Patent Publication Number: US-6908635-B2

Title: Flat plate flaking device

Description:
CONTINUATION DATA 
     This application is a continuation-in-part of U.S. application Ser. No. 09/659,530 filed Sep. 12, 2000, now U.S. Pat. No. 6,649,202, and a continuation-in-part of co-pending U.S. application Ser. No. 10/047,579 filed Jan. 15, 2002. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to the manufacture of flakes or chips of congealed fats, or more technically triglycerides, including edible fats, lard and various commercial food products such as edible oils and emulsifiers. In addition, the present invention relates to the field of layering or encapsulating solid or flaked material within other materials. This layering or encapsulation of solids can take the form of: (1) solids mixed in a liquid oil which is hardened and flaked; (2) solids directly added to a liquid which is in the process of being hardened and flaked; and (3) encapsulation of solids with liquids and liquid/gas mixtures of both edible and inedible material. 
     The present invention is particularly suited to flaking emulsifiers. Emulsifiers or emulsifying agents include mono- and diglycerides of fatty acids, propylene glycol, mono- and di-esters of fatty acids, glycerol-lactose esters of fatty acids, ethoxylated or succinylated mono- and diglycerides, lecithin, diacetyl tartaric acid esters or mono- and diglycerides, sucrose esters of glycerol, phospholipids or equivalents thereof and mixtures thereof. 
     A variety of edible oils are contemplated for use with the present invention, in particular, oil from oil seeds including cotton seed oil, soy bean oil, corn oil, peanut oil, sunflower oil, castor seed oil, safflower oil, palm and olive oils, and the like. The term “fat” is used generally to refer to edible fats and oils comprising triglycerides, fatty acids, fatty alcohols, and ester of such acids and alcohols. For the purposes of this invention, appropriate components are triglycerides of straight chain or branch chain, saturated or unsaturated monocarboxylic acids having from 10 to 28 carbon atoms. Suitable sources of such fats are: (1) vegetable fats and oils, as indicated above; (2) meat fats, such as tallow or lard; (3) marine oils, such as menhaden, pilchard, sardine, whale or herring; (4) nut fats and oils such as coconut palm or peanut; (5) milk fats, such as butter fat; (6) coca butter and coca butter substitutes, such as shea or illipe butter; and (7) synthetic fats or a re-esterified fats with fractionated fatty acids. 
     The fatty material can be blended with frequently sticky or liquid or semi-liquid fatty emulsifiers or blends thereof, such emulsifiers being one or more alkoxylated or plain partial glycerides of edible fatty acids, lecithin, hydroxylated lecithin, alkoxylated and plain glycol esters of edible fatty acids, ethoxylated or plain sorbitol or sorbitan esters of fatty acids, and food emulsifiers in salt form such as calcium stearyl lactylic acid, mixtures thereof and the like. Such sticky, liquid, or semi-liquid fatty emulsifiers can be considered condiments for purposes of this invention. 
     The fatty material can be an edible vegetable fat, nut fat, animal fat, mixtures of these fats. Such fats and mixture of fats have a SFI profile, is below the Agglomeration Boundary when the fat or fat mixture has a Solids Fat Index profile comprising approximately 50% at 50° F. and approximately 35% at 70° F., free fatty acids (e.g., 8-26 carbon chains) and corresponding alcohols, and/or a fatty food emulsifier such as a monoglyceride, diglyceride or a partial glycolate of such fatty acids, derivatives of monoglycerides such as glycerol monostearate, succinyl monoglyceride, lactylated monoglyceride, acetylated monoglyceride, diacetyl-tartare ester of monoglyceride, polyoxyethylene monoglyceride, propylene glycol monoester, sucrose esters of fatty acids, and mixtures of the same. Thus, the fatty material to be flaked for the instant purpose include triglycerides, fatty emulsifiers, and mixtures of the same, free fatty acids. Additives which can be included as a very minor fraction of the fatty material include antioxidants fungistats, and bacteriostats. 
     The present invention further contemplates the addition of various additives into the mixtures to be flaked. It will be appreciated that the use of additives in liquid compositions will lower the melting point of the liquid composition. These additives can be flavorings such as butter, buttermilk, cinnamon, or color such as beta carotene or annoretta or saffron. Solids or solid powders may be included such as non-fat dry milk solids or the pulp of various fruits such as raspberry and blueberry and along with other natural or imitation flavorings or colorings. The present invention overcomes the depression of the melting point which occurs when additives are included in a liquid. 
     The fatty flakes can contain a condiment or mixtures thereof. The condiment-containing flakes can be a mixture or dispersion of the condiment in fatty material, or the condiment coating partially, or completely the flaked fatty material. A condiment for purposes of this invention can be a liquid, vapor, or solid phase seasoning, flavoring, salting, sweetening, souring, spicing, and/or coloring ingredient or ingredient mixture suitable for producing or enhancing a flavor, texture and/or color in an edible product. It can include or consist of single or mixed pungent or spicy solids, flavoring oils, essences, oleoresins, extracts and other zesty flavorings, for example oleoresin of ginger, oils, or extracts or solid forms of sage, pimenta, coriander, parsley, garlic, caraway, nutmeg, cardamom, cloves, celery, monosodium glutamate; edible gums, stabilizers, and other food ingredients such as gelatin, soy protein, sodium carboxymethyl cellulose, edible “microcrystalline” cellulose, baking powder, hydroxypropyl cellulose, dextrose, sucrose, saccharin, hydrolyzed cereal solids, cornstarch, wheat flour, rice flour, breadcrumbs, and the like, and mixtures of the same. 
     BACKGROUND OF THE INVENTION 
     It has long been known that fatty substances could be cooled to a solid or semi-solid by applying a hot or warm liquid or semi-liquid of the fat to a rotating drum or continuous cooling belt. In U.S. Pat. No. 788,446 to A. R. Wilson, a liquid fat is sprayed onto a rotating drum or cylinder which is cooled with ice or ice and salt. As the drum rotates, the previously applied liquid is scraped from the drum, and the scraped area of the drum is then subsequently presented for another application of the fat or liquid to be congealed. 
     These types of drum cooling or mechanical cooling are relatively successful for substances having a sufficiently high melting point. However, as the melting point decreases, the resident&#39;s time of the substance on the drum must be increased in order to chill the liquid to a sufficient hardness that upon scraping the substance from the drum, the material cleanly breaks free of the drum and is sufficiently solid that it does not melt together with other materials scraped from the drum. In addition, as the melting point of the liquid applied to the drum becomes lower and lower, the opportunity for the material to melt together again, or to agglomerate, increases due to the continued release of heat from within the formerly liquid substance as it becomes more and more solid after being scraped from the roller and packaged. 
     In particular, as a substance is chilled to change the material from a liquid to a solid, the heat within the liquid substance is removed, and the material is reduced in temperature to a point at which crystallization of the material begins and a solid of the material begins to form within the liquid. The solid formation increases as heat is removed from the liquid substance. After a time, sufficient heat will have been removed from the substance so that the once liquid material becomes generally solid. However, while a material has become generally solid, it may not be fully crystalized and stabilized at a useful temperature. Rather, the material will continue to undergo greater solidification as an increasing percentage of the material becomes a solid crystal. During this period of continued crystallization, heat continues to be given off by the material as it turns from a semi-solid into a solid or becomes stabilized at a particular temperature below the melting point of the original liquid substance. This represents the release of the “heat of crystallization” or the release of the “latent heat of crystallization” of the substance. 
     In the process of forming chips or flakes from triglycerides, emulsifiers or other edible and non-edible materials, the general process is to apply the liquid substance to a rotating, chilled drum, and to allow the material to stay in contact with the drum for sufficient time to permit the liquid to become sufficiently solid that it can be scraped from the drum. During the scraping process, it is preferred that the solid or semi-solid break into flakes or fragments rather than peeling from the drum as a continuous sheet. Once the flakes or fragments of the substance are removed from the drum, they are usually packed into a container and placed into a cooling room for additional cooling and to retain the material in a solid state. It is during this period in the cooling room that additional solidification of this substance continues. As a result of this further solidification, internal heat is given off by the material which is referred to as the “latent heat of crystallization.” Once crystal growth, or solidification, has been initiated in a substance, it is necessary, for additional solidification to occur, that heat be removed or transferred from the body undergoing crystallization or solidification. In the case of a partially solidified liquid which has been placed into a packing box, the latent heat of crystallization becomes trapped within the mass of material in the box and begins to generally raise the temperature of the substance. This can result in the material within the package agglomerating due to the latent heat of crystallization partially melting the solid which was formed on the rotating cold drum. 
     A graphical representation of this phenomenon can be seen in FIG.  6 . In  FIG. 6 , the intermittent line indicates material having a melting point of approximately 114° F. which was initially cooled for 10-30 seconds on a roller. The graph shows that during the mechanical cooling period (T 1 ) the temperature decreases from generally 5° F. above the melting point temperature of the fat to be flaked to approximately 50° F.-60° F. At time T 2 , packaging occurs as the material is scraped off the roller. At time T 2 , the time interval changes to days. Once the material is removed from the roller the temperature of the material begins to rise. This rise in temperature continues during the first portion of time T 2  and after the packaged material is placed into a 40° F. cooling room. It is shown in  FIG. 6  that the temperature of the material once packaged and residing in a cooling room continues to rise. This temperature increase is due to the latent heat of crystallization which causes the temperature of the packaged material to increase to approximately 100° F. The temperature of the material then decreases to the temperature of the cooling room over a period of an additional two to three days. This increase in temperature in the packaged material resulting from the latent heat of crystallization can cause agglomeration of the packaged material. 
     This rise in latent heat is a particular problem in materials having a Solids Fat Index which is below the line graphed in FIG.  10 .  FIG. 10  shows the solids content of a mixture of fats at various temperatures. The solids fat index is a manufacturing standard used to measure the extent of hydrogenation in the fat components used in a mixture. Over a limited range, the solid fat index (SFI) value is numerically, approximately equal to the actual percent solids in the mixture. At high temperatures, the fat product will be completely melted. At low temperatures, the fat can be completely solid. In between these low and high temperature ranges, there are varying degrees of solid fat content in the fat composition. By selection of varying degrees of hydrogenated triglycerides, a variety of SFI profiles for various fat compositions can be developed. With respect to fat mixture suitable for flaking, the line in  FIG. 10  represents an agglomeration boundary. For mixtures of hydrogenated triglycerides having solids compositions which fall below the agglomeration boundary, conventional drum and belt methods of flaking do not provide sufficient chilling time or sufficient temperature reduction in the mixture to: (1) produce sufficient nucleation in the fat mixture to allow flaking; (2) prevent the solidified fat from forming a sheet of material, rather than flaking; and (3) reduce the temperature of the solidified material sufficiently to avoid re-melting of the material due to the latent heat of crystallization once the material is removed from the belt or roller and packaged. 
     The present invention avoids all these problems of roller and belt flaking devices and permits the flaking of fat and/or emulsifier mixtures which have a solids content which is below the agglomeration boundary shown in FIG.  10 . 
     Yet another drawback of the use of drum cooling for materials of the kind previously described is that when the melting point of the material becomes sufficiently low, generally 105° or below, the latent heat of crystallization will tend to be sufficient to virtually remelt the material or to cause the flakes or chips of the material to become a connected mass within the packaging material. Therefore, the use of rotating drum devices to cool materials having low melting points becomes ineffective, and triglycerides and other oils which have low melting points cannot be mixed with other substances which would have the effect of lowering the melting point of the triglyceride or the fatty substance to a point at which the drum cooling method would be ineffective as a result of the latent heat of crystallization causing the newly solidified material to form a mass once placed into packaging. 
     Another problem is commonly encountered with emulsifiers that do not contain a sufficient amount of nucleating hard fat to initiate crystallization. In this case the emulsifier does not form a flake or a chip when cooled, but forms a continuous sheet of material which peels off the belt or drum cooling device 
     It will be appreciated by those skilled in the art that increasing retention time on the cooled rotating drum is an insufficient solution to this problem. Depending on the material being applied to the drum, if it is cooled too completely while on the drum, it will crack away from the drum and fall off the drum prior to it reaching the scraper blade or reaching a point at which collection of the material is desired. In certain types of drum cooling systems, the liquid is applied by the bottom of the drum rotating through a vat or pool of warmed liquid. The liquid then adheres to the drum and is cooled during the rotation of the drum, and the material is scraped from the drum prior to a second emersion in the vat of liquid. In this situation, slowing the drum can result in substantial loss of heat into the vat of hot or warm oil or triglyceride and can result in the heating of the material in the vat and the cooling of the drum operating at cross purposes. 
     Therefore, it would be beneficial to the food industry in general if an apparatus and method were available to solidify low-melting triglycerides and edible oils, emulsifiers and mixtures thereof and the like which avoided the drawbacks of the cold drum method of forming such solids. In addition, it would be a great benefit to the food industry if the method and apparatus allowed multiple substances to be layered upon one another to form a sandwiched solid of several different materials which could then be chipped or flaked and incorporated into foodstuffs. 
     The aforementioned debilities are overcome by the present invention, and the desirable advantages and solutions of the present invention will become apparent to those skilled in the art upon reading the following specification in conjunction with the drawings provided herein of a preferred embodiment of the invention. 
     SUMMARY OF THE INVENTION 
     The present invention utilizes a generally horizontal surface of a cold plate to allow longer contact times of a liquid with a cold plate in order to convert the liquid to its solid form and to effect a greater degree of solidification of the liquid than is possible using the chilled rotating drum method of solidification of liquids. The present invention further allows for increased removal of the latent heat of crystallization from the substance being solidified to reduce the rise in temperature within the material once it is packaged which results from the latent heat of crystallization in materials which are initially solidified using chilled rotating drum or moving belt apparatus and methodology. 
     In particular, the present invention utilizes a horizontal cooling plate to receive applications of a liquid material for conversion of the liquid from the liquid phase or form to the solid phase or form, and to provide the material with sufficient cold plate contact time to greatly reduce the remaining latent heat of crystallization after solidification of the material. The material is then scraped from the work surface of the cooling plate. The present invention accomplishes this method of solidifying liquids by moving an applicator or dispenser or spray nozzle across the surface of the cooling plate to dispense onto the cooling plate the liquid material. The method then scrapes the cooling plate to remove the solidified material from the work surface of the cooling plate by moving the scraper across the surface of the cooling plate. In a preferred embodiment of the invention, the apparatus utilizes a motor-driven screw drive rod to move a carriage holding spray nozzles and scrapers across the surface of the cooling plate to perform the previously described functions. However, it will be appreciated that any manner of moving the dispenser and scraper across the cooling plate would be an equivalent device. 
     In this apparatus and method, the objects of the present invention can be achieved which consist of cooling a liquid to a solid form while removing substantially all of the latent heat of crystallization from the formed solid to allow flaking of mixtures having a high percentage of low melting components. 
     Another object of the present invention is to allow increased retention time of a liquid on a cooling surface to permit removal of nearly all of the latent heat of crystallization and to lower the temperature of the resulting solid to a temperature which will allow the solid to easily be flaked and to avoid formations of sheets of material. 
     Another object of the present invention is to provide for simultaneous application of multiple liquids or multiple solids or mixtures of solids, liquids and/or gasses such as nitrogen or air onto a cooling plate so that multiple layered solids and solid solutions can be produced. 
     Yet another object of the present invention is to allow sequential applications of liquids and solids to a cold plate to provide multi-layered solids which can then be removed from the plate in their solid form. 
     The foregoing and other objects are intended to be illustrative of the invention and are not meant in a limiting sense. Many possible embodiments of the invention may be made and will be readily evident upon a study of the following specification and accompanying drawings comprising a part thereof. Various features and subcombinations of invention may be employed without reference to other features and subcombinations. Other objects and advantages of this invention will become apparent from the following description taken in connection with the accompanying drawings, wherein is set forth by way of illustration and example, an embodiment of this invention. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
       Preferred embodiments of the invention, illustrative of the best modes in which the applicant has contemplated applying the principles, are set forth in the following description and are shown in the drawings and are particularly and distinctly pointed out and set forth in the appended claims. 
         FIG. 1  is a longitudinal cross-sectional view taken along line  1 — 1  of  FIG. 7  of a preferred embodiment of the invention showing a scraper and a dispenser disposed for travel across the plate work surface; 
         FIG. 2  is a longitudinal cross-sectional view of another preferred embodiment of the invention showing a scraper and a first and a second dispenser disposed for travel across the plate work surface; 
         FIG. 3  is a fragmented plan view of the cooling plate of the embodiments of  FIGS. 1 and 2  and showing the exterior coolant lines and showing, in phantom lines, the voids in the cooling plate to allow circulation of coolant within the plate; 
         FIG. 4  is a transverse cross-sectional view taken along line  4 — 4  of FIG.  1  and showing the mounting of the scraper on a carrier for movement across the plate work surface and showing the scraper in contact with the cooling plate surface; 
         FIG. 5  is a transverse cross-sectional view taken along line  5 — 5  of FIG.  1  and showing the mounting of the dispenser on a carrier for movement of the dispenser across the plate work surface to dispense a substance onto the work surface; 
         FIG. 6  is graph of temperature with respect to time for a liquid undergoing initial mechanical cooling on the present invention and on a rotating drum followed by a residence period in a cooling room and showing the rise in temperature of the packaged solid formed on a rotating drum during the residence period; 
         FIG. 7  is a top and left-side perspective view of the embodiment of  FIG. 1  showing a dispenser on a carrier for movement of the dispenser across the plate work surface and showing the switches to activate and terminate various actions of the device; 
         FIG. 8  is a transverse cross-sectional view of an embodiment of the present invention in which two cold plates, dispensers and scrapers are mounted side-by-side and operated by a single screw drive; and 
         FIG. 9  is a longitudinal cross-sectional view of another preferred embodiment of the invention showing a double scraper and a double dispenser disposed on a single carrier for travel across the plate work surface; 
         FIG. 10  is graph of temperature with respect to the Solids Fat Index of a mixture of triglycerides and showing the various solids and liquid content of the mixture at different temperatures and showing the agglomeration boundary for such mixtures. 
     
    
    
     DESCRIPTION OF A PREFERRED EMBODIMENT 
     Referring now to  FIG. 1 , a longitudinal cross-sectional view of plate flaker  10  is shown. Plate flaker  10  is comprised of cooling plate  12  which is supported by a frame or base (not shown). Cooling plate  12  is cooled to a selected temperature by circulating coolant through voids  42  of cooling plate  12 . Mounted above work surface  13  of cooling plate  12  is carriage  28  which is mounted on screw drive  18  to permit back and forth or reciprocating movement of carriage  28  across work surface  13  of cooling plate  12 . Screw drive  18  is mounted generally above cooling plate  12  by bearings  24   a ,  24   b  which are mounted on head plate  14  and end plate  16 . Screw drive  18  extends through bearing  24   a  for connection to belt  22  which is attached to screw drive motor  20 . Drive motor  20  is a reversible motor which allows screw drive  18  to be turned selectively in the clockwise or counter-clockwise direction in order to impart reversible movement to carriage  28  to allow carriage  28  to move back and forth across cooling plate  12 . 
     Still referring to  FIG. 1 , in a preferred embodiment, carriage  28  has spray nozzle  32  and flow valve  30  attached to carriage  28  to accomplish the distribution or spraying of a liquid material  47  onto cooling plate  12 . The spraying of material onto cooling plate  12  is accomplished during the movement, or reciprocation, of carriage  28  on screw drive  18  along the distance of work surface  13  of cooling plate  12 . Also attached to carriage  28  is scraper  34 . Scraper  34  is moveable between a raised position which is out of contact with work surface  13  and a lowered position which is in contact with work surface  13 . Scraper  34  is raised and lowered by pneumatic cylinders  36  which are provided with cylinder guide rods  38  to stabilize movement of scraper  34 . In a preferred embodiment (FIG.  4 ), cylinders  36  are pneumatically activated by gas pressure from line  37 ′ causing downward travel of scraper  34 . The upward movement of scraper  34  is operated by gas pressure in line  37  ( FIG. 4 ) to active cylinder  36 . It will be appreciated by those skilled in the art that carriage  28  can carry more than one spray nozzle  32  and flow valve  30 . For example, multiple spray nozzles  32 , each equipped with a flow valve  30 , allow the spraying of multiple components onto work surface  13  of cooling plate  12 . By way of example and not limitation, it will be appreciated that a first spray nozzle  32  could deliver a first liquid onto work surface  13 , while simultaneously, a second spray nozzle  32  is delivering a second liquid onto work surface  13 , and while a third spray nozzle  32  or additional spray nozzles  32  are delivering additional liquids onto work surface  13 . In this manner, a number of different liquids could be simultaneously delivered onto work surface  13  of cooling plate  12 . Alternatively, the multiple spray nozzles  32  previously mentioned, could be operated in a sequential manner by alternating spray nozzles during multiple passes of carriage  28  on screw drive  18  across work surface  13 . 
     By further way of example and not limitation, it may be useful to equip carriage  28  with multiple spray nozzles  32 , each of which delivers a separate liquid or solid material onto work surface  13 . For instance, during a first reciprocation or pass across work surface  13 , a first spray nozzle  32  might deliver a base liquid onto work surface  13  to solidify the liquid into a solid. On a second pass, a second spray nozzle  32  might spray a powder aerosol onto the first layer, and on a third pass, a third spray nozzle  32  could deliver a second liquid layer or solid powder aerosol or solid via a solids applicator onto work surface  13  to build up a multiple layered product on work surface  13  of cooling plate  12 . It will be appreciated by those skilled in the art that by the use of separate spray nozzles to deliver differing amounts of material onto work surface  13  that differential layer thicknesses could be provided onto work surface  13  to accumulate. Alternatively, it will be appreciated that the pump speed can be varied by slowing and increasing the pump speed to affect the flow of the material onto work surface  13  or to slow the travel of the carrier while maintaining constant material thickness on work surface  13 . In addition, such variation in layer thickness could be achieved by increasing or slowing down the speed at which screw drive  18  rotates. 
     The addition of solid material onto work surface  13  can be accomplished through the use of a solids applicator which is well known in the industry. The solids applicator consists of a hopper having a flow tube descending therefrom and a rotating breaker bar mounted in the bottom of the hopper. As the hopper is moved across work surface  13 , whether by attachment to a carriage  28  or another device for moving the hopper, the solid material which has been loaded into the hopper is distributed across work surface  13  to mix with other materials which have been loaded onto work surface  13 . 
     Referring now to  FIG. 2 , an alternate method of providing for multiple applications of materials onto work surface  13  of cooling plate  12  will be discussed. In  FIG. 2 , an embodiment of the invention is shown in which a second applicator  46  is provided. Second applicator  46  allows for a second layer of material to be dispersed onto work surface  13  in a sequential manner by using applicators on multiple carriers. 
     In operation, the embodiment of  FIG. 2  can apply a second layer from applicator  46  while following close behind first applicator  45 . In  FIG. 2 , second applicator  46  has already completed laying down second applicator layer  47  onto work surface  13  and first applicator  45  is applying a second layer. In placing layer  47  on work surface  13 , second applicator  46  has traveled from near first applicator  45  toward head plate  14 , or in the direction of Arrow B. In placing a second layer onto work surface  13 , and on top of second applicator layer  47 , first applicator  45  travels toward second applicator  46  while spraying a liquid or a powder from nozzle  32   a  or from a solids applicator onto layer  47 . Once first applicator  45  has completed its application of material onto work surface  13  on top of second applicator layer  47 , scraper  34  of first applicator  45  can be lowered onto work surface  13 . First applicator  45  is then moved in the direction of Arrow A to scrape the now solid material off of work surface  13  and toward end plate  16  where the solid material  47  will fall through opening  17  and onto conveyor  39 . 
     Referring now to  FIG. 3 , the assembly used to cool plate  12  and work surface  13  is shown.  FIG. 3  is a fragmenting plan view of cooling plate  12 . Cooling plate  12  is provided with voids  42  which are bored completely through cooling plate  12 . Voids  42  allow a coolant to be introduced into cooling plate  12  by coolant inlet pipe  40 . The coolant is selected to establish cooling plate  12  at a temperature sufficient to change the material layered onto work surface  13  from a liquid into a solid that flakes. The coolant circulates through a section of cooling plate  12  and exits from cooling plate  12  by coolant return pipe  44 . The coolant is then circulated through a compressor or refrigeration system to again reduce the temperature of the exiting coolant to the appropriate temperature for reuse to cool cooling plate  12 . 
     Referring now to  FIG. 4 , the transverse cross-sectional view of the embodiment shown in  FIG. 1  presents scraper bar  34  in its downward position so that it is in contact with work surface  13  of cold plate  12 . Scraper  34  is raised and lowered by pneumatic cylinders  36  and is stabilized during its movement by cylinder guide rods  38 . In operation, once a material has been placed onto work surface  13  and has solidified, scraper  34  is lowered onto work surface  13  and the carriage advanced in order to scrape the material off of work surface  13  and to push the material toward void or opening  17  ( FIG. 1 ) and onto conveyor  39 . 
     Referring now to  FIG. 5 , the mounting of carriage  28  will be discussed in greater detail.  FIG. 5  is a transverse cross-sectional view of the embodiment of FIG.  1  and shows work surface  13  of cooling plate  12  to be below spray nozzle or dispenser  32 . Dispenser  32  receives a liquid fluid supply by connection with feed tube  58  which is connected to a supply (not shown) of material to be layered onto work surface  13 . Feed tube  58  travels toward dispenser  32  from a supply and terminates at flow valve  30 . Flow valve  30  is, in a preferred embodiment, pneumatically operated and provides positive flow and flow shut off to dispenser or spray nozzle  32 . Adjacent flow valve  30  is carriage drive block  26  containing a threaded nut mounted to a flange which is adapted to receive the threads of acme screw drive rod  18  which passes through carriage drive block  29 . Carriage drive block  29  allows carriage  28  to travel along screw drive rod  18  as drive rod  18  is rotated in either a clockwise or counterclockwise direction by motor  20  and belt  22  (FIG.  1 ). Carriage  18  is directed in its movement along the distance of cooling plate  12  by traveler bearings  50  which are attached to carriage  28 . Traveler bearings  50  are connected to traveler rod  52  which is secured to support plate  54 . This particular arrangement imparts stability and strength to the preferred embodiment and allows carriage  28  to operate continuously for long periods of time and reduces the number of moving parts which could result in failure during long hours of operation. Above support plate  54  is stand off plate  56  which can be used to mount a second carriage  28   b  ( FIG. 2 ) to allow use of additional dispensers or spray nozzles  32 . 
     Referring now to  FIG. 6 , a graphical analysis of the beneficial results obtained from the present invention is shown. In  FIG. 6 , the temperature with respect to time is shown for a single substance which has been mechanically cooled by both a conventional rotating drum or roller method and the cooled flat plate of the present invention. Using the roller or rotating drum, it can be seen by examination of broken line that the liquid is placed on the drum at time T 1  at a temperature of approximately 120° F. During the approximately 10-20 seconds exposure time to the chilled roller or drum, the temperature of the substance is reduced to approximately 60-65° F. which is the temperature at which the material sufficiently hardens to enable the material to be scraped off the drum and fragmented into flakes or chips at time T 2 . At time T 2 , packaging of the material occurs just after removal of the material from the belt, drum or roller. 
     In the case of the rotating drum method, the material is placed into a package and the package placed into a cooling room of approximately 40° within about two minutes of packaging. At time T 2 , the time period on  FIG. 5  changes from seconds to days. The material which has been flaked on the rotating drum method then begins a rise in temperature shortly after removal from the drum. This deviation of temperature which continues over approximately the first three days the material is stored in the cooling room. This development of heat within the packaging is a result of the latent heat of crystallization which is given off as the material continues to harden within the package within the cooling room. At approximately the third day in the cooling room, the temperature of the packaging material begins to approach the temperature of the cooling room. 
     The temperature rise observed during the first one to three days in the cooling room due to the latent heat of crystallization is a substantial problem which results from the incomplete initial solidifying or crystallization of the material using the rotating drum method. Since the material is only partially solidified or crystallized on the rotating drum during the mechanical cooling period, additional solidification of the material continues during the cooling room, and the latent heat of crystallization is given off. This latent heat of crystallization as previously described tends to result in a rise in temperature of the packaged material. This rise in temperature can oftentimes be sufficient to bring the material again close to its melting point which results in fusion of the material within the package. This fusion problem is compounded by the palletizing of the packages for shipment. The grouping of the packages reduces the removal of heat from the packages and the internal packages on the pallet reach even a higher temperature than the outer packages. 
     This is a highly undesirable state and reduces the value of the material produced and also causes manufacturers of the material to institute a long holding period within a cooling room prior to shipment of the material. This long holding period increases inventory and stocks of packaged material which must be maintained in a cooling room for days, if not weeks, prior to shipment of the material. The present invention allows the reduction or elimination of the latent heat of crystallization temperature increase in packaged material and substantially shortens the amount of inventory which a producer needs to keep on hand prior to shipment and also reduces the amount of holding time of material prior to shipment. Both of these factors result in a substantial savings in production costs to the manufacturer. 
     Referring now to the solid line shown in  FIG. 6 , the results of the inventive method on the same liquid as was applied to the rotating drum will be discussed. The liquid is applied to the inventive flaking plate of the present invention at approximately 120°. During approximately the first ten to thirty (10-30) seconds of time in contact with the plate, the liquid drops in temperature from approximately 120° to approximately 25° and is converted to its solid state. The material is then scraped off of work surface  13  ( FIG. 1 ) prior to time T 2  after which it is immediately packaged. Subsequent to time T 2 , the material formed on the cold plate of the present invention undergoes only a slight rise in temperature due to latent heat of crystallization and production room temperature. In fact, in the example shown in  FIG. 6 , the temperature of the material rises to the temperature of the cooling room and stabilizes at the cooling room temperature of approximately 40° Fahrenheit. As is shown in the graph of  FIG. 6 , the material produced using the inventive method and apparatus exhibits little or no increase in temperature within the package due to the latent heat of crystallization. 
       FIG. 7  is a perspective view of the embodiment of FIG.  1 . Shown in  FIG. 7  are several switches which are switched off and on during the travel of carriage  28  along the work surface of the invention. An operation cycle of the invention will now be described beginning when carriage  28  is positioned at limit switch  63 . At this position, switch  63  has been pushed in the direction of plate  14  by the movement of carriage  28  toward plate  14 . This movement of switch  63  stops the movement of carriage  28  toward plate  14  and reverses the direction of operation of motor  20  and lowers scraper  34  ( FIG. 1 ) to contact work surface  13  and starts a timer for a timing interval. At the conclusion of the timing interval, the timer activates motor  20  to send carriage  28  toward plate  16 . During this movement toward plate  16 , carriage  28  activates limit switch  62  to cause the opening of valve  30  to turn-on the flow of liquid from dispenser  32 . Carriage  28  continues toward plate  16  and activates limit switch  65  to close valve  30  and turn-off the flow of the liquid from dispenser  32 . Carriage  28  continues until it contacts limit switch  60  which stops the carriage, raises scraper  34  and activates a timer. At the end of the timing interval, motor  20  is activated in the reverse direction. In the reverse direction, limit switch  62  is reset to its initial position so it can again activate the flow of liquid on the return trip of carriage  28  toward plate  16 . Adjacent plate  14  and plate  16  are limit switches  61  and  64  which, if tripped, cut the power to the invention to emergency stop the travel of carriage  28 . 
     In this manner, one cycle of operation of the invention is accomplished. That is, a liquid material has been laid onto work surface  13  and solidified while on work surface  13  which is then followed by a pass along work surface  13  and cold plate  12  by carriage  28  with the scraper in the downward position to remove the material from work surface  13  whereupon the material is pushed through void  17  ( FIG. 1 ) and onto conveyor  39  (FIG.  1 ). It will be appreciated that the previous description of the operation in  FIG. 7  has only described the very basic mode of operation of the present invention. It will be appreciated from the foregoing discussion that multiple passes of carriage  28  could be made on work surface  13  in order to distribute multiple layers of materials or multiple liquid and solid phases of material onto work surface  13 . 
     Referring now to  FIG. 8 , yet another embodiment of the present invention is shown wherein two iterations of the invention are placed side by side whereupon they are operated by a single screw drive  18  which is attached to carriage  28   a  and to carriage  28   b . In the embodiment of  FIG. 8 , a single cooling system is utilized which introduces coolant at pipe  40  which then travels through cold plate  12   a  and onto cold plate  12   b  of the second iteration of the invention to exit from pipe  44 . It will be appreciated that many such iterations of the invention could be connected in a series to operate simultaneously in order to increase the quantity of material generated during any portion of time. 
     Referring now to  FIG. 9 , another embodiment of the invention is shown having dual scrapers  34   a ,  34   b  and dual dispensers  32   a ,  32   b  on a single carrier  28  and dual conveyors  39   a ,  39   b  at either end. This embodiment permits layer  47  of a mixture to be dispensed onto work surface  13  while the scraping function is conducted upon a previously dispensed layer to produce flakes  35 . In  FIG. 9 , the embodiment is shown scraping flakes  35  into void  17  for movement by conveyer  39 . After an appropriate interval of time to allow sufficient solidification, scraper  34   a  will be lowered and carrier  28  will be moved toward end  14  to scrape off layer  47 . 
     In the foregoing description, certain terms have been used for brevity, clearness and understanding; but no unnecessary limitations are to be implied therefrom beyond the requirements of the prior art, because such terms are used for descriptive purposes and are intended to be broadly construed. Moreover, the description and illustration of the invention is by way of example, and the scope of the invention is not limited to the exact details shown or described. 
     Certain changes may be made in embodying the above invention, and in the construction thereof, without departing from the spirit and scope of the invention. It is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not meant in a limiting sense. 
     An operation cycle of the invention will now be described beginning when carriage  28  is positioned at limit switch  63 . In this position switch  63  has been pushed in the direction of plate  14  by the movement of carriage  28  toward plate  14 . This movement of switch  63  stops the movement of carriage  28  toward plate  14  and reverses the direction of operation of motor  20  and lowers scraper  34  ( FIG. 1 ) to contact work surface  13  and starts a timer for a timing interval. At the conclusion of the timing interval, the timer activates motor  20  to send carriage  28  toward plate  16 . During this movement toward plate  16 , carriage  28  activates limit switch  62  to cause the opening of valve  30  to turn on the flow of liquid from dispenser  32 . Carriage  28  continues toward plate  16  and activates limit switch  65  to close valve  30  and turn off the flow of the liquid from dispenser  32 . Carriage  28  continues until it contacts limit switch  60  which stops the carriage, raises scraper  34  and activates a timer. At the end of the timing interval motor  20  is activated in the reverse direction. In the reverse direction, limit switch  62  is reset to its initial position so it can again activate the flow of liquid on the return trip of carriage  28  toward plate  16 . 
     Having now described the features, discoveries and principles of the invention, the manner in which the inventive Plate Flaker is constructed and used, the characteristics of the construction, and advantageous, new and useful results obtained; the new and useful structures, devices, elements, arrangements, parts and combinations, are set forth in the appended claims. 
     It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.