GB1586461A - Packaged frozen confectionery product and its preparation - Google Patents

Description

(54) PACKAGED FROZEN CONFECTIONERY PRODUCT AND ITS PREPARATION (71) We, UNILEVER LIMITED, a company organised under the laws of Great Britain, of Unilever House, Blackfriars, London E.C.4, England, do hereby declare the invention for which we pray that a patent may be granted to us and the method by which it is to be performed, to be particularly described in and by the following statement: The present invention concerris frozen packaged confectionery products including ice confectionery articles, and processes for their manufacture.

Ice confections are normally of a size which is larger than that which allows consumption in a single bite or mouthful.

Thus a cornet ice cream may be of about 4 to 5 cm in diameter, or a briquette may be 8 to 10 cm long to fit within two wafers, so that each takes numerous bites, licks or mouthfuls to consume.

Attempts have been made in the past to provide smaller sized ice cream portions, but there is a problem in making such smaller pieces in sizes which are easily manufactured on a commercial scale, and which then can be handled by the consumer without difficulty.

The present invention provides a packaged frozen confectionery product comprising a plurality of ice confectionery articles each having a fat-based coating and each of 2 to 8cc in volume, contained in a thermoformed packaging tray having cavities conforming in shape to the shape of the articles contained therein, the articles having been moulded in the cavities. According to the invention a process for preparing the product comprises forming moulded ice confectionery articles each having a fat-based coating and each of 2 to Scc in volume by filling ice confection into each of a plurality of mould cavities previously dosed with the coating material, in a thermoformed tray.

The ice confection will usually be ice cream, but other ice confections such as mousses, sorbet and water ices can be moulded into the cavities. Either the finished product can consist of the ice confectionery articles moulded in the tray, or by subsequent packaging the tray can form part of the packaging of the product.

The ice confectionery articles are composite, having a fatty coating, for example chocolate. This coating can be a thin shelllike covering fully enclosing the ice confection.

By use of the present invention these small, bite-size, portions (the term bite-size meaning a size which can be conveniently accommodated in the mouth as one mouthful i.e. from 2 cc to 8cc), can be readily manufactured on a large scale, the tray provides an attractive packaging vehicle, and at the consumption stage enables individual portions to be conveniently handled.

In regard to the tray forming an attractive packaging vehicle, the tray can be of a shape which is appealing to the eye, and/or it may have identification features appropriate to the product within each cavity. For example different shaped indentations in the bases of different cavities can be present and for example can identify different flavours.

The tray is preferably packed in a carton, and it may be either way up. Thus objection may take place onto a backing card or sheet within the carton when the tray is upside down, or ejection may take place after removal of the tray from the carton.

Thus at the consumption stage it is possible for the consumer to hold a number of the bite-size portions within the tray and eject each in turn for consumption. Use of a thermoformed tray for the ice confection is particularly suitable since when the ice confection is in the frozen state, and particularly if it is chocolate coated, it is very readily ejected from the mould cavity. It is quite noticeable that if the ice confection is allowed to that it is subsequently more difficult to eject. Thus, the tray method is more effective for frozen products than it would be for conventional confectionery in view of the greater ease of ejection when the material is frozen.

The product may be manufactured by a process using a series of multi-nozzle fillers corresponding in layout and location to the cavities in the tray, for firstly depositing a layer of a fat coating material, for example chocolate, in the base of each cavity, then depositing ice confection so as to partly displace the fat coating material and cause it to form an outer shell round the ice confection, and the depositing an upper layer of the fat coating to completely enclose the ice confection. Such a process enables a thin shell-like coating fully enclosing the ice confection to be achieved.

An embodiment of the invention will now be described by way of example with reference to the diagrammatic drawings accompanying the Provisional Specification.

In the drawings, Figure I shows a perspective view of a thermoformed tray; Figure 2 shows a perspective view of five outlet multijet filling nozzles for chocolate; Figure 3 shows schematically the initial step of filling chocolate into a cavity in the tray; Figure 4 shows a perspective view of a double five outlet ice cream filling nozzle arrangement; Figure 5 is an enlarged view of one ice cream filling nozzle; Figures 6 and 7 show schematically the filling of ice cream into a cavity in the tray; Figure 8 shows a double five outlet multi-orifice filling nozzle for the final chocolate capping; Figure 9 shows schematically the chocolate capping stage; and Figure 10 shows the finished product.

Referring to Figure 1 a thin-wall thermoformed plastics tray 1 has ten mould cavities, 2, each having a volume of about 6 cc, being about 2 cm square in plan view, with slightly rounded corners, and just under 2 cm deep. Thus the volume of these cavities is such as to provide a "bite-size" product.

In a machine for manufacturing the product in these trays, a system is used which indexes each tray into position followed by sequential movement to subsequent stations where various different filling operations take place. The layout of this machine is not described as such, since various possibilities are available and their provision is straightforward for the man skilled in the art. Those aspects which clarify the present invention are described herein.

Referring to Figure 2, two five outlet filling nozzles 3 are provided, and at each outlet, corresponding to a mould cavity 2, eight jets are provided, for discharge of chocolate into the mould cavity. Use of eight jets ensures even filling at the corners.

Figure 3 shows a schematic diagram of the filling of chocolate into the bottom of the mould cavity, although the details of the jets are not depicted in that figure. In practice a measured amount of hot chocolate 5 at a temperature in the range 35 to 400C is deposited into each of the ten mould cavities 2, and the tray is then indexed on to the next station for filling with ice cream.

At the ice cream filling station, two five outlet fillers 6 are used, which are capable of vertical movement. In this case a single jet 7 is used for each mould cavity, and this jet has a slightly squared off outlet (see Figure 5) to ensure filhng to the corners. A bottom up filling technique is used (see Figures 6 and 7), and a measured amount of ice cream 8 is deposited into each of the ten cavities as the nozzle is moving upwards. This displaces the hot chocolate and forces it up the side walls of each cavity to form a shell containing the ice cream and at the same time the chocolate is chilled by the ice cream and hardens. The quantities, densities, temperatures and flow properties of the ice cream and chocolate are adjusted to ensure that the chocolate is displaced right up the side walls of the cavities.

Since two separate five outlet fillers are used, it is a simple matter to fill different flavours into the different groups of five cavities. The bottoms of the relevant cavities can (see Fig.1) have different identifiying indentations for the consumer to be able to identify the different flavours.

On completion of filling of each cavity with ice cream, the tray is indexed on to a chocolate capping stage.

At the chocolate capping stage again two five outlet fillers 9 are used but in this case to ensure an even film of chocolate covering the complete surface of the ice cream to the corners of the squared off cavities, each cavity individual filler consists of a multiplicity of jets 10 (about 25). Figure 9 then shows the final filling operation where a layer of hot chocolate 11 is deposited on top of the previously formed chocolate shell and the top surface of the ice cream to harden and totally enclose the ice cream. Finally the filled tray is ejected and passed out to a take-off conveyor. Figure 10 shows the tray containing its filled ice cream chocolates.

WHAT WE CLAIM IS: 1. A packaged frozen confectionery product comprising a plurality of ice confectionery articles each having a fat-based coating and each of 2 to 8cc in volume, contained in a thermoformed packaging tray having cavities conforming in shape to the shape of the articles contained therein, the

**WARNING** end of DESC field may overlap start of CLMS **.

Claims (11)

**WARNING** start of CLMS field may overlap end of DESC **. allowed to that it is subsequently more difficult to eject. Thus, the tray method is more effective for frozen products than it would be for conventional confectionery in view of the greater ease of ejection when the material is frozen. The product may be manufactured by a process using a series of multi-nozzle fillers corresponding in layout and location to the cavities in the tray, for firstly depositing a layer of a fat coating material, for example chocolate, in the base of each cavity, then depositing ice confection so as to partly displace the fat coating material and cause it to form an outer shell round the ice confection, and the depositing an upper layer of the fat coating to completely enclose the ice confection. Such a process enables a thin shell-like coating fully enclosing the ice confection to be achieved. An embodiment of the invention will now be described by way of example with reference to the diagrammatic drawings accompanying the Provisional Specification. In the drawings, Figure I shows a perspective view of a thermoformed tray; Figure 2 shows a perspective view of five outlet multijet filling nozzles for chocolate; Figure 3 shows schematically the initial step of filling chocolate into a cavity in the tray; Figure 4 shows a perspective view of a double five outlet ice cream filling nozzle arrangement; Figure 5 is an enlarged view of one ice cream filling nozzle; Figures 6 and 7 show schematically the filling of ice cream into a cavity in the tray; Figure 8 shows a double five outlet multi-orifice filling nozzle for the final chocolate capping; Figure 9 shows schematically the chocolate capping stage; and Figure 10 shows the finished product. Referring to Figure 1 a thin-wall thermoformed plastics tray 1 has ten mould cavities, 2, each having a volume of about 6 cc, being about 2 cm square in plan view, with slightly rounded corners, and just under 2 cm deep. Thus the volume of these cavities is such as to provide a "bite-size" product. In a machine for manufacturing the product in these trays, a system is used which indexes each tray into position followed by sequential movement to subsequent stations where various different filling operations take place. The layout of this machine is not described as such, since various possibilities are available and their provision is straightforward for the man skilled in the art. Those aspects which clarify the present invention are described herein. Referring to Figure 2, two five outlet filling nozzles 3 are provided, and at each outlet, corresponding to a mould cavity 2, eight jets are provided, for discharge of chocolate into the mould cavity. Use of eight jets ensures even filling at the corners. Figure 3 shows a schematic diagram of the filling of chocolate into the bottom of the mould cavity, although the details of the jets are not depicted in that figure. In practice a measured amount of hot chocolate 5 at a temperature in the range 35 to 400C is deposited into each of the ten mould cavities 2, and the tray is then indexed on to the next station for filling with ice cream. At the ice cream filling station, two five outlet fillers 6 are used, which are capable of vertical movement. In this case a single jet 7 is used for each mould cavity, and this jet has a slightly squared off outlet (see Figure 5) to ensure filhng to the corners. A bottom up filling technique is used (see Figures 6 and 7), and a measured amount of ice cream 8 is deposited into each of the ten cavities as the nozzle is moving upwards. This displaces the hot chocolate and forces it up the side walls of each cavity to form a shell containing the ice cream and at the same time the chocolate is chilled by the ice cream and hardens. The quantities, densities, temperatures and flow properties of the ice cream and chocolate are adjusted to ensure that the chocolate is displaced right up the side walls of the cavities. Since two separate five outlet fillers are used, it is a simple matter to fill different flavours into the different groups of five cavities. The bottoms of the relevant cavities can (see Fig.1) have different identifiying indentations for the consumer to be able to identify the different flavours. On completion of filling of each cavity with ice cream, the tray is indexed on to a chocolate capping stage. At the chocolate capping stage again two five outlet fillers 9 are used but in this case to ensure an even film of chocolate covering the complete surface of the ice cream to the corners of the squared off cavities, each cavity individual filler consists of a multiplicity of jets 10 (about 25). Figure 9 then shows the final filling operation where a layer of hot chocolate 11 is deposited on top of the previously formed chocolate shell and the top surface of the ice cream to harden and totally enclose the ice cream. Finally the filled tray is ejected and passed out to a take-off conveyor. Figure 10 shows the tray containing its filled ice cream chocolates. WHAT WE CLAIM IS:

1. A packaged frozen confectionery product comprising a plurality of ice confectionery articles each having a fat-based coating and each of 2 to 8cc in volume, contained in a thermoformed packaging tray having cavities conforming in shape to the shape of the articles contained therein, the

articles having been moulded in the cavities.

2. A confectionery product according to claim 1, having indentations in the bases of the cavities.

3. A confectionery product according to claim 2, in which the indentations in the bases of the cavities are of a plurality of distinct shapes with the flavour of the respective contained ice confectionery arti cle different for each shape.

4. A confectionery product according to any preceding claim in which the ice confectionery articles comprise ice cream, mousse, sorbet or water ice.

5. A frozen packaged confectionery product according to claim 1, substantially as hereinbefore described with reference to Figures 1 to 10 of the drawings accompanying the Provisional Specification.

6. A process for preparing a packaged frozen confectinery product, which comprises forming moulded ice confectionery arti cles each having a fat-based coating and each of 2 to 8ce in volume by filling ice confection into each of a plurality of mould cavities previously dosed with the coating material, in a thermoformed tray.

7. A process according to claim 6, in which the cavities have indentations in their bases.

8. A process according to claim 7, in which a plurality of different-flavoured ice confections is filled into respective cavities in which the indentations are of distinct respective shapes.

9. A process according to any one of claims 6 to 8, in which ice cream, mousse, sorbet or water ice articles are moulded into the cavities.

10. A process according to any one of claims 6 to 9, in which a series of filling nozzles is used to deposit successively in the cavities a first layer of chocolate or other fat coating material, a quantity of ice confection partly to displace the first layer and cause it to form an outer shell around the ice confection, and an upper layer of the coating material completely to enclose the ice confection.

11. A process accordng to claim 6, substantially as hereinbefore described with reference to Figures 1 to 10 of the drawings accompanying the Provisional Specification.