Patent Publication Number: US-2016227811-A1

Title: Mold in place system and method of making confectionery products

Description:
FIELD OF THE INVENTION 
     This present invention relates generally to systems and methods for forming and packaging food items, and more specifically to mold-in-package systems and methods for forming confectionery products directly in their final packaging. 
     BACKGROUND OF THE INVENTION 
     In known confectionery production systems and methods, products are first formed in a mold and then must be sufficiently cooled, crystalline and/or solidified to be removed from the mold before packaging can occur. This increases the per-unit production time for these products, increases the length of the production line, results in higher production costs, limits the producer&#39;s ability to form the products into unique shapes and transfer the products into packaging without damaging the product, and places constraints on the producer&#39;s ability to adjust the dimensions of products due to concerns about product integrity during de-molding and packaging. 
     There is a need for improved systems and methods that overcome these and other drawbacks of the prior art. 
     BRIEF SUMMARY OF THE INVENTION 
     Aspects of the Invention 
     Additional aspects of the invention include: 
     Aspect 1. A method of making a confectionery having at least one component, the method comprising:
         (a) forming at least one film cavity in a carrier film by causing each of the at least one film cavity to conform to and nest with one of at least one mold cavity of a first mold, each of the at least one mold cavity having a mold shape;   (b) depositing a first confectionery component of the at least one component into each of the at least one film cavity, the first confectionery component being in liquid phase at the beginning of the depositing step;   (c) cooling the deposited first confectionery component until it at least partially solidifies; and   (d) attaching a sealing film to the carrier film to create at least one sealed internal volume, each of the at least one sealed internal volume being defined by the sealing film and one of the at least one film cavity.       

     Aspect 2. The method of one or more of aspects 1-17, further comprising:
         (e) after performing step (b), applying a forming mold having a forming shape to the deposited first confectionery component until the deposited first confectionery component is sufficient solidified to retain the forming shape when the forming mold is separated from the deposited first confectionery component.       

     Aspect 3. The method of one or more of aspects 1-17, further comprising, prior to and/or during the performance of step (e), cooling the forming mold to a temperature that is no greater than a temperature at which the first confectionery component will solidify. 
     Aspect 4. The method of one or more of aspects 1-17, further comprising:
         (f) after performing step (b), depositing a second confectionery component of the at least one confectionery component into each of the at least one cavity.       

     Aspect 5. The method of one or more of aspects 1-17, further comprising:
         (f) before performing step (b), depositing a second confectionery component of the at least one confectionery component into each of the at least one cavity, the second confectionery component being in solid phase.       

     Aspect 6. The method of one or more of aspects 4-17, further comprising:
         (g) after performing step (f), depositing a top layer comprising the first confectionery component or a third confectionery component into each of the at least one cavity.       

     Aspect 7. The method of one or more of aspects 1-17, wherein the forming step comprises heating and applying a vacuum to each of the at least one film cavity. 
     Aspect 8. The method of one or more of aspects 7-17, wherein the step of applying a vacuum to each of the at least one film cavity comprises applying a vacuum to at least one hole formed in each of the at least one mold cavity. 
     Aspect 9. The method of one or more of aspects 1-17, further comprising:
         (h) performing step (b) with each of the at least one film cavity nested with one of the at least one mold cavity.       

     Aspect 10. The method of one or more of aspects 1-17, further comprising:
         (h) after performing step (a), keeping each of the at least one film cavity nested with one mold cavity at least until step (d) has been performed.       

     Aspect 11. The method of one or more of aspects 1-17, wherein step (a) comprises forming at least one film cavity of a carrier film by causing each of the at least one film cavity to conform to and nest with one of at least one mold cavity of a first mold, each of the at least one mold cavity having a mold shape, the first mold comprising a platen having a plurality of mold cavities. 
     Aspect 12. The method of one or more of aspects 1-17, further comprising:
         (i) before performing step (a), extending over a platen a first portion of the carrier film from a roll of the carrier film, securing the first portion of the carrier film to the platen, and cutting the first portion of the carrier film thereby completely disconnecting the first portion of the carrier film from the roll of the carrier film.       

     Aspect 13. The method of one or more of aspects 1-17, further comprising:
         (j) performing steps (a) through (d) along a path that is non-linear.       

     Aspect 14. The method of one or more of aspects 1-17, further comprising:
         (k) providing a carrier film having sufficient rigidity to maintain a shape of the at least one film cavity if the first confectionery component is warmed to a liquid phase after step (d) has been performed.       

     Aspect 15. The method of one or more of aspects 1-17, further comprising:
         (l) after performing step (d), cutting the carrier film and sealing film into a plurality of units, each unit comprising at least one of the at least one film cavity.       

     Aspect 16. The method of one or more of aspects 1-17, wherein step (d) further comprises bonding the sealing film to the carrier film, the sealing film having a thickness that is less than a thickness of the carrier firm. 
     Aspect 17. The method of one or more of aspects 1-17, wherein step (d) comprises attaching a sealing film to the carrier film, the sealing film comprising a portion of the carrier film. 
     Aspect 18. A method of making a confectionery having at least one component, the method comprising:
         (a) securing a carrier film to a platen having a plurality of mold cavities, each of the plurality of mold cavities having a mold shape;   (b) forming a plurality of film cavities in the carrier film by causing the film to nest with and conform to the mold shape of each of the plurality of mold cavities;   (c) depositing a first confectionery component of the at least one component into each of the plurality of film cavities, the first confectionery component being in liquid phase at the beginning of the depositing step;   (d) cooling the deposited first confectionery component until it at least partially solidifies;   (e) attaching a sealing film to the carrier film to create a plurality of sealed internal volumes, each of the of sealed internal volumes being defined by the sealing film and one of the plurality of film cavities; and   (f) after performing step (b), keeping the carrier film secured to the platen and keeping each of the plurality of film cavities nested with one of the plurality of mold cavities at least until step (e) has been performed.       

     Aspect 19. The method of one or more of aspects 18-27, further comprising:
         (g) after performing step (c), applying a forming mold having a forming shape to the deposited first confectionery component until the deposited first confectionery component is sufficient solidified to retain the forming shape when the forming mold is separated from the deposited first confectionery component.       

     Aspect 20. The method of one or more of aspects 19-27, further comprising, prior to and/or during the performance of step (g), cooling the forming mold to a temperature that is no greater than a temperature at which the first confectionery component will solidify. 
     Aspect 21. The method of one or more of aspects 18-27, further comprising:
         (h) after performing step (c), depositing a second confectionery component of the at least one confectionery component into each of the plurality of film cavities.       

     Aspect 22. The method of one or more of aspects 18-27, further comprising:
         (h) before performing step (b), depositing a second confectionery component of the at least one confectionery component into each of the at least one cavity, the second confectionery component being in solid phase.       

     Aspect 23. The method of one or more of aspects 21-27, further comprising:
         (i) after performing step (h), depositing a top layer comprising the first confectionery component or a third confectionary component into each of the plurality of film cavities.       

     Aspect 24. The method of one or more of aspects 18-27, wherein the forming step comprises heating and applying a vacuum to each of the plurality of film cavities. 
     Aspect 25. The method of one or more of aspects 24-27, wherein the step of applying a vacuum to each of the plurality of film cavities comprises applying a vacuum to at least one hole formed in each of the plurality of mold cavities. 
     Aspect 26. The method of one or more of aspects 18-27, wherein step (a) further comprises extending over the platen a first portion of the carrier film from a roll of the carrier film, securing the first portion of the carrier film to the platen, and cutting the first portion of the carrier film thereby completely disconnecting the first portion of the carrier film from the roll of the carrier film. 
     Aspect 27. The method of one or more of aspects 18-27, wherein step (e) comprises attaching a sealing film to the carrier film, the sealing film comprising a portion of the carrier film. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The foregoing summary, as well as the following detailed description of the invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention disclosed herein, certain embodiments in accordance with the herein disclosed invention are shown in the drawings. It should be understood, however, that the herein disclosed invention is not limited to the precise arrangements shown. It should also be understood that, in the drawings, the parts are not necessarily drawn to scale. The present invention will hereinafter be described in conjunction with the appended drawing figures, wherein like numerals denote like elements. In the drawings: 
         FIG. 1  is a schematic top plan view of a first embodiment of a line according to the present invention; 
         FIG. 2  is a flow chart detailing steps of the stations thereof; 
         FIG. 3 a    is a top perspective view of a platen for forming confectionery products according to the present invention; 
         FIG. 3 b    is a bottom perspective view thereof; 
         FIGS. 4 a  and 4 b    are perspective views of steps performed at a film and frame loading station of the line of  FIG. 1 ; 
         FIGS. 5 a -5 c    are perspective views of steps performed at a thermoforming station thereof; 
         FIGS. 6 a -6 c    are perspective views of steps performed at a sealing station thereof; 
         FIGS. 7 a -7 c    are perspective views of steps performed at a cut station thereof; 
         FIG. 8  is a schematic perspective view of a second embodiment of a line according to the present invention; 
         FIG. 9  is a perspective view of a thermoforming station thereof; 
         FIG. 10  is a close-up partial view of a cutting station thereof; 
         FIG. 11  is a schematic perspective view of a third embodiment of a line according to the present invention; 
         FIG. 12  is a close-up partial view of a film feeding and thermoforming station thereof; 
         FIG. 13  is a close-up partial view of a filling and cooling station thereof; 
         FIG. 14 a    is a perspective view of a cutting station thereof; and 
         FIG. 14 b    is a close-up partial view of the cutting station shown in  FIG. 14   a.    
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The ensuing detailed description provides preferred exemplary embodiments only, and is not intended to limit the scope, applicability, or configuration of the herein disclosed inventions. Rather, the ensuing detailed description of the preferred exemplary embodiments will provide those skilled in the art with an enabling description for implementing the preferred exemplary embodiments in accordance with the herein disclosed invention. It is understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope of the invention, as set forth in the appended claims. 
     To aid in describing the invention, directional terms may be used in the specification and claims to describe portions of the present invention (e.g., upper, lower, left, right, etc.). These directional definitions are merely intended to assist in describing and claiming the invention and are not intended to limit the invention in any way. In addition, reference numerals that are introduced in the specification in association with a drawing figure may be repeated in one or more subsequent figures without additional description in the specification, in order to provide context for other features. 
     In the claims, letters are used to identify claimed steps (e.g., (a), (b), and (c)). These letters are used to aid in referring to the method steps and are not intended to indicate the order in which claimed steps are performed, unless and only to the extent that such order is specifically recited in the claims. 
     Mold-in-place packaging provides several benefits over prior art methods of making confectioneries. No transfer from a mold to packaging is required, thereby simplifying production. The product form follows the form of the pack, thereby increasing opportunities for three-dimensional product production and branding. Mold-in-place production renders the product more easily and cleanly removable from the pack. The product can be made more easily accessible through a peelable lid. The product packaging base and lid materials can differ, thereby imparting different aesthetic and/or functional characteristics. 
     Referring to  FIG. 1 , a first embodiment of a production line  101  for forming confectionery products, comprising a plurality of stations, will be described in detail. In this embodiment, the line  101  comprises—in sequential order—a film and frame loading station  108 , a thermoforming station  110 , a depositor station  111 , cold stamping stations  112 , 113 , a filling A station  114 , a wafer/biscuit station  115 , a filling B station  116 , a cooling station  117 , an inserter station  118 , a deposit station  119 , a cooling station  120 , a sealing station  121 , and a cut station  122 . Packing of the product and additional cooling steps (not shown) will often be performed after the product has been cut at the cut station  122 . 
     The arrangement of stations between the thermoforming station  110  and the sealing station  121  will depend upon the product being made. For example, a filled chocolate product may require the depositor station  111  (to deposit chocolate), cold stamping station  112  (to form the deposited chocolate into a shell), filling A station  114  (to introduce the filling), and deposit station  119  (to apply the top layer of chocolate). In this example, the wafer/biscuit station  115 , filling B station  116 , cooling station  117 , and inserter station  118  could be omitted. 
     A pre-heater  109  could optionally be provided as part of the film and frame loading station  108  to pre-heat and thereby softens the carrier film before it is loaded onto the platen. The pre-heater  109  is more likely to be needed for relatively thick and/or stiff carrier films. 
     In this embodiment, the line  101  is operated in a non-continuous manner using a moveable platen in which the product is formed and packaged. As will be described in further detail below, in this embodiment, the platen is transported from station to station with the carrier film attached. The non-continuous platen based line  101  allows for independent control at each of the stations, with the individual platens used as carrying supports at every stage of the product forming process. 
       FIG. 2  is a flow chart detailing exemplary steps performed at various stations of the line  101 . At the film and frame loading station  108 , as shown in  FIGS. 4 a  and 4 b   , a thermoplastic film is unwound from a reel, placed under tension, secured to a platen, and the thermoplastic film is then cut approximately to the size of the platen. At the thermoforming station  110 , the platen is sealed to a vacuum source, the film is heated and vacuum formed into one or more mold cavities in the platen to form corresponding film cavities, and the film is retained in place on the platen. In alternate embodiments, pressure forming could be used instead of vacuum forming. If pressure forming is used, it could optionally be implemented with a plug assist. 
     At depositor station  111 , a confectionery (e.g., chocolate) is deposited into the at least one film cavity to form the base of the product, and if necessary the product is agitated or vibrated in one or more planes to spread the confectionary and/or remove air from the confectionery. If necessary, the confectionery is then cold stamped at one or both of cold stamping stations  112 , 113  using one or more tools (e.g., a “frozen cone,” as would be appreciated by one having ordinary skill in the art) in order to partially cool the confectionery and shape it such that one or more fillings and/or inclusions (e.g., nuts, candies, toppings) can be provided. At additional stations: if applicable, one or more fillings and or biscuits/wafers can be placed on top of the product at stations  114 , 115 , 116 ; if necessary the product can be further cooled at cooling station  117 ; if applicable additional inclusions can be placed on top of the confectionery at inserter station  118 ; if applicable a top layer of confectionery (e.g., chocolate) can be placed on top of the product at depositor station  119 ; and if necessary the product can be further cooled at cooling station  120 . 
     Stations  111 - 120  of the present embodiment can be implemented using methods and equipment known in the art. It should further be understood that the selection and arrangement of stations  111 - 120  is based on the particular characteristics and components of the confectionery which is being produced on the line  101 , and that stations may be added or removed from the line  101  as necessary based on the confectionery that is to be produced on the line  101 . 
     In this embodiment, the film cavity  180  is sealed by attaching a top layer of film thereto at sealing station  121 , thereby forming a filled-in pack that holds one or more units of confectionery product. If necessary, individual units of product are then cut apart at cut, pack, and cool station  122 , where the product is also removed from the line  101  and packaged. In other embodiments, sealing could be performed by folding a portion of the cavity film  144  over the film cavity  180  instead of providing a separate layer of film. 
     Referring now to  FIGS. 3 a  and 3 b   , a platen  124  according to the present embodiment will be described. In this embodiment, the platen  124  comprises a plurality of mold cavities  125 , each of the mold cavities  125  comprising a wall  126 , a floor  127 , and a plurality of vacuum holes  128  located therein. The upper side of the platen  124  may contain a plurality of corner guides  130  that may be used to align the platen  124  during later stations within the line  101 . The lower side of the platen  124  comprises a perimeter wall  131  and an interconnected volume  132  that extends around and between the lower sides of the mold cavities  125 . As can be seen in  FIG. 3 b   , each of the vacuum holes  128  extend through the platen  124 , and the lower side of each mold cavity  125  comprises an extension  129  that increases the rigidity of the platen  124  and reduces deformation thereof during the thermoforming step. 
     The functionality of the thermoforming station  110  is shown in  FIGS. 4 a  and 4 b   . In order to index the carrier film  144  onto the platen  124 , first the platen  124  is placed onto a support surface and the carrier film  144  is fed off of a reel  133 , over top the platen  124 , until it extends at least to a front gripper  134 . The leading end of the carrier film  144  is clamped between an upper portion  135  and a lower portion  136  of the front gripper  134 , and the trailing end of the carrier film  144  is clamped between an upper portion  138  and a lower portion  139  of a rear gripper  137 . A frame  143  is then placed on top of the carrier film  144  and platen  124  to index the carrier film  144  in place. A cutter  140  comprising a blade  141  and a lower portion  142  is then used to cut the carrier film  144  behind the rear gripper  137 . In this embodiment, the portion of the carrier film  144  secured to the platen  124  is completely disconnected from film remaining on the reel  133  after being cut. 
     Many different materials and material gauges (thicknesses) are available for use as thermoforming films. The materials used range from soft materials to semi-rigid materials, and include but are not limited to PP, PE, PA/PE, PC/PE, PETg, and PVC. Preferred thicknesses are between 65 micrometers and approximately 300 micrometers. The material used for sealing films can have similar characteristics to the material used for the carrier film (i.e., for forming the film cavities), or the sealing films can be thinner since there is no need to thermoform the sealing film. 
     As shown in  FIGS. 5 a   - 5   c,  the platen  124  is then transferred to the thermoforming station  110  where the one or more film cavities  180  are formed in the carrier film  144 . As shown in  FIG. 5 a   , the platen  124  is supported by a frame  145  below a heater  146 , which in this embodiment is an infrared heater. Located below the platen  124  is a plate  148  having an opening  151  therein. The opening  151  is attached to a vacuum hose  150 , which is attached to a vacuum source (not shown). The height of the plate  148  and attached vacuum hose  150  is adjustable via a pair of lift shafts  152   a , 152   b  so that the plate  148  can be brought into contact with the lower side of the platen  124 . The upper side of the plate  148  comprises a plurality of locating pins  153  that help to align the plate  148  with the platen  124  and support the platen  124  after it has been lifted off of the frame  145 . The upper side of the plate  148  also comprises a sealing strip  149  that forms a vacuum-tight seal with the lower side of the platen  124  when the plate  148  is brought into contact with the platen  124  with a sufficient amount of pressure. The lower side of the heater  146  also comprises a compression strip  147 . The compression strip  147  makes a vacuum-tight seal between the film and the upper side of the platen  124  when the platen has been brought into contact with the platen  124  with a sufficient amount of pressure. As shown in  FIG. 5 b   , the lift shafts  152   a , 152   b  are used to bring the plate  148  into contact with the platen  124 , lift the platen  124  off of the frame  145 , and bring the platen into contact with the lower side of the heater  146 . The heater  146  is used to soften the material of the carrier film  144 . Once sufficient pressure has been applied to both the upper and lower sides of the platen  124 , the vacuum source is used to draw a vacuum through the vacuum hose  150 , thereby evacuating the air from the volume located between the sealing strip  149  and the underside of the carrier film  144  clamped on to the top of the platen  124 . Due to the presence of the plurality of vacuum holes  128  through the one or more mold cavities  125  of the platen  124 , the carrier film  144  is stretched and drawn into each of the one or more mold cavities  125  in a conforming manner, thus forming a film cavity  180  (see  FIG. 5 c   ) within each of the mold cavities  125 . 
     Once the film cavities  180  have been formed within the platen  124 , the platen  124  is lowered away from the heater  146 , as shown in  FIG. 5 c   . Once the film cavities  180  have been formed, the platen  124  is then moved through an appropriate combination of stations in order to fully prepare the confectionery, the specific steps being performed depending upon the shape and composition of the confectionery. During one or more of the steps in which components of the confectionery product are inserted into the film cavity  180 , it may be desirable to apply a vacuum to the film cavities  180  to hold the film civilities  180  in a firmly nested position within each respective mold cavity  125 . This is most likely to be desirable during the step in which the first component of the confectionery product is deposited. Once the confectionery has been fully prepared, the platen  124  is then moved to the sealing station  121 . Once the film cavities  180  have been formed, each film cavity  180  preferably remains nested in a respective one of the mold cavities  125  until after the sealing step has been performed in the sealing station  121 . In this embodiment, the mold cavities  125  are female molds formed in the platen  124 . In other embodiments, male molds could be used. 
     As shown in  FIGS. 6 a   - 6   c,  the platen  124  is transferred to the sealing station  121 , where a sealing film  155  is used to seal each or a plurality of the film cavities  180 , thus defining an internal volume and encasing a confectionery  182  therein. In this embodiment the sealing film  155  is also a thermoplastic and may be comprised of the same material as the carrier film  144 . Alternatively, the sealing film  155  could be thinner and/or less rigid, or thicker and/or more rigid. In further alternate embodiments, the sealing film  155  could consist of a portion of the carrier film  144  that is folded over the film cavities  180 , then sealed in place. 
     As shown in  FIG. 6 a   , the sealing film  155  is fed from a lid film reel  154  and over the platen  124  until it extends at least to a front gripper  156 . The leading end of the sealing film  155  is clamped between an upper portion  157  and a lower portion  158  of the front gripper  156 , and the trailing end of the sealing film  155  is clamped between an upper portion  160  and a lower portion  161  of a rear gripper  159 . A cutter  162  comprising a blade  163  and a lower portion  164  is then used to cut the sealing film  155  behind the rear gripper  159 . As shown in  FIG. 6 b   , a sealing unit  165  is then lowered down via a pair of shafts  166   a , 166   b  such that a plurality of inner sealing heads  167  are each brought into indirect contact with the platen  124  outside of the upper perimeter of a respective film cavity  180 , and a plurality of outer sheaths that each surround a respective inner sealing head  167  are likewise lowered into contact with the sealing film  155 . As shown in  FIG. 6 c   , once the sealing film  155  has been sealed in respective locations to the top of the carrier film  144 , the frame  143  is removed via one or more electromagnets (not shown) and an array of filled-in packs  169  has been created. It should be understood that this array  169  can comprise one or more individual units of confectionery product. 
     Optionally, a vacuum could be used as the sealing film  155  is being applied in order to cause the sealing film  155  to conform to the top surface of the confectionery product. This may be particularly desirable in embodiments in which the top of the confectionery product protrudes from the film cavity  180  or if it is desirable to reduce the head space of the confectionery product. 
     Once the array of filled-in packs  169  has been created, in this embodiment the array  169  is transferred to cut station  122 . As shown in  FIGS. 7 a  and 7 b   , at the cutting station  122  a robot arm  170  is used to pick up the array of filled-in packs  169  and move it to a cutting location. The robot arm  170  comprises a top plate  171  and a plurality of vacuum extensions  172 , each of which terminates in a vacuum head  173  that is brought into contact with the array  169 . The vacuum heads  173  are operably connected to a vacuum source (not shown), which allows the vacuum heads  173  to create a seal with the array  169  and use the force of the suction provided by the vacuum source to lift and transfer the array  169 . As shown in  FIG. 7 b   , a cutter plate  174  having a plurality of pack cavities  175 —each of which corresponds with the size and dimensions of an individual unit of confectionery product of the array  169 —supports the array  169  during the cutting step of the process. As mentioned above, in alternate embodiments, the cutter plate  174  could be configured to correspond to the size of a plurality of units of the confectionery product in the array  169 . 
     As shown in  FIG. 7 c   , a die cutter  176  having a plurality of appropriately-sized blades  177  is then used to cut through the layers of film  155 , 144  so that individual units of filled-in-pack confections are created. In this embodiment, the die cutter  176  is a rotary cutter that functions by rolling along its longitudinal axis over the cutter plate  174 . In alternate embodiments, the die cutter  176  may be a plate-style cutter or could comprise one or more anvil-style linear or grid-like cutting blades, as appropriate based on the arrangement of the array  169 . After the cutting step, waste film is removed from the cutter plate  174 , and optionally an additional active cooling step may occur at this point. The filled-in-pack confections are then transferred to a packaging station (not shown), where they are packaged for end use, display, and/or transport. 
     Referring now to  FIGS. 8-10 , a second embodiment of a line  201  for forming confectionery products in place, comprising a plurality of stations, will be described in detail. Generally, the line  201  of  FIGS. 8-10  differs from the line  101  of  FIGS. 1-7   c  in that, in the line  201 , any platens used as part of the production process remain at each station and the reel of film that is used to form the one or more film cavities is maintained as a continuous web throughout the forming and filling stations and is simultaneously used to advance the confectionery product from station to station. 
     As shown in  FIG. 8 , the line  201  comprises a reel  225  from which the film  226  is fed to the line  201 , a film feeding and thermoforming station  210 , a depositor A station  211 , a cold stamping station  212 , a depositor B station  214 , a wafer/biscuit station  215 , a depositor C station  216 , an inserter station  218 , a depositor D station  219 , a cooling station  220 , a sealing station  221 , and a cutting station  222 . The stations  211 - 220  should be understood to be comparable to those discussed above with respect to the embodiment of  FIGS. 1-7   c,  and will not be discussed again in detail. It should be understood that the selection and arrangement of stations  211 - 220  is based on the particular characteristics and components of the confectionery which is being produced on the line  201 , and that stations may be added or removed from the line  201  as necessary based on the confectionery that is to be produced on the line  201 . Where the film that is being used to form the film cavities is above a certain minimum thickness, it is preferable to provide a pre-heater  209  as part of the film feeding and thermoforming station  210  that pre-heats and thereby softens the film  226  before it is fed into the thermo former. 
     As seen in  FIG. 9 , the film feeding and thermoforming station  210  comprises a cavity forming plate  223  comprising a plurality of mold cavities  224 . The film  226  is fed from the reel  225  over the top of the cavity forming plate  223  and indexed in place. A vacuum former  229  is provided below the cavity forming plate  223 , and is operably connected to a vacuum source (not shown). The cavity forming plate  223  has a plurality of vacuum holes (not shown) located therein, corresponding with individual mold cavities  224 . A heater  228 , which in this embodiment is an infrared heater, is provided above the cavity forming plate  223 . The heater  228  is brought down into contact with the upper side of the cavity forming plate  223  and the vacuum former is brought up into contact with the lower side of the cavity forming plate  223 , thereby sealing the film  226  therein. The vacuum source is then activated, which after evacuating the air from the volume draws the film  226  into the mold cavities  224  to form corresponding film cavities  227 , as shown in  FIG. 9 . After the thermoforming step, the film  226  is then advanced through the stations  211 - 220  via the use of a series of edge-grabbing mechanisms that intermittently hold the outer edges of the film  226  and advance the film  226  through the various stations of the line  201 . The sealing station  221  of the line  201  of  FIGS. 8-10  is conceptually the same as the sealing station  121  of the line  101  of  FIGS. 1-7   c  discussed above, and comprises a lid film reel  240  and a sealing waste take-up reel  241  (see  FIG. 8 ) that collects the unused sealing film after the array of filled-in packs  269  has been formed. 
       FIG. 10  shows a portion of a cutting station  222  of the line  201 . Once the array of filled-in packs  269  has been formed, the film advancement mechanisms move the array  269  into a cutter plate  230  having a plurality of pack cavities  231 , which supports the array  269  during the cutting step of the process. In this embodiment, the cutting station  222  has a plurality of cross-cut blades  232  that cut the array  269  widthwise. A pair of rotary cutters  234   a , 234   b,  each having a plurality of blades  235   a , 235   b,  are used to cut the array in the opposite directions, thereby leaving a plurality of filled-in packs  239 . In other embodiments, it may be preferable to position the rotary cutters  234   a,    234   b  before the cross-cut blades  232 . 
     The filled-in packs  239  are then moved via a belt  238 , optionally to an additional cooling station or a packaging station (not shown). In this embodiment, the die cutters  234   a , 234   b  are rotary cutters that function by spinning in place about their respective longitudinal axis. In alternate embodiments, the die cutter(s) may be a plate-style cutter or could comprise one or more anvil-style linear or grid-like cutting blades, as appropriate based on the arrangement of the array  269 . In this embodiment, after the cutting step, the trimmed edge material  236   a , 236   b  is taken up by the cutting waste take-up reel  242  (see  FIG. 8 ). 
     Referring now generally to  FIGS. 11-14   b,  a third embodiment of a line  301  for forming confectionery products in place, comprising a plurality of stations, will be described in detail. Generally, the line  301  of  FIGS. 8-10  differs from the line  201  of  FIGS. 8-10  in that the line  301  operates in a true continuous manner without any intermittent pauses at individual stations. The overall output rate of the line  301  is primarily dictated by the speed of its slowest operating station, which may be the filling and cooling station  311 . In the line  301  shown in  FIGS. 11-14   b,  the confectionery is of a single component (e.g., a single chocolate layer); therefore, no depositor, inserter, or other intermediate stations are provided in the line  301 . 
     As shown in  FIG. 11 , the line  301  comprises a reel  325  from which the film  326  is fed to the line  301 , a film feeding and thermoforming station  310 , a filling and cooling station  311  comprising a cooling unit  312 , a sealing station  321 , and a cutting station  322 . Where the film that is being used to form the film cavities is above a certain minimum thickness, it is preferable to provide a pre-heater  309  as part of the film feeding and thermoforming station  310  that pre-heats and thereby softens the film  326  before it is fed into the thermoformer. 
     As shown in  FIG. 12 , the film feeding and thermoforming station  310  comprises a cavity forming unit  323  comprising a plurality of mold cavities (not shown) and a pair of tensioner rollers  324   a , 324   b  that keep the film  326  taut over the cavity forming unit  323 . The cavity forming unit  323  is operably connected to a vacuum former  329  that permits a vacuum to be drawn in the cavity forming unit  323 , which thereby draws the film  326  into the mold cavities in the cavity forming unit  323  so that a plurality of corresponding film cavities  327  are formed therein. In this embodiment, the film cavities are formed by vacuum-forming female mold cavities. In alternate embodiments, a male mold cavity/protrusion could be used. The film  326  is then advanced to the filling and cooling station  311 . 
     The filing and cooling station  311  is partially shown in  FIG. 13 , and comprises a filling unit  330 , a filling tube  331 , and a plurality of feed nozzles  333  that move around a track  332 . As the film  326  is advanced down the line  301 , confectionery product is fed from the filling unit  330 , through the filling tube  331  and feed nozzles  333 , and into the individual film cavities  327  that have been formed in the film  326 . The rotational speed of the track  332  is matched with the linear speed of the movement of the film  326 . The confectionery  382  located in the filled film cavities  327  then passes below the cooling unit  312  before reaching the sealing station  321 , where a lid film  343  is fed from a lid film reel  342  and sealed to the film  326  to form an array of filled-in packs  369 . 
     The cutting station  322  is shown in detail in  FIGS. 14 a  and 14 b   , and comprises a cutting roller  335  comprising a plurality of blades  336  and a pack holding and transfer roller  337  comprising a plurality of pack cavities  338 . Each of the pack cavities  338  corresponds with the size and dimensions of an individual unit of confectionery product. The array of filled-in packs  369  enters the plurality of pack cavities  338  and come into contact with the blades  336  of the counter-rotating cutting roller  335 , thereby leaving a plurality of filled-in packs  340 . The filled-in packs  340  are then moved via a belt  339 , optionally to an additional cooling station or a packaging station (not shown). 
     Although exemplary implementations of the herein described systems and methods have been described in detail above, those skilled in the art will readily appreciate that many additional modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of the herein described systems and methods. Accordingly, these and all such modifications are intended to be included within the scope of the herein described systems and methods. The herein described systems and methods may be better defined by the following exemplary claims.