Patent Description:
Testing methods are widely known in the food industry whenever confectionery mass is to be tested before or during production. The temper curve is evaluated as the curve shape is regarded as characterizing the "quality" of the obtainable or achieved temper of the particular mass. Especially, the inclination or slope of a line through the point of inflection of the curve is regarded as a strong and reliable indicator for the tempering qualities of the particular mass. The slope of the line is often graduated as a tempering index having a range of <NUM>-<NUM>.

It is well known that it is a challenge to prepare and achieve high quality confectionery mass, such as for example chocolate mass, each time a recipe is altered. It could be by addition of other emulsifiers or types of fat, or when the tempering procedure itself is amended in temperatures or in time. Though the temper index measured is equal at a subsequent production, it does not mean at all, that the same crisp break, long shelf life or shiny appearance will be obtained.

The masses applied within the invention are any confectionery mass having a fat-content, that is able to crystallize into a stable, solid mass. It could for example be chocolate or chocolate-like mass, which may encompass all types of suspensions of non-fat particles such as sugar, milk powders and cocoa solids mixed up with a liquid fat constituent, so that the suspensions are capable of crystallizing. It could be chocolate or chocolate-like mass types used in any kind of production of confectionery articles.

When it comes to the most widely used chocolate mass types, the fat constituent comprises genuine cocoa butter typically in a content of up to approximately <NUM>%. However, the fat phase may also comprise substitutes as well. A small content of up to <NUM>-<NUM> % of genuine cocoa butter may still be left in the recipe. Substitutes may be in the form of other types of fat-containing oils such as palm-kernel oil. Chocolate types having the cocoa butter been replaced by other fats are often named commercially as compound chocolate, especially when the cocoa butter has been replaced completely by palm-kernel oil.

For the continuous tempering of the confectionery mass to be performed, it is decisive, that whether the fat phase constitutes of genuine cocoa butter or substitutes, the fat phase must be capable of crystallizing into stable crystal types, such as the βV-crystals developing in genuine cocoa butter. However, it is important to avoid instable crystals in the solidified mass. Only then, eatable chocolate articles with good taste, crisp break and shiny appearance are created. The solidified chocolate articles will also achieve the longest possible shelf life and the best resistance against bloom, as instable crystals are diminished. If there is a content of in-stable crystals left in the mass, they will give rise to shorter shelf-life as the articles will bloom more quickly as when in-stable crystals are not present.

For the manufacturers of articles made by such masses, it is always desirable, that the tempering process and apparatus can be adjusted to deliver tempered mass having a content of the stable crystal-type only, such as βV-crystals in chocolate mass. Only then, the manufacturer can rely on, that the quality of their chocolate products is consistent. Consequently, the manufacturer is testing their mass before and during the tempering by means of a temper curve and evaluating the shape and temper index thereof.

In an example useful for understanding the invention, a tempermeter is disclosed, the tempermeter comprising a casing having a cooling unit at the top carrying a cup with the sample as well as a computer unit adapted to calculate and provide a temper curve. The temper curve is printed on a strip chart recorder or shown on a screen or both. The computer is adapted to calculate the point of inflection and mark it at the temper curve. The slope of the line at the point of inflection may also be calculated and displayed as well as the temper index may.

The invention also relates to a production line according to <NUM> comprising, inter alia, at least a tempering apparatus, which has an in-line tempermeter.

The in-line tempermeter has a unit arranged at the continuous mass flow conduit and is adapted to extract a sample of the mass. The tempermeter has a cooling unit adapted to cool the sample, and is connected to a computer unit adapted to calculate and provide a temper curve and calculate the size of the area above or below the temper curve and a control means for the cooling circuit of the tempering apparatus is connected with the computer unit, which is further adapted to convert the actual size of the area to an expression for the actual energy amount required to cool and solidify the particular mass sample.

The invention also relates to a computer program according to claims <NUM>-<NUM>, that in preferred embodiments provides a temper curve for the above mentioned apparatuses, as well as calculates a point of inflection on the curve.

<NPL> discloses a survey over different testing methods available, as well as factors and measures to take into account when tempering chocolate mass during production for obtaining a fine and attractive result of the solidified chocolate articles. Focus is on obtaining a suitable number of crystals seeds and especially the attractive Beta V crystals in the tempered chocolate mass. By performing the tempermeter test differently obtained tempering curves are discussed; "overtempered, well-tempered and under-tempered," and the impact on the constitution of the particular tempered chocolate mass. In practical use it is recommended, that the so-called Temper Index is calculated for the particular tempering curve obtained, and used as a concrete numerical value for recording and communication. When discussing the challenge of how the tempering machine should be set in practice to obtain the correct degree of tempering, the conclusion is, that it can only be found by trials. At each trial the tempermeter test must be performed and the tempercurves evaluated until they are satisfactory, whereafter that the production of tempering the mass with the particular settings can begin.

<CIT>, Aasted ApS discloses a tempering apparatus having a cooling stage A, a crystallisation stage B and a mixing stage C. A CPU is connected with temperature sensors at the output of cooled mass from stage A, at the output of mass from the cooling stage B and from the output of the tempered chocolate mass from the mixing stage C. A part of the mass steam leaving stage A is by-passed stage B and supplied to stage C. Premature tempering tests are carried out for the particular mass and the temper curves are obtained until the desired tempering degree, temper index value and output temperature of the tempered mass are obtained and recorded. The values are coded into the CPU as well as an equation. When tempering is started the operator gives in the desired values to be constant; the output temperature and the temper index value. The CPU then controls the tempering process automatically.

<CIT>, Sollich KG discloses a tempering apparatus with a programmable logic controller and an in-line tempermeter arranged after the cooling and crystallisation stages. With regular time intervals mass probes are obtained by the in-line tempermeter and results of tempercurves and temper degree, such as temper index value, are maintained by the software of the logic controller. The software evaluates if the temperature of the tempered mass is constant and if the desired temper degree is constant, and if not confirmative, the software compares with the values obtained by preceeding results. The software then calculates an incremental regulation of the process controlling parameters such as the cooling water temperature or flow of the stages. The evaluation procedure goes on and on automatically.

<CIT>, Aasted ApS discloses a tempering apparatus controlled by a HMI-unit with a touch-screen. A set-point value for the outlet temperature of the tempered mass is entered at the touch screen and the crystallisation amount to be achieved is adjusted as a control value on a scale at the touch-screen. The HMI-unit calculates and transmits a value for the water temperature cooling of the crystallisation stage whereafter the HMI-unit continuedly repeats; receiving the actually measured outlet temperature, calculating deviation from the set-point value, if any, calculating and transmitting a new set-point value for the water temperature cooling. The simplicity of the few numbers to be coded in, and the automatic control during tempering, makes the tempering apparatus straightforward to operate.

It is well-known, that though the measured temper index is approximately equal for different batches of the same mass recipes, difficulties in relation to control and renewed setting of process parameters of the tempering and cooling of the masses in the production is often experienced.

A severe challenge in the production of articles using prior art temper curve methods are, that the measured temper index is approximately equal regardless of the setting of the cooling temperature of the mass being tempered. For many mass types it means, that even if the cooling temperature is several degrees higher than the optimal cooling temperature for crystallization of that mass, the observed temper index is approximately the same.

So, if the operator is not observant to the cooling water temperature read-out, there is a severe risk, that the production is proceeding to the end with a to high cooling temperature, i.e. such as for example <NUM>-<NUM> degrees higher than the optimal cooling temperature for the particular mass crystallization. The result is, that the mass is not sufficiently crystallized and that the whole batch of articles made is waisted. The required tempering quality is not achieved. Gloss, crisp break, taste and shelf life are not perfect.

The problem to be solved by the present invention is to provide a method for testing and continuous tempering of a liquid, fat-containing, and crystallizable confectionery mass, by which is obtained values, that represent trustable characteristics for the particular mass.

The method according to the invention is defined in claim <NUM>.

Hereby is obtained that the area values are directly appliable when comparing different batches of mass and are directly transferable to the setting and control of the production line control parameters, such as in the cooling control of the tempering apparatus.

As the sample is extracted from the liquid mass before being tempered, the size of the area calculated is a genuine expression for the heating amount needed to be removed from the liquid, crystal free mass sample. The new method then provides the manufacturer with an unforeseen reliable result in testing different batches of mass before tempering, achieving fully comparable and trustable values.

According to the method of the invention, samples are extracted continuously from the tempered mass during continuous tempering in a production line. The actual size of the area above or below the temper curve is continuously calculated by the computer, and the tempering process is regulated so that the size of the area is maintained at a desired, constant level. Consequently, the manufacturer is sure, that the produced mass articles are of the high tempering quality they choose, even as the production runs automatically.

It is further advantageous, when the cooling water temperature for the mass being tempered is lowered, then the actual size of the area is increased, and when the cooling water temperature for the mass being tempered is raised, then the actual size of the area is decreased.

With the inventive production line comprising an in-line tempermeter, the computer unit is further adapted to calculate the size of the area below or above the temper curve, and further convert the actual size of the area to an expression for the actual energy amount required to cool and solidify the particular sample and mass in a production.

The computer unit is connected with the control means for the cooling circuit of a tempering apparatus. The computer unit may also be connected with the control means for a cooling unit of a cooling tunnel in a production line.

According to a preferred embodiment of the invention, the computer program comprises the instructions, that it determines a starting point of a maximum temperature of the temper curve, it determines a first point of inflection of the temper curve, it determines at least one further second point of inflection of the temper curve, and that it is calculating the area above the temper curve limited by:
the temper curve, a horizontal upper line through the starting point and a vertical line through the second point, or is calculating the area below the temper curve as limited by:
a vertical line through the starting point and a horizontal lower line through the second point.

Hereby is obtained a very simple manner of achieving a highly accurate result and expression representing the actual energy amount required to cool, crystallize and solidify the particular mass sample. The result in the form of a size of the area is directly comparable with results from earlier or subsequent mass sample test according to the invention. The results are easily comparable on a screen to the non-skilled operator of a line.

The computer program may advantageously convert the area size to an actual energy amount simply by dividing with a factor in the range of <NUM>-<NUM>, advantageously <NUM>-<NUM>.

An even further accuracy in the calculation of the area size is obtained when the computer program instead of the second point of inflection uses a third point of inflection limiting the area in the calculations. The calculations are then done by the computer by means of simple integral mathematics adapted to the temper curve in question.

The invention is explained further below under reference to preferred embodiments as well as the drawing, in which.

The tempermeter apparatus <NUM> disclosed in <FIG> has a casing <NUM> and a schematically depicted cooling unit <NUM> at the top <NUM>. The cooling unit <NUM> is carrying a metal cup <NUM> with a sample <NUM> of confectionery mass, such as of chocolate mass. The mass sample <NUM> is typically extracted from a major batch of confectionery mass before it is brought into the production. The mass sample may also be taken out from the mass flow in a production line, for example after it has been tempered and before it is deposited into articles.

The mass sample <NUM> is cooled, crystallized and solidified in the metal cup <NUM> by the cooling unit <NUM>. Simultaneously is provided a temper curve <NUM> at the touch screen <NUM> of the tempermeter <NUM>.

The computer unit <NUM> is adapted to calculate and provide the temper curve <NUM> as with the prior art tempermeters. However, in addition, the tempermeter <NUM> is also adapted to calculate the size of the area above 9a or below 9b the temper curve <NUM>.

In <FIG> and <FIG> are disclosed two different temper curves <NUM>, <NUM> obtained with samples from the same dark chocolate batch, however, undergoing different cooling treatments through a tempering apparatus.

The dark chocolate of <FIG> is correctly tempered as indicated by the temperature being <NUM> when leaving the tempering apparatus. The slope in the <NUM>. point of inflection is <NUM> and consequently the temper index is calculated to be <NUM>. Every calculation is depicted at the bottom of the read out of <FIG> and <FIG>.

Referring to the dark chocolate sample of <FIG>, the slope in <NUM>. point of inflection is <NUM> and the temper index is then <NUM>. The temperature being <NUM> when leav-
ing the tempering apparatus - it actually means, that the temperature is <NUM> too high in comparison to the well-tempered mass of <FIG>. as the mass has not been sufficiently cooled and tempered.

However, this fact is not being revealed by a simple comparison of the temper index of <NUM> of the under-tempered batch of <FIG> with the temper index of <NUM> of the well-tempered mass of <FIG>.

So, when contemplating the temper index only, as traditionally done, the operator gets no hints as far as to the fact that the mass could be severely far from being properly tempered, i.e. such as not being cooled sufficiently and consequently being under-tempered as in <FIG>.

The area 10a above the temper curve <NUM> of <FIG> is calculated by the computer CPU <NUM> of <FIG> by applying traditional integral mathematics for curves. The calculated area 10a is 350mm2. The area 11a above the temper curve <NUM> of <FIG> is calculated by the computer <NUM> to be 3452mm2.

However, when comparing the area of 350mm2 of <FIG> with the area of 3450mm2 of <FIG> it is pretty evident, that it is around <NUM> times bigger. Then, the operator is in no doubt of that the two masses are differently tempered.

Applying the actual size of the area calculated above or below the temper curve as representing the size of the actual energy amount required to cool, crystallize and solidify the particular mass, as required by the method according to the invention, surely reveals to the operator in a simple manner, that they must amend the settings of the cooling energy to achieve a properly tempered mass and consequently a high-quality chocolate production.

The above example of <FIG> reveals to the operator, that they must increase the cooling energy so that the area 11a above the temper curve <NUM> is reduced to the size of the area 10a in figure <NUM> of the well-tempered mass before they can start the production of the mass articles.

In <FIG> is disclosed a temper curve of a sample of a milk chocolate provided with the tempermeter <NUM> of <FIG>, comprising a further, highly accurate example, useful for understanding the invention, of a computer program calculating the area 12a above the temper curve <NUM>.

The program determines a starting point <NUM> of a maximum temperature of the temper curve <NUM>. It determines a first point of inflection <NUM>, and a second point of inflection <NUM>. When the highest accuracy is to be obtained a third point of inflection <NUM> is determined as well.

The computer program then calculates the area 12a limited by the temper curve <NUM>, a horizontal line <NUM> through the starting point <NUM> and a vertical line <NUM> through the second point <NUM>. When the highest accuracy is to be obtained the computer program calculates the area 12a+ limited by the temper curve <NUM>, the horizontal line <NUM> through the starting point <NUM> and a vertical line <NUM> through the third point of inflection <NUM>.

Instead of calculating the area above the temper curve <NUM>, the area below the temper curve <NUM> may be calculated within the inventive idea.

In <FIG> is disclosed the same temper curve <NUM> as in <FIG>. The starting point <NUM> of the maximum temperature, the first point of inflection <NUM>, the second point of inflection <NUM> and the third point of inflection <NUM> are all calculated by the computer program and marked at the temper curve as in <FIG>. However, different is, that the area <NUM> below the temper curve <NUM> is calculated as limited by the temper curve <NUM>, a vertical line <NUM> through the starting point <NUM> and a horizontal line <NUM> through the third point <NUM>.

The production line apparatus <NUM> according to the invention, is comprising a tempering apparatus <NUM> with an in-line tempermeter <NUM> as well as a computer unit CPU <NUM> and program adapted to execute the steps according to the invention.

The in-line tempermeter is arranged in the mass flow conduit <NUM>, which connects the temperer <NUM> with a depositor <NUM>, depositing the liquid, tempered chocolate into underlying moulds <NUM>. The moulds <NUM> are arranged on a belt or is engaging with a chain drive <NUM> transporting the moulds through the cooling tunnel <NUM>.

The computer <NUM> of the tempering apparatus <NUM> is connected via wires <NUM> with the in-line tempermeter <NUM>, so that the results and temper curves <NUM> provided by the in-line tempermeter <NUM> is displayed on the touchscreen <NUM> at the front of the tempering apparatus <NUM>.

The in-line tempermeter <NUM> itself is schematically disclosed in <FIG>. It has a cooling unit <NUM> in which is arranged a known device for collecting a sample of mass either in the mass flow or for extracting the sample therefrom and cool it, simultaneously providing a temper curve <NUM> at the screen <NUM> of the tempering apparatus <NUM>.

During continuous tempering of the mass and solidification of the mass articles the cooling tunnel <NUM> in the production line <NUM>, samples are provided continuously from the tempered mass with the in-line tempermeter <NUM>. The actual size of the area above or below the temper curve <NUM> is maintained at a desired, constant level.

The size of the area could be calculated by the computer <NUM> as explained above under reference to either of <FIG>.

In <FIG> is disclosed a screen dump <NUM> from the screen <NUM> of the tempering apparatus <NUM> during a production run with dark chocolate. The computer <NUM> calculates continuously the size of the area <NUM> above the temper curve <NUM> as explained in relation to <FIG>, i.e. calculating the best mode of the area 12a+ above the temper curve <NUM>.

Before starting the production run, premature tests have disclosed, that a target area of <NUM> mm2 calculated above the temper curve <NUM> provides the most well-tempered quality for the particular chocolate mass. The size of <NUM> mm2 of the target area <NUM> during production run is then coded into the computer <NUM> via the touchscreen <NUM>, as disclosed to the left side of the screen dump <NUM>.

At the column "Results" of the screen dump <NUM> is disclosed data for each of the continuously taken samples by the in-line tempermeter <NUM>. Date and time as well as computer calculated areas above the temper curves for the particular sample taken.

Wires <NUM> connect the computer <NUM> with non-disclosed control means for the cooling circuit of the tempering apparatus. The computer <NUM> then regulates the cooling energy in accordance with the size of the target area. In the present example the cooling water temperature for the mass being tempered is lowered when the actual size of the area is increased in relation to the target area, and the cooling water temperature for the mass being tempered is raised when the actual size of the area is decreased in relation to the target area.

The control of the tempering machine is then performed automatically without any knowledge of the actual temper index.

Claim 1:
Method for testing and continuous tempering of a liquid, fat-containing, crystallizable confectionery mass, wherein a sample (<NUM>) of the mass is extracted from the liquid mass before being tempered , further being cooled, crystallized and solidified, simultaneously providing a temper curve (<NUM>, <NUM>, <NUM>, <NUM>), characterized in that at least part of the size of the area above (9a, 10a, 11a, 12a, 12a+, <NUM>) or below (9b, <NUM>) the temper curve (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) is calculated, and in that the actual size of the area calculated is applied as representing the actual energy amount required to cool, crystallize and solidify the particular mass sample (<NUM>), that the actual size of the area calculated is applied in further production of mass articles as representing the actual energy amount required to cool, crystallize and solidify the particular mass, and in that during continuous tempering and solidification of the mass in a production line (<NUM>), samples are provided continuously from the tempered mass as the actual size of the area above (<NUM>) or below the temper curve (<NUM>) is continuously calculated by a computer and the tempering process is regulated so that the size of the area is maintained at a desired, constant level.