WO2016046691A1

WO2016046691A1 - Processing a foodstuff

Info

Publication number: WO2016046691A1
Application number: PCT/IB2015/057047
Authority: WO
Inventors: Emma MCLEOD; Lucian MOISE; Richard Andrews
Original assignee: Kraft Foods R&D Inc USA
Current assignee: Kraft Foods R&D Inc USA
Priority date: 2014-09-25
Filing date: 2015-09-14
Publication date: 2016-03-31
Anticipated expiration: 2017-03-25
Also published as: AU2015323405A1; EP3197286A1; CA2948987A1; GB2530544B; AU2015323405B2; GB2530544A; GB201416962D0; CN106687387B; CN106687387A

Abstract

There is provided a method of processing a foodstuff comprising the steps of: supplying flowable foodstuff into an open package, wherein the package is formed from at least one sheet of material, and an internal shape of the package changes into a predefined internal shape during the supplying of the foodstuff, the internal shape of the package changing toward and finally into the predefined internal shape dictated by one or more structural modifications in the sheet of material that forms the package and the foodstuff within the package, the structural modifications being distinct from any seal of the package; sealing the package; and at least partially setting the flowable foodstuff to maintain the predefined internal shape.

Description

Processing A Foodstuff

The present invention relates generally to a method of processing a foodstuff and related arrangements for processing a foodstuff.

A foodstuff, such as a chocolate based product, is often packaged in a package which is made from a sheet of material so that after removing the foodstuff from the package, the package can be flattened and discarded quickly. Since the package is made from a sheet of deformable material, it is deformable. When processing the foodstuff, either the package is placed in a mould before depositing the foodstuff therein and setting the foodstuff, or the foodstuff is set to a certain shape before introducing the foodstuff into the deformable package.

In both cases, a mould, a stamp, or an external shaping means is required to shape the foodstuff, which requires further processing steps/apparatuses to facilitate the use thereof. Also, if the foodstuff is set by cooling, after the foodstuff has been cooled, sealing the package, which can involve heat, may introduce undesirable shape deformation of the foodstuff and the package unless the mould/stamp remains engaged with the foodstuff during the sealing process.

Further, use of the mould/stamp may also lead to a deformation of the shape as the foodstuff or the package is disengaged from the mould/stamp. These issues can cause failure in achieving the desired shape of the foodstuff or the package, or demand use of a more complex apparatus to enable the sealing process and/or a clear disengagement with the mould/stamp which can have cost implications. Therefore, identifying a simple and improved way of processing the foodstuff, and how to implement the process using what kind of apparatus, is a problem.

It is an example aim of example embodiments of the present invention to at least partially obviate or mitigate one or more disadvantages of the prior art, whether identified herein or elsewhere, or to provide an alternative or improvement with respect to the prior art.

According to the present invention there is provided a method or an apparatus/arrangement as set forth in the appended claims. Other features of the invention will be apparent from the dependent claims, and the description which follows.

According to a first aspect of the invention, there is provided a method of processing a foodstuff comprising the steps of: supplying flowable foodstuff into an open package wherein the package is formed from at least one sheet of material; sealing the package; and at least partially setting the flowable foodstuff, wherein a predefined internal shape of the package is dictated solely by one or more structural modifications in the sheet of material that forms the package, and the foodstuff within the package (e.g. flow of the flowable foodstuff within the package). Suitably, the internal shape of the package changes during the supplying of the flowable foodstuff and/or the at least partially setting of the flowable foodstuff, e.g. toward and finally into the predefined shape. Suitably, the flow of the flowable foodstuff within the package changes the internal shape, e.g. toward and finally into the predefined shape.

The supplying the flowable foodstuff into the open package might define the predefined internal shape of the package such that at least a part of that foodstuff adopts that internal shape wherein the predefined internal shape of the package is dictated solely by the one or more structural modifications in the sheet of material that forms the package.

The package might define the predefined internal shape under an internal pressure applied by the foodstuff to a freestanding portion of the package. The package might assume the predefined internal shape without a surface of the predefined internal shape forming portion of the package physically engaging an external support.

The flowable foodstuff might be supplied at pressure so that the internal pressure is increased and the package is filled with the flowable foodstuff more uniformly. Additionally or alternatively, the package might be positioned under the flowable foodstuff so that the weight of the flowable foodstuff under gravity contributes to the internal pressure.

The external support might comprise a mould or a stamp. The predefined internal shape might mainly comprise a shape of the freestanding portion adopted when an internal pressure applied on an inner surface of the freestanding portion reaches an equilibrium with an atmospheric pressure applied on an external surface of the freestanding portion.

At least a half of the predefined internal shape might be formed by the shape of the freestanding portion at equilibrium with the atmospheric pressure. More than 75% of the predefined internal shape might be formed by the shape of the freestanding portion at equilibrium with the atmospheric pressure. The whole predefined internal shape excluding an opening of the package might be formed by the shape of the freestanding portion at equilibrium with the atmospheric pressure.

The sealing of the package might take place before the at least partially setting the flowable foodstuff.

The sealing of the package might comprise the step of sealing a first surface of the sheet with a second surface of the sheet to form a tubular shape with the package. An opening of the package (e.g. formed in the tubular shape) might be sealed across the width of the package. The sealing of the package might comprise cross sealing to form an open package (with one end sealed by the cross sealing). The supplying the flowable foodstuff into the open package might comprise the step of forming the open package by sealing a first opening of the package so that the flowable foodstuff can be supplied through a second opening of the package and remain retained therein. The sealing the package, or the sealing the first opening or second opening of the package might comprise the steps of: engaging the package with a sealing tool; and sealing an opening of the package with the sealing tool so that only a portion of the engaged area of the package forms a seal, whereby an unsealed portion between the foodstuff in the package and the sealed portion of the package is created after the sealing tool is disengaged from the package. The unsealed portion might define a sealed space.

The structural modifications might be distinct from any seal of the package. The structural modification might comprise one or more of a predefined: crease; fold; scoring; region of relative strength; or region of relative weakness. A seal might not include any structural modifications. The structural modifications might be separate to or away from any sealed portion of the package. The structural modifications might be provided in addition/separate to any longitudinal/cross seals of the package.

The method of processing a foodstuff might comprise the step of, before supplying the flowable foodstuff, providing the structural modifications in the sheet of the material that forms the package.

The structural modifications in the sheet might be formed by embossing the sheet or by use of electromagnetic radiation on the sheet.

The embossing the sheet might comprise the step of engaging a first surface of the sheet with a second surface of an embossing tool, wherein the second surface comprises a protrusion or a recess. The embossing tool might comprise a rotatable cylinder comprising the second surface, and the engagement of the first and second surfaces take place as the sheet passes by the rotating cylinder.

The method of processing a foodstuff might further comprise the step of, before supplying the flowable foodstuff, patterning the sheet so that a texture or a decoration is formed on an internal and/or external surface of the package.

The predefined internal shape of the package is dictated solely by one or more structural modifications in the sheet of material that forms the package, and the foodstuff within the package, and the predefined internal shape of the package may be maintained by at least partial setting of the foodstuff.

According to a second aspect of the invention, there is provided an arrangement for processing foodstuff comprising: an open package formed from at least one sheet of material having one or more structural modifications provided in the sheet; a foodstuff supply configured for supplying flowable foodstuff into the open package; and a sealing tool for sealing the package, wherein, in use, a predefined internal shape of the at least partially filled package is dictated solely by the one or more structural modifications in the sheet of material that forms the package, and the foodstuff within the package (e.g. flow of the flowable foodstuff within the package). Suitably, the internal shape of the package changes during the supplying of the flowable foodstuff and/or the at least partially setting of the flowable foodstuff, e.g. toward and finally into the predefined shape. Suitably, the flow of the flowable foodstuff within the package changes the internal shape, e.g. toward and finally into the predefined shape.

According to a third aspect of the invention, there is provided an arrangement for processing foodstuff comprising: a structural modifier for forming one or more structural modifications in at least one sheet of material; a foodstuff supply configured for supplying flowable foodstuff into an open package formed from the sheet of material; and a sealing tool for sealing the package, wherein, in use, a predefined internal shape of the at least partially filled package is dictated solely by the one or more structural modifications in the sheet of material that forms the package, and the foodstuff within the package (e.g. flow of the flowable foodstuff within the package). Suitably, the internal shape of the package changes during the supplying of the flowable foodstuff and/or the at least partially setting of the flowable foodstuff, e.g. toward and finally into the predefined shape. Suitably, the flow of the flowable foodstuff within the package changes the internal shape, e.g. toward and finally into the predefined shape.

The foodstuff supply might supply the flowable foodstuff at pressure so that an internal pressure of the flowable foodstuff in the package is increased. Additionally or alternatively, the package might be positioned under the flowable foodstuff so that the weight of the flowable foodstuff under gravity contributes to the internal pressure.

The structural modifier might further comprise an embosser for embossing the sheet or an electromagnetic radiation emitter for using the radiation on the sheet, whereby the one or more structural modifications are formed in the sheet. The arrangement might further comprise a rotatable cylinder and the embossing the sheet might comprise a step of engaging a first surface of the sheet with a second surface of the rotatable cylinder, wherein the second surface comprises a protrusion or a recess and the engagement of the first and second surfaces take place as the sheet passes by the rotating cylinder, and the engagement between the first and second surfaces embosses the sheet.

The structural modifier might further comprise a patterner for patterning the sheet so that a texture or a decoration is formed on a surface of the package. An imprint and/or a relief of the texture or the decoration might be transferrable to a surface of the set foodstuff. According to a fourth aspect of the invention, there is provided a processed foodstuff in a package processed according the aforementioned method of processing the foodstuff or using the aforementioned arrangement for processing the foodstuff.

One or more features of one or more aspects of the present invention may be combined with and/or replace one or more features of one or more other aspects of the present invention, unless understood to be clearly mutually exclusive to the skilled person after a reading of this disclosure.

For a better understanding of the invention, and to show how embodiments of the same may be carried into effect, reference will now be made, by way of example, to the accompanying diagrammatic Figures in which: Figures 1 a and 1 b schematically depict methods of processing a foodstuff in accordance with example embodiments;

Figures 2a - 2d schematically depict arrangements for processing foodstuff in accordance with example embodiments;

Figures 3a - 3c depict an arrangement for processing foodstuff in accordance with an example embodiment;

Figure 4 depicts an arrangement for processing foodstuff in accordance with another example embodiment;

Figures 5a - 5c depict details of a sealing tool in accordance with an example embodiment; Figures 6 and 7 depict details of a sheet of material comprising one or more structural modifications therein in accordance with an example embodiment; and

Figures 8 to 10 depict examples of processed or packaged foodstuff and/or set foodstuff processed in accordance with example embodiments. The present invention at least partially obviates or mitigates one or more disadvantages of the prior art by taking a completely different approach to, for example, how best to shape a flowable foodstuff packaged in a package made from a sheet of material. The approach is different in that the shaping of the foodstuff and the package is largely dictated by the interaction between the foodstuff and the package. That is, the shape of the foodstuff and the package is defined without using and/or being heavily dependent on the use of a mould or stamp. Structural modifications in the sheet allow for tailored shaping for aesthetic and/or functional reasons. Suitably, the internal shape of the package changes during the supplying of the flowable foodstuff and/or the at least partially setting of the flowable foodstuff, e.g. toward and finally into the predefined shape. Suitably, the flow of the flowable foodstuff within the package changes the internal shape, e.g. toward and finally into the predefined shape. Figure 1 a schematically depicts a method of processing a foodstuff according to an example embodiment. The method shown in Figure 1 a comprises the following steps: at step 1100, flowable foodstuff is supplied into an open package wherein the package is formed from at least one sheet of material; at step 1200, the package is sealed and/or at least one opening of the package is sealed; and at step 1300, the flowable foodstuff is at least partially set. By sealing the package before at least partially setting the flowable foodstuff, the sealing process does not disturb the shape of the at least partially set foodstuff, whereby a predefined shape can be better retained. Figure 1 b schematically depicts a method of processing a foodstuff according to another example embodiment. The method steps are the same as the method shown in Figure 1 a except the order of the steps 1200 and 1300 have been swapped in the method of Figure 1 b. So the package is sealed after at least partially setting the flowable foodstuff.

In the method of Figure 1 a or 1 b, the flowable foodstuff and the open package engage and interact with each other as the method steps are performed so that a predefined internal shape of the package is dictated solely by one or more structural modifications in the sheet of material that forms the package, and the flowable foodstuff within the package, for example the flow of the flowable foodstuff within the package. Then the flowable foodstuff is allowed to at least partially set to retain the predefined internal shape after setting. This allows the eventual sealed package with the set foodstuff to comprise a predefined shape. This predefined shape is influenced by the shape of the set foodstuff which in turn is formed by the predefined internal shape of the package.

The order of the steps 1200 and 1300 might depend on the properties of the foodstuff, e.g. when the foodstuff becomes structurally solid enough to retain a shape, the sealing technique used and/or whether the sealing can reverse the setting and/or the structural solidity of the flowable foodstuff. Additionally and/or alternatively, the predefined shape may also take any effect of the sealing process into account so that both orders of the steps 1200 and 1300 can achieve the desired predefined shape. For example, the sealing process at step 1200 may introduce a tapering portion near a sealed portion of the package. If such a tapering shape is not desirable for the set foodstuff, the step 1300 takes place before the step 1200 so that the at least partially set foodstuff does not adopt the tapering shape thereafter. Alternatively, the tapering shape may be desirable and the step 1300 takes place after the step 1200. Additionally and/or alternatively, the at least partially setting of the foodstuff enables the foodstuff to only partially adopt a shaping, such as the tapering shape, introduced by the sealing process.

It is understood that according to another embodiment, the steps 1200 and 1300 of the method of Figure 1 a or 1 b can also take place simultaneously and/or overlap in part or in full. This reduces the time needed in performing both steps 1200 and 1300, which can be advantageous when processing many foodstuff and/or packages.

According to an embodiment, an opening of the package is sealed across the width of the package so as to form a closed seal. For example, by sealing an opening of the package, which is of a tubular shape comprising a first opening at a first portion and a second opening at a second portion, an open package can be formed by sealing across the width of the package so as to form a closed seal at the first portion whereby the first opening is closed or sealed. This then enables the open package to function as a receptacle for receiving the foodstuff through the second opening and retain the foodstuff therein. After receiving the foodstuff, the second opening can also be closed or sealed in the same manner to form a sealed and/or closed package wherein the foodstuff is packaged and/or stored. According to an embodiment, the sealing of the package might comprise the step of sealing a first surface of the sheet with a second surface of the sheet to form a tubular shape with the package. In this embodiment, this sub-step of the sealing step will take place before supplying the flowable foodstuff at step 1 100 and before sealing an opening of the package at step 1200. Then, the sealing of the opening of the package at step 1200 enables the tubular shape to constitute the open package with an opening at one end of the tubular shape sealed. In this case, the sealing of the package comprises cross sealing of the opening to form the open package. In the method depicted in Figure 1a or 1 b, as the flowable foodstuff is supplied into the open package at step 1100, this supplying defines the predefined internal shape of the package such that at least a part of the supplied foodstuff adopts that internal shape, wherein the predefined internal shape of the package is dictated solely by the one or more structural modifications in the sheet of material that forms the package.

When processing a foodstuff, if an external structural support such as a mould or stamp is used to shape a package and/or a foodstuff into a predefined shape, more than half of the entire external surface of the package and/or foodstuff will have to be in physical contact/engagement with the mould or the stamp. This is because at least a bottom surface and side walls of the predefined shape of the package and/or foodstuff will have to be formed whilst being in contact with the mould or the stamp.

According to an embodiment, as the flowable foodstuff is supplied into the package, this supplying also defines the predefined internal shape under an internal pressure applied by the foodstuff to a freestanding portion of the package. The flowable foodstuff might be supplied at pressure so that the internal pressure is increased and the package is filled with the flowable foodstuff more uniformly. Additionally or alternatively, the package might be positioned under the flowable foodstuff so that the weight of the flowable foodstuff under gravity contributes to the internal pressure.

The package can then assume the predefined internal shape without a surface of the predefined internal shape forming portion of the package physically engaging an external structural support such as a mould or a stamp. The predefined internal shape mainly comprises a shape of the freestanding portion. The shape of the freestanding portion is adopted by the freestanding portion when an internal pressure applied on an inner surface of the freestanding portion, by the foodstuff, reaches an equilibrium with an atmospheric pressure applied on an external surface of the freestanding portion as the foodstuff engages and/or interacts with the inner surface of the freestanding portion. Specific and/or tailored shaping of the package is dictated by the structural modification in the sheet.

According to an embodiment, typically at least a half of the predefined internal shape is formed by the shape of the freestanding portion at equilibrium with the atmospheric pressure. Preferably, more than 75% of the predefined internal shape is formed by the shape of the freestanding portion at equilibrium with the atmospheric pressure. And yet more preferably, the whole predefined internal shape excluding a portion comprising an opening of the package and/or a sealed opening of the package is formed by the shape of the freestanding portion at equilibrium with the atmospheric pressure.

According to an embodiment, at step 1 100 the supplying the flowable foodstuff into the open package also comprises the step of forming the open package by sealing a first opening of the package so that the flowable foodstuff can be supplied through a second opening of the package and remain retained therein.

According to an embodiment, at step 1200 the sealing the package, and/or the sealing the first opening or second opening of the package comprises the steps of: engaging the package with a sealing tool; and sealing an opening of the package with the sealing tool so that only a portion of the engaged area of the package forms a seal, whereby an unsealed portion between the foodstuff in the package and the sealed portion of the package is created after the sealing tool is disengaged from the package. The unsealed portion defines a sealed space so that when the sealed package is opened by a consumer, the sealed space provides some slack for the consumer's fingers/hands to facilitate easier opening/unsealing of the sealed package. In other words, the unsealed portion secures a head-space or region within the package to stop the foodstuff taking up all space, which allows the package to be opened more easily. An example embodiment of the sealing tool for creating such an unsealed portion will be discussed in more detail in relation to Figures 5a - 5c. The one or more structural modifications in the sheet of material that forms the package are most likely distinct from any seal of the package. According to an embodiment, the structural modification comprises one or more of a predefined: crease; fold; scoring; region of relative strength; or region of relative weakness. In comparison, a seal might not include any structural modifications in the sheet of material. Suitably, the structural modifications are separate to and/or away from any sealed portion of the package. Suitably, the structural modifications are provided in addition/separate to any longitudinal/cross seals of the package. However, it is understood that the seals of the package can also influence the desired predefined internal shape of the package and the influence thereto is taken into account when providing the additional/separate structural modifications in the sheet of material.

According to an embodiment, in order to form the sheet of material comprising the structural modifications, the method of processing a foodstuff depicted in Figures 1 a and 1 b also comprises the step of, before supplying the flowable foodstuff at step 1100, providing the structural modifications in the sheet of the material that forms the package. The structural modifications in the sheet may be formed by embossing the sheet or by use of electromagnetic radiation on the sheet. The embossing the sheet comprises the step of engaging a first surface of the sheet with a second surface of an embossing tool, wherein the second surface comprises a protrusion and/or a recess so that the protrusion and/or the recess embosses the first surface with an imprint of the protrusion and/or a relief of the recess. The embossing tool may also comprise a rotatable cylinder comprising the second surface, so that as the rotatable cylinder rotates and the sheet passes by the rotating cylinder the engagement of the first and second surfaces takes place. This engagement then embosses the first surface of the sheet. An example embodiment of the embossed sheet of material and a package formed therefrom will be discussed in more detail in relation to Figures 6 and 7.

According to an embodiment, the method of processing a foodstuff depicted in Figures 1 a and 1 b also comprises the step of, before supplying the flowable foodstuff at step 1100, patterning the sheet so that a texture and/or a decoration is formed on an internal and/or external surface of the package. The texture and/or decoration on the internal surface can then be adopted by the set foodstuff so that the set foodstuff comprises an imprint and/or a relief of the texture and/or decoration. The texture and/or decoration on the set foodstuff and/or the external surface are then visible and/or tactile to the consumer, which can be useful in branding the foodstuff and/or package and/or communicating a message to the consumer. Patterning may be implemented using the embossing and/or electromagnetic radiation. Patterning might be implemented as a part of and/or at the same time as the process for forming structural modifications in the sheet of the package material.

According to an embodiment, the flowable foodstuff is molten chocolate and the package formed from the sheet of material is a deformable package of a tube formation with one end being sealed before each step 1 100 of supplying the foodstuff, i.e. before the introduction of chocolate. The tube formation may be provided in a flattened shape. A sequential sealing of an opening at step 1200 and introduction/supply of the chocolate at step 1 100 is repeated on a continuous (flattened) tube shaped packaging material to process the chocolate. The setting of the chocolate at step 1300 can also be performed whilst this sequential supply and sealing 1100, 1200 steps are taking place. The introduction/supply of the chocolate changes the internal shape, urging the shape toward (and, finally, into) the predetermined internal shape. A first opening of the package is sealed first to form an open package or a receptacle. Then the chocolate is introduced into the open package at step 1100 by pouring of the molten chocolate into the (flattened) tube shaped packaging material, i.e. the open package, through a second opening of the open package. It is understood that the sealing of the first opening package can also be performed as a step 1200 of a previously processed foodstuff and/or package in the sequential supplying and sealing steps 1100, 1200, or as a separate step of the method of processing the current foodstuff and/or package whereon the supply and sealing 1100, 1200 steps are currently being performed. The sealing of the first, second or any opening of the package may include any one or combination of mechanical, ultrasound or thermal sealing of an opening on an edge portion of the package.

According to an embodiment, the setting (cooling) of the chocolate at step 1300 further comprises shaping or stamping the package with chocolate therein using a mould and/or a stamp before the chocolate is fully solidified so that the fully solidified chocolate adopts the shaped/stamped form on the package. This further setting step 1300 supplements the shape-forming process by applying further steps before the chocolate has fully set. It is understood that for providing finer shapes, such as smaller textures and/or decoration, on the chocolate, this supplementary shaping or stamping step can be effective since fully (or greater setting and/or close to fully) setting is likely to be required to achieve such fine shapes/details.

Figures 2a - 2d schematically depict arrangements for processing foodstuff in accordance with example embodiments. The depicted arrangements illustrate exemplary arrangements for implementing the method of processing foodstuff as described herein, for example in relation to Figures 1 a and 1 b. It is understood that other combinations of a subset of the features of the depicted arrangements may also be used to implement the methods described herein. Figure 2a depicts an arrangement for processing foodstuff comprising: an open package formed from at least one sheet of material 2500 having one or more structural modifications 2550 provided in the sheet; a foodstuff supply 2100 configured for supplying flowable foodstuff into the open package; and a sealing tool 2200 for sealing the package, wherein, in use, a predefined internal shape of the at least partially filled package is dictated solely by the one or more structural modifications 2550 in the sheet of material 2500 that forms the package, and flow of the flowable foodstuff within the package.

According to an embodiment, the flowable foodstuff is molten chocolate and the package formed from the sheet of material 2500 is a deformable package of a (flattened) tube formation with one end being sealed by the sealing tool 2200 (or a like sealing tool) before and/or after supplying the foodstuff by the foodstuff supply 2100 into the open package 2500. The deformable package is likely to be of a tube formation with one end being sealed before each introduction of chocolate, i.e. sequential sealing of an opening and introduction of chocolate repeated on a continuous (flattened) tube shaped packaging material.

The open package is provided with the one or more structural modifications 2550 provided therein. According to an embodiment, the open package is provided in a (flattened) tube formation and the arrangement also comprises an opening tool for forming an opening on the tube formation after and/or at the same time as an opening of the open package enclosing the previously processed foodstuff, i.e. supplied chocolate, is sealed by the sealing tool 2200.

The sealing tool 2200 may include any one or combination of tools for mechanical, ultrasound or thermal sealing of an opening on an edge portion of the package.

Figure 2b depicts an arrangement for processing foodstuff comprising: a structural modifier 2600 for forming one or more structural modifications 2550 in at least one sheet of material 2500; a foodstuff supply 2100 configured for supplying flowable foodstuff into an open package formed from the sheet of material 2500; and a sealing tool 2200 for sealing the package, wherein, in use, a predefined internal shape of the at least partially filled package is dictated solely by the one or more structural modifications 2550 in the sheet of material 2500 that forms the package, and flow of the flowable foodstuff within the package.

The arrangement depicted in Figure 2b is similar to the arrangement depicted in Figure 2a except that the package provided therewith does not comprise the one or more structural modification 2550 therein yet. The package is provided in one sheet of material formation 2500, and the structural modifier 2600 forms the one or more structural modifications 2550 in the sheet of material before the sheet of material 2500 is provided to the foodstuff supply 2100 for forming the package for the flowable foodstuff. The sealing tool 2200 is also arranged to seal a first surface of the sheet of material 2500 with a second surface of the sheet of material 2500 to form an open package of a tube formation.

Figure 2c depicts a structural modifier 2600 in more detail. The structural modifier 2600 comprises an embosser for embossing the sheet and/or an electromagnetic radiation emitter for emitting the radiation at the sheet, whereby the one or more structural modifications 2550 are formed in the sheet 2500. According to an embodiment, the arrangement comprises a rotatable cylinder 2900 and the embossing the sheet 2500 comprises a step of engaging a first surface of the sheet 2500 with a second surface of the rotatable cylinder 2900, wherein the second surface comprises a protrusion or a recess 2600 and the engagement of the first and second surfaces take place as the sheet 2500 passes by the rotating cylinder 2900, and the engagement between the first and second surfaces embosses the sheet 2500. The embossed sheet 2500 then comprises one or more structural modifications 2550 therein. The structural modification might be one or more of a predefined: crease; fold; scoring; region of relative strength; or region of relative weakness. The structural modification might be used to tailor the shape of the package, once filled.

According to an embodiment, the structural modifier 2600 also comprises a patterner for patterning the sheet 2500 so that a texture and/or a decoration is formed on a surface of the package. An imprint and/or a relief of the texture and/or the decoration can then be transferred onto a surface of the foodstuff, for example a branding on a chocolate.

Figure 2d shows an example patterner according to an embodiment wherein the patterner is incorporated into the rotating cylinder 2900 of Figure 2c. It is understood that the patterner and/or a structural modifier 2600 may comprise a stamp and/or any other means for providing a texture and/or decoration on a surface and/or embossing a sheet.

Figures 3a - 3c depict an arrangement for processing foodstuff in accordance with an example embodiment wherein the arrangement also uses a Vertical form fill sealing machine (VFFS). The VFFS is a type of automated assembly-line product packaging system for constructing an open package while simultaneously filling the package with a product and sealing the filled packages.

Each component and/or feature of the arrangement functions in a similar manner to the corresponding component and/or feature of the arrangements described in relation to Figures 2a - 2d.

The arrangement of the Figures 3a - 3c (referred to in combination) comprises a foodstuff supply 2100 and a sealing tool 2200. A sheet of material 2500 is then provided via a rotatable cylinder 2900. The embodiment shown in Figures 3a - 3c comprises a sheet of material with one or more structural modifications 2550 shown in Figures 2a - 2c already formed therein. The sheet of material 2500 is also provided in a (flattened) tube formation. It is understood that according to an alternative embodiment, the structural modification 2550 can also be formed by a structural modifier 2600, which is either on the rotatable cylinder 2900 or provided separately. The arrangement also comprises an opening tool 3200 for forming an opening on the continuous (flattened) tube formation of the sheet of material 2500. Any tool capable of creating an opening on the sheet of material 2500 could be used. For example, a scoring tool might be used as the opening tool 3200 so that a scoring introduced on a surface of the sheet of material 2500 forms an opening.

It is understood that according to an alternative embodiment, the sheet of material 2500 can also be provided with the opening already provided thereon, in which case the sheet of material 2500 will be provided in a (flattened) tube formation with openings and/or scorings therefor provided on and/or in the sheet 2500 beforehand.

According to an embodiment, as the sealing tool 2200 seals a first opening of a previous package portion, i.e. a last portion of the sheet of material 2500 lastly supplied with foodstuff, the opening tool 3200 forms a second opening on the current package portion, i.e. a current portion of the sheet of material 2500, as shown in Figure 3a.

As shown in Figure 3b, then the foodstuff supply 2100 supplies the flowable foodstuff, for example molten chocolate, through the second opening in to the current package portion, an end of which has been sealed by the sealing tool 2200 as described above. The rotatable cylinder 2900 then rotates to position the next package portion, i.e. a next portion of the sheet of material 2500 for supplying with and/or packaging foodstuff, for engagement by the sealing tool 2200 and/or the opening tool 3200.

As shown in Figure 3c, after the positioning of the next package portion, the sealing tool 2200 seals the second opening of the current package portion and the opening tool 3200 forms a third opening on the next package portion. The same process steps shown in Figures 3a - 3c are then repeated to process more foodstuff whereby a number of packaged foodstuff are produced using the arrangement. The packaged foodstuffs are shown as remaining attached to one another, e.g. in a string or strip of packages. In another embodiment, the packages may be separated from one another. It is understood that the arrangement can also comprise a setter for at least partially setting the flowable foodstuff. This enables the at least partially set foodstuff and/or the package around the foodstuff to retain a predefined shape dictated by a predefined internal shape of the package. The predefined internal shape of the package, in turn, is dictated solely by the one or more structural modifications 2550 in the sheet of material 2500 that forms the package, and the flow of the flowable foodstuff within the package.

Depending on the desired predefined shape of the foodstuff and/or the package and the nature of the flowable foodstuff, the setter can commence/terminate the at least partially setting of the foodstuff at any moment in time after the supplying of the flowable foodstuff by the foodstuff supply 2100 to the sealing of the second opening by the sealing tool 2200.

According to an embodiment, the setter may commence/terminate the at least partially setting of the foodstuff after the sealing of the second opening by the sealing tool 2200 as long as the desired predefined shape can be retained by the foodstuff after the setting process.

Figure 4 depicts an arrangement for processing foodstuff in accordance with another example embodiment wherein the arrangement uses a Vertical form fill sealing machine (VFFS). The arrangement is very similar to that described in relation to Figures 3a - 3c except that the rotatable cylinders 2900 rotate in the opposite direction and two sealing tools 2210, 2220 are provided therewith. The sheet of material 2500 is provided with the one or more structural modifications 2550 and the first, second and third openings at ends of each package portion, i.e. a previous, current or next package portion. As the rotatable cylinders 2900 rotate to position the sheet of material 2500, the first sealing tool 2210 seals the third opening of the next package portion as the foodstuff supply 2100 supplies flowable foodstuff into the current package portion through the second opening of the current package portion. The second sealing tool 2220 also seals the first opening of the previous package portion.

It is understood that as discussed in relation to the arrangement of Figures 3a - 3c, other features such as a structural modifier 2600, an opening tool 3200 and/or a setter can also be provided in a number of different subset combinations thereof to process the foodstuff.

Figures 5a - 5c depict details of a sealing tool in accordance with an example embodiment of the sealing tool 2200 described in relation to the methods of Figures 1a and 1 b and the arrangements of Figures 2a - 4.

Depending on the implementation, the sealing tool 2200 may be capable of any one or combination of mechanical, ultrasound or thermal sealing of a sheet of material 2500 which forms the package. The sealing tool 2200 can be used to form a seal whereby an opening, for example on an edge portion of the package, can be sealed and/or closed.

As shown in Figures 5a - 5c, the sealing tool 2200 comprises a sealing portion 2290 and a non-sealing portion 2280. As the sealing tool 2200 engages the package as shown in Figure 5a, the foodstuff 5000 is displaced by the sealing tool 2200 within the package as shown in Figure 5b.

The sealing portion 2290 then mechanically, ultrasonically and/or thermally seals the package by bonding a first surface of the sheet of material 2500 with a second surface of the sheet of material 2500. The non-sealing portion 2280 merely displaces the foodstuff 5000 but does not form seal on a surface of the sheet of material 2500. It is understood that use of the non-sealing portion 2280 can also provide extra protection for the foodstuff 5000 since the non-sealing portion 2280 keeps the foodstuff 5000 away from the sealing portion 2290. This is because the foodstuff 5000 can be sensitive to mechanical, ultrasonic and/or thermal stimuli. For example, if the sealing portion 2290 thermally seals the package and the foodstuff 5000 is heat sensitive, i.e. reacts to the heat and/or gets damaged by the heat, the non-sealing portion 2280 keeps the heat sensitive foodstuff 5000 away from the sealing portion 2290, which may produce potentially damaging heat to perform the sealing.

As shown in Figure 5c, as the sealing tool 2200 is disengaged and/or withdrawn from the engagement with the package, a sealed portion 2590 of the package is created whereby the package is sealed. As the sealing tool 2200 is disengaged and/or withdrawn, an unsealed portion 2580 is also created between the foodstuff 5000 and the sealed portion 2590. The unsealed portion 2580 defines a sealed space so that when the sealed package is opened by a consumer, the sealed space provides a slack for the consumer's fingers/hands to facilitate easier opening/unsealing of the sealed package. In other words, the unsealed portion 2580 secures a head-space within the package to stop the foodstuff 5000 taking up all space which allows the package to be opened more easily. In another related example, the unsealed portion may not define a space, but may still allow for easier package opening (i.e. in, through or via the region where no sealing takes place).

It is understood that this sealing of the package by the sealing tool 2200 can take place before, during and/or after at least partially setting the foodstuff 5000 with a setter. According to an embodiment, the sealing of the package by the sealing tool 2200 and the at least partially setting by the setter is performed at the same time. According to yet another embodiment, the non-sealing portion 2280 of the sealing tool 2200 is the setter and performs the at least partially setting of the foodstuff 5000 when the non-sealing portion 2280 is engaged with the package and/or foodstuff 5000, for example by cooling the foodstuff 5000.

It is understood that the sealing tool 2200 can also comprise a structural modifier 2600, such as protrusions and/or recesses, so that when the sealing tool 2200 engages the package and/or foodstuff 5000, a structural modification 2550 can be provided on an engaged surface of the package and/or foodstuff 5000. The structural modifications 2550 are distinct from any seal, for example the sealed portion 2590, of the package. The structural modification 2550 might comprise one or more of a predefined: crease; fold; scoring; region of relative strength; or region of relative weakness. The structural modifications 2550 are separate to or away from any sealed portion 2590 of the package. The structural modifications 2550 are provided in addition/separate to any longitudinal/cross seals of the package. It is also understood that the sealing tool 2200 can also comprise a patterner, such as protrusions and/or recesses, so that when the sealing tool 2200 engages the package and/or foodstuff 5000, a texture and/or decoration can be formed on a surface of the package and/or foodstuff 5000. The texture and/or decoration on the surface of the set foodstuff and/or the package are then visible and/or tactile to the consumer, which can be useful in branding the foodstuff and/or package and/or communicating a message to the consumer.

It is also understood that such a texture and/or decoration may be provided by a choice of the material the sheet of the package is made from, or by applying food grade inks and/or lacquer thereon. For example, a film/sheet of material with a rough surface is used to give a matt finish and/or a film/sheet of material with a smooth surface is used to give a glossy appearance. Alternatively, a surface of the package is applied with food grade inks and/or lacquer to print the texture and/or decoration thereon.

Figures 6 & 7 depict details of a sheet of material comprising one or more structural modifications therein in accordance with an example embodiment. The structural modification formed in the sheet shown in Figure 6 comprises a first line of relative weakness 6100 and a second line of relative weakness 6200.

The sheet is then folded over and sealed on a longitudinal side to form a package of a hollow tube formation comprising a first opening and a second opening. The first opening is sealed to form a receptacle and as the flowable foodstuff is supplied into the package through the second opening, the foodstuff fills the package so that the package expands until the forces acting on the internal surface of the package and on the surface of the foodstuff reaches an equilibrium, whereby the foodstuff and/or the package achieves the predefined shape as shown in Figure 7. It is understood that the package of the tube formation may be provided in a flattened shape or configuration. The tube formation might be additionally or alternatively described or defined as tube-like, or a formation from which the tube may be formed by expansion or opening of the flattened configuration. It is also understood that the flattened tubular package may be provided on a roller so that easy and efficient provision and/or transportation of the package material can take place. The first and second lines of weakness 6100, 6200 facilitate the package to fold at the lines of weakness 6100, 6200 as the foodstuff fills the package. This then allows the package to achieve the predefined shape of Figure 7.

According to an embodiment, the package also comprises an easy-break portion 6150 defined by the first line of weakness 6100 and an end portion 6250. The easy-break portion 6150 can be easily broken off from the package along the first line of weakness 6100 to enable a consumer access to the foodstuff therein. The end portion 6250 comprises a sealed portion 2590 similar to those shown in Figures 5a- 5c, and the second line of weakness 6200 defines a break line so that once more than one package portion is processed and set, each package portion can be separated along the second line of weakness. In other words, connected packages (e.g. a string pack) can be separated.

The processed or packaged foodstuff shown in Figure 7 is an example of a processed foodstuff in a package processed according the aforementioned method of processing the foodstuff and/or using the aforementioned arrangement for processing the foodstuff.

Figures 8 to 10 depict examples of processed or packaged foodstuff and/or set foodstuff processed in accordance with example embodiments. The processed/packaged foodstuff and/or set foodstuff are produced by using the methods and/or arrangements described herein. As can be seen from Figures 8 to 10, processed foodstuff and/or packages with different predefined shapes can be produced by using the methods and/or arrangements described herein. Further, at reduced cost, time and effort, a chain/strip of processed/packaged foodstuff may also be produced as shown in Figure 10, wherein each package portion can then be broken off easily by the consumer and/or seller/vendor along a line of weakness provided in the sheet of material forming the package.

The embodiments of the present invention, described herein in relation to the Figures, enable shaping of the foodstuff and/or package by using the properties of the flowable foodstuff and the package comprising one or more structure modification rather than relying on the use of a rigid mould, stamp and/or external shaping means. For example, when molten chocolate is used as the flowable foodstuff and sheet of material for the package is a film of plastic and/or polymer, a good quality surface finish can be achieved. The embodiments enable a mass production/manufacture of packaged chocolate, i.e. processed foodstuff, whilst reducing complexity of production by removing and/or minimising at least some of the steps and components needed for the production, i.e. a processing system and method comprising a mould, setting station, a de-moulding station and/or a transportation into and out of a packaging system.

As described herein, by providing one or more structural modifications in the sheet of material forming the package, the package not only functions as a wrapper of the chocolate, the package also functions as an adaptable mould which is capable of exploiting the flowable nature of the chocolate and the deformable nature of the sheet of material, and the interaction therebetween. It is understood that when any of the methods described herein are implemented in practice, the order of any of the steps described herein may be changed. This order may be decided depending on a number of parameters such as the property of the foodstuff and/or the sealing technique used in the method. It is also understood that when any of the methods described herein are implemented in practice, any of the steps may be performed simultaneously and/or during an overlapping period of time. That is, the steps may take place simultaneously and/or overlap in part or in full. This reduces the overall time needed for the method which can be advantageous when processing many foodstuff and/or packages, i.e. when mass producing the processed foodstuff.

It is understood that the foodstuff supply of the arrangements described herein may supply the flowable foodstuff at pressure so that an internal pressure of the flowable foodstuff in the package is increased and the package is filled with the flowable foodstuff more uniformly. Additionally or alternatively, the package might be positioned under the flowable foodstuff so that the weight of the flowable foodstuff under gravity contributes to the internal pressure.

It is understood that a sheet of material for the package may be a polymer based film. It is also understood that the structural modifications are provided to change the shape of the package, once at least partially filled, in comparison with a similar package without such structural modifications. It is understood that the sheet of material for the package can comprise more than one type of material. For example, the sheet of material might comprise a first layer for providing an external surface of the package and a second layer for providing an internal surface (for engagement with the foodstuff) of the package. Additionally and/or alternatively, the structural modifications are provided in at least one of the first and/or second layer, and/or an additional layer which is also provided in the sheet of material for the package. In other words, the sheet of material might be a laminate with more than one layer provided therein.

It is also understood that the package can be made from more than one sheet of material, for example each sheet forming opposite sides of the package.

Providing the structural modifications might also comprise thermoforming at least one of the layers of the sheet of material for the package and/or using an additional material in the sheet of material for the package. The additional material may comprise a different physical property, such as stiffness, hardness and so on, so that when the sheet of material with the additional material undergoes a deformation, the resultant shape thereof is changed in comparison with a similar package made from the sheet of material without the additional material. The additional material might be present in the first, second and/or additional layer of the sheet of material for the package. The additional material might also facilitate improved structural modifying and/or patterning functionality. In other words, the additional material might be more easily embossed and/or patterned in general for providing more effective structural modification, texture and/or decoration. This allows improved functional and/or aesthetic functionality of the sheet when it forms the package.

The sheet of material might come provided with this additional material, e.g. a lacquer, or the additional material might be introduced onto a surface of the sheet before and/or at the same time as the structural modification, texture and/or decoration for shaping the open package is provided. It is also understood that the foodstuff might be chocolate, cheese or any type of food that can flow and then at least partially set. In other words, any type of food that can transition from a flowable state to the at least partially set state. The at least partially setting of the foodstuff might involve temperature change (either or both increase or decrease of temperature of the foodstuff) and/or addition of a catalyst for causing this transition of the state of the foodstuff.

It is also understood that the flowable foodstuff might include non-flowable material/deposits enclosed and/or suspended therein. For example, according to an embodiment, the flowable foodstuff such as chocolate includes one or more of non- flowable material/deposits such as nuts, jellies, fruits, or any solid/gel state confectionary therein, which are deposited. Since these deposits are enclosed/suspended in the flowable foodstuff, the method and/or arrangement described herein still works with such flowable foodstuff including the deposits.

The preferred example embodiments of the present invention use a Vertical Form Fill Sealing machine (VFFS) as shown in Figure 3a - 3c or Figure 4. According to an example embodiment, most or all the processing steps described herein are performed in the vertical orientation, or at least the filling process. According another example embodiment, all of the processing steps described herein are not performed in the vertical orientation. That is, one or some of the steps described herein are performed using an arrangement configured to process the package and/or foodstuff in another orientation, for example horizontal. For example, according to an example embodiment, supplying flowable foodstuff into a package by a foodstuff supply, and sealing of the package by a sealing tool are performed vertically to use gravity to allow the flowable foodstuff to flow in to a package, but at least partially setting the flowable foodstuff by a setter is performed off-vertical for example in the horizontal orientation, to avoid a potential mess that might result if setting in a vertical direction. It is understood that according to the preferred example embodiments of the present invention, at least one, or all, of the processing steps described herein are performed in the vertical orientation. A vertical form fill sealing apparatus is preferred, since this may assist in the filling process, and also, as a result of gravity, the changing of the shape of the package into its final form, all without external moulds and the like. Also, setting when in vertical direction, e.g. when the pack is suspended, might allow for setting without affecting the shape of the package/the product within. It is also understood that according to an alternative example embodiment, all the processing steps described herein may be performed in the horizontal orientation. According to a yet another alternative example embodiment, the method and/or arrangement does not use a Vertical form fill sealing machine (VFFS) at all.

The provision of foodstuff into the package will define the shape of the package, in conjunction with the shape-defining structural modifications, as already discussed. That shape may be maintained, as opposed to being initially defined, by the at least partial setting of the product.

The embodiments provide an efficient way of providing shaped, packaged products. Since the filling, shaping and packaging are all part of the same process, speed is increased in comparison with individual filling, shaping and /or packaging processes. Since the filling, shaping and packaging are all part of the same process, undertaken with the same apparatus, there is no need for individual and specific shaping apparatus, filling apparatus, packaging apparatus, etc. This means that the embodiments likely have a smaller physical footprint than existing apparatus, saving on space. Costs may also be reduced.

It is understood that according to an embodiment, to provide further convenience, the package also comprises an easy open feature. For example, the easy open feature may be provided by using tear-able material in the sheet, providing a notch and/or tear strip on the sheet, laser cutting or embossing a tear feature or a cross cut seal.

Attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Claims

1. A method of processing a foodstuff comprising the steps of:

supplying flowable foodstuff into an open package, wherein the package is formed from at least one sheet of material, and an internal shape of the package changes into a predefined internal shape during the supplying of the foodstuff, the internal shape of the package changing toward and finally into the predefined internal shape dictated by one or more structural modifications in the sheet of material that forms the package and the foodstuff within the package, the structural modifications being distinct from any seal of the package;

sealing the package; and

at least partially setting the flowable foodstuff to maintain the predefined internal shape.

2. The method of claim 1 , wherein:

the package defines the predefined internal shape under an internal pressure applied by the foodstuff to a freestanding portion of the package.

3. The method of any preceding claim, wherein the package assumes the predefined internal shape without a surface of the predefined internal shape forming portion of the package physically engaging an external support.

4. The method of any preceding claim, wherein the sealing the package takes place before the at least partially setting the flowable foodstuff.

5. The method of any preceding claim, wherein the supplying the flowable foodstuff into the open package comprises the step of forming the open package by sealing a first opening of the package so that the flowable foodstuff can be supplied through a second opening of the package and remain retained therein.

6. The method of any preceding claim, wherein the sealing the package, or the sealing the first opening or second opening of the package comprises the steps of: engaging the package with a sealing tool; and

sealing an opening of the package with the sealing tool so that only a portion of the engaged area of the package forms a seal, whereby an unsealed portion between the foodstuff in the package and the sealed portion of the package is created after the sealing tool is disengaged from the package.

7. The method of claim 6, wherein the unsealed portion defines a sealed space.

8. The method of any preceding claim, wherein the structural modification comprises one or more of a predefined: crease; fold; scoring; region of relative strength; or region of relative weakness.

9. The method of any preceding claim further comprising:

the step of, before supplying the flowable foodstuff, providing the structural modifications in the sheet of the material that forms the package; and/or

the step of, before supplying the flowable foodstuff, patterning the sheet so that a texture or a decoration is formed on an internal and/or external surface of the package.

10. The method of claim 9, wherein the structural modifications and/or texture or decoration are formed by embossing the sheet or by use of electromagnetic radiation on the sheet.

1 1. An arrangement for processing foodstuff comprising:

an open package formed from at least one sheet of material having one or more structural modifications provided in the sheet;

a foodstuff supply configured for supplying flowable foodstuff into the open package, wherein an internal shape of the package changes into a predefined internal shape during the supplying of the foodstuff, the internal shape of the package changing toward and finally into the predefined internal shape dictated by the one or more structural modifications and the foodstuff within the package, the structural modifications being distinct from any seal of the package;

a sealing tool for sealing the package; and

a setter for at least partially setting the flowable foodstuff to maintain the predefined internal shape.

12. An arrangement for processing foodstuff comprising: a structural modifier for forming one or more structural modifications in at least one sheet of material;

a foodstuff supply configured for supplying flowable foodstuff into an open package formed from the sheet of material, wherein an internal shape of the package changes into a predefined internal shape during the supplying of the foodstuff, the internal shape of the package changing toward and finally into the predefined internal shape dictated by the one or more structural modifications and the foodstuff within the package, the structural modifications being distinct from any seal of the package; a sealing tool for sealing the package; and

13. The method of any one of claims 1 to 10, or the arrangement of claim 1 1 or 12, wherein the method uses a vertical form fill sealing arrangement, and/or wherein the arrangement is a vertical form fill sealing arrangement.

14. A processed foodstuff in a package processed according the method of any one of claims 1 to 10 or 13, or using the arrangement of any one of claims 11 to 13.

15. A method, an arrangement or a processed foodstuff substantially as described herein, and/or substantially as described herein with reference to the accompanying Figures, and/or substantially as shown in the accompanying Figures.