Field of invention

The invention relates to an enhanced apparatus for forming a viscous food product. In particular, the invention relates to an apparatus and a process for enabling a moulding operation within an outer packaging of such product into a desired form.

Background of the invention

A very common way for forming viscous food products such as a confectionary product into a desired geometrical form is a moulding process, in which the food product is poured in its liquid state into a preformed mould, followed by cooling of the product in the mould.

This well-known manufacturing process can be executed in different ways, such as for example with shape giving exchangeable moulds in confectionary production or fixed forming plates in culinary presses. The known moulding processes however suffer the disadvantage that packaging of the shaped product cannot be carried out immediately, as the product has to cool a sufficient time before being wrapped .

Moreover, in the conventional manufacturing processes, the formed food product has to be fed either manually or automatically to a dedicated wrapping machine for providing an outer primary packaging of the product. This adds complexity to the production process as the transportation of the food product from the processing mould to the wrapping apparatus may be a complex, labour intensive and/or expensive process, depending on how fragile the formed food product is.

EP 0 776 608 relates to a process for forming an extruded fat-containing confectionery material which comprises feeding the confectionery material into an extrusion device and applying pressure to the confectionery material in a substantially solid or semi-solid non-pourable or non-flowable form upstream of a flow constriction. Thereby, the temperature, pressure, contraction ratio and extrusion rate are chosen such that the confectionery material is extruded substantially isothermally and remains in a substantially solid or semi-solid non- pourable or non-flowable form and which has a temporary flexibility or plasticity. Thereby, while the extruded product exhibits the temporary flexibility, the product is compression moulded into the desired shape. A preformed packaging film of polyvinyl chloride may be placed into the moulding tool before the product is poured into the mould, such that when the mould is closed, the provided chocolate product is formed into the packaging material and may then be ejected together with the packaging material .

This known apparatus however suffers the drawback that additional handling such as the removal of the product and packaging from the mould and transportation to a dedicated wrapping machine is required. Object and summary of the invention

The present invention seeks to address the above-described problems and to provide an improved moulding apparatus and manufacturing process. The invention also aims at other objects and particularly the solution to other problems as will appear in the rest of the present description.

In a first aspect, the invention proposes an in-pack moulding apparatus for a food product comprising filling means designed to provide a predefined amount of a food product in a liquid or viscous state within a (closed or open) deformable packaging, and shape forming means which are designed to receive the (closed or open) packaging from the filling means and to form the liquid or viscous food product within the (closed or open) deformable packaging into a predefined final product shape.

In one embodiment of the present invention, the deformable packaging is a closed deformable packaging.

The term "liquid state" or "viscous state" of the food product relates to any state in which the food product is deformable when a pressure and/or force is exerted thereon or to portions thereof without undergoing breakage. The food product is preferably brought into its liquid or viscous state by means of heating it to a predefined temperature in which the particular food product is present in liquid or viscous form.

The food product according to the invention may be any kind of food product suitable for being used with the shape forming means. The food product may in particular comprise confectionary products and/or animal food.

A preferred example of a food product according to the present invention is a confectionary such as chocolate that is present in a molten and thus in its liquid or viscous state when heated. Thereby, the chocolate food product is preferably heated or tempered to a temperature between 28 to 45°C.

The food product according to the invention is preferably a chocolate food product such as dark chocolate, milk chocolate, unsweetened chocolate, semisweet chocolate, bittersweet chocolate, black chocolate, white chocolate, chocolate compound, aerated chocolate and/or heat resistant chocolate.

The chocolate food product may be a single-component or a multi-component respectively a compound food product. The food product may comprise small inclusions in order to provide a compound chocolate food product. The inclusions within the chocolate food product may comprise different food substances e.g. in a solid state. In a preferred embodiment, the chocolate food product is heated or tempered to a temperature of between 35 and 45°C, more preferably between 38 and 42°C in case of a compound chocolate food product. In case of a single- component chocolate food product, the food product is heated or tempered to a temperature of between 28 and 37°C, more preferably between 30 and 34 °C. In the final product shape into which the food product is formed by means of the shape forming means, the food product such as e.g. chocolate is preferably present in a highly viscous or essentially solid state.

The terms "highly viscous state" or "solid state" refer to a state in which the food product does not undergo further deformation within the provided packaging during resting or storage of the product. In particular, such state of the food product refers to a state in which no further deformation occurs when the closed packaging is removed from the mould or moulding section of the shape forming means. Accordingly, in this highly viscous or essentially solid state of the food product in its final product shape, storage and/or transportation of the product is enabled, e.g. by means of a conveyor belt, without the risk of further deformation.

The term "open packaging" refers to a packaging portion wherein at least one end portion is closed and the other end portion is open. During the filling process, the "open packaging" is to be understood as also comprising open packaging which at least partially encloses the food product .

The term "closed packaging" refers to a packaging which fully encloses respectively surrounds the food product contained within the packaging material. Thereby, the closed packaging is preferably void of any aperture or opening. In a preferred embodiment, the "closed packaging" may be the primary packaging used for storage and/or transportation of the food product to a consumer. For the sake of clarity, the final packaging enclosing the food product and resulting from the apparatus and method of the present invention is always represented by a "closed packaging". The term "deformable" packaging relates to a packaging designed to be deformable respectively capable of being reshaped when pressure and/or external force is exerted onto at least portions of an outer surface of the packaging. The deformable packaging is preferably a flexible packaging which is designed to be capable of being reshaped such as to adapt to outer contours and/or geometrical shape of a food product enclosed by the packaging . The packaging is preferably made from foil such as e.g. plastic, metal or metalised foil. The packaging may however also be made from continuous paper and/or a fabric product void of any apertures and/or openings. The packaging material is preferably designed such that leaking of a viscous food product from the closed packaging is prevented.

According to the invention, the problem of handling the food product for packaging purposes after a forming or moulding process from a dedicated moulding station to a packaging station is overcome. Moreover, a fully wrapped packaging is already provided around the food product at the beginning of the manufacturing process. Therefore, any hygienically measures which are usually to be taken for the transport of the food product from a moulding station to a packaging station can be omitted.

In comparison to the known moulding and subsequent packaging process, no exchangeable moulds and no complex mould management is required. In addition, the risk of product contamination for example due to inclusion of foreign bodies in the food product is minimized. Furthermore, no mould cleaning steps are required which leads to a reduction in energy consumption and manufacturing costs of the products. In a preferred embodiment, the shape forming means of the apparatus are designed to exert a force respectively pressure and/or a temperature treatment to at least portions of the food product within the packaging. The shape forming means preferably comprise cooling means designed for passively and/or actively cooling the liquid or viscous food product within the packaging. Due to such cooling process, the food product will be transferred more rapidly from its liquid or viscous state into its highly viscous or solid state in which no further deformation occurs during resting or storage of the product. In case chocolate is used as food product, the molten chocolate product will be brought into its solid state by means of being subjected to a cooling treatment.

The cooling means are preferably designed for applying a cooling temperature which is energetically optimised to form the food product. For chocolate food product, for instance, a temperature between -20 and -5°C may be used, preferably a temperature of -12 and -17°C, most preferably about -15°C to the closed packaging. According to the invention, the food product is formed by the shape forming means when being still in its liquid or viscous state. During and/or after the shape forming process by means of the dedicated forming means, the food product may be actively and/or passively cooled, such that the final food product maintains the predefined final product shape .

The shape forming means preferably comprise enclosing means designed for exerting a pressure and/or force onto predefined portions of the outer surface of the deformable packaging such as to form the enclosed viscous food product into the predefined final product shape.

The enclosing means may comprise protrusions, recessions, convex and/or concave portions at a contact surface thereof designed to be pressed against the outer surface of the packaging. In a preferred embodiment, the shape forming means comprise at least two enclosing means comprising e.g. two moulding jaws designed to be brought from an open to a predefined closed position to form a moulding section, in which the (closed or open) packaging holding the food product is formed into a predefined shape . In one embodiment, the packaging holding the food product which is formed in a predefined shape is a closed packaging . The shape forming means may be designed to provide a large variety of different final geometrical product shapes to the food product such as for example an oblong form of triangular or squared cross-section, a rod-shaped form, or an oblong form comprising a plurality of spherical portions .

The filling means of the apparatus preferably comprise supply means for supply of the packaging or wrapping material. The supply means are preferably designed to continuously provide a standardised packaging or wrapping material such as a packaging foil. The provided packaging may comprises in its initial state at least one aperture through which the food product is filled and which may be closed-off and/or sealed after the provision of the food product into the packaging in order to provide a closed deformable packaging.

The filling means preferably also comprise dosing means for dosing a predefined or measured amount of the food product into the provided packaging. The dosing means may comprise a volumetric measuring device designed for metering a predefined amount respectively volume of food product into the respective packaging.

The filling means preferably also comprise closing means for closing-off or sealing at least a portion of the packaging material. In a preferred embodiment, after the filling of the food product into the packaging, the packaging is sealed or hermetically sealed by means of dedicated closing or sealing means such as to conserve the food product within the provided packaging.

The filling means is preferably a vertical form fill sealing machine. Such a vertical form fill sealing machine is an automated assembly-line product packaging system, which machine is designed for simultaneously constructing bags or packages out of a flat roll of film material such as plastic, metal or metalized material, whereby simultaneously a filling of the respective packaging and sealing thereof is carried out.

The vertical form fill sealing machine may be provided with a continuous roll of plastic, metal or metalized film. The vertical form fill sealing machine may be designed for provision, filling and sealing of packaging material made from plastic, paper or fabric. Dependent on the material of the packaging, the vertical form fill sealing machine comprises dedicated sealing means.

The general principle of such form fill sealing machine is that a packaging film of a continuous roll of e.g. plastic, metal or metalized material is made to approach a hollow forming tube, whereby the outer edges of the packaging film form flaps that wrap around the forming tube. The film is then pulled downward around the outside of the tube. Vertically arranged heat-sealing means bond the film together to form a vertical seam. A provided horizontal sealing means clamp across a bottom edge of the tube in order to bond the packaging material together. Thereby, any packaging material below said horizontal sealing means may be cut off. Accordingly, a packaging bag is obtained having at least one opening through which the food product may be filled into the inside of the packaging. In particular, the food product may be filled into the packaging by means of the conical tube. When the predefined amount of food product is filled into the packaging, the filling process stops and the horizontal sealing means seal the top of the packaging in order to provide a closed packaging.

According to the present invention, the forming tube of the vertical form fill sealing machine may be formed by at least one filling nozzle designed for providing a liquid or viscous food product to the inside of the packaging during the form fill and sealing process. The filling nozzle is preferably designed for provision of a metered amount of liquid or viscous food product such as chocolate to the packaging.

The filling nozzle may be a standard filling nozzle suitable for providing a metered amount of food product according to the invention to the inside of the packaging.

The filling nozzle may be as well pressure- or high- pressure nozzles. These nozzles are particularly suitable for provision of an aerated food product such as an aerated chocolate food product to the packaging. By way of example, a description of an apparatus to provide and dose an aerated food product is reported in WO2010/102716 or WO2005/063036. The vertical form fill sealing machine is preferably vertically arranged with respect to the shape forming means. Accordingly, the (partially) filledpackaging may be directly transferred in essentially vertical manner from the vertical form fill sealing machine to the shape forming means .

In one embodiment, the above mentioned transferred packaging is a filled and closed packaging.

The shape forming means is preferably a corrugator device. Such corrugator devices are well known in the plastic tube industry .

In general, a corrugator device preferably includes moulding jaws which are movably arranged and circulate in a linear moulding path. The moulding jaws are arranged in a paired relationship in the moulding path. The pairs of moulding jaws may be formed from each a left-hand and right-hand moulding jaw. Between these pairs a mould cavity respectively a mould section is enclosed when they are brought together at the moulding path. The device may include a driving means attached to the respective left- hand and right-hand moulding jaws for guiding the moulding jaws from the end of the moulding path back to the start of the moulding path e.g. in a circular motion. Thereby, the left-hand and right-hand moulding jaws are preferably each connected to separate drive and guide means .

The corrugator device preferably comprises clamping segments which are designed for selectively clamping and/or moving the (closed or open) packaging within the corrugator device. The clamping segments are preferably designed for pulling the (closed or open) deformable packaging into the corrugator device. In one embodiment, the packaging within the corrugator device is a closed packaging . he clamping segments are preferably designed for selectively clamping respectively enclosing at least a portion of the (closed or open) packaging. Preferably, the clamping segments are arranged to selectively enclose an end portion of the (closed or open) packaging.

The clamping segments may assume an open and a closed position such as to release and/or clamp at least a portion of the (closed or open) packaging.

The apparatus preferably further comprises transportation means such as e.g. a constrainer for providing the packaging from the filling means to the shape forming means .

Preferably, the transportation means are designed for providing a particular orientation to the packaging when being provided from the filling means to the shape forming means. Thereby, the transportation means are preferably designed for avoiding a pinching of the packaging material such as the packaging foil. The transportation means may as well be designed for facilitating shaping of the packaging when being provided to the shape forming means.

In a preferred embodiment, the transportation means are formed by a constrainer designed for assuming at least an open and a half-closed position, in which at least a portion of the closed packaging may be constrained between dedicated enclosing members of the constrainer. In the half-closed position, an inner diameter of the enclosing members is preferably arranged to be essential equal to or slightly larger than the widest outer diameter of the closed packaging. Accordingly, the constrainer is designed for carrying out a guiding operation for the packaging being transported from the filling means to the shape forming means. In the half-closed position, the inner diameter of the enclosing members of the constrainer may as well be arranged to be smaller than the widest outer diameter of the closed packaging. The transportation means are preferably designed to interact with clamping segments of the shape forming means in order to stretch, guide, center and/or align the closed packaging with respect to the shape forming means. In a further aspect, the invention relates to a method for in-pack moulding of a food product comprising the steps of:

providing a predefined amount of food product in a liquid or viscous state within a (closed or open) deformable packaging, and

forming the food product in its liquid or viscous state within the (closed or open) deformable packaging into a predefined final product shape. In one embodiment of the method of the present invention, the deformable packaging is closed.

Accordingly, a process for in-pack moulding of a food product in its liquid or viscous state within a (closed or open) packaging is provided which enables to obtain a desired final product shape of the food product without the need for an additional wrapping operation. The method preferably further comprises the step of passively and/or actively cooling the food product during and/or after the forming of the food product within the (closed or open) packaging such that in its final product shape the food product is in a highly viscous or essentially solid state.

Accordingly, cooling of the food product may be accelerated such that the food product is brought from its liquid or viscous state into its highly viscous or solid state, in which state no further deformation of the food product during storing thereof takes place. The geometrical final product shape obtained is thus maintained and the food product may be stored and/or transported.

In a preferred embodiment of the invention, the method further comprises the steps of

dosing a predefined amount of food product in its liquid or viscous state into a provided packaging, and enclosing the food product within the packaging.

A vertical form fill sealing machine preferably carries out the dosing and enclosing operation into a predefined packaging material such as e.g. a plastic, metal or metalized packaging. Before dosing of the predefined amount of food product into the packaging, a food product such as chocolate may be brought from its initial solid state into a liquid or viscous molten state by heating the food product.

During the forming step of the food product, external forces may be applied to at least portions of the circumference of the (closed or open) packaging such as to form the liquid or viscous food product into the desired predefined shape. The external forces are preferably applied by means of the inner moulding surface of dedicated moulding jaws of the shape forming means.

Preferably, the method further comprises the step of stretching, guiding, aligning and/or centering the (closed or open) packaging before and/or during forming of the food product.

The method may also comprise the step of providing a particular orientation and/or geometrical shape of the (closed or open) packaging before the forming step of the food product.

The apparatus and process according to the invention is applicable to any food product suitable for being moulded inside a packaging material such as e.g. a closed and/or sealed packaging foil. Thereby, the food product according to the invention encompasses any food products, which may assume a deformable liquid as well as a solid or highly viscous state. The food product may as well comprise different food substances, which are filled into the packaging by means of the same or different dosing means. The food product may as well comprise animal food products .

Brief description of the drawings

Further features, advantages and objects of the present invention will become apparent for the skilled person when reading the following detailed description of embodiments of the present invention, when taken in conjunction the figures of the enclosed drawings.

Figure 1 shows a block diagram of the respective parts of the in-pack moulding apparatus according to a preferred embodiment of the present invention.

Figure 2 shows a schematic figure of a preferred, first embodiment of an in-pack moulding apparatus according to the present invention.

Figure 3 shows preferred shapes of the final product obtained by the form shaping means of the apparatus according to the present invention.

Figure 4 shows a schematic figure of a preferred, third embodiment of an in-pack moulding apparatus according to the present invention. Detailed description of embodiments

Same reference signs throughout the figures designate the same parts or elements.

Figure 1 relates to a schematic representation of the apparatus and the operations carried out within preferably a single integrated in-pack moulding apparatus 20. The device 20 preferably comprises a filling means 20a and a shape forming means 20b.

The filling means 20a is preferably a vertical form fill sealing machine. The filling means 20a preferably comprise a food product supply means 30 such as a hopper providing for providing molten chocolate. The food product supply means 30 may be equipped with heating means (not shown) for heating and thus melting the food product. The food product supply means 30 are connected to dosing means 12 such as at least one nozzle. The dosing means are preferably designed to provide a metered or dosed amount of food product to a filling station 21 of the filling means 20a.

The filling means 20a further comprise a packaging supply means 11 for providing a supply of packaging material to the filling station 21. The packaging supply means 11 comprise a roll 11a on which flexible and/or deformable packaging material respectively flexible wrapper such as e.g. a plastic, metal or metalized foil material is stored and which is fed to the filling station 21.

The filling station 21 preferably comprises a forming tube 22 for forming the packaging material fed from the roll 11a into a desired shape. Thereby, the packaging material is fed from roll 11a to the forming tube 22, at which outer edges of the packaging material form flaps which wrap around the forming tube 22. Vertical heat- sealing means are arranged for bonding the packaging material together, thereby forming a vertical seam. Dedicated horizontal heat-sealing means are arranged to bond the tubular packaging material together at a bottom portion and top portion thereof.

At the filling station 21, the bottom and side seals of the packaging wrapper are formed into a single open-end tube which step is schematically depicted as step 23a in figure 1. Next, the viscous food substance such as e.g. chocolate is filled into the formed wrapper tube which is depicted as step 23b in figure 2. Then, the bonding respectively heat-sealing of the packaging at a top portion thereof (schematically depicted as step 23c in fig. 1) takes place. Furthermore, cutting of any additional packaging material from the closed respectively sealed packaging maybe carried out by the device (schematically depicted as step 23d in fig. 1) .

In one embodiment, the closed packaging holding the predefined amount of food substance in its liquid or viscous state then proceeds to the shape forming means 20b. The shape forming means 20b is preferably a corrugator device 26.

In another embodiment, the open packaging proceeds to the shape forming means 20b before it is completely filled with the food product and sealed. The shape forming means 20b is preferably a corrugator device 26.

The shape forming means 20b preferably comprise a cooling means 24 such as e.g. a chilled water circulation designed to provide a cooling of the shape forming means and in particular of enclosing means 7a, 7b, 8a, 8b (see figure 2) designed to be in contact with the packaging during the forming into the desired final product shape. The cooling means 24 are preferably designed to provide a cooling of the enclosing means 7a, 7b and/or the moulding jaws 7 of the corrugator device 26 to a temperature between -20° and -10°, more preferably between -17° and -12°, most preferably about -15°C. The cooling means 24 may comprise a cooling fluid such as e.g. glycol based brine .

The cooling means 24 enable the cooling of the (closed or open) packaging during the shape forming process. Accordingly, an enhanced shape retention of the final product is obtained.

In one embodiment, forming means operate on a closed packaging.

The shape forming means 20b may also comprise vacuum generation means 25. The vacuum generation means 25 may comprise an air compressor. The vacuum generation means 25 are preferably designed to provide a vacuum to a particular portion of the corrugator device 26 to improve shaping of the food packaging.

The corrugator device 26 is preferably designed for clamping, moulding and cooling of the food product 1. Thereby, a multitude of movable moulding jaws 7 respectively enclosing means 7a, 7b (see figure 3) arranged at the corrugator device 26 are preferably arranged to move in an intermittent motion (see arrow A) such as to clamp, shape respectively mould and simultaneously cool the (closed or open) packaging 3 within the device 26.

At an end portion of the corrugator device 26, the packaging shaped into the predefined final product shape will be discharged (arrow B) from the mould respectively clamp assembly of the corrugator device. Thereby, the product may be placed onto transportation means 27 such as e.g. a conveyor belt in order to enable further transportation of the product in a manufacturing line.

Figure 2 relates to a schematic figure of a preferred first embodiment of an in-pack moulding apparatus according to the present invention.

As shown in figure 2, the filling means 20a of the device 20 are preferably arranged vertically above the shape forming means 20b. Thereby, the closed packaging 3 formed, filled and sealed at the device 20a is preferably transported in a continuous vertical path from the filling means 20a to the forming means 20b. According to such arrangement, the footprint size and the space occupied by the device 20 is minimized.

The forming means 20b may also be installed vertically inclined or horizontal with respect to the filling means 20a. Accordingly, the closed packaging 3 formed, filled and sealed at the device 20a will be transferred from the filling means 20a to the forming means 20b in which the packaging 3 will then be further transported in a vertically inclined or horizontal path. As shown in figure 2, an open packaging portion 3a (in some instances also referred to as "open packaging" as above defined) having at least one opening 3b is arranged about the forming tube 22 of the filling means 20a.

Due to the opening 3b of the packaging wrapper 3a, filling of the open packaging portion 3a is obtained by means of dosing means 12 and/or the forming tube 22. It is noted that the dosing means 12 preferably comprise at least one dosing nozzle. In an alternative, second embodiment, the dosing means 12 may comprise at least two or more dosing nozzles for providing different food products respectively different food substances into the open packaging 3.

The filling means 20a further comprise horizontal sealing means 5 such as sealing and cutting jaws. The horizontal sealing means 5 enable a horizontal sealing and cutting of the open packaging portion 3a respectively closed packaging 3. The horizontal sealing means 5 are moveable horizontally with respect to the packaging 3 (see arrows E) in order to seal and/or cut an end portion 3c of the packaging. The sealing means 5 are preferably also moveable vertically with respect to packaging 3 (see arrow D) .

After filling of the open packaging 3a with a food product 1, the packaging 3 is fed down towards the horizontal sealing means 5 such as to obtain a sealing of the filling aperture 3b respectively filling side of the packaging 3. Due to this operation, a closed packaging 3 is obtained as indicated in figure 2. Between the filling means 20a and the shape forming means 20b a transportation means 13 is arranged which is preferably a constrainer, the operation of which will be described below. The corrugator device 20b comprises at least a first and second enclosing element 8a, 8b which are arranged on respective opposite sides of a moulding path 4 designed to accommodate the packaging 3 and for transporting the packaging 3 through the corrugator device 20b. The moulding path 4 comprises a plurality of moulding sections 4a. The amount of moulding sections 4a depends on the length of the corrugator device 20b.

The enclosing elements 8a, 8b each comprise a plurality of enclosing segments respectively moulding jaws 7 arranged moveable at an outer circumference of the enclosing elements 8a, 8b. Thereby, the enclosing segments 7 are preferably arranged on a chain 10 of the respective enclosing element 8a, 8b, which is moved by dedicated drive means (not shown) in a counter-rotated manner about the circumference of the respective enclosing element 8a, 8b (see arrows CI, C2) . The chain 10 of each of the enclosing elements 8a, 8b is preferably arranged within an insulated housing (not shown) in order to avoid condensation. The insulated housing is preferably filled and/or flushed with dry air. Accordingly, the formation of ice at the chain and/or the moulding jaws 7 is prevented.

The enclosing segments 7 preferably comprise clamping segments 7a designed for clamping an end portion of the packaging 3 there between. The clamping segments 7a may comprise clamping jaws 9 connected to the outermost portion of the clamping segments 7a which is designed for being in contact with the end portion 3c of the closed packaging 3. The clamping jaws 9 may be made from resilient or flexible material. The clamping segments 7a are arranged for selectively engaging respectively clamp a portion of the closed packaging 3 and for enabling a continuous movement of the packaging 3 through the corrugator device 20b. The enclosing segments 7 further comprise forming segments 7b which comprise a particular shaped surface 6 designed for obtaining a desired geometrical shape of the food product and the packaging 3. A plurality of forming segments 7b may be arranged on the chain 10 of the respective enclosing elements 8a, 8b. In the shown embodiment, 4 forming segments 7b are arranged in series, each series being divided by 1 clamping segment 7a.

Each individual forming segment 7b of the corrugator 26 may have different shapes, arranged and designed to obtain the desired final product shape (see figure 3) . In a preferred embodiment, the forming segments 7b each comprise a recession designed to be pressed against the packaging 3 within the moulding path 4 of the device such as to form a cylindrically shaped product.

The forming segments 7b and/or the clamping segments 7a of the corrugator device 26 are preferably made from metal such as e.g. aluminium. The segments 7a, 7b are preferably connected to the cooling means 24 of the device such as to cool the closed packaging 3 during the moulding process within the moulding path 4.

In the moulding path 4, while the clamping segments 7a clamp at least an end portion 3c of the closed packaging 3, the forming segments 7b are designed to exert a force onto predefined portions of the packaging such as to form the packaging into the desired final product shape, thereby enabling an in-pack moulding operation of the product. Thereby, each packaging 3 is held within a moulding section 4a of the respective opposite enclosing means 8a, 8b formed of preferably one clamping segment 7a and preferably between 2 to 10 forming segments 7b.

The movement of the corrugator chain 10 is preferably triggered by the cutting and sealing means 5 of the device .

The shape forming means 20b preferably further comprise vibrating means (not shown) . The vibrating means are preferably connected to the chain 10 and/or the segments 7 in order to enable a vibration of the segments. Accordingly, the shape forming process is enhanced as the distribution of the food product respectively the food substance within the closed packaging 3 during the forming process is improved.

During the filling process, the cutting and sealing jaw 5 is moved downwards together with the filled packaging 3 (arrow D in figure 2) . At the same time, a newly open packaging 3a to be filled is pulled downwards.

During this downwards movement, the constrainer 13 which may be moved at least into an open, a half closed and a closed position (arrow F) is brought into its half closed position in order to automatically center and align the closed packaging in with regards to the corrugator 20b. Thereby, the constrainer 13 positions the closed packaging 3 such as to be fed into the moulding path 4 of the corrugator 20b. In this half-closed position, the constrainer 13 preferably provides an inner diameter which is essentially equal to or slightly larger than the outer diameter of the closed packaging. Accordingly, the constrainer 13 carries out a guiding operation for the packaging 3 being transported from the filling means 20a to the shape forming means 20b.

The clamping segments 7a of the respective enclosing members 8a, 8b are moved towards each other, thereby pinching an end portion 3c of the packaging 3. At the same time, the sealing j aw 5 is moved such as to release the respective opposite end of the packaging 3. Thereby, the constrainer 13 moves to its closed position in which the constrainer 13 presents an inner diameter which is preferably smaller than the outer diameter of the packaging 3. The corrugator chains 10 are moved such that the packaging 3 is transported along the moulding path 4 within the corrugator 20b. Thereby, due to the constrainer 13 being held in its closed position, the packaging 3 is stretched such as to have a relatively smaller outer diameter than the inner diameter of the respective moulding section 4a of the moulding path 4. Accordingly, it is ensured that the packaging material of the closed packaging 3 is not pinched between the individual segments 7b of the enclosing member 8a, 8b.

During further movement of the chain 10 and the segments 7a, 7b arranged thereon, the packaging 3 is fed through the corrugator along the moulding path 4 and is discharged at an end portion of the corrugator 20b (see also figure 1 ) .

By means of the cooling of the packaging 3 within the corrugator 20b, the food product 1 is brought from an initial viscous or liquid state into a highly viscous or solid state, in which no further deformation of the packaged food product 1 occurs. Thereby, crystallization of the food product 1 held within the closed packaging 3 preferably occurs. The length of the cooling means 24 is preferably chosen due to the time necessary for cooling the food product 1 within the closed packaging 3 respectively the time needed for the product 1 to be brought from its viscous or liquid state into its highly viscous or solid state.

It is noted that the present invention is not limited to a single filling means. Instead, the filling means 20a may comprise a plurality of nozzles for filling different food substances into the same and/or different packages. Moreover, the same and/or different food substances may be filled in different chambers formed within the same packaging.

Moreover, the corrugator 26 may comprise at least two or more moulding paths 4 through which the respective packaging is fed such as to form the food substance held within the respective packaging into a desired shape.

The constrainer 13 may as well be designed for pre-shaping or shaping the food product within the closed packaging 3. Figure 3 shows preferred geometrical forms for the final product shape. The product may thus have an outer oblong shape 41,42,43. The cross-section of the final product may be e.g. squared (41a), triangular (42a) or circular (43a). As indicated by reference numeral 40, the final food product may comprise different portions of varying outer shape such as for example a plurality of spherical portions 40a having the same or different diameters, and oblong portions 40b of e.g. squared cross-sectional form.

The respective portions of the final product are formed by recesses and/or protrusions provided in a contact surface of the forming segments 7b. Accordingly, the forming segments 7b comprise a contact surface of negative form with regards to the final product to be obtained during the in-pack moulding operation according to the invention.

Figure 4 shows an in-pack moulding apparatus 20 according to a third embodiment of the invention. As will be apparent from Figure 4, the transportation means 13 is not present .

Figure 4a shows the in-pack moulding apparatus 20 in a state according to Figure 2.

The filling means 20a comprises an additional element compared with former embodiments of the invention. This additional element comprises a section formed by a mandrel 31 and a thermoforming section 28. Sections 28, 31 are preferably modifications of known corresponding standard parts of vertical form fill sealing (VFFS) machines.

The interior of the modified mandrel 31 is shaped like the wished outer end shape of the final product 1 leaving the corrugator chain 10, or of the packaging 3. In its simplest form the mandrel 31 will be a cylindrical ring extension being fixed at each forming and dosing nozzle 29 of the in-pack moulding apparatus 20. If a square product will be needed the mandrel 31 will have an inner square shape .

The thermoforming section 28 forms a same shaped counterpart to the mandrel 31 and is designed in a way that the mandrel 31 fits into the section 28. So the packaging material of the packaging 3 can be shaped accordingly. The section 28 is mounted at the top of the sealing jaw 5, i.e. at a side of the sealing jaw 5 facing the open packaging portion 3a. By using a sealing heat impulse of the section 28, the packaging 3 will be pre- shapened .

In the result, both sections 28, 31 form together a preforming portion of the in-pack moulding apparatus 20 which ensures that the packaging material (or open packaging 3) will have a preferably perfect (flat) bottom shape before transported into the corrugator chain 10. As illustrated in Figure 4a, the mandrel 31 which is mounted at the end of dosing nozzle 29 will push forward the packaging foil of the open packaging 3 into the counterpart, i.e. the thermoforming section 29 at the top side of the sealing jaw 5. This will happen at the same moment the sealing j aw 5 is executing aforementioned cutting and sealing steps. The heat of the jaw 5 will harden the packaging foil of the open packaging 3 in its current shape like it is already known from thermoforming processes .

This process is a prerequisite for the future package to ensure here a flat bottom of the packaging 3 and, so, of the product 1 which bottom faces the j aw 5 and chain 10, respectively. Without this equipment the packaging 3 will always be wedge shaped and not having the wished flat shape appearance. After cutting and performing the packaging 3 for the product 1 currently to be produced, sealing jaw 5 opens as aforementioned described, and the forming tube 22 is moved towards the chain 10 (along arrow G downwardly in Figure 4) until a position shown in Figure 4b.

At this movement, chain 10 is moved in that way that for each packaging 3 firstly a pair of two opposite enclosing means 7a, 7a corresponding with each other are brought into contact with each other to provide a begin of a moulding form for the corresponding packaging 3. This position of enclosing means 7a, 7a in relation to each other allows that, through the dosing nozzle 29, the product 1 in its liquid or viscous state can be filled in the open packaging 3 and consequently in the moulding form currently formed by aforementioned two enclosing means 7a, 7a. In further progression, chain 10 is moved further such that one after the other three pairs of respectively two opposite enclosing means 7b, 7b corresponding with each other as aforementioned means 7a, 7a and belonging to the same packaging 3 are brought into contact with each other and with pair of opposite two means 7a, 7a; 7b, 7b being brought into contact with each other directly before. That is, the function of chain 10 with all elements 7 essentially is the same as in former embodiments.

Because of cooling function of shape forming means 20b, current product 1 is brought into its final form immediately after being filled in corresponding part of moulding form or after filling in material for the whole packaging 3. That is, filling in product 1 into open packaging 3 and forming it into its final shape effectively occurs at the same time. After product 1 in its liquid or viscous state has been filled in last pair of means 7b, 7b belonging to current packaging 3 and after bringing product 1 into its solid state, forming tube 22 gets moved away from chain 10 and towards jaws 5 into position shown in Figure 4a (along arrow G upwardly in Figure 4), and the process for the next packaging 3 can start .

Although the present invention has been described with reference to preferred embodiments thereof, many modifications and alternations may be made by a person having ordinary skill in the art without departing from the scope of this invention which is defined by the appended claims. All embodiments, in part or as a whole, can be exchanged against or combined with each other. For instance, transportation means 13 can be provided in third embodiment, thereby assisting or performing alone movement of forming tube 22.

Furthermore, mandrel 31, dosing nozzle 29 and/or thermoforming section 28 can be integrated in the other, i.e. the first and the second, embodiments according to the invention.

Aforementioned modifications for the first and second embodiment also can be carried out in the third embodiment . List of Reference Signs

I food product

3 (closed or open) packaging / packaging wrapper

3a open packaging portion

3b opening

3c end portion

4 moulding path

4a moulding section

5 sealing means

6 shaped surface

7 moulding jaw

7a, 7b enclosing means

8a first enclosing element

8b second enclosing element

9 clamping jaw

10 chain

II packaging supply means

11a roll

12 dosing means

13 transportation means

20 In-pack moulding apparatus

20a filling means

20b shape forming means

21 filling station

22 forming tube

23a step

23b step

23c step

23d step

24 cooling means

25 vacuum generating means corrugator device

transportation means thermoforming section dosing nozzle

food product supply means mandrel

final product

a spherical portion

b oblong portion

oblong shape

a squared cross-section

oblong shape

a triangular cross-section oblong shape

a circular cross-section