Method for producing fatty confectioneries having three-dimensional decoration deposited thereon

A method for producing fatty confectioneries having three-dimensional decoration deposited thereon comprising the steps of providing a mold having three-dimensional recesses in design, pattern and/or letter configuration, placing a plate mold having through holes corresponding to said recesses in configuration and position on said mold, spraying decorative fatty confectionery material in the form of fine particles into said recesses through said through holes, removing said plate mold from the mold, pouring base fatty confectionery material into said mold over said decorative fatty confectionery material, cooling said mold to cool and solidify said base and decorative fatty confectionery material and removing the resulting confectionery from said mold.

BACKGROUND OF THE INVENTION 
This invention relates to a method for producing fatty confectioneries such 
as chocolate products having attractive three-dimensional decoration in 
design, pattern and/or letter configuration deposited thereon. 
The fatty confectioneries having three-dimensional decoration in design, 
pattern and/or letter configuration deposited thereon as mentioned above 
have been conventionally produced by preparing a base confectionery having 
a desired shape and depositing a fatty confectionery material having a 
color tone different from that of the base confectionery material such as 
white, red, yellow or orange or any combination of them on the base 
confectionery material. The decorative fatty confectionery material may be 
chocolate or its substitute fatty material having a different color tone 
from that of the base fatty confectionary material. 
For producing the fatty confectioneries referred to above, the squeezing 
method (1), the casing method (2), the stencilling method (3), the 
printing method (4) and the scraping method (5) have been generally 
utilized. 
(1) The squeezing method 
In this method, a compressible bag formed of cloth or paper and having a 
nozzle attached to one end thereof is filled with a fatty confectionery 
material in a fluid state having a different color tone from that of the 
base fatty confectionery material on which the decoration material is to 
be deposited and the bag is manually compressed down to extrude the fatty 
confectionery material through the nozzle in the form of rope or spot onto 
the selected area of the base fatty confectionery material so as to form a 
decorative design, pattern and/or letter configuration on the base fatty 
confectionery material. This method has been widely employed in the art. 
However, the design, pattern and/or letter configuration formed by this 
method tends to become a monotonous decoration such as one stroke writing. 
In addition, when the decorative fatty confectionery material is extruded 
in the form of rope, portions of the extruded rope tend to lie one above 
the other and thus, this method is not suitable for forming 
three-dimensional design, pattern and/or letter having a complex and fine 
configuration and an acute angle as obtainable by the method of the 
present invention. 
(2) The casting method 
In this method, a chocolate mold having decorative design, pattern and/or 
letter configurations engraved therein is provided, a decorative fatty 
confectionery material in a fluid state having a different color tone from 
that of the base fatty confectionery material is poured into the recesses 
defined by the engraved design, pattern and/or letter configurations in an 
amount only sufficient to fill up the recesses, the base fatty 
confectionery material in a fluid state is then poured into the mold over 
the decorative fatty confectionery material before the decorative fatty 
confectionery material solidifies to allow the base material and 
decorative material to unite together, the thus obtained confectionary 
product is cooled to solidify and finally, the solidified confectionary 
product is removed from the mold. This method is disclosed in Japanese 
Utility Model Appln. Publication No. 29401/1969 for "Picture-Framed 
Chocolate", for example. 
According to this method, although the decorative fatty confectionery 
material in a fluid state is poured into the recesses defined by the 
design, pattern and/or letter configuration engraved in the forming mold 
in an amount just sufficient to fill up the recesses and the mold is 
vibrated so as to distribute the decorative confectionery material 
uniformly within the recesses, since the base fatty confectionery material 
such as chocolate to be decorated by the decorative fatty confectionery 
material generally has a high viscosity and a low fluidity even in a fluid 
state, the base fatty confectionery material can not be easily distributed 
uniformly within the recesses. Thus, in this method, the decorative fatty 
confectionery material is employed to be formed only in such chocolate 
molds as having a design, pattern and/or letter engraved therein having a 
relatively monotonous and coarse configuration and an obtuse angle and 
thus, this method is not applicable to the production of three-dimensional 
decorative fatty confectioneries comprising a base fatty confectionery 
material decorated with a fatty confectionery material deposited thereon 
in a three-dimensional design, pattern and/or letter having a complex and 
fine configuration and an acute angle. 
(3) The stencilling method 
In this method, a stencil having through holes or slits in the shape of a 
design, pattern and/or letter is placed over a cooled and solidified 
chocolate product to define recesses by the through holes or slits and the 
upper surface of the chocolate product, a decorative fatty confectionery 
material is filled in the recesses, any excess amount of the decorative 
fatty confectionery material which overflows the recesses is scraped off 
by the use of a scraper, the stencil is removed from the thus decorated 
chocolate product and the decorated chocolate product is cooled to 
solidify. 
In this method, since the excess decorative fatty confectionery material 
overflowing the through holes or slits in the stencil is removed and at 
the same time, the decorative fatty confectionery material is subjected to 
pressure which forces the material into the slits, the decorative fatty 
confectionery material can be satisfactorily filled in the recesses even 
they have complex, minute and acute-angled design, pattern and/or letter 
configurations and the decorative fatty confectionery material remains in 
the recesses in an amount corresponding to the total volume of the through 
holes or slits to thereby form a three-dimensional decorative area on the 
chocolate product. 
However, in this method, the shape of the through holes or slits to be 
provided in the stencil is subjected to limitations. When the stencil is 
formed with annular through holes or slits, it is necessary to form a 
plurality of bridge portions connecting the areas surrounded by the 
respective annular through holes or slits and the stencil matrix and thus, 
when the decorative fatty confectionery material is actually stencilled, 
there is the disadvantage that the formed design, pattern and/or letter 
decoration contains discontinuous portions therein. In addition, there are 
the disadvantages that the scraping of the excess decorative fatty 
confectionery materials roughens the surface of the decorative fatty 
confectionery material deposited on the chocolate-product and that the 
decorative fatty confectionery material surface becomes lustreless. 
In order to eliminate the disadvantages inherent in this stencilling 
method, it has been proposed a method in which a stencil having a 
configuration adapted to be fitted in a mold and through holes having a 
design, pattern and/or letter configuration is fitted in the mold to 
define recesses by the inner surface of the bottom of the mold and the 
through holes, the decorative fatty confectionery material is stencilled 
by the use of a scraper and deposited on the inner surface of the bottom 
of the mold in the shape corresponding to that of the through holes, the 
stencil is then removed from the mold, a base fatty confectionery material 
in a fluid state is poured into the forming mold and finally, the base and 
decorative fatty materials are cooled to solidify in the conventional 
manner. In this way, the surface of the formed decorative fatty 
confectionery material is imparted lustre thereto. However, in such a 
case, the decorative fatty confectionery material deposited on the bottom 
inner surface of the mold and the base fatty confectionery material poured 
into the mold over the decorative fatty confectionery material lie in 
substantially the same plane and the obtained fatty confectionery will 
rather have a flattened decorative area than an intended three-dimensional 
decorative one. 
(4) The printing method 
In this method, a cooled and solidified fatty confectionery such as 
chocolate is directly printed thereon an edible decorative fatty material 
such as edible ink in the form of a design, pattern and/or letter by the 
use of a screen. In another method, as shown in Japanese Patent Appln. 
Publication No. 6156/1967 for "Method and Apparatus for Confectioneries 
Having Design Printed Thereon", an edible ink is printed in a design on a 
plastic film or on the inner surface of a mold, a fatty confectionery 
material such as chocolate in a fluid state is poured onto the plastic 
film or into the mold, and the confectionery material is cooled to 
solidify to thereby transfer the design ink onto the confectionery 
material resulting in a confectionery having the design thereon. 
By this method, although it is possible to print the fatty confectionery 
with a design, pattern and/or letter in a desired fine configuration, 
since the printed design, pattern and/or letter lies in substantially the 
same plane as the base chocolate or confectionery and lacks 
three-dimensional appearance. In addition, because an edible ink is 
different in nature from the fatty confectionery such as chocolate, the 
ink will possibly spoil the flavour of the chocolate. 
(5) The scraping method 
As shown in Japanese Patent Appln. Publication No. 2254/1980 for "Method 
for Forming Confectionery Having Design", for example, in the scraping 
method, (i) a flat plate mold having decoration recesses engraved in the 
upper surface thereof having a design, pattern and/or letter is provided, 
an edible decorative fatty confectionery material in a fluid state is 
poured into the recesses and any excess amount of the material overflowing 
the recesses is removed by a scraper or the like or (ii) a second flat 
plate mold having through holes corresponding to the recesses in the 
first-mentioned flat plate mold in configuration and position is placed on 
the first plate mold, an edible decorative fatty confectionery material in 
a fluid state is poured into the aligned through holes and recesses in the 
two plate molds with the recesses and through holes in alignment, a frame 
mold is placed on the second plate mold surrounding the area of the plate 
mold where the through holes are present, a base fatty confectionery 
material in a fluid state is poured into the frame mold, the base and 
decorative material are cooled in the conventional manner to solidify 
them, and finally, the solidified fatty confectionery is removed from the 
frame mold. 
In the two alternate scraping methods described above, it is possible to 
stencil the edible decorative fatty material into the fine engraved 
decoration deposition area of the plate mold containing the decoration 
deposition recesses under pressure and upon the cooling and solidification 
of the obtained fatty confectionery, the edible decorative fatty material 
deposited on the base fatty confectionery material will have the lustrous 
surface and the obtained confectionery will have a fine three-dimensional 
appearance. 
However, in the method (i) disclosed in Japanese Patent Appln. Publication 
No. 2254/1980, the removal of the excess amount of the fluidal edible 
decorative fatty material overflowing the engraved recesses in the first 
flat plate mold requires an additional operation by the use of a scraper 
or the like and the scraping operation is applicable to only flat or 
substantially flat surface areas and if the flat mold plate has intricate 
concaves and convexes and/or engraved recesses having fine 
three-dimensional configurations, when a base fatty confectionery material 
such as chocolate having a high viscosity is formed by the use of such a 
plate mold, the confectionery material is difficult to be distributed to 
all the corners of the recesses and accordingly, after the cooling and 
solidification, the obtained confectionery will have defects therein. 
In the method (ii) referred to hereinabove, although the fluidal decorative 
fatty material is poured into the engraved recesses in the first flat 
plate mold through the through holes in the second plate mold disposed on 
the first plate mold, in such a case, the decorative material tends to 
build up over the engraved recesses above the upper surface of the first 
plate mold by the presence of the second plate mold over the recesses and 
the spaces defined between the bulges are narrow. Thus, when the first 
plate mold having the fine design, pattern and/or letter engraved therein 
and the second plate mold having the through holes corresponding to the 
recesses in shape and position are employed in the manner mentioned above, 
since the base fatty confectionery material to be poured into the recesses 
through the through holes has a high viscosity and a low fluidity as 
mentioned hereinabove, the base confectionery material may not enter the 
narrow spaces. Thus, after the cooling and solidification, the obtained 
fatty confectionery will contain voids caused by the absence of the base 
fatty material in the spaces and the voids impair the value of the 
confectionery as a commercial article. 
Furthermore, if the engraved design, pattern and/or letter recesses are 
shallow and have a small area and thus, the adhesion power of the 
decorative fatty material to the recesses is insufficient, when the 
decorative fatty material is poured through the through holes in the 
second plate mold into the engraved recesses in the first plate mold and 
the second plate mold is separated from the first plate mold, the adhesion 
power of the decorative fatty material to the engraved recesses is 
overcome by the adhesion power of the decorative fatty material to the 
walls of the through holes and the undersurface of the second plate mold 
and thus, there is the disadvantage that a portion or the whole of the 
decorative fatty material is separated from the first plate mold as the 
second plate mold is separated from the first plate mold. 
Furthermore, in the method (ii) referred to hereinabove, when the excess 
amount of the decorative fatty material overflowing the engraved recesses 
in the plate mold is removed by the use of a scraper or the like, the base 
fatty confectionery material with high viscosity and adhesion power such 
as chocolate is not wholly scraped off but remains on the upper surface of 
the first plate mold in a thin layer. And when the frame mold is disposed 
on the upper or second plate mold surrounding the decoration through holes 
in the plate mold and the base fatty confectionery material such as 
chocolate is poured through the through holes in the upper plate mold into 
the recesses in the lower plate mold followed by the cooling and 
solidification of the united decorative and base fatty confectionery 
material, the decorative fatty material adheres to the adjacent surface of 
the base fatty confectionery material in a thin layer. In this case, if 
the decorative fatty material has a light color whereas the base fatty 
confectionery material has a dark color such as the color of ordinary 
chocolate, the thin layer of the decorative fatty material is not so 
conspicuous. However, if the base fatty confectionery material is white 
chocolate with a light color and the edible decorative fatty material is 
ordinary chocolate with a dark color, the thin layer of the decorative 
fatty material is conspicuous. When the decorative fatty material is so 
called non-tempered chocolate which uses non-lauric hard butter containing 
from 30 to 50% by weight of trans-form mono double bonded unsaturated acid 
the cacao butter in the base chocolate and the fat in the decorative fatty 
chocolate melt together and when the cacao butter content in the fat 
exceeds 40% by weight based on the total weight of the fat, the 
characteristic of non-tempered chocolate is lost and the non-tempered 
chocolate exhibits a polymorphism phenomenon to generate a white 
powder-coated like fat bloom. The non-tempered chocolate which is not 
perfectly scraped off but remains to adhere to the base chocolate in a 
thin layer contains non-tempered fat in a reduced ratio and an increased 
ratio of cacao butter. Thus, a marked fat bloom occurs to reduce the 
commercial value of the chocolate product substantially. And when ordinary 
chocolate is used as the decorative fatty material and non-tempered 
chocolate is employed as the base fatty confectionery material, variation 
in the combination of the decorative fatty material and base fatty 
confectionary material is likewise limited to a narrow range. 
SUMMARY OF THE INVENTION 
Therefore, the present invention is to provide a method for producing fatty 
confectionery which effectively eliminate the disadvantages inherent in 
the prior methods referred to hereinabove. 
The purpose of the present invention is to provide a method for producing 
fatty confectioneries such as chocolate products having decorative fatty 
material deposited thereon in fine and acute-angled three-dimensional 
design, pattern and/or letter configuration containing intricate concaves 
and convexes. According to the present invention, there has been provided 
a method for producing fatty confectioneries comprising the steps of 
providing a mold having a plurality of decoration deposition recesses 
having desired design, pattern and/or letter configuration for depositing 
a decorative three-dimensional fatty confectionery material on a base 
fatty confectionery material, placing a plate mold having a plurality of 
through holes corresponding to said recesses in shape and position on the 
mold with the through holes in alignment with the recesses, spraying a 
fluid decorative fatty confectionery material in the form of fine 
particles through said through holes into said recesses to deposit said 
decorative fatty material in said recesses, removing said plate mold from 
the mold, pouring a base fatty confectionery material having a different 
color tone from said decorative fatty confectionery material into said 
mold, cooling and solidifying said base and decorative fatty confectionery 
material combination and removing the solidified fatty confectionery from 
said mold having fine and acute-angled three-dimensional decorative fatty 
confectionery material deposited on the confectionery. 
The above and other objects and attendant advantages of the present 
invention will be more readily apparent to those skilled in the art from a 
reading of the following detailed description in conjunction with the 
accompanying drawings which show apparatus for use in carrying out the 
present invention for illustration purpose only, but not for limiting the 
scope of the invention in any way.

PREFERRED EMBODIMENT OF THE INVENTION 
The present invention will be now described referring to the accompanying 
drawings and more particularly, to FIGS. 1 through 5 thereof in which a 
representative apparatus for use in carrying out the present invention are 
shown. 
Reference numeral 1 denotes a mold the bottom inner surface of which is 
formed with a plurality of similar recesses 2. The recesses 2 are in the 
form of a design, pattern and/or letter and have a width of at least 0.5 
millimeters and preferably, 1 millimeter and a suitable depth within a 
range for allowing molded goods to be removed. A plate mold 4 is disposed 
over the mold 1 and secured to the mold 1 by means of set bolts 14 which 
in turn secure the mold assembly 1, 4 to a support framework 15. The plate 
mold 4 is formed with a plurality of through holes 3 substantially 
corresponding to the recesses 2 in configuration (as seen in plan) and 
position. Decorative fatty confectionery material in a fluid state is 
sprayed in the form of fine particles through the through holes 3 of the 
plate mold 4 into the recesses 2 of the mold 1 to deposit in the recesses 
by the use of a spray device of which description will be made 
hereinafter. While the spray device is spraying the decorative fatty 
confectionery material, the spray device is moved along rails 16, 16 by 
means of the wheels 12, 12 at the bottom of the spray device to fill the 
successive recesses 2 in consecutive order with the decorative fatty 
confectionery material so as to cause the material to deposit uniformly in 
the recesses 2. The size of the decorative fatty material particles should 
be substantially smaller than the cross-section area of the openings of 
the recesses 2 of the mold 1 and through holes 3 of the plate molds 4. 
Otherwise, the decorative fatty material particles tend to adhere to the 
edges and/or the walls of the through holes 3 of the plate mold 4 and/or 
the side faces of the recesses 2 in the mold 1 to clog the openings of the 
holes 3 and/or recesses 2 to thereby block the arrival and deposition of 
the succeeding decorative material particles resulting in a reject having 
defects such as voids. 
And when the decorative fatty material which may be ordinary chocolate or 
white chocolate is to be sprayed, if the temperature of the material is 
substantially high, .beta.-type crystal nuclei in the cacao butter melt to 
nullify the tempering effects of the pre-tempered decorative fatty 
material or chocolate and as a result, the volume contraction does not 
occur in the deposited decorative fatty material when the fatty 
confectionery having the decorative fatty material deposited thereon is 
cooled and solidified to thereby make it difficult to release the 
resulting fatty confectionery from the mold and the confectionery product 
will be disposed as a reject. In addition, after the mold release, the 
fatty confectionery will have the lustress surface and the so-called fat 
bloom occurs to impair the commercial value of the fatty confectionery. 
Therefore, excess rise in the temperature of the decorative fatty 
confectionery material at the time of spraying should be avoided. 
As one of the conventional methods for spraying fatty confectionery 
materials, the spray-under-pressure method has been known and according to 
this method, the fatty confectionery material is sprayed under pressure 
into air at high speed through a small diameter nozzle which atomizes the 
material. Although this method is applicable when the viscosity of the 
fatty confectionery material is on the order of several hundred 
centipoises, the fatty confectionery material exhibiting this order of 
viscosity is one which contains at least 80% by weight of cacao butter or 
combined cacao butter and vegetable fat based on the total weight of the 
fatty material. Such a high fat confectionery material is only a specific 
fatty confectionery material which is used as the primary coating for the 
center of the chocolate with liquid center. Such high fat content in 
chocolate naturally dilutes the chocolate and is not desirous because the 
fat substantially impairs the flavor of the chocolate. An ordinary 
chocolate containing 50-65% by weight of solids such as sugar, powdered 
milk and others based on the total weight of the chocolate will have the 
viscosity on the order of 20,000-30,000 centipoises or higher at 
28.degree.-29.degree. C. after the screening through a 325 mesh sieve and 
tempering depending upon the particle size and the temperature of the 
chocolate, and because of a high inner friction resistance in the nozzle 
orifice, it is impossible to spray a high viscosity fatty confectionery 
material having a high viscosity such as chocolate in the form of fine 
particle at a high speed by the spray-under-pressure method and thus, this 
method is not suitable for spraying such a high viscosity fatty 
confectionery material. 
On the other hand, although the two fluid nozzle spray method utilizing air 
or other gas is applicable to the spray of a fatty confectionery material 
such as chocolate having the viscosity on the order of 20,000-30,000 
centipoises, because of the high viscosity, the particle size of the fatty 
confectionery material provided by the method will exceed 1 millimeter in 
diameter, and when the material is sprayed into the mold at a short 
distance therefrom, since a substantial amount of air or other gas 
carrying the particles of the fatty confectionery material therein and 
issuing at a high speed from the nozzle tend to blow off the previously 
sprayed and deposited fatty confectionery material particles deposited in 
the recesses in the mold as will be described in connection with the 
present invention hereinafter. 
One method for spraying decorative fatty confectionery material such as 
chocolate is shown in FIGS. 1 and 2. As shown in these Figures, when 
decorative fatty material 7 in a fluid state is fed through a feed conduit 
6 to a rotary member 5 of truncated conical cross-section, the material 7 
is centrifugally uniformly spread over the inner surface of the rotary 
member 5 by the rotation of the member 5 and then flied off the outer edge 
8 to become fine particles. The rotary member 5 is hollow and rotated by a 
high speed motor 10 operatively connected to the rotary member 5. By the 
spray method, even if the decorative fatty material has a high viscosity 
on the order of 90,000 cps which could not be sprayed by the conventional 
methods referred to hereinabove, the material can be sprayed into fine and 
substantially uniform particles of 0.5 mm diameter at the largest. And 
since the rotary member 5 does not have any portion where the material 
being sprayed at a high speed frictionally contacts and is stirred up and 
no heat is generated in the decorative fatty material and accordingly, 
this method is especially suitable for the spraying of high viscosity 
fatty confectionery material such as tempered chocolate. 
Decorative fatty confectionery material such as chocolate is first 
perfectly melted at 50.degree. C., then cooled to about 
24.degree.-25.degree. C. and thereafter maintained at 
28.degree.-30.degree. C. in a tempering device. The fatty confectionery 
material is then fed to the rotary member 5 while being maintained at the 
temperature. In this case, when the decorative fatty confectionery 
material has the particle size capable of passing entirely through a 325 
mesh sieve and the total fat content of 35-42% by weight including cacao 
butter, vegetable oil and milk fat based on the total weight of the 
material the viscosity of the material is on the order of 25,000-90,000 
cps. 
The decorative fatty material is fed in a metered amount by a metering pump 
such as a geared pump to the vicinity of the axis of the rotation of the 
truncated conical rotary member 5 through the conduit 6. By adjusting the 
rotational velocity or circumferential velocity of the rotary member 5 
depending upon the above-mentioned viscosity and the rate of feed of the 
decorative fatty material, the material can be sprayed in the form of fine 
particles having a uniform particle size on the order of 0.5 mm at the 
largest. 
Furthermore, in the spray method described just above, the spray efficiency 
and the particle size of sprayed particles substantially vary depending 
upon the shape and circumferential velocity of the truncated conical 
rotary member 5. When the truncated conical rotary member has the sloped 
inner surface of an excessively obtuse angle, the sprayed decorative 
material will not be spread over the sloped inner surface, but immediately 
flies off the outer peripheral edge of the rotary member and the material 
is sprayed into coarse particles. Similarly, also when the rotary member 
is a rotary disc, the material is sprayed into coarse particles. However, 
when the outlet of the conduit 6 through which the decorative fatty 
material is fed is brought to a position in which the conduit outlet 
substantially contacts the vicinity of the center of the rotary disc, the 
decorative fatty material issuing through the conduit outlet is forcibly 
spread over the rotary disc and deposited thereon and the material is then 
flied off the peripheral edge of the disc. However, in the spray method 
using the rotary disc, when the supply amount of the decorative fatty 
material is increased, any excess amount of the fatty material other than 
the portion of the material which is deposited on the disc scatters about 
in coarse particles resulting in substantial reduction of the spraying 
efficiency. 
In order to obtain fine particles of the decorative fatty material in a 
stabilized state and a large amount, the truncated conical rotary member 5 
which flares towards the opening of the member 5 and has the sloped inner 
surface with the suitably obtuse angle as shown in FIG. 2 is preferably 
employed. 
When the decorative fatty material is fed to the vicinity of the axis of 
rotation of the rotary member 5 through the feed conduit 6 as shown in 
FIGS. 1 and 2, the fatty material is subjected to a force which urges the 
material radially outwardly under the centrifugal force and thus, the 
fatty material is spread over the sloped inner surface of the rotary 
member 5, then forced to move along the sloped inner surface of the member 
and finally flied off the outer peripheral edge of the member 5 in the 
form of fine particles. Since the centrifugal force in the vicinity of the 
axis of rotation at the bottom of the rotary member 5 is substantially 
lower than that at the outer peripheral edge 8 of the member 5, the 
decorative fatty material 7 is forced to deposit on the bottom of the 
rotary member 5 and uniformly spread over the rotary member bottom without 
scattering about. 
In the truncated conical rotary member 5 described hereinabove, the greater 
the angle .alpha. of the sloped inner surface with respect to the bottom 
of the rotary member 5 is, the spraying efficiency of high viscosity 
decorative fatty material is the higher. However, even the truncated 
conical rotary member 5 is employed, when the decorative fatty material 
has a high viscosity and a low fluidity, the rate at which the decorative 
fatty material 7 is spread over the sloped inner surface of the rotary 
member 5 is lower than the rotative velocity of the rotary member and 
thus, a portion of fatty material 7 tends to scatter about the outer 
peripheral edge of the rotary member 5. The scattering of a portion of the 
fatty material can be prevented by the provision of an annular flat plate 
9 having substantially the same diameter of the opening of the rotary 
member 5 and positioned adjacent to the opening of the member 5. 
The scattering prevention effect provided by the annular plate 9 is 
probably due to the fact that the scattering fatty material is arrested by 
the annular plate 9 and the arrested fatty material is sprayed under the 
centrifugal force provided by the annular plate 9. 
The angle .alpha. of the sloped inner surface with respect to the bottom in 
the rotary member 5 is preferably at least 15.degree. and for the 
arrangement it is effective that the higher the viscosity of the 
decorative fatty material is, the greater the angle .alpha. is. For a 
decorative fatty material having the viscosity on the order of 90,000 
centipoises, the angle .alpha. is required to be at least 35.degree.. 
The annular plate 9 to be positioned adjacent to the opening or outer 
peripheral edge 8 of the rotary member 5 is usually spaced from the outer 
peripheral edge 8 at a distance of 0.5-2 millimeters. If the annular plate 
9 is positioned closer to the outer peripheral edge 8 of the rotary member 
5, since the fine particles of the fatty material are required to be 
sprayed through the clearance between the outer peripheral edge 8 of 
rotary member and annular plate 9, the size of the particles has to be 
excessively small. For the purpose, the rotative velocity of the rotary 
member 5 is required to be unnecessarily high and the unnecessarily high 
rotative velocity brings about waste of energy. On the other hand, when 
the annular plate 9 is positioned further away from the outer peripheral 
edge 8 of the rotary member 5, large particles of the decorative fatty 
material will pass through the clearance between the annular plate 9 and 
the other peripheral edge 8 of the rotary member and the annular plate 9 
will not exhibit its prevention function from scattering. Therefore, in 
order to effectively prevent the particles of the decorative material from 
the scattering, the annular plate 9 is required to be positioned spaced 
from the outer peripheral edge 8 of the rotary member within 
above-mentioned distance range. 
Furthermore, when the decorative fatty material 7 has a viscosity over 
100,000 centipoises and a substantially low fluidity, such fatty material 
can not be easily spread over the sloped inner surface of the hollow 
truncated conical rotary member 5 and the material will fly off the outer 
peripheral edge 8 in the form of block rather than five particle. Thus, 
for the purpose of the present invention, the decorative fatty 
confectionery material having such exceedingly high viscosity is not 
suitable for use. 
The particle size of sprayed particles of the decorative fatty 
confectionery material is principally determined depending upon the 
circumferential velocity of the rotary member 5, and the viscosity and 
feed amount of the fatty confectionery material to the rotary member 5. 
For example, when a decorative fatty confectionery material having the 
viscosity of 40,000 centipoises is fed at the rate of 20 grammes per 
minute by a metering pump to the vicinity of the axis of rotation of the 
rotary member 5 having the sloped inner surface with the angle .alpha. of 
37.degree. and the circumferential velocity at the outer peripheral edge 8 
of 3.78 m/sec, the particle size of sprayed particles of the fatty 
confectionery material will be 1.03 mm at the largest. With the same angle 
.alpha. and the same material viscosity, when the circumferential velocity 
at the outer peripheral edge 8 is 9.25 m/sec and 13.42 m/sec, 
respectively, the particle size of sprayed material will be 0.57 mm and 
0.49 mm at the largest, respectively. However, it is to be noted that the 
determination of the particle size in the experiments described above was 
made by the use of a micrometer built in a microscope for the same 
decorative fatty confectionery material sprayed on a glass sheet using the 
said rotary member 5. As clear from the measurement results, it will be 
understood that the higher the circumferential velocity is the smaller the 
sprayed particle size is. And in order to spray a decorative fatty 
confectionery material having the viscosity of 87,500 centipoises into 
particles of 0.5 mm diameter at the largest, the circumferential velocity 
at the outer peripheral edge of the rotary member 5 should be at least 12 
m/sec. And in order to spray the same decorative fatty confectionery 
material into particles of 0.5 mm diameter at the largest with the supply 
amount of 110 grammes per minute for the material, the circumferential 
velocity at the outer peripheral edge of the rotary member 5 should be 
20.88 meters per second. Thus, it will be understood that in order to 
obtain fine particles of the decorative fatty confectionery material, the 
circumferential velocity of the rotary member 5 should be increased in 
proportion to increase in the viscosity and supply amount of the 
decorative fatty confectionery material. 
On the other hand, when the decorative fatty confectionery material to be 
sprayed is a non-tempered chocolate, the material is sprayed by the 
above-mentioned method maintaining the chocolate at a temperature above 
the melting point of the non-tempered fat in the chocolate. 
In the spray of the tempered chocolate by the use of the spray device 
having the above-mentioned rotary member 5 incorporated therein, the 
decorative fatty confectionery material is sprayed in the form of particle 
having the diameter of 0.5 millimeters at the largest through the through 
holes 3 of the plate mold 4 disposed on and secured to the forming mold 1 
by means of set bolts 14 into a selected one or ones of the recesses 2 in 
the mold 1 to be deposited in the recesses, the spray device having the 
rotary member 5 is moved along the guide rails 16, 16 by means of the 
wheels 12, 12 at the bottom the spray device to fill the fatty 
confectionery material into the successive recesses 2 in succession so as 
to uniformly deposit the fatty material in the recesses 2 and the plate 
mold 4 is then removed from the mold 1. On the other hand, the particle 
portion of the sprayed decorative fatty confectionery material other than 
that directed to the mold is arrested by the shield cover 11 and falls 
into the collection tray 13 positioned below the spray device to be 
recycled by a metering pump (not shown) for reuse. 
As mentioned hereinabove, according to the present invention, since the 
decorative fatty confectionery material is sprayed into the recesses 2 
engraved in the mold 1 and caused to deposit in the recesses, the 
operation for scraping the excess decorative fatty material from the plate 
mold 4 and the operations for forcing the decorative fatty material into 
the fine engraved recesses 2 are eliminated. Furthermore, the building up 
of the decorative fatty material on the engraved recesses 2 in a height 
corresponding to the thickness of the thin plate mold 4 which is one of 
the disadvantages inherent in the above-mentioned scraping method can be 
eliminated. The plate mold 4 can be repeatedly used in conjunction with 
second and third forming plates 1. 
When the plate mold 4 is merely disposed on the mold 1, and not secured to 
the mold 1 by the set bolts 14, the plate mold 4 will not closely contact 
the forming mold 1 and the sprayed fatty material tends to enter the 
clearance between the plate molds 4 and the mold 1 whereby the fatty 
material may deposit itself at areas other than the recesses 2 resulting 
in a defective confectionery. If the plate mold 4 is extremely thin, the 
strength of the mold 4 is insufficient and tends to warp and thus, the 
mold 4 may not closely contact the plate 1. On the contrary, when the 
plate mold 4 is excessively thick, although the mold 4 may contact the 
mold 1 closely, the increase in the thickness extends the distance from 
the opening of the through holes 3 to the bottom of the engraved recesses 
2. Thus, the sprayed decorative fatty confectionery material particles 
will stray in different directions and deposit on the wall faces of the 
through holes 3 to thereby impede free passage of the sprayed particles 
through the through holes 3 to the recesses 2 resulting in difficulty for 
filling of the sprayed particles in the recesses. Therefore, it is 
preferable that a plate mold 4 having a thickness one half the width of 
the engraved recesses 2 or a plate mold 4 having the depth in the areas 
defining the through holes 3 corresponding to about one half the width of 
the recesses 2 is employed. 
When the recesses formed in the mold are annular shaped, as mentioned 
hereinabove, a plurality of bridge portions 17 are necessary to connect 
between the circular shielding areas of the plate mold and the matrix of 
the plate mold. The plate mold having such a construction is shown by 
reference numeral 4' in FIG. 4. In this plate mold, the sprayed fatty 
material tends to migrate under the bridge portions and the recesses 
positioned below the bridge portions may not be perfectly filled with the 
sprayed material. However, if the bridge portions 17 are replaced by 
upwardly warped wire sections, since a sufficient space is provided apiece 
between the bridging wire sections and the recesses 2, the sprayed 
decorative fatty material particles migrate below the wire sections in 
different directions whereby the particles are uniformly filled and 
deposited in the recesses. 
As described hereinabove, according to the present invention, the operation 
for scraping of the excess material is eliminated and the warped bridge 
portions formed of wire sections will not impede the material deposition 
and filling whereby the plate mold can be repeatedly employed. However, if 
the sprayed decorative fatty material particles deposit on the plate mold 
4 excessively, the excessively deposited particles have to be removed by a 
suitable means. The removal of excessively deposited material can be 
performed by blowing warmed air against the plate mold 4 to blow the 
material off the mold or lightly vibrating the plate mold to allow the 
material to drip down. By either of the removal methods, the excess 
material can be removed without impeding the spraying and filling of the 
decorative fatty material into the recesses. 
As to the recesses 2 to be engraved in the mold 1, the recesses should have 
an inverted trapezoid cross-section with the larger dimensional opening 
portion so that the resulting fatty confectionery can be smoothly removed 
from the mold 1 after the cooling and solidification thereof. If the 
opening of the recesses 2 is excessively narrow, the recesses will have a 
substantially triangular cross-section with a reduced depth. Although the 
recesses of triangular cross-section form a three-dimensional design, 
pattern and/or letter configuration decoration, the trapezoid 
cross-section recesses having a greater depth form a more excellent 
three-dimensional design, pattern and/or letter configuration decoration. 
The trapezoid cross-section recesses should have the opening width of at 
least 1 mm. The depth of the recesses may be increased if a large design, 
pattern and/or letter configuration decoration is desired to be formed. 
However, when the recesses have design, pattern and/or letter 
configuration of different depths, the deposition height of the decorative 
fatty material should be adjusted in conformity with the different depths 
of the recesses. This makes the spraying operation very difficult. 
Generally, the recesses 2 are formed having substantially the same depth, 
corresponding to the depth of the recesses 2 having the smallest opening 
width because of the reason mentioned hereinabove. Therefore, although the 
diameter of the sprayed decorative fatty material particles may be 1 mm at 
the largest, the particle size should be substantially smaller than the 
opening width of the recesses for the reason mentioned hereinabove. 
Generally, the particle size is 0.5 mm at the largest. 
When ordinary chocolate is desired to be employed as the decorative fatty 
material to be sprayed into and deposited in the recesses 2, the fatty 
material is cooled to a temperature below the melting point of cacao 
butter and when non-tempered chocolate is desired to be employed, the 
chocolate is cooled to a temperature below the melting point of the 
non-tempered fat. The cooling of the chocolate deprives the chocolate of 
the fluidity. After the cooling of the decorative fatty material sprayed 
into the recesses the base fatty confectionery material is poured into the 
recesses 2 over the deposited decorative fatty material and the mold 1 is 
vibrated to eliminate all the air bubbles from the base fatty material, 
and the resulting confectionery is cooled and solidified and removed from 
the forming mold. 
The elimination of the fluidity from the decorative fatty material sprayed 
into and deposited in the recesses is necessary for the two reasons. One 
of the reasons is that the displacement and leakage of the sprayed and 
deposited decorative material from the recesses is to be prevented when 
the mold assembly is vibrated for deaeration. The other is that if the 
sprayed and deposited decorative fatty material is perfectly cooled and 
solidified before the base fatty confectionery material is poured, the 
decorative fatty material insufficiently unites with the base fatty 
confectionery material. The non-fluid decorative fatty material such as 
chocolate maintains its uniting capability with the base fatty 
confectionery material within the viscosity range of 100,000-200,000 cps. 
When the decorative fatty material is sprayed into and filled in the 
recesses disposed at an angle such as when the recesses are formed in a 
sloped surface of the mold or the mold is inclined, the sprayed material 
requires a rather long time before the material loses its fluidity, the 
material tends to flow from its intended position and thus, if the mold is 
previously cooled so as to deprive the sprayed decorative fatty material 
of its fluidity in a short time to thereby prevent the sprayed material 
from flowing. 
In such a case, the cooling temperature of the mold is related to the 
viscosity of the decorative fatty material to be sprayed thereon. For 
example, when the decorative fatty material has the viscosity of 25,000 
centipoises, the temperature of the mold surface is 14.degree. C., for the 
viscosity of 50,000 centipoises, the temperature is 24.degree. C. and for 
the viscosity of 78,000 centipoises, the temperature is 27.degree. C., 
respectively. In an alternative method, the mold is cooled to 11.degree. 
C. or below, the decorative fatty material is sprayed into and deposited 
in the recesses in the mold, immediately thereafter the mold is cooled to 
solidify the fatty material, just prior to the pouring of the base fatty 
confectionery material such as chocolate, the mold is warmed by means of a 
heater such as an infrared ray lamp to soften the decorative fatty 
material to a degree not to impart fluidity to the fatty material and 
finally, the base fatty confectionery material is poured into the mold to 
cause the two materials to unite together. 
And as mentioned hereinabove, according to the present invention, since the 
decorative fatty material is exclusively sprayed and deposited in the 
recesses 2 of the mold 1, even if the decorative fatty material is 
non-tempered chocolate, the so-called fat bloom which requires the further 
scraping over the plate mold will not occur. Therefore, the present 
invention has the advantage that any combination of non-tempered chocolate 
and ordinary chocolate requiring tempering can be freely employed as the 
combination of the decorative fatty material and base fatty confectionery 
material. 
Referring now to FIGS. 6 through 9 in which alternative apparatus useful in 
carrying out the method of the present invention is shown, since the 
apparatus is substantially similar to the apparatus shown in FIGS. 1 
through 5 except for the rotary member, description will be made on only 
the rotary member. 
In this apparatus, the rotary member is replaced by a rotary member 
assembly and the rotary member assembly comprises a pair of hollow 
truncated conical similar rotary members 20, 20 which are assembled 
together at their outer peripheral edges with the concaved sides of the 
members facing each other to define a space S therebetween. The rotary 
member 20 is formed at the outer peripheral face with a plurality of 
equally spaced projections 21 and a plurality of equally spaced spouting 
orifices 22 positioned between the adjacent projections 21. The 
projections 21 taper radially outwardly to define spaces 23 therebetween 
which flare outwardly. Therefore, as the decorative fatty confectionery 
material is sprayed through the orifices 22 under centrifugal force as the 
rotary member assembly rotates, the decorative fatty confectionery 
material is subjected to a frictional resistance lower than that in the 
case of the foregoing apparatus and the sprayed particles can be more 
uniformly and nearly at the rate of twice volume per second distributed to 
all the corners of the design, pattern and/or letter configuration 
recesses of the forming mold. 
The viscosities of the base and decorative fatty materials such as 
chocolates were measured by a B-type viscosimeter manufactured by Toki 
Sangyo K.K. and the particle size of the decorative fatty materials were 
measured by removing fat from the decorative fatty material by petroleum 
ether and passing the residue through a JIS (Japanese Industrial Standard) 
Z 8801 Standard 325 mesh sieve. 
EXAMPLE 1 
A mold having the bottom surface area of 80.times.60 mm and the depth of 10 
mm and provided with a plurality of three-dimensional design, pattern 
and/or letter configuration recesses with inverted trapezoid cross-section 
each having the width of at least 1 mm and the depth of 1 mm is provided, 
the mold is cooled to the mold surface temperature of 18.degree. C. by 
exposing the mold to cold air maintained at 12.degree. C. and flowing at 
the rate of 0.7 meters per second for two minutes, a copper plate mold 
having the thickness of 0.5 mm and a plurality of through holes 
substantially corresponding to the recesses in configuration and position 
is disposed on and secured to the mold in close contact therewith and the 
mold assembly is maintained in its erect position. 
With the mold assembly maintained in this position, a hollow truncated 
conical rotary member having the sloped inner surface at the angle of 
15.degree. is horizontally positioned spaced from the mold assembly by the 
distance of 12 centimeters with the opening directing upwardly. 
On the other hand, 41.5 parts of pulverized sugar, 21.4 parts of whole fat 
powdered milk, 36.3 parts of cacao butter, 0.5 parts of soy bean lecithin, 
0.05 parts of food flavor and a small amount of yellow food color are 
admixed, and the mixture is ground to the particle size capable of 
entirely passing through a 325 mesh sieve with a three-roll refiner to 
obtain a yellowish white decorative chocolate. 
The decorative chocolate is heated to 50.degree. C. to perfectly melt the 
chocolate and then cooled to 24.degree. C. while being stirred and 
thereafter heated to 29.degree. C. to temper the chocolate. The 
temperature chocolate has the viscosity of 38,500 centipoises. 
The tempered chocolate is fed at the rate of 85 grammes per minute through 
the conduit to the center of the bottom of the truncated conical rotary 
member positioned in the above-mentioned position and rotating at the 
circumferential velocity of 4.3 meters per second and sprayed in the form 
of particle through the through holes in the plate mold into the recesses 
of the mold to be uniformly deposited in the recesses. 
Thereafter, after the plate mold is removed the mold is returned to its 
horizontal position with the bottom disposed down, and the mold is left at 
room temperature of 27.degree. C. for one minute. 
Meantime, 20.0 parts of cacao mass, 45.0 parts of pulverized sugar, 19.0 
parts of whole fat powdered milk, 16.0 parts of cacao butter and 0.5 parts 
of soy bean lecithin are admixed and ground in the same manner as 
described in connection with the preparation of the decorative fatty 
material or chocolate to provide a base chocolate. The base chocolate is 
tempered and poured into the mold by 23 grammes, and the mold is vibrated 
to remove air bubbles from the chocolate. Thereafter, the mold filled with 
chocolate is left in a tunnel where air at 12.degree. C. flows to be 
cooled and solidified. Thereafter, the base chocolate having the 
decorative chocolate deposited thereon is removed from the mold. 
The thus obtained chocolate has the excellent lustrous surface having the 
yellowish white decorative chocolate deposited thereon in 
three-dimensional design, pattern and/or letter configuration having the 
thickness of 1 mm to give excellent attractive appearance to the 
chocolate. 
EXAMPLE 2 
A mold identical with said mold as described in Example 1 is cooled by 
being exposed to cold air at 12.degree. C. flowing at the rate of 0.5 
meters per second for three minutes to adjust the surface temperature of 
the mold to 16.degree. C. Immediately after the adjustment, a copper plate 
mold having the through holes corresponding to the recesses in 
configuration and position and the thickness of 0.5 mm is disposed on and 
secured to the mold in close contact therewith. The mold assembly is 
inverted to dispose the bottom surface of the mold top and is maintained 
in its horizontal position as illustrated in FIG. 1, 2. Thereafter, a 
hollow truncated conical rotary member having sloped inner surface at the 
angle of 30.degree. and spaced from the mold assembly by the distance of 
10 cm and with an annular plate positioned spaced from the outer 
peripheral edge of the rotary member by the distance of 2 mm is vertically 
positioned with the opening or outer peripheral edge of the rotary member 
facing the mold assembly. 
Meantime, 45.0 parts of pulverized sugar, 16.0 parts of whole fat powdered 
milk, 3.6 parts of cacao butter, 32.4 parts of non-tempered fat (Merano 
STM having the melting point of 36.degree. C. manufactured by Fuji Seiyu 
K.K., Japan), 3.0 parts of lactose, 0.05 parts of food flavor and 0.5 
parts of soy bean lecithin are admixed and ground to the same particle 
size in the same manner as in Example 1 to provide a yellowish white 
non-tempered chocolate capable of entirely passing through a 325 mesh 
sieve. 
The thus obtained yellowish white non-tempered decorative chocolate is 
maintained at 40.degree. C. (the viscosity of 35,000 centipoises) and fed 
at the rate of 120 grammes per minute by a metering pump through a conduit 
to the center of the bottom of a hollow truncated conical rotary member 
rotating at the circumferential velocity of 4.0 meters per minute and is 
sprayed off the outer peripheral edge of the rotary member to be uniformly 
deposited in the recesses of the mold. 
Thereafter, the plate mold is removed from the mold and the mold is 
inverted. The mold is then left in a refrigerator for ten minutes to cool 
and solidify the decorative non-tempered chocolate in the recesses. 
Thereafter, the mold is taken out of the refrigerator and only the upper 
surface of the decorative non-tempered chocolate (the surface unites with 
the base chocolate to be poured later) is exposed to an infrared ray lamp 
of 200 Watts to be warmed and softened to a degree not to impart fluidity. 
A base chocolate having the same composition as that employed in Example 1 
is poured by 23 grammes into the mold, the mold is then vibrated to 
completely remove air bubbles from the resulting chocolate and is left in 
a cooling tunnel in which air at 12.degree. C. flows to be cooled and 
solidified. The solidified resulting chocolate is then removed from the 
mold. 
The thus obtained chocolate has the lustrous surface with the yellowish 
white decorative non-tempered chocolate deposited thereon in 
three-dimensional design, pattern and/or letter configuration with the 
thickness of 1 mm and thus, the chocolate is attractive. 
While two embodiments of the invention have been shown and described, it 
will be understood that these are described only for the purpose of 
illustration and should not to be taken as a definition of the invention, 
reference being made for this purpose to the appended claims.