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Confectionery

Equipment for molding chocolate products.

 In modern confectionery production, the formation of chocolate products is carried out on special units, which are a complex of technological machines connected in series with a system of transporting devices.

The main method of forming chocolate products is the casting of chocolate masses into metal (sometimes plastic) molds. Depending on the type of chocolate products, the units for their formation can be divided into three groups: units for forming chocolate products without toppings (Goebel-Lesh company, Heidenau plant of types 315-Е-9, 316-Е-4 and 317- E-9, “Rutter-Lesch”);

units for forming chocolate with fillings and making hollow chocolate figures (Max-Lesch company); universal units for the manufacture of chocolate products with both filling and without filling (Heidenau plant of 850 type, Caivemil cream 275 and 600 / 205, Carle and Montanari, as well as the Avtomold type unit of Savi - Jean-Jean "). The technical characteristics of the units for molding chocolate products are given in the summary table at the end of the paragraph.

The unit for forming slab chocolate type "Heidenau 316-E-4".Machine for molding slab chocolate, type "Heidenau 316-E-4". The unit (Fig. VI. 14, a) is designed for casting bars weighing 100, 50 and 18 g from liquid and thick chocolate masses, as well as chocolate with an admixture of chopped nuts. continuous double-chain conveyor 6 fixed form holders, on which removable forms are installed. The molds are filled with chocolate mass in a casting machine 7 and pass through a vibrating device 5 to compact the mass and remove air bubbles from it. Here, the forms move along guides that receive vibration from the shafts with unbalances. To prevent the vibration of the molds from being transmitted to the conveyor chains, the molds are lifted above the conveyor when. using permanent magnets. In the cooling chamber, 3 forms successively pass through several horizontal tiers of the cozweiler, rising to the upper part of the chamber. In order to prevent the form from turning over when moving from one tier to another, the mold holders are fixed to the chain with hinges. At the ends of the mold frame, rollers are installed that fit into a short horizontal groove. When the hinge of the mold holder passes through the inter-tier transitional sprockets 4, the guide also rises up, supporting the mold holder in a horizontal position.
Air circulation in the cooling chamber is created by four individually switched fans. The air is supplied in such a way that the temperature in the middle part of the chamber is lower than at its entrance and exit. After passing the chambers, the molds are lowered on the vertical branch of the conveyor and on stars 2 are turned down in cells. In the device 9 for sampling chocolate, vibration is transmitted to the molds, due to which the chocolate bars fall out of the cells onto the plates of the conveyor 10, which takes the tiles to the conveyor of finished products 1. Empty molds pass through the heating chamber 8, where 60 infrared lamps are installed, divided sequentially into three groups ... In order to better absorb heat, the outer surface of the molds is painted with a dark matte paint. From the heating chamber the molds return to the casting machine. The movement of all working bodies is strictly synchronized. All units of the machine are driven by a common electric motor with a gearbox installed in the lower part of the cooling chamber. From the gearbox there are two chain drives for driving a chain conveyor with molds, a plate conveyor and a finished product conveyor, as well as a longitudinal shaft to the casting machine. The unit is controlled from a central control panel. The location of the return branch of the conveyor under the working one makes the unit compact, with a high removal of products from 1 m2 of occupied area. The unit for molding slab chocolate of the Heidenau 317-E-9 type (Fig. VI. 14,6). This unit is similar to the previous one. It is designed for molding chocolate products with a minimum fat content (26%). The design of the casting machines allows molding chocolate with various additives (for example, with crushed nuts, waffles, etc.), introduced into the mass. The presence of two casting machines makes it possible to simultaneously produce two types of chocolate bars. A distinctive feature of this unit is the automatic feeding of chocolate bars into wrapping machines. The bars are formed as follows. The tempered chocolate mass by casting machines 1 and 2 is poured into molds, which are continuously supplied to them along the lower branch of the conveyor 3 from the zone 5 for heating the molds located under vibratory conveyors 4. It contains 90 infrared heaters with a power of 300 W, which are divided into three groups. The combination of these groups allows you to turn on 20, 40, 60 and 80 and 100% of the heaters and, accordingly, weaker or more intensively heat the molds.
Forms are hinged on the 3 chain conveyor with a length of about 200 m, they can be easily removed or put on the conveyor at the point of rotation of the conveyor in front of the casting machines. When making chocolate bars of various weights (for example, 100 and 50 g), the forms for these types of products are mounted on a conveyor belt alternately. Each of the casting machines fills the corresponding forms (24 forms per minute). The forms filled with chocolate mass go to the 4 vibrating conveyors. To reduce the noise usually caused by shaking the molds, the sections of the vibrotransporter are enclosed in a wooden casing, while the forms themselves are forcibly moved by chains above the surface of the permanent magnets. Each of the six sections of the vibrating conveyors has independent regulation. After the vibrating conveyor, the molds enter the cooling chamber 6. Successively passing nine branches of the cooling conveyor *, the forms are lowered along its vertical section, turned over and move back towards the casting machines. In this area, under the action of vibrating conveyors, chocolate bars fall out of the forms onto the 8 plate conveyor, and empty forms on the way to the casting machines are heated. In the 6 chamber, the forms with chocolate are cooled for 19 minutes. Air circulation in the zone of more intensive cooling 11 and in the lower zone 12 - the zone of acclimatization - is created by four separate 7 centrifugal fans arranged in pairs, which are self-powered. To control the cooling mode are thermometers. Cooling chocolate bars to a temperature close to the air temperature of the workshop allows them to be sent for wrapping without prolonged drying. To the wrapping machines, tiles are fed from the 9 plate conveyor with four 10 belt feeders. Tiles lying in parallel rows on 9 conveyor plates are automatically dropped onto belt conveyors arranged in pairs on both sides of the 9 conveyor. In the case of a forced stop of one of the wrapping machines, the tiles are transferred to the backup 8 belt conveyor, from which they are removed manually.

Unit "Rutter-Lesch" for the manufacture of fine chocolate bar, wrapped in foil. This unit uses foil in rolls. On one side of the foil applied multicolor pattern. Served from 1 rolls (fig. VI. 15), six strips of foil come into the 2 stamping mechanism, squeezing out the recesses in them, corresponding in shape to future products. Depending on the width of the foil strip and the shape of the stamp, there are recesses of various depths and shapes, and consequently, products of various shapes and weights. Then the strip with grooves are transmitted to the metering mechanism 3, which fills the grooves with the necessary amount of chocolate mass. The 4 knife cuts the strips into individual blanks that pass through the 5 vibrator and then sent to the 6 cooling chamber.Rutter-Lesh unit

After cooling on the surface of the frozen chocolate, foil blanks are applied, cut from the other six strips fed from rolls 7. Due to the slight heating, the foil is fixed on the surface of the chocolate. In the process of wrapping, the free edge of the foil remaining in the recesses is evenly bent by the mechanism 3, covering the lower surface of the products. The unit of the "Heidenau-320" type for the manufacture of hollow chocolate figures. It uses a two-piece drop-down hinge shape. When the mold is closed, the cells of both its parts are exactly the same. The chocolate mass is dosed into the cells of one half of the mold, then the mold is closed and fed to the vibratory conveyor. Here, thanks to vibration in the longitudinal and transverse directions, the chocolate mass flows from one half of the cell to the other and is evenly distributed along the walls. Passing further through the cooling chamber, the molds receive a rotational motion simultaneously around their longitudinal and transverse axes. After the cooling chamber, the molds are opened and fed to a vibratory conveyor, where finished products are removed from them. The molds freed from the products then pass through the heating chamber and, with a temperature of about 32 ° C, again enter the dosing mechanism.
Universal units for molding chocolate products with and without filling. In all units, the technology of making chocolate products "Assorted" with filling is essentially the same. In fig. Vi. 16 shows a diagram of the main technological operations for the manufacture of these products. Forms with figured cells are fed to the casting mechanism (a, b), then to the vibrating device and to the tipper (c), where the filled forms are turned upside down; about 75% of the mass in this case pours out of the cells, and onThe basic operations of making chocolate products with filling:Fig. VI16. The basic operations of making chocolate products with filling:a, b, c - the formation of the walls of the body of the product; g - fill the filling; e - compaction and cooling of the filling; e - bottom filling and cooling; W - sample products from the form.the walls remain a small layer. Next, the molds enter the centrifugal machine, where the layer of chocolate mass is leveled and reaches a thickness of 1 —1,7 mm.The molds then pass through a cooling chamber. After cleaning the forms are served under the casting mechanisms (g) to fill the filling into the cells, the walls of which are covered with a frozen chocolate mass. At the same time, the cells are not filled to the brim (d) with the filling, so that there is room for subsequent filling of the bottom of the chocolate figures. The filled in forms pass through the vibrator and the cooling chamber. Next, the form is fed under the electric heater, which heats and softens the upper edges of the chocolate shell of the cells. After that, the form enters the casting machine to fill the chocolate mass of the bottom of the product (e). After removing the excess chocolate mass from the surface and sides of the form, the form scrapers installed on the machine enter the cooling chamber, from which they are transferred to the machine for sampling products from cells (g). The Xvem-600 / 205 cream unit from Carle and Montanari the layout is a two-line machine system closed in a horizontal plane (Fig. VI. 17). Forms are not attached to the conveyors. On the line you can produce chocolate products with fillings (loaves, "Assorted") and without fillings (slab and patterned chocolate, medals).
In the manufacture of chocolate with fillings, the line works as follows. Empty forms, passing through the 2 conveyor, enter the 3 forms heater with the length of 10 m, divided into two zones. In this area, the forms are heated for 2 minutes to 28 — 30 ° C with hot air at a temperature around 70 ° C. The cells of the heated forms are filled with portions of shooter using a multi-piston two-sided casting machine.Universal chocolate-forming unit "Kavemil-cream 600 / 205"Fig. Vi. 17. Universal chocolate-forming unit "Kavemil-cream 600 / 205" of a fair mass. With the help of two groups of pistons (36 each), the machine doses the mass simultaneously to all the cells of the forms. Removable plates numbered for each type of product are used to direct the chocolate mass precisely into the cells. Casting machines of this type make it possible to use molds with any arrangement of cells. The casting machine has a funnel heated by water, inside of which the stirrer rotates with a blade, which cleans the walls of the funnel. The temperature of the water circulating in the funnel water jacket is maintained at a predetermined level automatically by means of an electric heater with a thermostat. To the casting machine, the tempered chocolate mass is fed from an automatic tempering machine through a pipeline with a water jacket that ends with a tubular filter. Forms filled with chocolate mass pass through the 5 vibrating table with four groups of vibrators condensing and smoothing the chocolate mass in forms, as well as removing masses of air bubbles. Then, in the 6 tipper, the forms are turned over to 180 ° and, in this position, pass through the 7 vibrator to remove excess chocolate in the cells and form the wrapper of the product.
Then the shapes are transferred to the vibrator 8, which imparts a circular oscillatory motion to them in order to equalize the thickness of the shell. The chocolate mass, removed from the molds, accumulates in the bath and is pumped back to the tempering machine. Then the device 9 turns the molds through an angle of 180 °, taking the initial position (cells up). The surplus of chocolate is removed from the surface of the molds by a stripping roller mechanism 10. It consists of a hollow metal roll rotating towards the movement of the molds, which is tightly pressed against the surface of the molds. The chocolate mass captured by the roller is scraped off from its surface with a knife and removed by means of an auger into the receiver. The cleaned forms are transferred further to the vertical cooling chamber 11 of the mine type. Then, the molds are transferred to the second branch of the line to the casting machines 12 for filling the molds with the filling by a transverse chain conveyor 14 with races. When casting products with alcoholized cherries or whole nuts, a dispenser 13 is connected in front of the casting machines for fillings, into the hopper of which calibrated cherries or nuts are loaded in advance. After passing the vibrating conveyor 15 to compact the filling, the molds enter the vertical cooling chamber 16. After that, the molds pass through an electric heater 18 to melt the edges of the product shell, which contributes to a more reliable connection of it with the bottom poured on the casting machine 19. The feed hopper of this machine is also equipped with tubular filter. Next, the molds go to the mechanism 20, where their surface is cleaned with a plate knife. The cleaned molds pass through the vibrating conveyor 22 and from it are transferred to the main cooling chamber 23 of the mine type with automatic temperature control. A mechanism 24 is installed behind the cooling chamber for overlaying plastic or cardboard sheets on the molds. pre-loaded into the cassette. The form, covered with a sheet, is turned over by the rotator 25 at an angle of 180 ° and transferred to the vibrating punching machine 26. The finished products are removed by the conveyor 27, and the released forms pass through the rotator 1, which turns them into their original position - cells up, and return to the first branch by the transverse conveyor For the production of products without fillings, the corresponding molds are installed on the conveyor 2, a plate of the required profile is placed on the casting machine and the operation of the pumps is regulated on it. For casting the articles, a casting machine 4 or one of the machines 14 for filling fillings is used. In the latter case, tilters, vibrators, a device for stripping molds, the first and second cooling chambers and other mechanisms are not used. The rest of the process is the same as described above.
For the preparation of slab chocolate with fillings, the appropriate molds are installed on the conveyor 2 and the mechanisms of the line are used in the same way as in the production of loaves or "Assorted" with fillings. When preparing chocolate with solid additives, the process is carried out using only the section for heating the molds and the mechanisms of the second branch of the unit starting from the casting machine 17. In this case, portions of crushed or whole nuts and other additives are mixed with the chocolate mass directly in the receiving hopper of the casting machine equipped with a mixer 17. The additives are introduced using a pocket-type mechanical dispenser installed above the casting machine. The casting machine has 16 pistons 40 mm in diameter and wide rectangular outlets. This design of the machine makes it easy to dispense mixtures of chocolate with whole or crushed kernels, raisins, etc. When using whole kernels and large additives, the vibration of the molds in front of the cooling chamber should be especially intense so that the maximum possible alignment of the outer surface of the products occurs. carried out from a common electric motor. From it, the movement is transmitted to individual machines through the gearbox 21 by means of cardan shafts, which ensure the synchronous operation of all the mechanisms of the unit. Independent electric motors have only separate auxiliary mechanisms (fans, pumps, etc.) The unit is started and monitored from the central control panel, on which the starting devices and lamps are mounted, signaling violations of the unit's operating mode. The drive has a stepless speed regulation (from 8 to 20 molds per minute), carried out by means of two buttons ("more" and "less") The productivity of the unit depends on the number of forms filled per minute and on the weight of products in one mold. From one mold, you can get 12 filled chocolate bars (1200 g), 7 chocolate bars with nuts (700 g), 80 pcs. "Assorted" (800 g), 16 loaves (800 g), 90 pcs. patterned chocolate (225 g). At a normal conveyor speed of 15 molds per minute, the productivity of the machine will be 1080, 630, 720, 720 and 202 kg / h, respectively.

Technical characteristics of units for molding chocolate products

Indicators "Heidenau 317-E-9"

"Hai

Dan

316-E-4 »

"Rutter

Lesh

"Heide-

Now-320 »

"Alone-

Helios-17

Throughput (kg / h) by type of products slab chocolate mass, g
100 1512 1000                        
50 1512 720            
15 907 300            
18 299
25 1512 500
4 153-306
filled chocolate, 100 g
baguettes with fillings, 50 g
"Assorted" stuffed, 10 g
blanks for medals 144-228
uzorchatыy chocolate 109-218
hollow figures, 50 g 140-186
Dimensions of forms, mm 570X 195 570X 195 426X275 275X175
The number of forms to be filled in a minute
for the tiled chocolate yes 42 24 50 15-30
for chocolate from the beginning
Hollow figures 8-12
The number of forms per cycle
for chocolate bars 886 712 460
Chocolate with filling
Hollow figures 129 - -
cold consumption, kW 75 58 22,5 27,5 16
Power of electric motors and heaters, kW 61,0 44,8 11,2 30,7 7,5
Overall dimensions, mm
length 42 725 31 250 48 300 33 000 12 700
width 3 200 1 730 1 500 1 750 3 770
height 2 650 2 650 1 750 2 000 3 170
The total weight of the line machines, kg 28 000 19 000 132 500 14 000
Indicators

coffeemilescream-

600 / 205 *

coffeemil-cream-275 »

sHaydeNow-850 »

"Auto-

Mold

"Max-

Lesh

Throughput (kg / h) by type of products slab chocolate mass, g
100 630 540 1110
50 540 837
15 324 666
18 389
25 540
4 639
filled chocolate, 100 g 1080 540
baguettes with fillings, 50 g 720 546 810 720 same 500
"Assorted" stuffed, 10 g 720 599 400
blanks for medals 315
uzorchatыy chocolate 202
hollow figures,
50 g
Dimensions of forms, mm 600X205 275X185 426X275 480X183 425X275
(480X222 with filling)
The number of forms to be filled per minute for slab chocolate
for chocolate with filling 15 20-26 15 29 11
Hollow figures . -
The number of forms per cycle
for chocolate bars 608 610 540 680
for chocolate with filling 709 835 860 650
Hollow figures 290
cold consumption, kW 91 36 60-70 93 30
Power of electric motors and heaters, kW 29,0 26,5 45,0 42,4 24,7
Overall dimensions, mm
length 34 500 22 000 33 000 '46 869 23 900
width 5000 5400 4365 3300 5250
height 3300 3300 3000 '3720 2940
Total weight of carsSRI kg 24 000 1670 36 000 22 000

Carlé and Montanari manufacture similar aggregates of lesser capacity Caivem-cream 275. The 850 type of the Heidenau plant (GDR) is also a universal unit.

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