WO2018050687A1

WO2018050687A1 - Apparatus and process for the manufacture of a frozen product

Info

Publication number: WO2018050687A1
Application number: PCT/EP2017/073007
Authority: WO
Inventors: Geoffrey Alec BURGESS; Mark WILLMOTT
Original assignee: Unilever Plc; Unilever N.V.; Conopco, Inc., D/B/A Unilever
Priority date: 2016-09-16
Filing date: 2017-09-13
Publication date: 2018-03-22

Abstract

An apparatus (1) for coating multiple edible receptacles simultaneously, the apparatus comprising: - a conveyer (2) containing a plurality of edible receptacle holders (3) arranged perpendicular to the direction of movement of the conveyer (2) - a plurality of nozzles (4) for applying a fat-based coating material to the internal surface of edible receptacles, said nozzles (4) being arranged to index with the plurality of edible receptacle holders (3) - a gas-dosing element (5) for spraying the internal surface of coated edible receptacles with a gas, said gas-dosing element (5) comprising a manifold (6) with at least one gas inlet (7) and a plurality of gas outlets (8), said gas outlets (8) also being arranged to index with the plurality of edible receptacle holders (3) characterised in that - the gas-dosing element (5) comprises a vacuum jacket (9) around the manifold (6) and further characterised in that - the manifold (6) comprises at least one expansion and contraction buffering zone (10) between the gas outlets (8) is provided.

Description

APPARATUS AND PROCESS FOR THE MANUFACTURE OF A FROZEN

PRODUCT

Technical Field

The present invention relates to an apparatus and process for the manufacture of edible receptacles for composite frozen products comprising an edible receptacle filled with a frozen confection. More specifically the present invention relates to an apparatus and process for the manufacture of edible receptacles that are coated with a fat-based coating such as chocolate, chocolate analogue, or couverture and that are intended to be filled with a frozen confection such as an ice cream. The present invention delivers improvements in barrier properties of the fat-based coating.

Background to the invention

Frozen confections are consumed as snacks or desserts worldwide and are often served in edible receptacles such as waffles, cones, shells, cups, and the like. These edible receptacles are typically made of baked wafer material and are used to contain the frozen confection. When eaten along with the frozen confections their crispness provides an enhanced sensorial experience that is highly desired by the consumer. The wafers used in edible receptacles are generally a baked preparation made from a batter of flour (such as wheat flour or refined wheat flour), sugar and other ingredients. Presence of starches from refined wheat flour, sugar anhydrides formed during high temperatures of baking and un-crystallised invert sugar makes the baked wafer highly hygroscopic. The edible receptacles may therefore absorb moisture immediately after baking or during storage. Contact with high moisture-containing food systems, especially frozen confections such as ice cream, therefore leads to absorption of moisture by the edible receptacles.

Moisture migration from the frozen confection to the edible receptacle depends on the amount of water and the water activity of the two components. Varying water activities (aw) and moisture content causes a state of non-equilibrium. Water activity (aw) or relative vapour pressure is the chemical potential of water vapour at constant or equilibrium relative humidity. Water thus migrates from areas of high water activity to areas of low water activity. Therefore, migration of water from a frozen confection (aw 0.97, 60 % moisture) to an edible receptacle (aw 0.2 to 0.3, 2 % moisture) occurs continuously in an attempt to reach equilibrium. As a result of this migration, edible receptacles tend to lose their crispness and other sensorial characteristics, they suffer a decrease in shelf life and also undergo undesirable changes in texture. During the migration of the water, water soluble colours may also migrate from the frozen confection to the edible receptacle which may further affect the visual appearance of the product.

Edible receptacles may be filled with a frozen confection immediately before consuming or they may be pre-packed with a frozen confection and stored in a freezer. In pre-packed edible receptacles, the edible receptacles may absorb water from the frozen confection at the time of filling and also during storage. This is even more pronounced when there are large fluctuations in storage temperature. In addition, frosting, ice, or other condensation may build up on the surfaces of the frozen confection and may subsequently melt upon exposure to ambient temperatures, further contributing to a reduction in crispness. Although this problem is predominantly found in edible receptacles for frozen confections, it applies equally to any crisp food product, notably wafers, cookies, biscuits and other common snacks. Such food products, although crispy when made, will become soft when combined with the food product they contain due to moisture penetration from the food product.

A common approach to the problem presented by moisture migration is to use a fat- based coating that is applied to the edible receptacle in order to act as a barrier between the edible receptacle and the frozen confection. This layer is typically a chocolate, a chocolate-like composition, a chocolate analogue, or a couverture and is used to coat at least the surface of the edible receptacle that will be in contact with the frozen confection.

WO 91/13557 discloses an apparatus for forming a layer of chocolate on the interior surface of an ice cream having a cone-shape mould that is interiorly cooled by ice water provided from a bucket, or other source, of ice water. For forming an interior chocolate coating, liquid chocolate is placed into the interior of the cone, and the cone is then placed on to the cone mould, and centred thereon by the upper end portion of the mould. The cone is allowed to remain there for a short while, while the cold mould surface solidifies the liquid chocolate, to thereby form the interior layer of chocolate. This application therefore discloses that a cooled mould can be used to displace a measure of molten chocolate from the base of a cone, thereby distributing the chocolate up the side walls of the wafer cone. The fact that the mould is cooled facilitates hardening of the chocolate to form the inner coating of the cone. Cooled moulds are similarly disclosed in US 2004/0265433, WO 02/15706, EP 1 103 188, and AU 642125. In these four disclosures, cooled forming elements are also used to displace a measure of molten chocolate from the base of a cone, thereby distributing the chocolate up the side walls of the cone to form a cone-shaped chocolate structure. However, the direct contact of a mould with the chocolate layer suffers disadvantages such as structural damage to the chocolate layer caused by direct contact and issues in disengaging the mould from the chocolate which may cause further damage and slow production. Moreover the approach requires very accurate dosing of the chocolate to the base of the cone and relatively high pressures to force the chocolate up the side of the cones. As can be seen from the foregoing, the use of fat-based coatings in edible receptacles for frozen confections has been known for some time and it is also acknowledged that it is not a perfect solution due to issues with the fat-based coatings solidifying correctly so that they have optimal barrier properties. Although the foregoing disclosures discuss approaches to improving the solidification of the fat-based coating they are not optimal and as a consequence the organoleptic properties of edible receptacles still degrade over time with the crispness being lost despite the application of the protective layer.

WO 81/00190 discloses a process for producing a composite edible product in which a dry edible material, for example a baked wafer container, is separated from direct contact with a water-containing edible material, for example ice confection, by a relatively water- impermeable edible fat-containing layer, by applying a spray of the fat-containing material to the dry edible material before application of the water-containing edible material, characterised in that the spray of fat-containing edible material is applied from an atomising spray gun and has a particular viscosity. This application utilises the use of spray to apply the fat-containing material to the dry edible material and therefore does not suffer the disadvantage of the use of a dose of molten chocolate in the base of the cone. The application therefore does not use a cooled moulding element to distribute the fat-containing material. One embodiment of WO 81/00190 discloses that good results have been achieved by cooling the sprayed-on fatty layer by an applied cooling fluid stream, for example liquid nitrogen.

Other disclosures also discuss the use of cooling fluid streams, for example liquid nitrogen.

WO2014/177313 provides an apparatus for coating an edible receptacle the apparatus comprising a nozzle for applying a fat-based coating material to the internal surface of the edible receptacle and a gas-dosing element with an external surface shape corresponding to the internal shape of the edible receptacle wherein the gas dosing element has at least one aperture suitable for the introduction of cooled gas into the edible receptacle. The invention also provides a process for manufacturing a coated edible receptacle for a frozen confection comprising the steps of: providing an edible receptacle; at least partially coating the internal surface of the edible receptacle by spraying a fat-based coating onto the internal surface of the edible receptacle; and introducing a gas-dosing element into the edible receptacle, wherein the gas-dosing element has an external surface shape corresponding to the internal shape of the edible receptacle and wherein cooled gas is introduced into the edible receptacle through the gas-dosing element and wherein the gas dosing element does not come into contact with the fat-based coating.

Although the use of cooling fluid streams, for example liquid nitrogen provide many advantages in the preparation of composite frozen confections, issues still remain. Frozen confection production lines are carefully engineered, have very high throughput, operate at very high speed and output, and are designed to function at normal ice cream production line temperatures. There are therefore very narrow and specific engineering tolerances in the production lines and the introduction of cooling fluid streams, especially cryogenic gases such as liquid nitrogen cause problems in tolerances and it has now been found that the resulting products can be unacceptable, in particular it is possible that the barrier properties of the fat-based coatings can be compromised thus creating composite frozen confections with soft, soggy edible receptacles that are unacceptable to the consumer.

It is therefore an object of the present invention to improve upon the current approaches for creating coated edible receptacles for frozen confections.

It is another object of the present invention to provide an edible receptacle for frozen confections that has improved moisture barrier properties.

It is another object of the present invention to provide an edible receptacle for frozen confections that retains its crispness at the time of consumption. It is another object of the present invention to provide a coating for edible receptacles for frozen confections that shows improved moisture barrier properties during long periods of cold storage even under varying temperature conditions.

It is another object of the present invention to provide a method and apparatus for manufacturing a coated edible receptacle for frozen confections.

It is yet another object of the present invention to provide an edible receptacle for frozen confections that has an improved shelf life period. It is yet another object of the present invention to provide coated edible receptacles that have good storage stability even at higher storage temperatures.

Summary of the drawings

Figure 1 shows a frozen confection production line comprising the apparatus of the invention.

Figure 2 shows the manifold of the gas-dosing element of the apparatus of the invention. Figure 3 shows the manifold of the gas-dosing element of Figure 2 within a vacuum jacket according to the invention. Figures 4 to 7 show various embodiments of the expansion and contraction buffering zone.

Figure 8 shows a schematic of the apparatus of the invention at rest and in use.

Figure 9 shows a schematic of an apparatus outside the scope of the invention in use.

Summary of the invention

We have now found that the above objectives are met through the use of a particular apparatus and process. Accordingly, in a first aspect the present invention provides an apparatus 1 for coating multiple edible receptacles simultaneously, the apparatus comprising:

a conveyer 2 containing a plurality of edible receptacle holders 3 arranged perpendicular to the direction of movement of the conveyer 2

a plurality of nozzles 4 for applying a fat-based coating material to the internal surface of edible receptacles, said nozzles 4 being arranged to index with the plurality of edible receptacle holders 3

a gas-dosing element 5 for spraying the internal surface of coated edible receptacles with a gas, said gas-dosing element 5 comprising a manifold 6 with at least one gas inlet 7 and a plurality of gas outlets 8, said gas outlets 8 also being arranged to index with the plurality of edible receptacle holders 3

characterised in that

the gas-dosing element 5 comprises a vacuum jacket 9 around the manifold 6 and further characterised in that

the manifold 6 comprises at least one expansion and contraction buffering zone 10 between the gas outlets 8.

Preferably the at least one expansion and contraction buffering zone 10 comprises at least one annular ring that is contiguous with the manifold, preferably an integral part of the manifold and that either protrudes from or intrudes into the manifold.

Where the annular ring protrudes, it may protrude from the manifold by at most 50% of the diameter of the non-protruded part of manifold adjacent to the protrusion, preferably at most 40%, more preferably at most 30%, more preferably still at most 20%, yet more preferably at most 15%, yet more preferably still at most 10%. The annular ring may protrude from the manifold by at least 1 % of the diameter of non-protruded part of manifold adjacent to the protrusion, preferably at least 2%, more preferably at least 5%, more preferably still at least 7.5%, yet more preferably at least 10%, yet more preferably still at least 15%.

Where the annular ring intrudes, it may intrude into the manifold by at most 20% of the diameter of the non-intruded part of manifold adjacent to the intrusion, preferably at most 17.5%, more preferably at most 15%, more preferably still at most 12.5%, yet more preferably at most 10%. The annular ring may intrude into the manifold by at least 1 % of the diameter of the non-intruded part of manifold adjacent to the intrusion, preferably at least 2%, more preferably at least 3%, more preferably still at least 4%, yet more preferably at least 5%, yet more preferably still at least 7.5%. Preferably the gas inlet 7 is in gas communication with a source of cooled gas.

Preferably the cooled gas is at a temperature of at most -20°C, more preferably at most -30°C, more preferably still at most -50°C, yet more preferably still at most -75°C, even more preferably at most -100°C, most preferably at most -120°C.

Preferably the cooled gas is at a temperature of at least -200°C, more preferably at least -180°C, more preferably still at least -150°C.

Preferably the cooled gas is nitrogen.

Alternatively the cooled gas is a noble gas.

In a second aspect the present invention provides a process for manufacturing a coated edible receptacle for a frozen confection that uses the apparatus of the first aspect and comprised the steps of:

providing a conveyer 2 containing a plurality of edible receptacle holders 3 arranged perpendicular to direction of movement of the conveyer; then

placing edible receptacles in the plurality of edible receptacle holders 3; then applying a fat-based coating material to the internal surface of the edible receptacles via nozzles 4, said nozzles 4 being arranged to index with the edible receptacles in the edible receptacle holders 3; then

spraying the internal surface of the coated edible receptacles with a gas via a gas- dosing element 5, said gas-dosing element comprising a manifold 6 with at least one gas inlet 7 and a plurality of gas outlets 8, said gas outlets 8 also being arranged to index with the plurality of edible receptacle holders 3.

It will be appreciated that the process uses the apparatus of the first aspect and is therefore also characterised in that

- the gas-dosing element 5 comprises a vacuum jacket 9 around the manifold 6 and further characterised in that

the manifold 6 comprises at least one expansion and contraction buffering zone 10 between the gas outlets 8. Preferably the gas is at a temperature of at most -20°C, more preferably at most -30°C, more preferably still at most -50°C, yet more preferably still at most -75°C, even more preferably at most -100°C, most preferably at most -120°C.

Preferably the gas is at a temperature of at least -200°C, more preferably at least -180°C, more preferably still at least -150°C.

Preferably the edible receptacle is a wafer-based edible receptacle.

Preferably the edible receptacle is a wafer-based cone.

Preferably the edible receptacle is coated with fat-based coating in a total amount of from 2 to 12g, more preferably from 4 to 10g, more preferably still from 6 to 8g.

Preferably the weight ratio of the total amount of the fat-based coating relative to the edible receptacle is from 5:1 to 1 :5.

Preferably the fat-based coating is selected from the group comprising of chocolate, chocolate-based compositions, chocolate analogues, and couvertures. Preferably the melting point of the fat-based coating is from 20°C to 50°C, more preferably from 25°C to 45°C, more preferably still from 30°C to 40°C. Preferably the thickness of the final fat-based coating on the coated edible receptacle is at least 0.5mm, more preferably at least 0.75mm, more preferably still at least 1 mm, most preferably at least 1.5mm.

Preferably the thickness of the final fat-based coating on the coated edible receptacle is at most 5mm, more preferably at most 3.5 mm, more preferably still at most 2.5mm, most preferably at most 2mm.

In a third aspect, the present invention provides a method for prolonging the crispness of edible receptacles for a frozen confection, the method comprising the steps of:

- providing edible receptacles and coating them according to the process of the second aspect.

The invention may also provide a coated edible receptacle produced by the process of the second aspect, or a composite frozen confectionary comprising this coated edible receptacle in combination with a frozen confection such as ice cream.

These and other aspects, features and advantages will become apparent to those of ordinary skill in the art from a reading of the following detailed description and the appended claims. For the avoidance of doubt, any feature of one aspect of the present invention may be utilised in any other aspect of the invention. The word "comprising" is intended to mean "including" but not necessarily "consisting of" or "composed of." In other words, the listed steps or options need not be exhaustive. It is noted that the examples given in the description below are intended to clarify the invention and are not intended to limit the invention to those examples per se. Similarly, all percentages are weight/weight percentages unless otherwise indicated. Except in the operating and comparative examples, or where otherwise explicitly indicated, all numbers in this description indicating amounts of material or conditions of reaction, physical properties of materials and/or use are to be understood as modified by the word "about". Numerical ranges expressed in the format "from x to y" are understood to include x and y. When for a specific feature multiple preferred ranges are described in the format "from x to y", it is understood that all ranges combining the different endpoints are also contemplated. Detailed description of the invention

Frozen confections are consumed as snacks or desserts worldwide and are often served inside edible receptacles. The combination of the frozen confection with the edible receptacle is referred to herein as a composite frozen confection. When eaten along with the frozen confections these edible receptacles provide an enhanced sensorial experience that is highly desired by the consumer. An especially preferred aspect of these edible receptacles is the firm and crisp texture that they impart to composite frozen confection products. Edible receptacles can be made of various materials that provide the desired organoleptic properties, in particular crispiness. Traditionally edible receptacles are made from baked wafer material. An edible receptacle can also be formed from other materials such as pieces of nut and/or biscuit which are held together with a binder such as a sugar based compound.

Although the invention is predominantly focussed on edible receptacles for frozen confections, it may also be employed with other baked dough based food products, such as cookies, biscuits and other baked dough based snacks.

In a preferred embodiment, the edible receptacle is an ice cream cone. Ice cream cones may be made from a batter of wheat flour or refined wheat flour, sugar, edible oil, lecithin and water. Cones can be made by methods known in the art. One method for preparing a cone is by a moulding process. This process includes the steps of depositing the batter into a mould; inserting a core into the mould such that the batter is forced to assume the shape of the cavity provided between the core and the mould; removing the core when the core of the mould is joined with the batter; subjecting the mould to heat for an appropriate length of time and discharging the cones from the mould at the completion of the specified time. Prepared cones are preferably discharged onto a conveyor for trimming, packing, coating, filling, storage and distribution. By this method cones of various shapes including but not limited to conical shapes or cups of various sizes and configurations may be made. Another method of preparing an ice cream cone is by a rolling process. This process includes the steps of depositing the batter between two plates; baking a flat wafer between the plates; transferring the flat wafer sheet to a rolling device; and rolling the flat waffle into a conical shape. Ice cream cones made by this process are sometimes referred to as sugar roll cones.

Such wafer-based edible receptacles may include 45 to 80 wt% wheat flour. Preferred compositions include 48 to 80 wt% wheat flour. More preferred compositions include 50 to 75 wt% wheat flour. Further preferred compositions include 55 to 70 wt% wheat flour, and optimal compositions include 58 to 65 wt% wheat flour. The wafer-based edible receptacles also include 15 to 50% by weight of sugar. Preferred compositions include at least 17 %, more preferably at least 19%, still more preferably at least 21 %, or even at least 25%, but preferably not more than 45%, more preferably not more than 40%, still more preferably not more than 35%, even more preferably not more than 30% by weight of sugar. They may also include 1 to 30 wt% edible oil. Preferred compositions include 1 to 15 wt% edible oil. More preferred compositions include 1 to 8 wt% edible oil. Further preferred compositions include 1 .5 to 6 wt% edible oil. Still further preferred composition include 2 to 5.5 wt% of edible oil, and optimal compositions include 2.5 to 4.5 wt% edible oil. The edible oil may be selected from any of the known sources. Preferably the edible oil is a C12-C18 edible oil. Preferably the edible oil is palm oil or coconut oil. Further, the wafer-based edible receptacles may include 0 to 3 wt% lecithin. Preferred compositions include 0.1 to 2 wt% lecithin. More preferred compositions include 0.2 to 0.8 wt% lecithin. Further preferred compositions include 0.3 to 0.7 wt% lecithin. Still further preferred compositions include 0.35 to 0.65 wt% lecithin, and optimal compositions include 0.4 to 0.6 wt% lecithin. Finally, a wafer-based edible receptacle may include a small amount of water. However, in order to keep the cone crispy during storage, it is preferred that the edible receptacle is substantially free of water. By substantially free of water is meant not more than 3%, more preferably not more than 2%, still more preferably not more than 1 %, even more preferably not more than 0.5%, yet more preferably not more than 0.2%, or even less than 0.1 % by weight of water.

Optional ingredients for wafer-based edible receptacles include caramel which acts as a colouring agent when added to the edible receptacle. It is an amorphous, dark-brown material that has been produced by the carefully controlled heat treatment of saccharine materials such as dextrose, invert sugar, lactose, malt syrup, molasses, sucrose, starch hydrolysates and fractions thereof, etc. The heavy-bodied, almost black syrup contains colour components that impart the amber shade found in carbonated beverages, pharmaceutical and flavouring extracts, candies, soups, bakery products, and numerous other foods. When caramel is present the edible receptacle preferably includes about 0.2 wt% of caramel. A wafer-based edible receptacle cone may also preferably include salt. Preferred salt is sodium chloride. When present the cone preferably includes about 0.2 wt% of salt. Although the cone format is particularly preferred an edible receptacle may also be provided in a range of other different shapes and sizes such as cups and shells. The edible receptacle can also be a flat waffle-type sheet such as those used in "sandwich"- like products. These waffle-type sheets can be coated at least over the area of the sheet that would otherwise come into contact with a frozen confection.

Fat-based coatings are commonly used in an attempt to create a barrier between the edible receptacle and the frozen confection it contains. Such fat-based coatings include chocolate, chocolate-based compositions, chocolate analogues, and couvertures. The term chocolate as used herein includes dark chocolate and milk chocolate. The term chocolate analogue means chocolate-like fat-based confectionery compositions made with fats other than cocoa butter (for example cocoa butter equivalents, coconut oil or other vegetable oils). Such chocolate analogues are sometimes known as couvertures. Chocolate analogues need not conform to standardized definitions of chocolate which are used in many countries. In addition to fat and cocoa solids, chocolate and chocolate analogues may contain milk solids, sugar or other sweeteners and flavourings.

These fat-based coatings will typically have a melting point of about 30-40°C and are therefore solid at room temperature and so are also solid under the conditions and temperatures at which frozen confections are dosed into edible receptacles and at which the coated edible receptacles are stored either in an empty state or having been filled with a frozen confection. The term 'frozen confection' means an edible composition made by freezing a mix of ingredients which includes water. Frozen confections include ice cream, water ice, frozen yoghurt and the like. Frozen confections typically contain fat, non-fat milk solids and sugars, together with other minor ingredients such as stabilisers, emulsifiers, colours and flavourings.

With reference to Figure 1 , the apparatus (1 ) of the invention is capable of coating multiple edible receptacles simultaneously. The apparatus (1 ) has a conveyer (2) which can be of any suitable form such as a belt or a series of moving plates and which moves in the direction of the arrow shown. The conveyer (2) has a plurality of edible receptacle holders (3) set into it. These can be in the form of simple apertures which correspond to the shape of the edible receptacles to be held in them, or more complex structures as required. An optional feederfor the edible receptacles is also shown in Figure 1 upstream of nozzles (4), but the edible receptacles themselves are not shown in Figure 1 for the sake of clarity.

As can be seen, the plurality of edible receptacle holders (3) are arranged perpendicular to the direction of movement of the conveyer (2) and a plurality of nozzles (4) for applying a fat-based coating material to the internal surface of edible receptacles are then provided. These nozzles (4) are arranged to index with the plurality of edible receptacle holders (3), that is to say that they are positioned such that as the conveyer (2) moves forward, each edible receptacle will be positioned directly underneath its respective nozzle (4) such that the internal surface of the edible receptacles is fully and accurately coated with the fat-based coating material. The nozzles (4) may be of a suitable configuration known to the skilled practitioner and are capable of distributing a fat-based coating across at least part of the interior of the edible receptacle. Typically the fat-based coating will be heated such that it is molten and flowable whereupon it is then applied by projecting it from the nozzles (4) at pressure onto the surface of the edible receptacle that a frozen confection would otherwise come into contact with. The nozzle sprays the internal surface of the edible receptacle in a manner akin to spray painting.

Downstream from the plurality of nozzles (4) is a gas-dosing element (5). This gas-dosing element (5) is provided in order to spray the internal surface of coated edible receptacles with a gas in order to set the fat-based coating and ensure it functions properly as a barrier. The gas can be cooled by suitable means such as extracting the gas direct from a refrigerating apparatus or by running the gas through a coil immersed in a cooling medium such as liquid nitrogen or a liquid noble gas. In an alternative embodiment a liquefied gas could be the fed into the gas-dosing element (5) through the inlet (7) and would exit the gas outlets (8) as a gas.

In certain embodiments, the cooled gas can be at a temperature of at most -20°C, more preferably at most -30°C, more preferably still at most -50°C, yet more preferably still at most -75°C, even more preferably at most -100°C, most preferably at most -120°C. The cooled gas is at a temperature of at least -200°C, more preferably at least -180°C, more preferably still at least -150°C.

With reference to Figures 2 and 3, due to the use of cooled gases the gas-dosing element (5) employs a vacuum jacket (9) around the manifold (6) in order to prevent the external atmosphere, which is typically at ambient temperature, from heating up the cooled gases.

The gas outlets (8) are arranged to index with the plurality of edible receptacle holders (3), that is to say that they are positioned such that as the conveyer (2) moves forward, the edible receptacles will be positioned directly underneath their respective gas outlet ensuring that the gas is directed into the coated edible receptacle. As mentioned above, frozen confection production lines have very narrow and specific engineering tolerances and the introduction of cooling fluid streams, especially cryogenic gases such as liquid nitrogen may cause problems. In the case of the present apparatus the introduction of the cooled gases will radically change (i.e. lower) the temperature of the gas-dosing element (5), especially the manifold (6). As a consequence the manifold will contract in size and even small variations caused by temperature will inevitably effect the performance of the apparatus and hence the quality of the product produced. Without wishing to be bound by theory, it is believed that as a cooled gas enters the gas-dosing element (5), the structure contracts and as a consequence the gas outlets (8) that were arranged to index exactly with the edible receptacle holders (3) will move and no longer be in the correct position. For example, the entire structure of the gas-dosing element (5) may shrink, the gas outlets (8) will move towards the centre and therefore will misalign to the edible receptacle holders (3). Alternatively the gas-dosing element (5) could contract inconsistently along its axes resulting in warping and twisting of the structure and again the gas outlets (8) will no longer be in the correct position. All of these issues ultimately cause the incorrect application of the gas to the coated edible receptacles and therefore the resultant products will have defective barrier properties. It also places stress and strain upon the apparatus, leading to mechanical failure.

It has surprisingly been found that if the manifold (6) comprises at least one expansion and contraction buffering zone (10) between the gas outlets (8) then the foregoing issues are addressed.

This expansion and contraction buffering zone (10) functions to absorb the effects of contraction when the gas is passed through the gas-dosing element (5) and then allows the structure to return to its original configuration when the gas flow finishes. Similarly, under conditions of extreme temperatures, for example in factories in hot climates, the buffering zone (10) also prevents the negative impacts of expansion of the gas-dosing element (5) structure.

The expansion and contraction buffering zone (10) can be of any suitable configuration. For example, it can be of a different material that is not as prone to expansion and contraction as the rest of the manifold and that is sufficiently plastic or deformable to absorb the expansion or contraction of the rest of the manifold (6). Alternatively, the buffering zone (10) could be an area of the manifold (6) that has a telescoping slide mechanism that varies in length to absorb the expansion or contraction of the rest of the manifold (6), akin to the slider on a trombone.

Preferably the expansion and contraction buffering zone (10) is in the form of at least one annular ring that is contiguous with the manifold, preferably an integral part of the manifold (6) and that either protrudes from (Figure 4) or intrudes into (Figure 5) the manifold (6). In this form, the whole manifold can be manufactured from the same material, with no requirement for complex seals between the different materials, which is advantageous in a system that employs pressurised gases. Where the annular ring protrudes, it may protrude from the manifold by at most 50% of the diameter of the non-protruded part of manifold adjacent to the protrusion, preferably at most 40%, more preferably at most 30%, more preferably still at most 20%, yet more preferably at most 15%, yet more preferably still at most 10%. The annular ring may protrude from the manifold by at least 1 % of the diameter of non-protruded part of manifold adjacent to the protrusion, preferably at least 2%, more preferably at least 5%, more preferably still at least 7.5%, yet more preferably at least 10%, yet more preferably still at least 15%. Where the annular ring intrudes, it may intrude into the manifold by at most 20% of the diameter of the non-intruded part of manifold adjacent to the intrusion, preferably at most 17.5%, more preferably at most 15%, more preferably still at most 12.5%, yet more preferably at most 10%. The annular ring may intrude into the manifold by at least 1 % of the diameter of the non-intruded part of manifold adjacent to the intrusion, preferably at least 2%, more preferably at least 3%, more preferably still at least 4%, yet more preferably at least 5%, yet more preferably still at least 7.5%.

A single annular ring may be used as shown in Figures 1 to 5. Alternatively, multiple rings may be used as shown in Figure 6. The rings may have a wave like structure as exemplified in Figure 6 or a peaked structure as exemplified in Figure 7. Where multiple rings are used the structure of the expansion and contraction buffering zone (10) can be shaped into a series of substantially parallel rings to form an area of corrugation having ridges and grooves running around the manifold (6). In use, the apparatus provides the second aspect the invention. A coated edible receptacle for a frozen confection is manufactured using the above apparatus as follows. A conveyer (2) is provided with a plurality of edible receptacle holders (3) arranged perpendicular to direction of movement of the conveyer (2) and edible receptacles are placed in the edible receptacle holders (3). A fat-based coating material is applied to the internal surface of the edible receptacles via nozzles (4). These nozzles (4) are arranged to index with the edible receptacles in the edible receptacle holders (3). In one embodiment, the edible receptacle is coated with fat-based coating in a total amount of from 2 to 12g, more preferably from 4 to 10g, more preferably still from 6 to 8g. The weight ratio of the total amount of the fat-based coating relative to the edible receptacle can be from 5:1 to 1 :5. The fat-based coating may be selected from the group comprising of chocolate, chocolate-based compositions, chocolate analogues, and couvertures. The melting point of the fat-based coating is typically from 20°C to 50°C, more preferably from 25°C to 45°C, more preferably still from 30°C to 40°C. When coated, the thickness of the final fat-based coating on the coated edible receptacle may be at least 0.5mm, more preferably at least 0.75mm, more preferably still at least 1 mm, most preferably at least 1.5mm and may be at most 5mm, more preferably at most 3.5 mm, more preferably still at most 2.5mm, most preferably at most 2mm.

Once coating has taken place, the internal surface of the coated edible receptacle is then sprayed with a gas via a gas-dosing element (5), said gas-dosing element (5) comprising a manifold (6) with at least one gas inlet (7) and a plurality of gas outlets (8). Preferably the cooled gas is at a temperature of at most -20°C, more preferably at most -30°C, more preferably still at most -50°C, yet more preferably still at most -75°C, even more preferably at most -100°C, most preferably at most -120°C. Preferably the cooled gas is at a temperature of at least -200°C, more preferably at least -180°C, more preferably still at least -150°C. In an alternative embodiment a liquefied gas could be the fed into the gas-dosing element (5) through the inlet (7) and would exit the gas outlets (8) as a gas.

As described above, the gas outlets (8) are arranged to index with the plurality of edible receptacle holders (3). The gas-dosing element (5) is provided with a vacuum jacket (9) around the manifold (6) to ensure that the gas is not affected by the external ambient conditions.

Figure 8 shows a schematic of the apparatus of the invention in which the manifold (6) is shown in silhouette and the vacuum jacket is not shown for the sake of clarity. Figure 8a shows that, prior to use, the manifold (6) is in its normal state at ambient temperature and the expansion and contraction buffering zones (10) are relatively narrow - in this representation the triangular profile of the annular rings are narrow at the base. The gas outlets (8) are still positioned over the edible receptacles (in this case, cones). Figure 8b shows that when the cooled gas is introduced into the gas dosing element the manifold (6) drops in temperature and contracts. The expansion and contraction buffering zones (10) have now expanded to compensate for the contraction of the rest of the manifold - in this representation the triangular profile of the annular rings is now much wider at the base. Nevertheless, it can readily be seen that although the overall structure of the manifold (6) has dramatically changed, the gas outlets (8) are still positioned exactly over the cones.

In contrast, Figure 9 shows that in the absence of any expansion and contraction buffering zones the gas outlets (8) will move as the rest of the manifold (6) contracts and will be incorrectly positioned. As a consequence the fat-based coating in the cones will not be properly formed into a barrier and may even be damaged.

As noted above, although the use of fat-based coatings in edible receptacles for frozen confections has been known for some time it is not a perfect solution and the organoleptic properties of the edible receptacles still degrade over time, in particular the crispness of the edible receptacle is lost despite the application of the protective layer. However, it has surprisingly been found that the use of an apparatus and process as described above that employs at least one expansion and contraction buffering zone is capable of enhancing the ability of the fat-based coating to maintain the required crispness of the edible receptacle. Therefore, the present invention makes use of the surprising finding that even if typical fat-based coatings are used and even if the same amount of the fat- based coating is used (i.e. there is no need to use excess amounts which could detract from the consumer acceptance of the product and would add extra cost and unhealthy ingredients) then the edible receptacle that is coated with the fat-based coating using the apparatus and process of the present invention will actually maintain the critical organoleptic properties for longer.

The invention therefore provides a coated edible receptacle with improved properties as described above. After coating, the coated edible receptacle can be stored in its empty state or filled with a frozen confection such as ice cream and optionally topped with a sauce, nuts, chocolate pieces or the like to provide a composite frozen confectionary product that can then be stored prior to distribution to the point of sale. Moreover, the apparatus of the invention has been used under typical manufacturing conditions wherein the cooled gas is sprayed for a certain period of time, thus cooling the apparatus and causing contraction. At the end of this period, the cooled gas flow is stopped and the apparatus expands back to its original state. Although this cycle of expansion and contraction was repeated many times, it was found that the apparatus of the invention could be used without issue under such conditions without failure and provided good quality coated edible receptacles with good barrier properties. In contrast, a similar apparatus without the expansion and contraction buffering zones was found to fail after a small number of expansion and contraction cycles due to weld fracture and other mechanical failures.

As has been outlined above, the process of the invention can be used for the production of coated edible receptacles that are resistant to changes in their organoleptic properties, specifically crispness. This invention therefore also provides a method for prolonging the crispness of an edible receptacle for a frozen confection. Through the use of this method it has been found that the organoleptic properties of coated edible receptacles are maintained for longer than coated edible receptacles prepared using apparatus that does not have expansion and contraction buffering zones.

Claims

1. An apparatus (1 ) for coating multiple edible receptacles simultaneously, the apparatus comprising:

a conveyer (2) containing a plurality of edible receptacle holders (3) arranged perpendicular to the direction of movement of the conveyer (2) a plurality of nozzles (4) for applying a fat-based coating material to the internal surface of edible receptacles, said nozzles (4) being arranged to index with the plurality of edible receptacle holders (3)

a gas-dosing element (5) for spraying the internal surface of coated edible receptacles with a gas, said gas-dosing element (5) comprising a manifold (6) with at least one gas inlet (7) and a plurality of gas outlets (8), said gas outlets (8) also being arranged to index with the plurality of edible receptacle holders (3)

characterised in that

the gas-dosing element (5) comprises a vacuum jacket 9 around the manifold (6)

and further characterised in that

the manifold (6) comprises at least one expansion and contraction buffering zone (10) between the gas outlets (8).

2. An apparatus according to claim 1 wherein the at least one expansion and contraction buffering zone (10) comprises at least one annular ring that protrudes from the manifold (6).

3. An apparatus according to claim 2 wherein the annular ring protrudes from the manifold (6) by from at least 1 % to at most 50% of the diameter of non-protruded part of manifold adjacent to the protrusion.

4. An apparatus according to any of claims 1 to 3 wherein the gas inlet (7) is in gas communication with a source of cooled gas.

5. An apparatus according to any of claims 1 to 4 wherein the cooled gas is nitrogen.

6. A process for manufacturing a coated edible receptacle for a frozen confection using the apparatus of any of claims 1 to 5 comprising the steps of:

providing the conveyer (2) containing the plurality of edible receptacle holders (3) arranged perpendicular to direction of movement of the conveyer; then

placing edible receptacles in the plurality of edible receptacle holders (3); then

applying a fat-based coating material to the internal surface of the edible receptacles via nozzles (4), said nozzles (4) being arranged to index with the edible receptacles in the edible receptacle holders (3); then spraying the internal surface of the coated edible receptacles with a gas via the gas-dosing element (5), said gas-dosing element comprising manifold (6) with at least one gas inlet (7) and a plurality of gas outlets (8), said gas outlets (8) also being arranged to index with the plurality of edible receptacle holders (3).

7. A process according to claim 6 wherein the gas is at a temperature of from at least -200°C to at most -20°C.

8. A process according to claims 6 or 7 wherein the edible receptacle is a wafer- based edible receptacle.

9. A process according to any of claims 6 to 8 wherein the edible receptacle is a cone.

10. A process according to any of claims 6 to 9 wherein the edible receptacle is coated with fat-based coating in a total amount of from 2 to 12g.

1 1 . A process according to any of claims 6 to 10 wherein the weight ratio of the total amount of the fat-based coating relative to the edible receptacle is from 5:1 to 1 :5.

12. A process according to any of claims 6 to 1 1 wherein the thickness of the final fat-based coating on the coated edible receptacle is at from least 0.5mm to at most 5mm.

13. A method for prolonging the crispness of edible receptacles for a frozen confection, the method comprising the steps of:

providing edible receptacles and coating them according to the process of any of claims 6 to 12.