MANUFACTURING METHOD THEREOF TECHNICAL FIELD

The present invention relates to egg-shaped chocolate products, and more particularly to chocolate products that are formed by joining the open faces of the shell halves in which the non-edible container referred to herein as "surprise" is disposed. PRIOR ART

Food products in the form of edible chocolate eggs obtained by joining hollow shell halves were first obtained by inspiration from "Easter Egg" and transforming it into chocolate form. The confectionery is obtained by joining like egg, thin-walled and hollow structure two half-shells made of chocolate cuts the longitudinal axis, and along the periphery of the non-edible container. The non-edible container is confined within the two half shells. The outer surface of the egg shaped chocolate is covered with foil material and packaged.

EP2386208 discloses a method for manufacturing a multilayer confectionery shell. The method comprises providing a first edible liquid in a core cavity, providing at least one other edible liquid on the first edible liquid on the core, the surface temperature can be suppressed by using a core that is under the solidification temperature of each edible liquid so that the edible liquids obtain at least two shell layers in the core cavity. The apparent viscosity of each edible liquid is 0.8 or less or 1 .5 or more. The viscosity of the liquids was measured at a shear rate of 5 s - 1 and a liquid temperature of 40°C. A multilayered layer of candy that can be obtained in this way is also explained.

BRIEF DESCRIPTION OF THE INVENTION

The object of the invention is to provide a chocolate egg confectionery product in a multi- layered shell structure having a high structural strength.

Another object of the invention is to accelerate the production of multilayered chocolate eggs.

In order to achieve the above objective, the present invention relates to a method of manufacturing chocolate eggs in a shell structure, supplying a liquid chocolate by means of a depositor to a mold assembly comprising a step of supplying at least one first cavity accessible from top and in an egg halve form. The production method includes the steps of supplying a first molten liquid chocolate to at least one second cavity equipped with a predetermined canvas at the periphery of the first cavity; cooling the first liquid chocolate in an at least partially crystal form an top chocolate layer; supplying a molten second liquid chocolate to the first cavity covering the top chocolate layer and pressing the first cavity by means of a frozen cone up to a distance of a thin wall thickness in such a way that the first cavity is covered with the second liquid chocolate forming a solid base chocolate layer of a thin wall. By allowing the first fluid chocolate to acquire its crystal structure before the second fluid chocolate is applied, the chocolate having different viscosities, e.g. bitter, milky, white etc. it is possible to apply them on one another. This is because the crystal structure of the first fluid chocolate constitutes a boundary layer which prevents mixing of the second chocolate from the depositor. The first fluid chocolate and the second fluid chocolate are provided at melt temperatures or at higher temperatures. Thus, by passing through the liquid form, it becomes fluid.

A preferred embodiment of the invention comprises a process step of aligning the depositor in a vertical axis in such a way that the providing the first liquid chocolate to the second cavity from a first injector by free fall. Thus, the depositor releases the first fluid chocolate in the second cavity and transmits it by means of gravity. In a possible embodiment, the injector of the depositor is carried by means of a robot arm, such that the injector is aligned with the desired cavity position on the mold.

In a preferred embodiment of the invention, the second cavity is arranged on the first cavity in multiple numbers at a distance from each other and the first injector is moved to predetermined coordinates defined within the first cavity boundary and is sequentially aligned on each second cavity and supplies the first liquid chocolate so as to fill the corresponding second cavity volume. With the first injector being routed over more than one second cavity, the upper chocolate layer is rapidly formed and begins to cool, allowing crystal formation during the injector movement.

In a preferred embodiment of the invention, the injector provided by the second fluid chocolate and an auxiliary injector, a second injector, are vertically aligned on the first cavity.fThus, the first and second injectors are aligned one after the other on the second and the first cavity respectively, forming the chocolate form in the multi-layered shell structure.

In a preferred embodiment of the invention, the first fluid chocolate type is bitter or white, the second fluid chocolate type is milky chocolate. Dark or white chocolate, that have a different viscosity values according to milky chocolate, after the first liquid chocolate is applied it helps to form separate layers by preventing the mixing of the second liquid chocolate with different viscosity value in addition to the border structure cooling and crystallization.

In a preferred embodiment of the invention, the volume of the second cavity is equal to or smaller than the volume of the first fluid chocolate provided. In this case, the first liquid chocolate provided in the second cavity is not overflowing from the volume and the second liquid chocolate filled in the first cavity is joined to support the upper chocolate layer from behind. In a preferred embodiment of the invention, a viscosity value of the first fluid chocolate is greater than a viscosity value of the second fluid chocolate. In this respect, in the first chocolate which starts to cool, a dense crystal structure is formed in a short time, allowing the subsequent transport of the second fluid chocolate. In a preferred embodiment of the invention, the upper chocolate layer forming temperature is set between 12 and 6°C, preferably 9°C. Thus, when the crystal structure is formed, it is prevented that the chocolate is excessively cooled and the flexibility for shaping in the mold is lost. In a preferred embodiment of the invention, the at least partial crystallization setting is configured in such a manner that the first liquid chocolate in the peripheries of the upper chocolate layer forms a shell structure. The shell structure forms a wall which prevents the second fluid chocolate from mixing with the upper chocolate layer from the top while retaining the plastic forming softness of the inner part of the upper chocolate layer.

A preferred embodiment of the invention in order to achieve the said aim is an top chocolate layer produced according to a chocolate egg production method and an top chocolate layer containing a base chocolate layer forming the egg shell under the laminating form therefrom in the form of a shell consisting of white and / or bitter chocolate egg confectionery product.

To achieve the said aim the invention comprises a chocolate shell in the form of a hollow body comprising a first chocolate portion and a second shell halve forming a first egg shell halve with a second chocolate portion having a different cocoa weight ratio and correspondingly an inner chamber. When the chocolate egg sits upright, it contains a non-edible container which is placed in the inner chamber, supporting the hollow body from an inner surface in the transverse direction. The non-edible container enhances its structural strength by supporting the first shell halve with the support of non-edible containers against stresses coming from the outside during transplantation in vertical position due to a structure with both a toy or other suprise product movement and a different cocoa content and having a tensile distribution homogeneous.

In a preferred embodiment of the invention, the non-edible container is made of plastic. The plastic has both a resilient structure and a higher strength than the chocolate layer, which prevents breakage during transport. In a preferred embodiment of the invention, the first chocolate portion and the second chocolate portion have a tempering index value of 5-6 hPa. At this value, an inseparable structure is obtained between the first and second chocolate portions during production.

In a preferred embodiment of the invention, the second chocolate portion is a chocolate weight greater than 0.1 gr. Under this value, no significant structural failure is observed.

In a preferred embodiment of the invention, the transverse distance between the first shell halve and the second shell halve is characterized by being less than or equal to the width of the non-edible container. Thus, the non-edible container forms a bridge between the first and second eggs in the transverse direction.

In a preferred embodiment of the invention, the second chocolate part forms a face figure together with the first chocolate part. The facial figure forms a complex geometric structure such as eyes, mouth, and the internal stresses formed between the first and second chocolate portions in the first half of the shell due to this structure prevent the breakage in transit by the transverse support of the non-edible container.

An embodiment of the invention in order to achieve the said aim is a chocolate egg production method comprises the process steps that provision of chocolate which forms a first chocolate part in a predetermined amount and coordinate within a core, crystallization of first chocolate part with a cooling element within the core, provision of chocolate which forms a second chocolate part in a predetermined amount and coordinate within the core, formation of the First Shell Halve with crystallization of second chocolate part with a cooling element within the core, and a second shell halve is covered on the first shell halve with the first shell halve being the first chocolate part and the second chocolate part being supported from behind with the provision of an non-edible container to the interior surface of the first shell halve and combining in form egg forms. DESCRIPTION OF THE FIGURES

FIG. 1 is a schematic representation of a production line of a confectionery product made from a chocolate-like egg-shaped chocolate shell having a multi-layered shell structure according to the invention.

Figure 2 is a top-down representation of a half-shell mold used in the production of a multi- layered chocolate shell candy. Fig. 3 is a front view of a chocolate-crusted product in the form of an egg produced by the mold shown in Fig.

Fig. 4 is a cross-sectional representation of an embodiment of an inventive chocolate egg. Figure 5 is a front view of the chocolate egg shown in Figure 4.

Figure 6 is a schematic representation of the inventive chocolate egg production method. DETAILED DESCRIPTION OF THE INVENTION

In this detailed description, the invention is described with references to illustrative examples for the better understanding of the present invention without limiting it in any way. Figure 1 schematically depicts a production system used to produce chocolate egg halves in a thin- walled shell structure. A mold assembly (10) comprises a second cavity (14) in the form of a longitudinally cut half of an egg, arranged in a row on a mold in the form of a tray,and a plurality of first cavitys (12) extending from the outer wall thereof to the depth of the mold to form a relatively shallow depression form on the second cavity (14). On the second cavity (14), the distribution of the first cavity (12) forms a depressed pattern, for example a face. An auxiliary depositor (20) is adapted to be movable in such a way that it can be adhered to a robotic manipulation arm (not shown) so that the first cavity (12) and the second cavity (14) can reach the desired coordinate in the horizontal plane on the open top faces. Having the auxiliary depository (20) and an auxiliary container (22) filled with a first fluid chocolate (25) held in a molten state such as bitter chocolate which includes a first injector (24) provided to allow fluid communication at its end. The position of the first injector (24) is adjusted to a first coordinate set (P1 ) by position information from a control unit (not shown). The first coordinate set (P1 ), in figure 2, in the top view of the core, an area corresponding to the upper opening of the first cavity (12) for instance, is giving a distance between the two points with reference to a corner of the core mechanism (10), two-dimensional or three-dimensional coordinate information including depth information. Alternatively, spherical coordinates can be used. The first injector (24) transmits the molten first liquid chocolate (25) held above the melting temperature fed from the upper end of the mold by the auxiliary container (22) in a perpendicular manner, onto the plurality of second cavitys (14) provided on the first cavity (12) from the open end of the lower end. In the embodiment shown in FIG. 2, the first coordinate set is at the center of the circle of the first cavity (12) forming an eye pattern. The first injector (24) fills the first cavitys (12) with the left and right eye caps respectively, with a total volume of 9 g of the molten first liquid chocolate (25) as bulk. In this process step, the mold assembly (10) is aligned from the open end of an intermediate cooling unit (30), with the first cavity (12) being filled with the first liquid chocolate (25), moving on a moving conveyor (not shown). The intermediate cooling unit (30) is beginning to form a top chocolate layer (62) forming a shell by crystallization on the upper surface of the first liquid chocolate (25) melted in the first cavity (12) by cooling for about 10 seconds to perform the intercooling (B) process. The top chocolate layer (62) is in this case only in the form of a shell, and the first liquid chocolate (25) is still in a plastic formable form despite its cooling. After this, the mold assembly (10) is moved to the base forming station (C) by sliding on the conveyor. This section provides transfer of a second liquid chocolate (45), in the case of milk chocolate, in a molten state of the container (42), to the second cavity (14), with the aid of a depositor (40), to form a base chocolate layer (64). To accomplish this, a second injector (44) of the depositor (40) with the manipulation arm is aligned with the second coordinate set (P2) on the second cavity (14). The second coordinate set (P2) corresponds to a center of equal distance from the far end of the second cavity (14). The molten second liquid chocolate (45) in the container (42) is supplied to the second cavity (14) from one end through the second injector (44).

In an alternative embodiment, the second injector (44) injects the molten second liquid chocolate (45) to an intermediate hole (13), for example in a wall which defines the boundaries between the first cavity (12) and to the shallow-like depression of the second cavity (12) and again for an intercooling (B) operation is recovered by taking it into the intermediate cooling unit (30) for cooling. In such an embodiment, the second liquid chocolate (45) may be supplied from the first liquid chocolate (25) with a different viscosity value, for example white chocolate or milky chocolate, in the structure of an interlayer chocolate (63). This process can be repeated for different intermediate holes (13) selected at different depths. It is also possible in the single process to fill both the first cavity (12) and the intermediate hole (13) with the first liquid chocolate (25) followed by the intercooling (C) process step. In the present embodiment, the second liquid chocolate (45) is gathered in the middle of the second cavity (14) due to the curvature of the base. By moving the conveyor, the second cavity (14) is taken to the flatting (D) station. A frozen cone suitable for passing through the second cavity (14) in the form of a half egg cooled below the chocolate freezing temperature rapidly presses the outer wall (54) and the second liquid chocolate (45) into the bottom of the second cavity (14). Thus, the second liquid chocolate (45) is plastered onto the surface in the form of containers for the second cavity (14) and forms a thin base chocolate layer (64) behind the top chocolate layer (62) in the shell structure. After this process the mold assembly (10) is combined with a production method involving the known state of the art with the other half of the eggs formed by a non-patterned or similar method, and cooled at a suitable rate until a desired elevator temperature value of 4-6 is reached in the elevator cooler (not shown).

In Figure 3, the front half of the chocolate egg obtained by the described production method is shown. The first cavity (12) with corresponding to top chocolate layer (62) are formed with an the intermediate hole (13) with the corresponding an interlayer chocolate (63) and the second cavity (14) in the form of an egg half cavity with the corresponding base chocolate layer (64). Thus, the final product is obtained from the top chocolate layer (62) with bitter chocolate and black color, the interlayer chocolate (63) with white chocolate and white color, the base chocolate layer (64) with milk chocolate and a brown chocolate. Through the flatting (D) process step, the inner wall of the base chocolate layer (64) is completely smooth and forms a casing for a non-edible element, e.g. a surprise toy box, to be placed in the laminar structure of the product.

Figure 4 shows a first shell halve (100) with a thin wall and a homogeneous thickness and a second shell halve (200) completely overlapping with it, is shown by taking a cross-section of a hollow egg that it forms together. On the first shell halve (100), an outwardly facing figurative part (160) is located. The first shell halve (100) is a thin chocolate structure made from a milky chocolate. As can be seen in Figure 5, the figurative part (160) contain a first chocolate part (400) is provided from the white chocolate provided on the first shell halve (100), and a second chocolate part (500) extending on its first shell halve (100) from the bitter chocolate, has outer wall within a joining border (420) and a face line drawn with the aid of a second joining border (520), which forms the boundary between the first chocolate part (400) and has walls. The first chocolate part (400) is provided on the first shell halve (100) by applying additional chocolate. In the present embodiment extends radially outwardly with respect to the first shell halve (100). Alternatively, it is clear that first shell halve (100) can be provided in line with and complementary to half. An non-edible container (300) of a cylindrical plastic capsule construction surrounds a surprise player (not shown) as two interlocking pieces. When the hollow body in the form of an egg is held in the upright position, along the circumferential edge of the base part, it contacts the interior surface (140) of the first shell halve (100) with an opposing front support edge (340) and the interior surface (140) to the second shell halve (200) with the opposite rear support edge (320). Thus, the base of the non-edible container (300) supports the first shell halve (100) internally along a transverse support axis of the non-edible container (300). The notch effect caused by the figurative part (160) makes the impact strength of the first shell halve (100) lower than the impact strength of the second shell halve (200).

Thus, when the chocolate egg is lifted upright during transport, the nonedible container (300) supports the firstshellhalve (100) against the pulley formed during transport by abutting on th e second shell halve (200) from the inner surface (140) of the lower part (180, 220). In this case, breaking of the first shell halve (100) is prevented.

Figure 6 shows schematically the method of chocolate egg production. From the first chocolate out (720) on the depository (700), the core (600), e.g. 1 gr of bitter chocolate is flowed into the first chocolate area (630) in a predetermined first coordinate set with a numerically controlled system. Thus, the bitter chocolate spreads to form the first chocolate part (400) and forms a black area in the first chocolate area (630) in the form of an eyebrow. A cooling element (800) is disposed in the core (600) in a structure of a frozen cone so that the first chocolate part (400) is solidified by crystallization. Next, a second chocolate area (640) is aligned with the predetermined second coordinate set and It will be filled as 5 gr. white chocolate. Thus, the second chocolate part (500) is obtained, which surrounds the joining border (420) of the first chocolate part (400). Also, the cooling element (800) enters into the core (600) to provide crystallization of the second chocolate area (640). These processes can be repeated with different cocoa weight or different colored chocolate contents depending on the desired shape to be obtained on the core (600). Finally, the first shell halve (100) from the milk chocolate is crystallized by flowing into the core (600). Thus, a first shell halve (100) is obtained for a chocolate egg completely made of chocolate having a figurative part (160) which does not contain any dyeing process or dyeing. The non-edible container (300) is placed in the first shell halve (100) and is closed and joined by the second shell halve (200). REFERANCE NUMBERS

10 Mold assembly 50 Frozen cone

12 First Hole 54 Outer Wall

13 Intermediate Hole 60 Chocolate Shell halve

14 Second Hole 62 Top Chocolate Layer

20 Auxiliary Depositor 63 Interlayer Chocolate 22 Auxiliary Container 64 Base Chocolate Layer

24 First Injector P1 First Coordinate Set

25 First Liquid Chocolate P2 Second Coordinate Set

30 Intermediate Cooling Unit A Figure Forming

40 Depositor B Intercooling

42 Container C Base Forming

44 Second Injector D Flatting

45 Second Liquid Chocolate x Transverse Support Axis 100 First shell halve 400 First Chocolate Part

1 10 Inner chamber 420 Joining Border

120 Upper part 500 Second Chocolate Part

140 Interior Surface 520 Second Joining Border

160 Figurative Part 600 Core

180 Lower Part 620 Core Gap

200 Second Shell Half 630 First Chocolate Area

220 Lower Part 640 Second Chocolate Area

300 Non-edible Container 700 Depositor

320 Rear Support Edge 720 First Chocolate Out

340 Front Support Edge 740 Second Chocolate Out

360 Body 800 Cooling Element