The present invention relates to a method of making make a chocolate bar and in particular to a method of making a chocolate bar with an embedded design without the use of a mould.

It is known to produce novelty chocolate bars to order, either en masse or to an individual specification. Prior art methods of making such chocolate bars require the use of a mould to form the chocolate bar, with the different types and/or colours of chocolate being applied in stages during the moulding process to create the design, or being applied to the surface of the chocolate bar once solid.

According to the present invention there is provided a method of making a chocolate bar comprising the steps of providing a plurality of individual packets containing individual portions of different types and/or colours or chocolate; depositing a first layer of a first chocolate from one of said plurality of packets onto a substrate in a desired pattern or arrangement; depositing at least one further layer of a second chocolate from one or more further packets onto said substrate in a desired pattern or arrangement and allowing said layers of chocolate to set before removing the resulting chocolate bar from said substrate, wherein said substrate is formed from a translucent or transparent material, said method comprising placing a pattern or image beneath said substrate prior to depositing said layer of chocolate thereon such that said pattern or image can be used as a guide for the desired pattern or arrangement to create a desired image on the finished bar.

The plurality of individual packets may be warmed prior to use to soften the chocolate contained therein. Preferably said packets may be warmed by placing the packets in warm water. The packets are preferably warmed to a temperature of between 20°C and 32°C. The required temperature may vary depending upon the type of chocolate being used.

Preferably the method comprises the step of cutting a corner of said individual packets to allow the chocolate contained therein to be extruded from the respective packet by squeezing the packet. The method may further comprise enrobing the layers of chocolate deposited in said desired pattern or arrangement to form the final chocolate bar. A pattern or image may be drawn, printed or embossed onto the substrate to be used as a guide.

Preferably said substrate comprises a tray. Preferably said individual portions or chocolate are sealed within the respective packets, the packets then being heated and subsequently cooled in accordance with a predetermined thermal profile in order to temper the portions of chocolate contained therein prior to use. According to a further aspect of the present invention there is provided a kit of parts for use in the first aspect, said kit of parts comprising a plurality of individual sealed packets containing individual portions of different types and/or colours of chocolate and a substrate upon which said chocolate may be deposited from said individual packets in a desired pattern or arrangement, wherein the substrate is formed from a translucent or transparent material. The substrate may have an image or pattern printed, embossed or drawn thereon for use as a template.

Preferably the portion of chocolate in each packet has been tempered to enable the chocolate to be extruded from the packet after cutting a corner of the packet by heating and subsequently cooling the packet in accordance with a predetermined thermal profile.

The present invention provides a method enabling consumers to deposit chocolate to form shapes or letters for the purpose of making personalised novelty chocolate bars without requiring the use of a mould. The method in accordance with the present invention provides a simple alternative technique to create novelty/personalised chocolate bar by constructing the design with a combination of different chocolates, then enrobing the design to form a chocolate bar.

An embodiment of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which :-

Figure 1 is a side view of a packet containing a portion of chocolate for use in the method in accordance with an embodiment of the present invention;

Figure 2 is a side view of the packet of Figure 1 showing the cut made to enable the chocolate to be dispensed from the packet; Figures 3A to 3C illustrate the stages of the method of the present invention;

Figure 4 shows a chocolate bar made in accordance with the method of the present invention. A method of making a chocolate bar in accordance with an embodiment of the present invention uses sealed disposable polythene packets 2, each containing an individual portion of chocolate 4, as shown in Figure 1 , shaped to allow for ease of use. Each packet 2 is formed from a triangular sheet of plastic which is folded around a portion of chocolate and heat sealed along its free edges 6. A plurality of individual packets 2 may be supplied containing different types and/or colours of chocolate so that different types and/or colours of chocolate may be selected to create a desired pattern or image, as will be described in more detail below. Other shapes of package are envisage, such as square or rectangular, and it is envisaged that different types of chocolate may be provided in packages of different shapes or sizes.

Prior to use, the chocolate is melted and tempered by heating and subsequently cooling the packets 2 in accordance with a predetermined thermal profile whilst remaining in the sealed packets, then allowed to set. The tempering process is preferably in accordance with that disclosed in European Patent Application No. 08734897.5 (published as WO 2008/1 19530), the contents of which are hereby incorporated by reference. This may produce chocolate of a smooth fluid consistency suitable for pouring and coating or a thick clay-like extrudible consistency, which is quick setting and which can maintain its extruded shape when setting, without the use of a mould.

When it is desired to create a chocolate bar, the selected packets 2 of chocolate may subsequently be heated to soften the chocolate again when it is desired to be used. The softening or re-melting of the chocolate may be be achieved gently by immersing the selected sealed packet 2 in warm water or similar, to heat the chocolate to a temperature of around 30°C. Other heating methods may be used.

A corner 8 of the selected packet 2 may be cut to a given profile to enable the chocolate to be extruded from the packet 2 in a steady controlled flow, as shown in Figure 2.

The selected packet 2 may be squeezed to expel trapped air from the bag. The selected chocolate 4A contained therein may then be dispensed from the packet 2 in a controlled manner onto a disposable translucent/transparent sheet/tray 10, under which can be placed a drawing/design, detailing size and shape of the desired image, as shown in Figure 3A.

The process can then be repeated, by selecting further packets 2 containing different types and colours of chocolate 4B,4C in order to build up a picture or image made entirely of layers of chocolate, as shown in Figure 3B. Then the completed design may then be covered or enrobed in the desired chocolate 4C, dispensed from further selected packets 2, to make the form of the chocolate bar, as shown in Figure 3C upon the tray 10. The chocolate is then left to cool and set. Once it has hardened sufficiently the completed chocolate bar 12 can be removed from the sheet, ready to be consumed, forming a chocolate bar having the desired pattern or image 14 visible on one side, as shown in Figure 4. While the method of the present invention has been described in relation to chocolate, it is considered that the method may also be suitable for use with other confectionary products or compositions comprising crystallisable fatty materials, preferably having a total fat content of approximately 10 to 85 % by weight. Therefore the term "chocolate" used herein is intended to encompass any such confectionary product or composition.

The invention is not limited to the embodiments described herein but can be amended or modified without departing from the scope of the present invention.