METHOD AND APPARATUS FOR FORMING MINIATURE SIZE CONFECTIONERY PRODUCTS

Abstract: A method and apparatus are provided for forming miniature size confectionery products. The apparatus includes a rolling machine (12) for forming a mass of a confectionery product, such as bubble gum, into a thin, flat sheet. A conveyor belt (24) carries the flat sheet into a cooling tunnel (26) to cool the flat sheet. A forming device (28) comprising at least two forming rollers (40, 42) is used to form the cooled flat sheet into a webbed mat having a plurality of desired configurations thereon. After the formation of the webbed mat, the conveyor belt carries the webbed mat into a drum roller (32). The drum roller tumbles the webbed mat to break apart the webbed mat and form a plurality of miniature size confectionery products in the form of the desired configuration.

Description: 6 P E C I F I C A T I O N TITLE METHOD AND APPARATUS FOR FORMING MINIATURE SIZE CONFECTIONERY PRODUCTS BACKGROUND OF THE INVENTION The present invention relates generally to the field of confectionery products. More specifically, the present invention relates to forming confectionery products into special shapes. Confectionery products have been molded, extruded or otherwise shaped into various forms over the years. For example, bubble gum has been formed into shapes such as flat sticks, cylinders, cubes, cigars, shredded chew, and the like. Providing a confectionery product, such as bubble gum, in novel shapes or forms can lead to enhanced marketability of such a product, particularly with younger consumers. An example of a traditional shape for chewing gum is the gum ball. For centuries, children as well as adults have enjoyed gum balls in a variety of flavors. The process of forming gum balls from a mass of confectionery products is well known. Initially, a confectionery product coupled with an extruder forms the mass of confectionery product into ropes of gum. The ropes of gum are approximately 1/2 inches in diameter. Next, the ropes of gum are forced via centrifugal force • through a plurality of spinning rods to form a multitude of individual gum balls. The individual gum balls are then sent through a cooling tunnel to harden. The resulting gum balls have a diameter of at least 1/2 inch. hile this conventional method produces satisfactory 1/2 inch gum balls, unfortunately, it cannot be used to produced smaller than 1/2 inch gum balls. Since continually changing the size and shape of confectionery products is desirable, a need exists for a method of forming miniature size confectionery products. For example, forming miniature size gum balls, as opposed to the traditional size gum balls, is a novel form that can ultimately lead to enhanced marketability of the bubble gum. Unfortunately though, no practical methods of making such miniature size confectionery products are currently available. Because chewy gum is soft, flexible and tacky, the industry has thought that producing bubble gum in miniature sizes to be infeaεible. SUMMARY OF THE INVENTION The present invention provides a method and apparatus for forming miniature size confectionery products. The method includes the following steps. Initially, a mass of confectionery product, such as bubble gum, is provided. This mass is then formed into a thin, flat sheet. The flat sheet is then cooled and ultimately formed into a webbed mat having a plurality of defined configurations thereon. Next, the webbed mat is tumbled to form a plurality of miniature size confectionery products in the form of the defined configuration. In an embodiment, the confectionery product is chewing gum. In an embodiment, the mass of confectionery product is formed into a thin, flat sheet having a thickness of approximately 50/1000 inches to 400/1000 inches. In an embodiment, the method includes a step of cooling the flat sheet to a temperature in the range of approximately 50°F to 85°F. In addition, the present invention provides an apparatus for forming miniature size confectionery products. The apparatus includes means for forming a mass of confectionery product into a thin, flat sheet. In addition, the apparatus includes means for cooling the flat sheet and means for forming the flat sheet into a webbed mat having a plurality of defined configurations thereon. Still further, the system includes means for tumbling the webbed mat to break apart the webbed mat and form a plurality of miniature size confectionery products in the form of the defined configuration. In an embodiment, the means for cooling the flat sheet is a cooling tunnel. In a preferred embodiment, the cooling tunnel cools the flat sheet to a temperature ranging from approximately 50°F to 85°F. In an embodiment, a forming device is used to form the flat sheet into a webbed mat. The forming device has forming rollers with a plurality of half-shaped moldings thereon. The forming rollers act in conjunction to form the defined configuration. An advantage of the present invention is that it provides a method and apparatus for forming miniature size confectionery products that was previously thought infeasible. Another advantage of the present invention is that it provides a unique engineering design for forming rollers that minimizes tackiness of a confectionery product. Additional features and advantages of the present invention are described in, and will be apparent from. the drawings and the detailed description of the presently preferred embodiments. BRIEF DESCRIPTION OF THE DRAWINGS FIGURE 1 is a side view of an embodiment of the present invention. FIGURE 2 is a perspective side view illustrating the forming device of the present invention. FIGURE 3 is an enlarged side view of a portion of the forming rollers acting in conjunction to form miniature size confectionery products. FIGURE 4 is a side view illustrating the half moldings of the forming rollers. FIGURE 5 is a top view illustrating the webbed mat formed after the forming device acts on the thin, flat sheet of confectionery product. DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS The present invention provides a method and apparatus for forming miniature size confectionery products. While methods and apparatuses may exist for forming confectionery products into normal size shapes, the industry has failed to develop a method or apparatus for forming miniature size confectionery products. As used herein, the term confectionery product(ε) iε broadly uεed and refers to candies, including hard and chewing candy, chewing gumε, and like productε. Referring now to the drawingε. Figure 1 illustrates one embodiment of the present invention. The apparatuε 10 includes means 12 for forming a flat rectangular εheet of a confectionery product. In an embodiment, means 12 for forming a flat rectangular εheet of a confectionery product is a conventional chewing gum rolling machine. For example, a suitable rolling machine 12 that may be used in the present invention can be purchased from the Gimpel Manufacturing Company, WLS of West Germany. Naturally, other machines with the ability to roll or extrude a εheet of confectionery product can alεo be uεed. The rolling machine 12 includeε an extruder 14 into which a maεε of the confectionery product is put. In an embodiment, the confectionery product is chewing gum. As set forth above, other confectionery products such as taffy, caramel, chewing candy, and the like can alεo be used. A serieε of rollerε 16 act on the maεε of confectionery product to form a relatively thin, flat εheet 22. The rollerε 16 εize the thin, flat εheet 22 to a few thousandthε of an inch larger than the deεired configuration εize. In an embodiment, the rollerε 16 εize the thin, flat sheet to a thicknesε ranging from approximately 75/100 incheε to 600/1000 incheε. Sizing the thin, flat sheet 22 to the desired thicknesε preventε εticking of the εheet 22 during formation of the miniature εize confectionery productε. In addition, a flat εheet 22 that iε too thick exerts too much presεure on a forming device uεed to form the sheet 22 into the desired configurations. The rolling machine 12 also includes a dusting apparatus 18 for dusting the εheet 22 in order to reduce any adhesiveneεε. Typically, εtarch may be used as the dusting compound. The rolling machine 12 further includes a cleaner 20. The cleaner 20 removes exceεs dusting compound, such as cornstarch, from the thin, flat εheet 22. After the excess duεting compound is removed from the thin, flat sheet 22, the sheet 22 iε carried on a conveyor belt 24 through a cooling tunnel 26. The conveyor belt 24 carries the thin sheet of confectionery product 22 into the cooling tunnel 26. The cooling tunnel 26 cools the confectionery product so as to minimize tackineεε and facilitate formation. In an embodiment, the cooling tunnel 26 coolε the confectionery product to a temperature of approximately 50°F to 85°F. The ideal temperature of the cooling tunnel 26 dependε upon the formulation of the confectionery product. Naturally, the formulation of the confectionery product effectε the tackineεε and ultimate formation of the desired configurations. If the temperature of the cooling tunnel 26 is too high, the confectionery product begins to stick. In contrast, if the temperature in the cooling tunnel 26 is too low, the confectionery product becomes too firm and will not form a uniform sheet having desired configurations thereon. The ideal dwell time (speed of the conveyor belt 24) within the cooling tunnel 26 also depends upon the formulation of the confectionery product. In an embodiment, the cooling tunnel 26 has sixty-εix feet of conveyor belt that carries the sheet 22 through the cooling tunnel 26. In an embodiment, the sheet 22 is maintained within the cooling tunnel for approximately one to three minutes. Preferably, a base-tack free formula iε uεed in the present invention. For example, a confectionery product, such aε chewing gum, that may be utilized in the preεent invention iε aε followε: Inαredientε Percent Poundε Sugar 60.629 620. .00 Gum Baεe 26.403 270. .00 Corn Syrup 8.312 85. .00 Glycerine 2.933 30. .00 Lecithin 0.635 6. .50 Red Artificial 0.410 4. .20 Color (Red 40) Art. Strawberry Flavor 0.312 3. .20 Art. Strawberry Flavor 0.312 3. .20 Carmine Red Color 0.048 0. ,50 Total Weight 1,022 .60 After exiting the cooling tunnel 26, the thin, flat sheet of confectionery product 22 iε paεεed through a forming device 28. The forming device 28 haε a unique engineering design to minimize the tackineεε of the confectionery product. For inεtance, the dual rollers used within the forming roller 28 are εpecially coated to reduce the tack of the confectionery product. A εuitable coating that may be uεed in the present invention is a low temperature nitride coating. Such nitride coating is applied to the dual roilerε with a conventional heat treating proceεε. In addition to the uεe of a cooling tunnel 24, the apparatuε 10 utilizes a nitrogen syεtem 30. The nitrogen syεtem 30 iε directly aligned over the forming device 28 such that the thin, flat sheet of confectionery product 22 iε kept at a low temperature during formation of the deεired configurationε. The nitrogen syεtem 30 coolε the entire forming device 28, thereby alεo cooling the thin, flat εheet of confectionery product 22. Aε with the cooling tunnel 26, the ideal temperature of the nitrogen syεtem 30 dependε upon the formulation of the confectionery product. In an embodiment, the nitrogen εyεtem 30 iε run at a temperature of approximately -30°F to -100°F. Figure 2 further illuεtrateε the forming device 28 of the preεent invention. The forming device 28 includeε at leaεt two forming rollers 40, 42. The forming rollers 40, 42 act in conjunction with each other to form desired configurations on the thin, flat sheet 22. In a preferred embodiment, each of the respective forming rollers 40, 42 has an exterior surface with a plurality of hemisphere shaped moldingε. In addition to the εurface coating on the forming rollers 40, 42, the shape of theεe hemiεphere moldingε minimizes the tack of the confectionery product. Specifically, the hemiεphere shaped moldings are constructed in such a manner so aε to reduce the radius of same and thereby minimize sharp edges on same. Figures 3 and 4 illustrate the forming rollers 40, 42 acting in conjunction to form a webbed mat 44. Naturally, the present invention is not limited to the formation of miniature size gum balls. Rather, a multitude of configurations fall within the εcope of the preεent invention. For example, εuitable forming rollerε 40, 42 can be conεtructed so as to form triangles, diamonds, oval eggs and the like. The positioning of the forming rollers 40, 42 in relation to each other serves an important role in the present invention. The forming rollers 40, 42 are positioned in such a way aε to allow for the formation of a webbed mat 44. The webbed mat 44, aε uεed in the preεent invention, refers to the formation of a plurality of desired configurations in the thin, flat sheet 22. The deεired configurationε are molded into the thin, flat sheet 22. The webbed mat 44 has a webbing of a defined thicknesε poεitioned in between the deεired configurations so as to maintain a uniform εheet of confectionery product. Since the configurations are miniature in size, the thin webbing between the plurality of desired configurations prevents the individual configurations from εticking to the forming rollε 40, 42. Inεtead, the webbing interlockε the formed configurationε together and thereby maintains the webbed mat 44 in a uniform sheet such that the entire webbed mat may be removed from the forming rollers 40, 42. Figure 4 is an enlarged view illustrating the formation of, in this embodiment, miniature size gum ballε. Aε εet forth above, the forming rollerε 40, 42 do not unite when forming the miniature εize gum ballε. Inεtead, a spacing ranging from approximately 2/1000 inches to 4/1000 inches remains between the forming rollers 40, 42. The spacing between the forming rollers 40, 42 forms a webbing 46 between the multitude of miniature size gum balls. The webbing 46 has a thickness sufficient to hold the miniature size gum balls together, but not too thick so as to prevent the ultimate breaking apart of the webbed mat 44. In an embodiment, the webbing 46 ranges in thicknesε from approximately 2/1000 inches to 4/1000 inches. The forming device 28 further includes a deflection shield 48. The deflection shield 48 cuts off scrappingε aε well aε half configured moldingε from the webbed mat 44. Figure 5 illuεtrateε the slicing off of the scrappingε aε well aε half moldingε from the webbed mat 44. Removing theεe scrappingε from the webbed mat 44 increases the yield of formed miniature εize gum ballε. The εcrappingε sliced off from the webbed mat 44 can be collected and again εent through the apparatus 10. As an alternative to a deflection shield 48, those skilled in the art will appreciate that other means exist for removing the scrappings from the webbed mat 44. For example, each of the forming rollers 40, 42 can be constructed so as to include a trimming edge (not shown) on the respective ends of each of the forming rollers 40, 42. The trimming edge will effectively cut off exceεε unformed confectionery product and result in a webbed mat 44 having a plurality of completely formed configurations thereon. After the formation of the webbed mat 44, the conveyor belt 24 carries the webbed mat 44 into a drum roller 32. The drum roller 32 tumbles the webbed mat 44 to break apart same and form individual miniature εize confectionery productε. Once the webbed mat 44 iε broken apart, repeated rolling of the drum roller 32 effectively εmooths the webbing 46 into each individual miniature size confectionery product. The smooth miniature size confectionery products are then collected and placed in appropriate packaging. It should be underεtood that variouε changeε and modificationε to the preεently preferred embodimentε deεcribed herein will be apparent to thoεe skilled in the art. Such changes and modificationε can be made without departing from the εpirit and scope of the preεent invention and without diminiεhing itε attendant • advantages. It is therefore intended that such changeε and modifications be covered by the appended claims.

Claims: WE CLAIM ; 1. A method of forming miniature εize confectionery products comprising the steps of: providing a masε of confectionery product; forming the maεε of confectionery product into a εheet; cooling the εheet; forming the εheet into a webbed mat having a plurality of deεired configurations thereon; and breaking apart the webbed mat to form a plurality of miniature size confectionery products. 2. The method of Claim 1 wherein the confectionery product is chewing gum. 3. The method of Claim 1 further compriεing forming the mass of confectionery product into a sheet having a thicknesε of approximately 50/1000 incheε to 400/1000 incheε. 4. The method of Claim 1 further comprising cooling the sheet to a temperature in the range of approximately 50°F to 85°F. 5. The method of Claim 1 further compriεing the step of cooling the sheet as it iε being formed into a webbed mat. 6. The method of Claim 1 wherein the deεired configuration is round gum balls. 7. The method of Claim 1 wherein the confectionery product has a tack free formulation. 8. The method of Claim 1 wherein the confectionery product is hard candy. 9. The method of Claim 1 wherein the method of breaking apart includes the step of tumbling the webbed mat. 10. The method of Claim 1 further comprising the step of removing exceεε dusting compound from the sheet. 11. An apparatus for forming miniature size confectionery products compriεing: meanε for forming a maεε of confectionery product into a εheet; means for cooling the sheet; means for forming the εheet into a webbed mat having a plurality of deεired configurationε thereon; and meanε for tumbling the webbed mat to break apart the webbed mat and form a plurality of miniature size confectionery products in the form of the desired configuration. 12. The apparatuε of Claim 11 wherein the meanε for cooling the εheet iε a cooling tunnel. 13. The apparatus of Claim 11 wherein the eaηε for cooling the εheet coolε the εheet to a temperature ranging from approximately 50°F to 85°F. 14. The apparatuε of Claim 11 wherein the meanε for forming the εheet into a webbed mat is a forming device. 15. The apparatus of Claim 14 wherein the forming device comprises at least two forming rollers with a plurality of half εhaped moldingε. 16. The apparatus of Claim 11 further comprising a means for cooling the sheet as it is being formed into a webbed mat. 17. An apparatus for forming desired configurations into a εheet of confectionery product comprising: at least two forming rollers having a plurality of half shaped moldingε; and a motor to rotate the forming rollerε. 18. The apparatuε of Claim 17 wherein the apparatuε further compriεes a means for slicing off unformed scrappings from the sheet. 19. The apparatus of Claim 17 wherein the half shaped moldings are hemiεpheres. 20. The apparatus of Claim 17 further compriεing meanε for cooling the forming rollerε.

Inventors: CORRIVEAU CHRISTINE, MCHALE MICHAEL, REAM RONALD L, VAN HORN SHARON, CORRIVEAU, CHRISTINE, MCHALE, MICHAEL, REAM, RONALD, L., VAN HORN, SHARON
Applicants: CORRIVEAU CHRISTINE, HORN SHARON VAN, MCHALE MICHAEL, REAM RONALD L, WRIGLEY W M JUN CO, CORRIVEAU, CHRISTINE, MCHALE, MICHAEL, REAM, RONALD, L., VAN HORN, SHARON, WM. WRIGLEY JR. COMPANY
Application year: 1995
Main classification: A23G3
IPC codes: A23G3, A23G4, B29C43