy. Suitable candy includes hard candy, chewy candy, gummy candy, jelly candy, toffee, fudge, nougat and the like. The body may be formed from more than one comestible material, which materials may be mixed or extruded in separate portions.

For use in the production of savoury comestible ts, the main material used to produce the body portion may comprise any one or more of a number of materials commonly use in the production of savoury products such as pasta, cereal, vegetable products and cheese.

It should also be noted that the term d” is used herein in relation to the material for filling the capillaries to mean a al which is in a liquid or flowable state when introduced into the capillaries through the nozzles. Thus the term not only covers als that remain in a liquid state in the capillaries at room temperature after extrusion but also materials that can be rendered liquid at elevated temperatures and/or pressure for the es of introducing it through the nozzles into the capillaries and which subsequently sets after extrusion. For example, a molten chocolate may be orated into the capillaries and allowed to set when cooled to room temperature. Alternatively, the capillaries may be filled with a material which is deposited as a liquid and which subsequently solidifies. In such embodiments, the solidification may be dependent or independent of heat. It will be apparent that solidification of a liquid filled capillary may be achieved in a number of ways. For example solidification may take place due to one or more of the following: g ~ the filling may be molten when deposited which then cools to a solid at room temperature; Heating — the filling may be liquid when deposited, and the heat of the extruded body portion sets the filling (e.g. pumping egg albumen into a hot hard candy extruded body portion will set the egg on contact); Drying - the filling may be a solution that dries into a solid (e.g. the moisture from the solution is ed into the extruded body portion); Solvent loss — the filling may be in a solvent, whereby the t is absorbed into the extruded body portion, leaving a solid; Chemical reaction - the filling may be deposited as a liquid but reacts or “goes off’ into a solid; linking — the filling may form a constituents for a cross-linked material due to mixing and/or heating; and Time - the filling may simply set with time (e.g. a solution of sugars and gelatin will eventually set over time).

Suitable liquid filling materials for the capillaries include, but are not limited to, aqueous media, fats, chocolate, caramel, cocoa butter, fondant, syrups, peanut butter, jam, jelly, gels, truffle, praline, chewy candy, hard candy, cheese, nuts, vegetable products or any combination or mixture f.

The ing embodiments are not intended to limit the scope of protection afforded by the claims, but rather to describe examples as to how the invention may be put into practice.

This description may contain subject matter that falls outside the scope of the claims. This subject matter is included to aid understanding of the invention.

Claims (1)

1. What is claimed l. Apparatus for producing a comestible product, the apparatus comprising a die head g flow path leading to a die aperture for extruding a main comestible material to form an extruded body, a ity of nozzles within the flow path for ucing a comestible fluid into the extruded body to form a ity of filled capillaries in the extruded body, and a control system, wherein the control system is configured so as to be able to independently connect each nozzle, or at least one of two or more groups of nozzles, with any one of at least two ent sources 10 of comestible fluid. Apparatus as claimed in claim 1, wherein the control system is ive to selectively connect each of the nozzles independently and/or collectively to any one of at least two fluid sources. Apparatus as claimed in claim 1 or claim 2, wherein at least some of the 15 nozzles are fluidly interconnected and the control system is operative to selectively connect the, or each, group of fluidly interconnected s to any one of at least two fluid sources. Apparatus as claimed in any one of the preceding claims, n the control system comprises an electronic control unit. 20 Apparatus as claimed in any one of the preceding claims, wherein the control system comprises a valve arrangement operative under the control of the electronic control unit to selectively connect the at least one of the nozzles to any one of the at least two fluid sources. Apparatus as claimed in claim 5 when dependent on claim 1 or claim 2, 25 in which each nozzle is independently fluidly connected with a valve for selectively connecting the nozzle with any one of at least two fluid sources, each valve being ndently controlled by electronic control unit. tus as claimed in any one of the preceding claims, wherein the nozzles are arranged in a matrix. Apparatus as claimed in any one of the ing claims, wherein each of the nozzles has an external width or diameter of 3mm or less. Apparatus as claimed in any one of the preceding claims, wherein the control system is configured so as to be capable of selectively changing the fluid source to which the at least one nozzle is connected whilst the main comestible material is being extruded through the die aperture. 10. A process for manufacturing comestible ts having an extruded 10 body portion formed from a comestible material, the body having a plurality of filled capillaries disposed therein using the apparatus of any one of the preceding claims, the s comprising: carrying out a first tion run to produce a first product, during which first production run a main ible product is extruded through the die to produce an 15 ate body and the control system is operative to connect the nozzles to fluid source(s) as appropriate for the first product; subsequently carrying out a second production run to produce a second product, during which second production run a main comestible product is extruded through the die to produce an extrudate body and the control 2O system is operative to connect the s to fluid source(s) as appropriate for the second product, wherein n production runs, different fluid sources are connected to the same or different nozzles and/or the same fluid (s) are connected to different nozzles. ll. A process for manufacturing comestible products having an extruded 25 body portion formed from a comestible material, the body having a plurality of aries filled with a fluid disposed therein using the apparatus as claimed in claim 1 or claim 2, the process comprising extruding a main comestible product through the die to e an extrudate body and using the control system to connect a first group of ed nozzles to at least one fluid source and the remaining nozzles to at least one other fluid source so that the fluid filled capillaries in the extrudate body define an image or pattern visible in lateral cross section of the extrudate body. 12. A process for manufacturing comestible products having an extruded body n formed from a ible material, the body having a plurality of capillaries disposed therein using the apparatus as claimed in any one of claims 1 to 9, the process comprising extruding a main comestible product through the die to produce an extrudate body and 10 using the control system to change the fluid source and/or flow of fluid to which at least one of the nozzles is connected whilst the main comestible t is being ed so that within each product length of the extrudate body, at least one of the capillaries is filled with a different fluid at different ons along its length and/or formed at 15 different positions at different portions along its length. 13. A process as claimed in claim 12, n at least some of the nozzles are fluidly interconnected and the control system is operative to selectively connect the fluidly interconnected nozzles collectively to any one of at least two fluid sources, wherein the process comprises using 2O the control system to change the fluid source to which the fluidly interconnected nozzles are connected whilst the main comestible product is being extruded so that each product length of the extrudate body has at least two portions in which the capillaries are filled with different fluid materials. 25 14. A process as claimed in claim 12, wherein each of the nozzles are independently connectable to any one of at least two fluid sources, wherein the process comprises introducing one fluid material through some of the nozzles and ucing at least one other fluid material through the other nozzles simultaneously so that in at least one portion of each product length of the extrudate body, some of the aries are filed with said one fluid material and other of the capillaries are filled with said at least one other fluid al. 15. A process as claimed in claim 14, wherein the process comprises changing the ratio of nozzles connected to said one fluid material and to said at least one other fluid material over the course of ing each product length of the extrudate body. 16. Apparatus as claimed in claim 1, substantially as herein described with reference to any one of the