WO2018206470A1

WO2018206470A1 - Method and apparatus for preparing an edible food composition

Info

Publication number: WO2018206470A1
Application number: PCT/EP2018/061622
Authority: WO
Inventors: Jamey GERMAN; Alessandra NEGREIROS; Jonathan Sutton; Adam Lee BALDWIN
Original assignee: Nestec S.A.
Priority date: 2017-05-08
Filing date: 2018-05-04
Publication date: 2018-11-15
Also published as: EP3621447A1; RU2019134413A; CL2019002892A1; RU2019134413A3; BR112019020494A2; AU2018265195A1; CA3058082A1; AU2018265195B2

Abstract

Described is a process for preparing an aerated edible food product having inclusions dispersed therein, the process comprising the steps of: a) providing an apparatus for depositing edible inclusions simultaneously with an edible fluid on a substrate, the apparatus comprising: a dual conduit nozzle comprising: an outer conduit extending from a first inlet to an outer outlet having an outer exit orifice; and an inner conduit, extending from a second inlet to an inner outlet having an inner exit orifice; the inner and outer exit orifices being proximate to one another, where during operation of the process the outer conduit is fluidly connected to a first source providing, optionally continuously, an aerated edible fluid; and the inner conduit is fluidly connected to a second source providing, optionally continuously, edible inclusions; at least one sensing means that measure at least one input parameter, where the at least one input parameter are capable of determining directly and/or indirectly: the instant density of the inclusions and/or the fluid in the apparatus; and density adjusting means is controllable by control means to alter the density of the fluid, where optionally the control means and sensing means are in direct or indirect connection so control parameters are capable of being generated directly and/or indirectly in response to changes in the input parameters; b) feeding the edible aerated fluid from the first source through the outer conduit to exit the outer exit orifice to form an outer stream of the fluid directed towards the substrate; c) feeding inclusions through the inner conduit to exit the inner exit orifice to form an inner stream of inclusions directed towards the substrate; d) depositing the inner stream of inclusions and the outer stream of aerated fluid onto a substrate at substantially the same time, where the streams exit the apparatus proximate to each other but remain substantially separate and where the outer fluid stream at least partially surrounding the inner inclusion stream as they travel towards the substrate; and where the streams mix on the substrate to form a mixture thereon; and e) optionally solidifying the mixture on the substrate; to form an aerated food compositions having inclusions dispersed therein.

Description

METHOD AND APPARATUS

The present subject matter is relates to an apparatus for depositing a liquid, semi-liquid or semi-solid food product that also comprises inclusions and to nozzles for use with such an apparatus. More particularly, but not exclusively, the subject matter relates to such an apparatus and nozzle for use in filling mould cavities forfinished confectionery products that comprise inclusions. The subject matter also relates to a method for depositing a liquid, semi-liquid or semi-solid food product in conjunction with inclusions and products made by this method.

It is known to deposit liquid, semi-liquid or semi-solid food products in confectionery manufacturing processes. Such products may, for example, be deposited into a mould cavity for producing a finished confectionery product. One example of such a process is the depositing of liquid chocolate into a mould cavity for the production of a chocolate bar. Fillings for confectionery products, such as fondants, caramels, mousses or truffles, may also be deposited. Such products may contain inclusions therein.

As used herein the term 'inclusion' denotes an edible body and/or particle of distinct composition which is embedded (or capable of being embedded) wholly or partially in a food product. Inclusions are often used to provide contrasting texture, hardness, visual appearance and/or flavour to the material in which they are embedded thus a unique eating and sensory experience to the consumer consuming the product. Typically more than one inclusion will be incorporated in single portion of the food product that comprises inclusions. It can be desirable in many products for inclusions to be dispersed as evenly as possible within the product (or within a sub-set of the product such as in a layer or filling thereof) so each mouthful of the product provides a consistent eating experience.

As used herein the term 'chocolate' denotes any products that meet a legal definition of chocolate in any jurisdiction and also include product in which all or part of the cocoa butter is replaced by cocoa butter equivalents (CBE) and/or cocoa butter replacers (CBR). The terms 'chocolate compound' or 'compound' as used herein (unless the context clearly indicates otherwise) denote chocolate analogues characterized by presence of cocoa solids (which include cocoa liquor/mass, cocoa butter and cocoa powder) in any amount, notwithstanding that in some jurisdictions compound may be legally defined by the presence of a minimum amount of cocoa solids. The term 'choco-material' as used herein denotes both chocolate and compound. The term 'chocolate coating' as used herein also refers to a chocolate shell and denotes coatings made from any choco-material. The term 'chocolate confectionery' as used herein denotes any foodstuff which comprises choco-material and optionally also other ingredients and thus may refer to foodstuffs such confections, cakes and/or biscuits whether the choco-material comprises a chocolate coating and/or the bulk of the product. Unless the context clearly indicates otherwise it will also be appreciated that in the present invention any one choco-material may be used to replace any other choco- material and neither the term chocolate nor compound should be considered as limiting the scope of the invention to a specific type of choco-material.

In order to produce certain types of food product, it is sometimes desirable to deposit food products (or components thereof) under high pressure, for example to deposit at high speeds (e.g. on a fast moving production line) and/or when producing aerated products e.g. where gas is added to the food product under pressure.

It is desirable to add a gas into liquid chocolate prior to depositing. This process is typically known as aeration, and can be used to provide different effects according to the pressures and gases used. Various pressures have been proposed in different applications ranging from about 4 bar to 12 bar. Different gases can also be used in different applications such as carbon dioxide, nitrogen or any other suitable gas (e.g. N2O). For example, adding gas to liquid chocolate prior to depositing can result in a chocolate product with visible bubbles in the final chocolate product; a process typically known as "macro aeration".

By way of a further example, adding gas to liquid chocolate prior to depositing can result in a chocolate product where the bubbles that are formed are too small to be seen by the naked eye in the final chocolate product; a process typically known as "micro aeration". Mixing solid inclusions such as raisins or nut pieces into aerated food compositions presents a challenge. As the inclusions are mixed into the composition they tend to break down the foam or, when inclusions are present before aeration, they reduce the effectiveness of foam generation. Food compositions such as confectionery compositions (e.g. chocolate) are typically be handled and deposited via conduits and orifices which have sizes comparable to that of common inclusions. Therefore adding inclusions to these compositions may restrict of block the flow of product. Accordingly, it is desired to find a solution to the problem of in the depositing food products that also have inclusions therein for example depositing aerated chocolate with inclusions.

The applicant has described in WO2016-198659 a nozzle for depositing aerated chocolate to address the problem of buildup of chocolate mass around the exit orifice of a nozzle of a depositing apparatus, an effect which is described herein as 'cauliflowering' in view of the similar appearance assumed by such chocolate mass.

WO 2010-102716 describes an example of an apparatus for depositing a liquid, semi-liquid or semi-solid food product, the apparatus comprising: a fixed volume chamber for receiving the food product under a positive pressure, the chamber being defined by chamber walls, one of the chamber walls being provided with an outlet orifice for depositing the food product, the outlet orifice being provided with a first sealing surface; and a valve spindle arranged for reciprocating movement within the chamber, the length direction of the valve spindle extending substantially perpendicular to the chamber wall in which the outlet orifice is provided, a first end of the valve spindle being provided with a second sealing surface; wherein the second sealing surface of the valve spindle is arranged for abutting the first sealing surface of the outlet orifice to thereby close the outlet orifice.

EP 2016837 discloses an apparatus with at least one discharge passageway extending to at least one elongate discharge outlet for depositing a confectionery mass, wherein at least one discharge passageway diverges in a direction towards the discharge outlet. It is described in paragraph [0014] that generally, in a plan view, the discharge passageway can be described to have the shape of a fishtail and that, described three-dimensionally, the passage is a hollow truncated pyramid, with the discharge outlet constituting the base, and the inlet end of the discharge passageway constituting the upper part of the pyramid. It is described in paragraph [0010] in EP2016837 that the length of the discharge outlet extends substantially perpendicular to a direction in which molds or any other molding means is moved relative to the discharge outlet, hence the confectionery mass can be deposited into the molds in the shape of relatively wide strips. It is described in paragraph [001 1] in EP2016837 that depositing a relatively wide strip of aerated confectionery mass into a mould can reduce a need for shaking or vibrating of the mould.

In terms of the incorporation of inclusions into foodstuffs at there are a number of challenges, both at the process and product level which increase when the foodstuff is held at high pressure for example confectionery products like aerated chocolate,

An aerated product such as aerated chocolate is inherently unstable, any form of mechanical stress causes destabilisation of the foam and coalescence. Aeration leads to an increase in viscosity and therefore poor flow in the mould. The addition of inclusions increases the viscosity further. Any method developed needs to minimise this effect as much as possible.

Chocolate aeration is undertaken in a pressurised system, incorporation of inclusions whilst maintaining pressure is complex engineering challenge. Typical nozzle diameters for depositing systems are less than 4 mm. This limits the size of inclusions that can be deposited (assuming they can be dosed into a pressurised system first). Increasing the nozzle diameter is not an option as the system pressure drop would be too great. There is also the risk of the inclusions blocking the nozzle. Existing solutions have focused on over- aerating chocolate (to compensate for any gas loss) and mixing the inclusions post pressure release into the pre-aerated chocolate. This however results in either visible aeration (in the case of micro-aeration) or destruction of bubbles and significant loss of aeration (in the case of macro-aeration).

For fat based fillings, where there are no legal constraints in terms of the fat component, specific fat blends can be selected in order to help ensure foam stability and resistance to mechanical mixing. This is however only effective for micro-aeration. Additionally for fat based fillings the increase in viscosity is less of a challenge because the filling is typically filled into a chocolate shell and backed off, therefore is does not need to flow in the mould in the same way as a chocolate tablet with inclusions. This means that it is possible to also decrease the temperature to increase the viscosity further, also helping to minimise coalescence.

Accordingly, it is desired to find a solution to the problem of depositing of aerated chocolate and other food products with inclusions.

COMBINATION

Therefore broadly in accordance with the present invention there is provided a process for preparing an [optionally aerated] edible food product having inclusions dispersed therein, the process comprising the steps of:

a) providing an apparatus for depositing edible inclusions simultaneously with an [optionally aerated] edible fluid on a substrate, the apparatus comprising:

a dual conduit nozzle comprising: an outer conduit extending from a first inlet to an outer outlet having an outer exit orifice; and an inner conduit, extending from a second inlet to an inner outlet having an inner exit orifice; the inner and outer exit orifices being proximate to one another, where during operation of the process the outer conduit is fluidly connected to a first source providing (optionally continuously) an [optionally aerated] edible fluid; and the inner conduit is fluidly connected to a second source providing (optionally continuously) edible inclusions;

at least one sensing means that measure at least one input parameter, where the at least one input parameter are capable of determining directly and/or indirectly: the instant density of the inclusions and/or the fluid in the apparatus; and density adjusting means is controllable by control means to alter the density of the fluid, where optionally the control means and sensing means are in direct or indirect connection so control parameters are capable of being generated directly and/or indirectly in response to changes in the input parameters;

b) feeding the edible [optionally aerated] fluid from the first source through the outer conduit to exit the outer exit orifice to form an outer stream of the fluid directed towards the substrate;

c) feeding inclusions through the inner conduit to exit the inner exit orifice to form an inner stream of inclusions directed towards the substrate;

d) depositing the inner stream of inclusions and the outer stream of [optionally aerated] fluid onto a substrate at substantially the same time, where the streams exit the apparatus proximate to each other but remain substantially separate and where the outer fluid stream at least partially surrounding the inner inclusion stream as they travel towards the substrate; and

where the streams mix on the substrate to form a mixture thereon; and

e) optionally solidifying the mixture on the substrate;

to form an [optionally aerated] food compositions having inclusions dispersed therein.

DUAL NOZZLE

In one embodiment of the present invention there is provided a process for preparing an [optionally aerated] edible food product having inclusions dispersed therein, the process comprising the further steps of:

a) providing an apparatus for depositing edible inclusions simultaneously with an [optionally aerated] edible fluid on a substrate, the apparatus comprising a dual conduit nozzle comprising:

an outer conduit extending from a first inlet to an outer outlet having an outer exit orifice; and

an inner conduit, extending from a second inlet to an inner outlet having an inner exit orifice; where during operation of the process the outer conduit is fluidly connected to a first source providing (optionally continuously) an [optionally aerated] edible fluid; and

the inner conduit is fluidly connected to a second source providing (optionally continuously) edible inclusions;

d) depositing the inner stream of inclusions and the outer stream of [optionally aerated] fluid onto a substrate at substantially the same time, where the outer fluid stream at least partially surrounding the inner inclusion stream as they travel towards the substrate; and where the streams mix on the substrate to form a mixture thereon; and

e) optionally solidifying the mixture on the substrate;

to form an [optionally aerated] food product having inclusions dispersed therein.

In another embodiment of the process of the present invention it is preferred that at the outer exit orifice the outer outlet may surround or substantially surround the inner outlet and during some or all of the depositing step d) the outer fluid forms an outer curtain that may surround or substantially surround the inner inclusion stream as both streams travel towards the substrate. More preferably the outer exit orifice may have has an annular or substantial annular cross-section, and the inner exit orifice has a rectangular, circular or ovoid cross section (each cross-section being viewed in a plane orthogonal to the main axis of their respective outlets) and in depositing step d) the fluid forms an annular or substantially annular curtain that surrounds or substantially surrounds the inner inclusion stream. Most preferably the outer outlet may form an annulus around the inner outlet when viewed in cross-section through a plane orthogonal to the main axis of the inner conduit, more preferably both outlets lie in the same plane, even more preferably the outlet plane is transverse and most preferably the outlet plane is horizontal.

DENSITY MATCHING

In another embodiment of the present invention there is provided a process for preparing a food composition having inclusions dispersed in solid material, the process comprising the steps of:

(a) providing an apparatus suitable for use in a process of the present invention, the apparatus comprising:

i) optionally at least one vessel suitable for receiving respectively fluid edible composition (fluid receiving vessel) and/or inclusions (inclusion receiving vessel); ii) at least one input conduit, optionally in fluid connection with the respective at least one receiving vessel where present, the least one conduit being suitable for transport of respective fluid and/or inclusions to a processing chamber;

iii) a processing chamber comprising a density adjusting means capable of altering the density of the fluid composition, optionally in the presence of inclusions, the density adjusting means being controlled by a controlling means;

iv) optionally an output conduit in fluid connection with the processing chamber so the material having inclusions dispersed therein can be transported through the output conduit to be collected for subsequent use and/or to other apparatus for further processing;

characterized in that:

A) optionally the input conduit and/or processing chamber (and optionally the at least one receiving vessel where present) comprise at least one sensing means that measure at least one input parameter, where the at least one input parameter are capable of determining directly and/or indirectly: the instant density of the inclusions and/or the fluid composition in the apparatus; and

B) the density adjusting means is controllable by control means to alter the density of the fluid composition, where optionally the control means and sensing means are in direct or indirect connection so control parameters are capable of being generated directly and/or indirectly in response to changes in the input parameters;

(b) adding an inclusion and/or plurality of inclusions to the inclusion receiving vessel and/or adding an edible fluid composition (precursor to the solid material) to the fluid receiving vessel;

(c) generating at least one input parameter from the fluid composition and/or inclusion(s) optionally using the at least one sensing means and optionally before the fluid and/or inclusions are present in the processing chamber; the least one input parameter being used to calculate a density of inclusion(s) and/or density of fluid composition that will be transported to the processing chamber optionally at a given moment;

(d) transporting the inclusion(s) and/or the fluid composition to the processing chamber; optionally the inclusion(s) being added to the fluid composition in a predetermined pattern;

(e) generating at least one control parameter to control:

(i) operation of the density adjusting means in the processing chamber and/or

(ii) transport of the fluid composition and/or inclusions to the processing chamber; (e) adjusting the density of the fluid composition in the processing chamber using the at least one control parameter to control the density adjusting means, the control parameter being calculated from the at least one input parameter so that the density adjusting means will substantially match (preferably match) the density of inclusion(s) added and/or to be incorporated therein; and

(f) optionally depositing the fluid composition through the output conduit onto a substrate;

(g) allowing the fluid composition to solidfy with the inclusion(s) dispersed therein; to form an food product comprising a solid material with inclusion(s) dispersed therein optionally in the pre-determined pattern.

In a preferred embodiment of the process of the present invention there is provided a process, for preparing an aerated food composition having inclusions dispersed in solid material where the material is aerated and optionally the dispersion is in a pre-determined pattern, the process comprising the steps of:

iii) a processing chamber comprising a density adjusting means which is an aerating means capable of incorporating gas into the fluid composition, optionally in the presence of inclusions, the aerating means being controlled by a controlling means;

iv) optionally an output conduit in fluid connection with the processing chamber so the aerated material having inclusions dispersed therein can be transported through the output conduit to be collected for subsequent use and/or to other apparatus for further processing;

characterized in that:

B) the aerating means is controllable by control means to control the amount of gas delivered to the fluid composition;

(c) generating at least one input parameter from the fluid composition and/or inclusion(s) using the at least one sensing means optionally before the fluid and/or inclusions are present in the processing chamber; the least one input parameter being used to calculate a density of inclusion(s) and/or density of fluid composition that will be transported to the processing chamber at a given moment;

(e) generating at least one control parameter to control:

(i) operation of the aerating means to aerate the fluid composition in the processing chamber and/or

(ii) transport of the fluid composition and/or inclusions to the processing chamber;

(e) aerating the fluid composition in the processing chamber using the at least one control parameter to control the aerating means so a density of a fluid portion of the composition after aeration is adjusted from the density of the fluid composition before aeration, the control parameter calculated from the at least one input parameter so that the aerating means will substantially match (preferably match) the density of inclusion(s) added and/or to be incorporated therein; and

(f) optionally depositing the aerated fluid composition through the output conduit onto a substrate;

(g) allowing the aerated fluid composition to solidify with the inclusion(s) dispersed therein;

to form an aerated food product comprising a solid material with inclusion(s) dispersed therein optionally in the pre-determined pattern.

In one more preferred embodiment of an aerating process of the invention in step B) the aerating means is controllable by control means operated on by control parameters in a feedback loop to control the amount of gas delivered to the fluid composition, where the control means and sensing means are in direct or indirect connection so control parameters are capable of being generated directly and/or indirectly optionally substantially in real time in response to changes in the input parameters. In another alternative more preferred embodiment of an aerating process of the invention the sensing means comprises measurement(s) taken before the process starts; and the aerating means is controllable by control means which comprises presetting the aerating means based on fixed control parameters and/or input parameters calculated from the sensing means measurement determined before the process starts.

PROXIMATE MIXING

In a still other embodiment of the present invention there is provided a process for preparing an edible [optionally aerated] food composition having inclusions dispersed therein the process comprising the steps of:

a) providing an apparatus for depositing edible inclusions simultaneously with an [optionally aerated] edible fluid on a substrate the apparatus having an exit orifice for inclusions and an exit orifice for the [optionally aerated] edible fluid;

b) optionally aerating the fluid by injecting a gas therein (optionally through an injection orifice in the apparatus);

c) adding the inclusions to a fluid at a location proximate to the exit orifice and/or injection orifice where present;

d) depositing the inclusions and the [optionally aerated] fluid onto a substrate at substantially the same time, where the fluid exits the fluid exit orifice as a fluid stream and the inclusions exit the inclusion exit orifice as an inclusion stream and both stream travel towards the substrate substantially at the same time and where the streams mix on the substrate to form a mixture thereon; and

e) optionally solidifying the mixture on the substrate;

to form an [optionally aerated] food composition having inclusions dispersed therein.

As used herein (unless the context clearly indicates otherwise) the term proximate generally means within a linear distance which is comparable to the mean size of the inclusions used in the process, a useful proximate distance being from about the mean inclusion size to twenty times the mean inclusion size, more usefully from mean size to ten times mean inclusion size, even more usefully from 1 to 5 times the mean inclusion size, most usefully from 1 to 3 times mean inclusion size. Preferably and/or in alternative embodiment proximate denotes within a linear distance of from 0.1 mm to 50 mm, more preferably from 0.2 to 20 mm, even more preferably from 0.3 mm to 10 mm, even more preferably from 0.5 mm to 5 mm, and most preferably from 1 mm to 3 mm. Proximity may be conveniently measured for features (such as an orifice) from the centre of that feature (e.g. an orifice opening of regular shape such as a circle) and/or from a mid-point and/or line defined by a series of such mid-points within the feature (e.g. the point or points within an orifice opening that is / are equidistant from the orifice sides and/or average of these distances if the orifice is of a shape whose centre lies outside the opening). In another alternative proximity may be measured from the closest part of one feature (such as an orifice edge) to the closest part of another feature (e.g. edge of a different orifice). Usefully both the fluid exit orifice and the inclusion exit orifice are located in substantially the same plane and proximate distances may be measured on this plane, which more usefully may be a transverse plane and most preferably horizontal plane as defined herein.

In one embodiment of the process of the invention is especially useful where the edible composition and fluid are aerated. More usefully before depositing step d) there may be performed an aerating step of injecting gas into the fluid to form an aerated fluid. Even more usefully the aerating step may comprise injecting gas into the fluid to form bubbles having a mean size of less than 100 microns (micro-aerating). Most usefully the fluid is aerated to the extent of having at least 5% of gas by volume (by total volume of the fluid) dispersed in the fluid as it leaves the outer exit orifice.

In another embodiment of the process of the present invention it is preferred that at the outer exit orifice the outer outlet may surround or substantially surround the inner outlet and during some or all of the depositing step d) the outer fluid forms an outer curtain that may surround or substantially surround the inner inclusion stream as both streams travel towards the substrate. More preferably the outer exit orifice may have has an annular or substantial annular cross-section, and the inner exit orifice has a rectangular, circular or ovoid cross section (each cross-section being viewed in a plane orthogonal to the main axis of their respective outlets) and in depositing step d) the fluid forms an annular or substantially annular curtain that surrounds or substantially surrounds the inner inclusion stream. Most preferably the outer outlet may form an annulus around the inner outlet when viewed in cross-section through a plane orthogonal to the main axis of the inner conduit, more preferably both outlets lie in the same plane, most preferably the outlet plane is horizontal.

Preferably the degree of aeration of the fluid composition at the point it leaves the outer exit orifice compared to that immediately after deposition on the substrate is reduced by no more than 20%, more preferably no more than 10% (measured as amount of gas dispersed by % volume of the fluid composition). Most preferably during the process of the present invention the degree of aeration of the aerated fluid composition is substantially the same once aerated, i.e. the deposition method and/or addition of inclusions according the process of the invention does not cause the composition to de-aerate to any significant extent. It will be appreciated that the aerated composition used in the process of the present invention has a degree of aeration of at least 5% by volume, that is the composition is aerated to a much high degree and optionally at much higher pressures that might in theory be caused incidentally by for example the fluid falling through the air during deposition. Any such minor and unintended additional incorporation of air due to deposition would be much less significant than the potential loss of gas (de-aeration) that might be expected due to interactions and mixing between inclusions and aerated fluid as the fall during deposition. It is this factor as well as the concern that using inclusions before a deposition step may be incompatible with sensitive gas injection equipment (e.g. block narrow outlets) that has previously deterred a skilled person from incorporating inclusions with aerated compositions a single deposition step.

The fluid composition used in the invention may already be aerated before it is added to the outer conduit in the process. Alternatively or as well the fluid composition may be aerated or further aerated by injecting gas into the fluid composition as it passes through the outer conduit (optionally through other gas injecting conduits fluidly connected to the outer conduit. In either the case pre-aeration and/or aeration during step b) in the process of the invention by the time the fluid exits the outer conduit it is aerated having gas dispersed therein to the extend indication (i.e. more than an accidental minimal extent due to mixing in air).

Preferably the food composition is a held at high pressure during at least one step selected from :(l) a gas injection pre-step; (II) gas injection to aerate or further aerate during fed step (b); and/or (III) fed step (b) without further gas injection.

Thus the gas injection step can be performed simultaneously with and/or before any of the steps of the invention up to the point the fluid leaves the outer orifice. Most preferably the food composition is aerated whilst being held under high pressure in a step (I) performed before step (b), i.e. the fluid is pre-aerated.

As used herein the terms 'atmospheric pressure' indicate that the pressure is ambient (i.e. the pressure is neither held above nor below that of its surroundings) and 'high pressure' indicate that the pressure is above atmospheric pressure, preferably from 1 .1 atmosphere to 3 atmospheres. Helpfully the food composition is aerated at high pressure, more helpfully the food composition comprises an aerated fat based confectionery composition, most helpfully is an aerated choco-composition.

Conveniently the food composition is aerated, more conveniently comprise an aerated fat based confectionery composition, most conveniently is an aerated choco-composition. The aeration can be performed simultaneously and/or before any of steps (a) and/or (b) and/or optionally at any pressure.

Where the food composition is aerated usefully the edible fluid composition used in step (a) that forms the outer fluid stream, may be aerated, more usefully comprises an aerated edible liquid, more usefully comprises an aerated fat based confectionery composition, even more usefully is an aerated choco-composition, even more usefully is an aerated compound or aerated chocolate composition, such as micro-aerated chocolate or micro-aerated compound.

Advantageously the substrate is a mould and the aerated food composition is a moulded aerated food product or part thereof.

In a still other convenient embodiment of the present invention there is provided a process is for preparing a moulded micro-aerated choco-product having inclusions dispersed therein, the process comprising the steps of

a) providing a combination nozzle comprising the outer conduit extending from the first inlet to the outer outlet with the outer exit orifice; and

the inner conduit, extending from the second inlet to the inner outlet with the inner exit orifice;

where the outer exit orifice has a substantially annular shape surrounding the inner exit orifice outlet having a substantially circular shape;

the process comprising the steps of:

b) feeding a micro-aerated choco-liquid through the outer conduit to exit the outer orifice to form therefrom an outer stream of micro-aerated choco-liquid in the form of substantially annular curtain;

c) feeding edible particulate inclusions through the inner conduit to exit the inner exit orifice to form thereform an inner stream of the inclusions located within the outer curtain of choco-liquid;

d) depositing the inner stream of inclusions and the outer stream of micro-aerated choco-liquid into a mould at the same time, where during depositing the inclusion stream remains within the outer curtain;

e) solidifying the moulded composition from depositing step d); and

f) demoulding a solid moulded product from solidification step e);

to obtain a moulded micro-aerated choco-product having inclusions dispersed therein.

Preferably in step (a) the choco-liquid is fed through the first outer conduit under high pressure.

Preferably in step (b) the edible particulate inclusions are fed through the second inner conduit at atmospheric pressure.

In another aspect of the present invention there is provided a dual conduit nozzle for use in the process of the invention and/or for an apparatus for depositing an edible optionally aerated fluid (such as liquid, semi-liquid or semi-solid food product) together with inclusions; the nozzle comprising:

a distal end and a proximal end: the distal end having respective outer and inner outlets for depositing the fluid and the inclusions an inner conduit extending from an inner inlet at the proximal end to an inner outlet having an exit orifice at the distal end; and

an outer conduit extending from an outer inlet at the proximal end to an outer outlet at the distal end; where the outer outlet comprises a substantially annular exit orifice substantially surrounding the inner exit orifice of inner outlet at the distal end; and where

the internal surfaces of both the outer and inner conduits consists of food grade material.

An apparatus for depositing the fluid (such as liquid, semi-liquid or semi-solid food product) can comprise a fixed volume chamber for receiving the food product under a positive pressure, the chamber being defined by chamber walls, one of the chamber walls being provided with an outlet orifice for depositing the fluid through a nozzle of the invention installed in the chamber wall. A valve spindle can be arranged for reciprocating movement within the chamber, a first end of the valve spindle being provided with a second sealing surface arranged for abutting the first sealing surface of the nozzle to thereby close the outlet orifice.

A method of depositing a liquid, semi-liquid or semi-solid food product can comprise operating an apparatus of the invention.

An axis orthogonal to and drawn through the centre of each of the planes lying on the proximal and distal ends of the dual conduit nozzle of and/or used in the present invention define a longitudinal axis of the nozzle (also referred to herein as main axis, longitudinal direction and/or axial direction). The longitudinal axis (or directions parallel thereto) is generally also the direction in which the fluid and inclusions pass through the nozzle (from proximal to distal ends). Transverse directions or planes are used herein to denote any direction or plane which is orthogonal to the longitudinal axis lying across the nozzle at or between the proximal and distal ends of the nozzle.

INNER CONDUIT (FOR INCLUSIONS)

The inner conduit is also designed by for example its shape, internal size and curvature to suitable for depositing inclusions therethrough and will be suitable for use in depositing edible food. The internal surface of the inner conduit that will come into contact with the inclusions will also consist of food grade material (preferably stainless steel). The inner conduit will also be easy to clean and also provide an easy path, preferably substantially straight path, through which inclusions can flow. Thus for example the inner conduit will have a diameter larger than the size of the largest inclusions present in any mixture of inclusions to be deposited. Optionally the inner conduit may comprise a straight substantially cylindrical bore, more optionally of substantially constant transverse cross- section. Preferably the inner conduit may be orientated along the longitudinal axis of the nozzle more preferably substantially along the centre of the nozzle (e.g. substantially equidistant from the exterior surfaces thereof if symmetrical). If the nozzle is orientated substantially vertically the inner conduit may also be oriented substantially vertically so that the inclusions may be deposited under gravity and fall vertically onto the substrate within an outer substantially annular curtain of edible fluid. Inclusions can flow through the inner conduit freely or via a transporting means such as a helical screw which can adjust, interrupt or stop the flow rate of inclusions to match the required deposition or dosing rate for example when the substrate is located on a moving conveyor that moves laterally with respect to the nozzle.

The minimum internal width (diameter if of circular cross-section e.g. a cylindrical bore) of the inner conduit may be at least 5% greater than, preferably at least 10% greater than, more preferably at least 20% greater than, even more preferably is at least 30% greater than, most preferably is 50% greater than, the largest size of the inclusions present in the inclusion mixture that will be deposited therethrough. Inclusion sizes are as described herein.

The minimum width of the inner conduit (and/or bore diameter for example if the inner conduit comprises or is a cylinder of constant bore) may be preferably from 2 mm to 50 mm; more preferably from 5 to 20 mm, even more preferably from 7 to 15 mm; and most preferably from 9 mm to 12 mm. The maximum width (e.g. where the inner conduit is not of constant bore) may be any suitable value greater than the minimum width, but usefully will be close to (for example no more than 100% more than, e.g. < 50% more than) the minimum width so that the inner conduit is reasonably uniform and not unnecessarily large which is both wasteful of material and may cause the nozzle (and hence depositor of which it forms part) to take up more space than is needed.

The inner exit orifice at the inner outlet at the distal end of the nozzle is usefully circular, more usefully having a diameterwithin any of the ranges given herein for the minimum width of the inner conduit (and also subject to the same constraints given above that depend on the size of inclusions to be deposited). In one embodiment conveniently the inner exit orifice is a circle of diameter from 5 to 20 mm; conveniently from 7 to 15 mm, most conveniently from 9 to 12 mm for example 1 1 mm.

OUTER CONDUIT (FOR FLUID, E.G. CHOCOLATE)

The outer conduit is designed by for example its shape, internal size and curvature to suitable for depositing the fluid edible composition therethrough and will be suitable for use in depositing food. Thus for example the internal surface of the outer conduit that will come into contact with the fluid will consist of food grade material (preferably stainless steel). The outer conduit will be easy to clean (e.g. be absent tight curves or sharp internal corners or cervices) especially for fluids which may be viscous (e.g. choco-materials) where fluid may otherwise accumulate within the conduit to create an increased risk of microbial build up and/or blockage.

In one embodiment the proximal end of the nozzle may thus comprise the outer inlet for receiving the edible fluid composition (preferably a liquid, semi-liquid or semi-solid food product) as well as the inner inlet for receiving the inclusions. In another embodiment the outer inlet that receives the food product may also be located other than at the proximal end of the nozzle, for example be located between the proximal and distal ends of the nozzle so the fluid initially enters the outer inlet transversely to the main axis of the nozzle before the outer conduit changes direction to directs the fluid along the longitudinal axis of the nozzle towards the outer outlet at the distal end of the nozzle.

Preferably the substantially annular exit orifice of the outer conduit has at least one circumferential gap therein at the proximal end so that the outer orifice does not form a continuous annulus rather lying within the footprint of an annulus the orifice forming only one or more parts of the annulus. More preferably the (almost) annular orifice has a plurality of circumferential gaps so that the outer outlet comprises a plurality of exit orifices (each also within the footprint of the annulus) and each fluidly connected to the outer conduit. The purpose of the at least one gap in the (almost) annulus of the exit orifice is to form corresponding (optionally vertical) gaps in the fluid curtain formed as the fluid is deposited when it exits the outer outlet (e.g. falls vertically under gravity onto the substrate below). Without wishing to be bound by any theory it is believed that at least one vertical gap in the fluid curtain allows the escape of air that would otherwise be trapped inside the fluid curtain within the stream of inclusions as they are deposited. Otherwise an increase of air pressure within the curtain may cause turbulence and undue mixing of the inclusion stream with the fluid curtain and thus destabilize the aerated fluid causing de-aeration and lose of gas before the fluid can be deposited onto the substrate. Usefully the size of each of the at least one gap in the outer orifice is such that the gap in the fluid curtain wall is less than the mean size, more usefully less than minimum size of the inclusions present in the inclusion mixture that is intended to be deposited from the inner orifice, so that the inclusion stream is substantially retained within the fluid curtain as they are both deposited,

Preferably the internal surfaces of both conduits, more preferably the conduits, consist of stainless steel.

Optionally in fluid connection with outer conduit there is located means to inject gas therein, more optionally under high pressure. In an alternative nozzle of the invention no gas injection means is provided in the outer conduit as the fluid is pre-aerated before it enters the outer conduit, for example pre-aerated under high pressure so that the fluid is held at high pressure until just before exiting the outlet of the nozzle.

At the distal end of the nozzle the outer outlet surrounds the inner outlet forming an outer exit orifice which may be an annulus defined by a two circles with the same centre a circle with an inner diameter and a larger circle with outer diameter. Preferably material extends into the foot print of the annulus to define an exit orifice which is a partial annulus that has at least one circumferential break therein so the annulus is not complete.

Usefully if the inner exit orifice is also circular the centre of all three circles (outer annulus, inner annulus and inner orifice) may lie along the same longitudinal axis and more usefully lie at the distal end on the same transverse plane.

Where they lie in the same plane the diameter of the inner circle of the substantially annular exit orifice will be at least 0.5 mm larger than the diameter of a circular inner exit orifice (to allow for the material of walls of the inner and/or outer conduits), and within these constraints the inner circle diameter may be preferably from 13 to 100 mm, more preferably from 15 to 60 mm, and even more preferably from 20 to 50 mm; most preferably from 25 to 40 mm, for example 30 to 40 mm.

The diameter of the outer circle of the substantially annular exit orifice will be larger than the diameter of the inner circle of the substantially annular exit orifice, the difference between the outer and inner circles corresponding to the width of the annulus. As the outer conduit transports fluid rather than inclusions it will be appreciated the width of the annulus is less constrained than the dimensions of the inner conduit and orifice and so may be narrower optionally from 1 mm to 10 mm, more optionally from 1 mm to 4 mm, most optionally from 1.5 mm to 3 mm. The outer circle diameter may be usefully from 20 to 1 10 mm, more usefully from 25 to 70 mm, and even more usefully from 30 to 60 mm; most usefully from 33 to 50 mm, for example 35 to 45 mm.

Where material extends into the annularfootprint to define at least one circumferential break in the outer annular exit orifice, the at least one break may each subtend an angle at the centre of the annulus of from 0.1 ° to 10°, conveniently from 0.2° to 7°, more conveniently from 0.5° to 5°, most conveniently from 1 ° to 3°. Alternatively the break in the annulus is very small subtending < 1 ° so that inclusions cannot pass through the resultant gap in the fluid curtain wall.

GENERAL NOZZLE DESIGN

An optional feature of the invention is to use of wheels with holes therethrough to intermediately interrupt the flow from the or both exit orifices so that deposition can be combined with screw feeder to control coating of one or more inclusions optionally before or whilst they are being deposited The exit angle could be subject to design modification / iteration. The nozzle could be used in an suitable orientation and may be mounted horizontally and/or vertically.

The material that may optionally be used to split the annulus of the outer exit orifice may comprise one or more split pins that for example break up the chocolate flow - hence potentially form more than one chocolate stream. The chocolate stream may be a complete annulus (if no pins are used) or annulus broken into one discontinuous section and/or two or more discrete sections (by respectively one or two or more pins).

Thus in another embodiment dry inclusions may be fed down the inner conduit which may be an inner centre tube within a cylindrical shell and aerated chocolate may be directed around the cylindrical shell to exit via the outer outlet in such a manner to direct the chocolate flow towards the central stream of dry inclusions, effectively meeting the stream and beginning to coat them mid-air. In this embodiment either the chocolate is not aerated or optionally if the chocolate is aerated the nozzle is designed so the chocolate and dry inclusion streams then meet sufficiently gently (e.g. at an acute angle (such as < 10 degrees) and with no or low relative velocity (such as < 2 ms^"1) between them) the coating can be achieved without substantially de-aeration of the chocolate.

A further preferred embodiment of the invention uses a screw as a conveying mechanism to transport the dry inclusions to the inner tube where the screw conveyer can be mounted horizontally to feed the inclusions to the inner inlet on the proximal end of the nozzle or directly to the inner inlet if located elsewhere between the proximal and distal ends of the nozzle. The screw conveyer may also be mounted vertically optionally within the inner tube so the screw conveyor may extends to the distal end of the nozzle to dose inclusions directly from the inner outlet.

The annulus cross sectional area; inner and outer diameters; and exit angle of the inclusions and chocolate deposited hereon may selected from any of those non-limiting values described herein (and/or calculated from the values described herein), however it will be appreciate that other values may be selected having values not disclosed therein if the value(s) achieve one or more of the objects of the invention.

The flow of aerated chocolate through the conduits described herein may be achieved by conventional means such as those described herein for example using a jet depositor optionally with a needle, valve spindle and nozzle arranged as described herein or known to those skilled in the art, optionally to pressurise the (optionally aerated) fluid prior to deposit.

Preferably after leaving the nozzle of the invention, the fluid and inclusions all exhibit atmospheric pressure and thus deposition, mixing and/or coating also occur at atmospheric pressure.

The applicant has surprisingly found in one embodiment of the invention a nozzle design which is optimized to incorporate inclusions into aerated edible compositions during deposition. Without wishing to be bound by any theory the applicant believes that nozzles of the invention may reduce the tendency for de-stabilisation of aeration during deposition by minimizing coalescence of gas bubbles dispersed therein because the fluid flows less turbulently and the inclusions are separated from the fluid during deposition until they reach the substrate.

Nozzles of the invention may also limit the increase in viscosity of a fluid which might otherwise occur when inclusions mix with the fluid. The process of the invention can thus be used to deposit fluid and inclusions into mould to provide a moulded aerated product having inclusions dispersed therein. A moulded product of the invention can have surface features with finer definition and detail that prior art products with inclusions due to an improved ability of the low(er) viscosity fluid to flow into the mould shape even in the presence of inclusions.

A preferred nozzle design the inclusions are incorporated as close to the point of deposit as possible, and thus the distance between the proximal and distal ends of the nozzle (also referred to as nozzle length) and hence length of the outer and inner conduits is as short as is practical. The deposition distance is the distance over which the fluid and inclusion streams travel from exiting their respective exit orifices to the point they reach the substrate on which they are deposited and this distance is also preferred to be as short as practical. The process and nozzle of the invention allows this to be done successfully, without significantly impacting the aeration quality so that the opportunity for mixing of inclusions and fluid (and hence de-aeration and/or viscosity increase) are minimised.

Preferably the nozzle length is from 10 to 80 mm, more preferably from 15 to 60 mm, even more preferably from 20 to 50 mm; most preferably from 25 to 40 mm, for example 30 to 40 mm.

Usefully the deposition distance is over a distance of from 10 to 100 mm, more usefully from 15 to 60 mm, even more usefully from 20 to 50 mm; most usefully from 25 to 40 mm, for example 30 to 40 mm.

In one embodiment of the invention (Nozzle 1 ) inclusions are fed through a cylinder of constant bore at centre of the nozzle (the inner conduit) and chocolate flows around the outside of the inner cylinder in annular conduit (the outer conduit) exiting at the distal through an annular orifice having two notches of material extending therein to defining two separate approximately equal almost half annular orifices each fluidly connected to the annular conduit. Using Nozzle 1 the inclusions are effectively encased in chocolate without any mechanical mixing element. Fluid chocolate and solid inclusions may be deposited into a mould as the substrate to form an aerated moulded chocolate which also comprises inclusions.

Nozzle 1 is designed so that as little amount of atmospheric air is incorporated into the product as possible.

An alternative design using a nozzle without the notches (Nozzle A) where the exit annulus was complete formed a circular curtain stream of chocolate that completely encased the inclusions, but then led to atmospheric air being entrained and less acceptable aeration quality was found in the final product deposited.

Without wishing to be bound by any theory it is believed that the features of short nozzle length, and the inner and outer exit orifices being in the same horizontal plane have been found to improve aeration quality of the product. Incorporation of two notches to split the chocolate stream into two, with a very small gap between them allows inclusions to still be encased in the chocolate flow, whilst also allowing any entrained atmospheric air to be pushed out as the fluid flows into the mould. Final mixing of inclusions and chocolate occurs in the mould, using gentle vibration to minimise bubble coalescence.

AERATION

The process and nozzle of the invention is in general designed for use with an aerated fluid however could also be used with a non aerated fluid (for example a fluid subject to high pressure) as the process and nozzle also provides a means to accurately control the rate at which inclusions are added and/or the dose of inclusions added to a product.

Aerating edible fluids (such as aerated chocolate) are advantageous. One of the reasons for this is the drive for the development more permissible confectionery, combined with improved consumer perception. The nozzles of the present invention allow aerated compositions to be produced that also have inclusions therein.

Micro-aeration delivers the same size impression but with less chocolate. By reducing the amount of chocolate it is possible to increase the level of inclusions (typically the healthier component of such a product, lower in sugar). Consumer perception is improved in terms of a greater number of inclusions being visible on the top surface of the bar. Contrast between inclusion and chocolate is greater, again positively impacting perception of more inclusions

A cost benefit is that less chocolate (and potentially inclusions) are required to deliver a product of the same volume as products made by prior art methods.

Various prior art aeration methods are known but none are adapted to be suitable with simultaneous deposition of inclusions.

EP2016836 (Kraft) describes deposition of aerated chocolate combined with inclusions where multiple layers of micro-aerated chocolate are formed in a mould with the option of sprinkling inclusions between each layer after they have been deposited. Kraft teaches that it is not possible and indeed undesirable to mix inclusions directly to the aerated mass as it is being deposited in the mould but that the aerated chocolate must be formed seperately.

EP 1673981 (Unilever) describes a nozzle for preparing frozen confectionery, the nozzle having three sealable passages therethrough for feeding frozen compositions to create a product have a spiral appearance. The nozzle is not designed for non solid compositions.

Unless otherwise indicated herein, in the embodiments and examples of the invention described herein used to deposit aerated material such as chocolate mass, the aeration was achieved using a gas injector which is referred to herein as a Novae injector (or Novae) and which is described in more detail in WO2005/063036. The various nozzles described herein are used in conjunction with Novae injector which was operated under standard operating conditions unless otherwise indicated herein. It will be appreciated that this equipment is by way for example only and non-limiting and other suitable aeration means known to those skilled in the art could also be used in conjunction with the nozzles of the inventon instead of the Novae .

The nozzles of the invention described herein may be used to incorporate inclusions in different ways.

In one embodiment of a depositing process and/or apparatus of the invention the nozzle of the invention may be located after the exit of the depositor (such as a Novae) and inclusions may be incorporated into the aerated fluid (e,g. aerated chocolate mass) at atmospheric pressure just after the mass leaves the depositor and before it enters the nozzle.

In further embodiment of a depositing process and/or apparatus of the invention the nozzle may be located before the exit of the depositor (such as a Novae) and inclusions may be mixed into the aerated fluid (e.g. aerated chocolate mass) at a pressure greater than atmospheric pressure before the fluid leaves the depositor the nozzles being sufficiently flexible and/or having inner and/or outer conduits of a sufficient size to allow passage of inclusions there through without blocking.

INCLUSIONS

The aerated compositions of the invention comprising one or more inclusions may preferably comprise an aerated confectionery fat based composition, for example a fat based confectionery composition such as filling and/or a choco-material. Usefully the inclusions may have a harder texture than the composition into which they are incorporated, more usefully comprising fruits, fruit pieces (including nuts) and/or other edible crispy and/or hard pieces.

Preferred inclusions have an average size from 1 to 50 mm, more preferably from 2 to 40 mm, and even more preferably from 3 to 25 mm; most preferably from 5 to 10 mm.

In a further embodiment of the invention the aerated food composition of the invention comprise inclusions with an average diameter greater than 2 mm, for example inclusions which are retained by a sieve with a 2 mm opening. The inclusions may have a diameter ranging from 2 mm to 22.6 mm, for example inclusions which pass through a sieve with an opening of 22.6 mm but are retained by a sieve with a 2 mm opening. The inclusions may have a diameter ranging from 2.83 mm to 1 1.2 mm, for example inclusions which pass through a sieve with an opening of 1 1 .2 mm but are retained by a sieve with a 2.83 mm opening.

Conveniently in one embodiment the inclusions are distributed substantially homogenously (evenly and uniformly) initially within fluid composition in the process of the invention. Usefully in another embodiment the inclusions are distributed in a predetermined pattern (which may not be homogenous) within the fluid composition in the process of the invention where the pattern is for example aesthetically pleasing to the end consumer

Conveniently the inclusions comprise any of the following non-limiting list (more conveniently selected from the group consisting of):

fruits or fruit pieces which may comprise: hard fruits (e.g. nuts such as hazelnuts, almonds, brazil nuts, cashew nuts, peanuts, pecans and/or similar); soft fruits (e.g. raisins, cranberries, blueberries, blackcurrant, apples, pear, orange, apricot and/or similar); and/or freeze-dried fruit pieces, candied fruit and/or alcohol-soaked fruit, preferred soft fruits are dried fruits;

crispy inclusions (e.g. caramel, coffee, biscuits, wafer, etc.);

herbs (for example chives, dill, coriander, parsley);

cereals (for example puffed rice, puffed wheat, extruded cereal pieces),

chocolate or choco material (for example chocolate vermicelli, chocolate shapes);

sugar confectionery (for example cinder toffee pieces, marshmallow, sugar-panned centres such as those available commercially from Nestle under the trade mark mini SMARTIES®) and/or

any suitable mixtures and/or combinations thereof.

It will be appreciated that an inclusion may fall into more than one of the above categories listed above.

In one embodiment of the invention the inclusions selected are a mixture of a plurality of different inclusions, where each inclusion has a similar size (usefully within 20%, more usefully ±10%, most usefully ±5% of the average size of the mixture) so the size range of the inclusion mixture is narrow, more preferably the size of each inclusion is substantially the same. This allows the geometry and size of the nozzle to be more closely match to the size distribution of the inclusions used.

In another embodiment of the invention the inclusions selected are the same and not a mixture of different inclusions so the size of the inclusions are substantially the same.

The present invention further relates to a confectionery product, for example a chocolate product such as a chocolate tablet and/or chocolate bar, filled with an aerated filling of the invention and having dispersed therein (optionally visible) inclusions provided by a method described herein. If the filling is enclosed within an opaque outer shell the inclusions will not be visible under the product is eaten.

In general the terms 'product' and 'composition' (such as 'confectionery composition' and 'confectionery product') may be used interchangeably herein unless the context clearly indicates otherwise, the difference between them being generally that a product is in a final or almost final form ready or acceptable to be commercialized and eaten by an end consumer and is typically sold under a brand name. Thus a product may have a plurality of different domains and textures of which a composition may comprise only one part. A composition (which may also be a product) may also be a component and/or ingredient used to prepare a product.

Preferably, the confectionery product comprises from 1 to 70%, more preferable from 1 to 20% and even more preferably from 2 and 15%, by weight of inclusions with respect to the weight of the filling (being 100% by weight).

In one embodiment of the invention confectionery products comprise an aerated choco- material such as compound or chocolate.

In another embodiment of the invention comprises a filled confectionery product, that comprises from 20 to 70% by weight of the product of an aerated compostion of the invention (preferably an aerated filling). Optionally the remainder of the product being a shell of choco-material such as compound or chocolate that substantially encloses (preferably completely encloses) the product. Even more preferably in the filled pralines of the inventions the aerated filling comprises from 1 to 70% by weight (with respect to the weight of filling) of inclusions homogenously dispersed therein.

In yet other embodiment of the invention comprises a filled confectionery product such as a praline, that comprises from 20 to 40%, more preferably from 25 to 35%, most preferably about 30% by weight of the product of an aerated filling of the invention optionally with 1 to 70% by weight of the filling of inclusions homogenously dispersed therein.

In still other embodiment of the invention comprises a filled confectionery product such as a filled chocolate tablet or bar, that comprises from 50 to 70%, more preferably from 55 to 65%, most preferably about 60% by weight of the product of an aerated filling of the invention optionally with inclusions homogenously dispersed therein.

It has been known to prepare chocolate containing gas bubbles (commonly nitrogen or carbon dioxide). However such products typically the bubbles are visible to the consumer (such as in the products sold by the applicant under the Aero® registered trade mark). Such visible bubbles with an average diameter of 100 microns or above are commonly known as macro-aeration. Chocolate with bubbles of a size which are sufficiently small so the bubbles are not visible to the naked eye, typically with an average bubble diameter of less than 100 microns is known as micro-aeration. There are technical challenges with micro-aerating chocolate. For example the gas must be injected into the chocolate mass in a more precise method using specialized equipment otherwise there is a risk that the bubbles may coalesce to form larger bubbles. Care has to also be taken in terms of depositing. Micro-aerated chocolate mass is very sensitive to any form of mechanical stress, which causes coalescence. A pressurized deposit, directly into the mould is therefore required to ensure optimal aeration quality.

Conveniently the plastic viscosity of the pre-aerated choco-material of the invention is measured herein according to ICA method 46 (2000) under standard conditions unless otherwise stated and more preferably is from 0.1 to 10 Pa.s. In an embodiment, this may be measured using a Haake VT550. The micro-aerated choco-material of the invention described herein (and/or made according to any process of the invention as described herein) has a total bubble surface area (TSA) of from 0.5 to 2.2, preferably from 0.5 to 1 .5, preferably from 0.5 to 1.2; preferably from 0.55 to 1.10, more preferably from 0.6 to 1.0; most preferably from 0.65 to 0.90, for example from 0.7 to 0.8 m² per 100 g of the aerated choco-material. The term surface area or total surface area (TSA) referred to herein can be calculated from equation (1 ) herein and/or measured by any suitable apparatus or method known to those skilled in art. In one embodiment of the invention the TSA is a specific surface area (SSA) and may be measured as described in the article 'Determination of Surface Area. Adsorption Measurements by Continuous Flow Method' F. M. Nelsen, F. T. Eggertsen, Anal. Chem., 1958, 30 (8), pp 1387-1390 for example using nitrogen gas and SSA calculated from the BET isotherm.

Equation (1 ):

TSA = ^≡ (1 )

ac-r

where TSA is total bubble surface area, P is porosity of the aerated choco-material, m_ac is mass of aerated composition (g), d_ac is density of aerated composition (g/cm³) and r is the radius of a bubble of mean size (cm) and the values for , P are from 1 1 to 19%.

In the invention, c/_acis density of aerated composition (g/cm³), which is lower than the density of a non-aerated composition. In an embodiment, the d_ac is less than 1 .33 g/cm³, less than 1 .30 g/cm^3, less than 1 .25 g/cm³, less than 1.20 g/cm³, less than 1.18 g/cm³, less than 1 .15 g/cm³, less than 1.10 g/cm³. In an embodiment, the d_ac is more than 1.00 g/cm³, more than 1 .03 g/cm^3, more than 1 .05 g/cm³, more than than 1.07 g/cm³, more than 1 .10 g/cm³, more than 1 .12 g/cm³, and more than 1.15 g/cm³. In a preferred embodiment, d_ac \s more than 1 .00 g/cm³ and less than 1 .33 g/cm³.

In an embodiment, the radius r, is less than 50 microns, less than 45 microns, less than 40 microns or less than 35 microns. In an embodiment, the radius r is greater than 5 microns, greater than 10 microns, greater than 20 microns and greater than 25 microns. For example, the radius r is less than 50 microns and greater than 5 microns.

Usefully the choco-material is chocolate or compound, more usefully chocolate, most usefully dark and/or milk chocolate, for example milk chocolate such as a moulded milk chocolate tablet (optionally with inclusions and/or fillings therein).

In one other embodiment of the invention the aerated food composition (and/or confectionery product comprising that composition) comprises inclusions that are dispersed therein following a pre-determined pattern which may or may not be homogenous. The process of the invention provides a means (e.g. by timing of when inclusions are added to the composition during deposition) to set an initial pattern if distribution of inclusions in a fluid composition which will be substantially retained in the final product.

Thus for example the inclusions may be arranged visible within or at the surface of a product such as chocolate product, i.e. that at least a portion of the inclusion facing to an external surface of the product is not covered with material, but is visible for a consumer. The inclusions are visible on the profiled side of the product which is opposed to the flat bottom side and so if the product is made in a mould the inclusions would be patterned at the bottom of the mould.

In one embodiment of the invention the homogeneity index that measures how uniformly the bubbles are distributed within the composition may be determined by taking an image (from X-ray tomography and/or CLSM) and measuring the number of bubbles that intersect along at least 3 parallel horizontal lines of equal length (preferably at least 1 cm) located on the image to be equally spaced from each other and the image edges. The ratio of the minimum number of bubbles on one of these lines to the maximum number of bubbles on one of these lines can be defined as a number bubble homogenous distribution index (NBHDI) which may be at least 0.8, preferably greater than or equal to 0.85, more preferably greater than or equal to 0.9, most preferably≥ 0.95, for example about 1.

In another alternative or cumulative embodiment of the invention the homogeneity index that measures how uniformly the bubbles are distributed may be determined by taking an image (from X-ray tomography and/or CLSM) and measuring along each of at least 3 parallel horizontal lines of equal length (preferably at least 1 cm) located on the image to be equally spaced from each other and the image edges, the length of each line that lies inside the void of a gas bubble. The ratio of the minimum void length on one of these lines to the maximum void length on one of these lines can be defined as a void length bubble homogenous distribution index (VLBHDI) which may be at least 0.8, preferably greater than or equal to 0.85, more preferably greater than or equal to 0.9, most preferably≥ 0.95, for example about 1 .

In another aspect of the micro-aerated choco-material of invention the inert gas bubbles are also characterised by the parameters

X(90,3) of 100 microns; and Q(0) of 20 microns.

Bubble size may be measured from images obtained using suitable instruments and methods known to those skilled in the art. Preferred methods comprise X-ray tomography and/or confocal laser scanning microscopy (CLSM), more preferably X-ray tomography.

Usefully the confectionery product of the invention comprises a choco-material such as chocolate or compound, more usefully chocolate, most usefully dark and/or milk chocolate, for example milk chocolate such as a moulded milk chocolate tablet (optionally with inclusions and/or fillings therein).

It will also be understood that the terms top and bottom referring to a product may be interchangeable and depend for example how the product is formed and its orientation under gravity. Thus for example the top of a product in use or when packed may be the bottom of the product when formed in a mould during production. The term 'substantially horizontal' refers to a plane through an axis of the product which during storage, transport and display of the product in store is likely to be held substantially horizontal, e.g. where the product is stored flat on a largely (preferably exactly) horizontal surface. A substantially horizontal surface is typically parallel to the major plane of the product, for example the flat bottom side of large area of a filled chocolate tablet. As used herein 'substantially vertical' refers to lines or planes which are substantially perpendicular (preferably perpendicular) to a substantially horizontal (preferably exactly horizontal) line or plane as defined herein. Preferred substantially vertical orientation is vertical, especially aligned with the direction of gravity in the typical position of the product in storage, transport and/or display.

AERATION METHODS

The applicant has also found that in a preferred embodiment of the present invention the aeration of the composition used in the process of the invention is controlled during the process of aerating such that the gas flow rate remains substantially within a range to achieve a desired target porosity in the final micro-aerated chocolate which matches the inclusion(s) that are added. Such control may be manual or automatic, for example using sensors to automatically adjust gas flow rate of the gas depositor in responses to changes in the process (for example changes in throughput of choco-material) and may be operated by a computer controlled apparatus and/or using a feedback loop. Without wishing to be bound by any mechanism it is believed that the main factors that influence deposit time are system pressure (back pressure), nozzle diameter and temperature after mixing (which impacts viscosity). There is also some evidence that as well as (or instead of) high shear mixing, pressure can be used to reduce marbling in the product (marbling is a due to non-uniform distribution of the bubbles within the chocolate). At high pressure (e.g.≥ 9 bar), no marbling was evident which is another advantage of using high system pressure for the inert gas up to the point of deposit.

Preferably the gas bubbles are produced in the aerated compositions of the invention using an aerating means comprising a machine selected from one or more of the following and/or components thereof:

(i) a rotor stator mixer;

(ii) a gas injector where the gas is injected into an (optionally high pressure) fluid at an injection site at a pressure higher than atmospheric pressure and lower than the fluid pressure and;

(iii) a jet depositor for depositing fluid onto a substrate under positive pressure; and/or

(iv) a modular mixing head with a plurality of different sets of rotor stators.

Each of these aerating machines (i) to (iv) are described more fully herein.

The rotor stator mixer may comprise at least one rotor state mixing head such as those rotor stators available commercially from Haas under the trade designation Mondomix®.

The gas injector may be injected into a fluid where preferably the fluid has an operating pressure of from 2 to 30 bar. The fluid may be transported by at least two pumps (optionally capable of being operated at pressures from 2 to 30 bar) to pass an injection site being located between said pumps. Advantageously by injecting gas between two pumps the pressure at the injection site may be lower than and/or shielded from the pressure in the rest of the apparatus. Inert gas may be dispersed into the fluid by injection at the injection site at high gas pressure (greater than atmospheric pressure). More usefully at gas pressure at the injection site may be less than or equal to 9 bar and/or the system pressure may be at least 9 bar after the injection site. Most usefully suitable gas injectors may comprise those gas injectors made by and on behalf of the applicant under the trade designation Novae™, which gas injectors are defined herein and/or are described in WO2005/063036, the contents of which are incorporated by reference.

As used herein the term 'jet depositor' refers to an apparatus for depositing a fluid food product (e.g. a liquid, semi-liquid or semi -solid food) under positive pressure (i.e. pressure above ambient pressure). A preferred jet depositor (also referred to herein as Jet Depositor) comprises a reciprocating valve spindle to deposit the food and/or is as described in the applicant's patent application WO2010/102716 the contents of which are hereby incorporated by reference.

Usefully in the process of the invention the composition is pumped by at least two pumps to pass an injection site being located between said pumps, where the inert gas is dispersed into the composition by injection at the injection site at high gas pressure, more usefully the gas pressure being greater than or equal to 9 bar.

A modular mixing head may conveniently comprise a plurality, more conveniently at least three, most conveniently three different sets of rotor stators, for example those modular mixers available commercially and/or used by the applicant under the trade designation Nestwhipper™.

More preferably the aerating means used herein comprises a Novae™ injector and/or a jet depositor; even more preferably a Novae™ injector, most preferably where the gas is injected into the composition in between two pumps, usefully at a pressure of from 2 to 30 bar, more usefully from 4 to 15 bar, even more usefully from 6 to 12 bar, most usefully from 8 to 1 1 bar, for example 9 bar or 10 bar.

For preparing the micro-aerated choco-material of and/or used in of the present invention gas injectors such as the Novae™ injectors offers several advantages. Firstly the gas injection is effectively isolated from any pressure fluctuations occurring in the rest of the system. This gives a more stable gas flow into the product. Secondly injectors such as Novae™ injectors can optionally operate at higher pressures compared to conventional rotor stator systems (9 bar is a typical operating pressure for a Novae™ injector compared to 6 bar typical operating pressure for a mixer using a rotor stator mixing head such as a Mondomix® mixer). When a gas injector is attached to a jet depositor, this is additionally useful as higher flow rates can be delivered with consequent faster line speeds. Thirdly the whole system is fully pressurized up to the point of deposit. This results in significant advantages described herein such as optimising final aeration quality and reducing the opportunity for bubble coalescence.

In one preferred embodiment of the present invention it was found that the two process parameters that impacted porosity and aeration quality to be most extent were gas flow and temperature. The control of other parameters in the aeration process was found to have little or no effect. Without wishing to be bound by any theory the applicant believes that when producing micro-aerated chocolate the crystallisation of the fat is the main factor which holds the aerated structure. Micro-aerated chocolate is also stable over time.

Preferred values of these parameters are described below.

Conveniently in step (a) the gas is dispersed into a molten choco-material at a mass flow rate of from 0.6 to 12 kg / min; more conveniently from 1.2 to 9 kg / min; most conveniently from 2.4 to 6 kg / min.

Usefully when the choco-material is chocolate and/or compound in step (a) the gas is dispersed into the composition when the composition is at a temperature of from 28 to 33°C, more usefully from 30 to 32°C, most preferably 31 °C.

It will be appreciated that to achieve a desired gas flow and temperature, other parameters of the specific equipment used will need to be adjusted (such as mixer speed, system pressure and/or jacket temperature). How to do so for a particular system (to achieve any given gas flow and temperature target) will be within the routine skill of a skilled person in the art. This is of course independent from the non-obvious appreciation of which gas flow and temperatures might be advantageous to select compared to other values. It is surprising that by controlling gas flow rate and temperature (in a process as described herein) certain porosity and bubble size properties in the resultant aerated compositions can be achieved reliably and controlled within narrow limits to produce stable micro-aerated bubbles in the final chocolate product which are also easier to demould. It is then further surprising that the micro-aerated compositions of the invention that have certain porosities (10% to 19%) and small homogenous bubble sizes exhibit unexpectedly useful properties compared to otherwise similar micro-aerated compositions with different porosity or bubble sizes.

Further preferred micro-aerated compositions that may be used in the process of the present invention may be any of those described in any of the applicant's co-pending applications: WO2018/041884, WO2018/041875 and WO2018/041870 their priority applications.

. Preferred porosities to be matched to typical inclusions may be from 10 to 19% by volume. Description of the Drawings Embodiments are described, by way of example only, with reference to the accompanying drawings, which are described below.

Figure 1 is a photograph showing use of the nozzle referred to herein as Nozzle 1 from which aerated chocolate is deposited showing a steady vertical flow of a stream of the aerated chocolate as it falls.

Figure 2 is a photograph of a cross-section through a prior art moulded chocolate bar without inclusions that was obtained by the depositing micro-aerated chocolate into a mould by the chocolate stream from Nozzle 1 , to show the aeration quality without inclusions as a point of comparison.

Figure 3 is a photograph of a cross-section through a moulded chocolate bar with inclusions that was obtained from Nozzle 1 where most of the larger visible air pockets in this bar correspond to the position of one of the inclusions.

Figure 4 is a photograph showing the flow of chocolate mass from the nozzle referred to herein as Nozzle 2.

Figure 5 is a photograph of a cross-section through a prior art moulded chocolate bar without inclusions that was obtained by the depositing micro-aerated chocolate into a mould by the chocolate stream from Nozzle 2, to show the aeration quality without inclusions as a point of comparison.

Figure 6 is a photograph of a cross-section through a moulded chocolate bar with inclusions that was obtained from Nozzle 2, where the presence of visible bubbles due to coalescence can be seen and also that this sample was very slightly darker than the corresponding sample produced using Nozzle 1 (shown in Figure 3).

Figure 7 is a photograph of the back of the chocolate bars produced by depositing a chocolate mass together with inclusions from Nozzle 2, showing an even distribution of inclusions across all bars.

Figure 8 is a photograph of de-moulded bars produced with Nozzle 2 where some large air bubbles are visible on the surface of the bars.

Figure 9 is a photograph of deposition of aerated chocolate using Nozzle B that illustrates that the flow of chocolate was not very even and depositing chocolate was quite challenging. Figure 10 is a photograph of chocolate deposited by Nozzle 3 showing the uneven deposits and tailing.

Figure 1 1 is a photograph of a cross section of a moulded aerated chocolate without inclusions deposited by Nozzle 3 that showing the micro-aeration quality achieved was poor as some visible bubbles are clearly present. Figure 12 is a schematic cross-sectional view of one embodiment of an nozzle (Nozzle 4) for use with apparatus of the invention showing an annular orifice and an inner and an outer conduit for use in an apparatus for depositing a liquid, semi-liquid or semi-solid food aerated composition together with inclusions, where the orifice is fluidly connected to an outer of two conduits the aerated composition passing through the outer conduit in the direction indicated by arrows A to A' from a respective proximal to distal end; and where inclusions are passing through an inner conduit in the direction indicated by arrows B and B' also from a respective proximal to distal end.

Figure 13 is a plan view of Nozzle 4 shown in Figure 12 viewed from the proximal end (from above) shown in cross-section along the plane indicated by line C to C;

Figure 14 is a schematic cross-sectional view of another embodiment of an nozzle (Nozzle 5) for use in the invention (similar to the Nozzle 4 of Figures 12 and 13) with a frusto conical deflector (105) partly defining the outer conduit through which the aerated composition may flow. Figure 15 is a plan view of Nozzle 5 viewed from the proximal end (from above) shown in cross-section along the plane indicated by line D to D.

Figures 16 to 18 are of another embodiment of a nozzle (Nozzle 6) for use in the invention. Figure 16 shows a cross section of Nozzle 6 in an up, open position.

Figure 17 shows a cross section of Nozzle 6 in a middle closed position.

Figure 18 shows a cross section of Nozzle 6 in a down, also open position.

Figures 19 to 20 are of yet other embodiment of a nozzle (Nozzle 7) for use in the invention having a screw to deliver the inclusions through the inner conduit of the invention where: Figure 19 shows a cross section of Nozzle 7 in closed position.

Figure 20 shows a cross section of Nozzle 7 in an up, open position.

Figures 21 & 22 and Figures 23 to 25 illustrate still other embodiments of nozzles (respectively Nozzles 8 without split pins & Nozzle 9 with split pins) for use in the present invention.

Figure 21 shows part of the geometry of the base of Nozzle 8 without split pins.

Figure 22 shows part of the geometry of the end section of Nozzle 8 without split pins. Figure 23 shows part of the geometry of the base of Nozzle 9 comprising split pins.

Figure 24 shows part of the geometry of the end section of Nozzle 9 comprising split pins. Figure 25 shows part of the geometry of the side section of Nozzle 9 comprising split pins.

Figure 26 shows in cross section of another embodiment of the invention Nozzle 10 with a central bore containing a screw feeder for the inclusions and where the chocolate mass enters the apparatus from a conduit orthogonal to the axis of the nozzle.

Figure 27 shows in cross section of another embodiment of the invention Nozzle 1 1 in which there is a central bore containing screw feeder for the inclusions movable along the main axis of the bore relative to the outer conduit through which the chocolate flows towards the exit orifice, where the respective surfaces of the annular ends of the central bore walls and the annular ends of the walls of the outer conduit are shaped at an angular to the main bore axis so that in one (closed) position of the central bore the surfaces faces can abut each other face to face to form a seal and thus close the outer orifice and prevent chocolate flow there through.

Figures 28 & 29 shows schematically cross sections through a conventional nozzle (Nozzle D) that may be used to deposit chocolate (without inclusions) for example in conjunction with a prior art depositor such as that described in WO2010/102716.

Figure 28 shows a cross section of Nozzle D in an up, open position.

Figure 29 shows a cross section of Nozzle D in a down, closed position.

EMBODIMENTS OF THE INVENTION

Although particular embodiments are described herein, it will be appreciated that the claimed subject matter is not limited to the specific embodiments described, and that alternative configurations are possible within the scope of the appended claims.

In the embodiments and examples described herein may be used in conjunction with any suitable apparatus for depositing and/or aerating an edible fluid (such as liquid, semi-liquid or semi-solid food product) with for example the nozzles of the invention as described herein. The problem of adding inclusions is not specific to a particular type of apparatus for depositing or aerating chocolate, but is experienced with different machines for depositing other food products, whether aerated or not. Examples of apparatus for depositing a liquid, semi-liquid or semi-solid food product that may be used in a process of the invention are described below. An example of a suitable depositing apparatus is described in WO 2010/102716, the contents of which are incorporated herein by reference. The example apparatus comprises a fixed volume chamber for receiving the food product under a positive pressure, the chamber being defined by chamber walls, one of the chamber walls being provided with an outlet orifice for depositing the food product, the outlet orifice being provided with a first sealing surface. The apparatus also comprises a valve spindle arranged for reciprocating movement within the chamber, the length direction of the valve spindle extending substantially perpendicular to the chamber wall in which the outlet orifice is provided, a first end of the valve spindle being provided with a second sealing surface. The second sealing surface of the valve spindle is arranged for abutting the first sealing surface of the outlet orifice to thereby close the outlet orifice. This apparatus may be used in a process and/or comprise part of an apparatus of the present invention and/or be operated in line with an apparatus of the present invention to provide the fluid composition to the outer orifice of a nozzle of the invention as described herein.

Examples of a suitable aerating apparatus (aerator) have already been described above. It will be seen that any of these or other known depositors and/or aerators may perform the steps of deposition and/or aeration of a fluid composition (such as chocolate) either in separate steps (e.g. aeration occurring via gas injection before deposition) when typically these functions are performed by separate pieces of equipment or together (e.g. aeration occurring via gas injection immediately prior to deposition) when typically the aerator and depositor are the same piece of equipment.

In either case known apparatus (either one or several pieces of equipment) can be modified as described herein (e.g. by addition of at least one nozzle as described herein) to form an apparatus of the invention which can be used in a process of the invention to deposit aerated fluids such as aerated chocolate in conjunction with inclusions. Figures 28 and 29 (Schematic conventional Nozzle D)

As a comparison, Figures 26 and 27 provide an enlarged view of a conventional Nozzle D (919) which is typical of a nozzle used to deposit optionally aerated chocolate under high pressure. Nozzle D would be unsuitable for use with compositions having inclusions therein as these would be trapped inside the nozzle which would rapidly be blocked. Turbulent mixing of inclusions within the chocolate during deposition with Nozzle D would also destabilize the chocolate causing it to de-aerate.

The Figures 26 and 27 show an interaction between an internal conical surface (928) of Nozzle D which forms a first sealing surface and a conical surface (930) provided at the end of the vale spindle (921 ), which forms a second sealing surface. Nozzle D has a generally cylindrical configuration. In the example shown in Figures 26 and 27, an external screw thread (919) on Nozzle D is screwed into an internal screw thread in an aperture (917) in the bottom plate (913) of the apparatus (91 ). A valve-receiving bore (932) in Nozzle D is open to the chamber (95) within the apparatus (91 ). The valve-receiving bore (932) is connected to an outlet bore (934) of a smaller diameter via the internal conical surface (928). The outlet bore (934), which has a constant cross-section and diameter, ends at the outlet (936) from Nozzle D. The valve spindle (921 ) reciprocates between a first (open) position as shown in Figure 26 and a second (closed) position shown in Figure 27. In the open position illustrated in Figure 26, the conical surface (930) of the valve spindle (921 ) is spaced from the internal conical surface (928) of Nozzle D so that the chamber (95) is connected via the valve-receiving bore (932) and the outlet bore (934) to the outlet (936) of the nozzle, whereby the food product in the chamber (95) can flow under pressure past the conical surfaces (928) and (930) to be deposited from the outlet (928) of Nozzle D (919). In the closed position shown in Figure 27, the conical surface (930) of the valve spindle is in contact with the internal conical surface (928) of the nozzle to block the connection between the valve-receiving bore (932) and the outlet bore (934), whereby the food product in the chamber (95) cannot flow past the conical surfaces (928) and (930) to be deposited from the outlet (928) of Nozzle D (919). As for the nozzles of and/or used in the present invention, the dimensions of Nozzle D vary depending upon various parameters including the composition of the food product and/or the gas used for aeration, the pressure under which the product is kept in the chamber (95) and the desired rate of deposition.

As discussed, when inclusions are incorporated with a fluid aerated food product either before or during aeration mixing between the fluid and solid inclusions can cause the aerated fluid to de-aerate and/or the gas injection or depositor orifices to be blocked in the aerator which is undesirable. An embodiment of a nozzle as claimed and/or described herein (such as any of Nozzles 1 to 9) seeks to eliminate or at least mitigate the problems described herein and can be used instead of a conventional nozzle such as Nozzle D.

Depositor

The example apparatus for depositing a liquid, semi-liquid or semi-solid food product comprises a fixed volume chamber for receiving the food product under a positive pressure in the range of 4 to 12 bars, for example 4 to 6 bars, optionally such food product having already been aerated (e.g. by gas injection or mixing) before being transported to the chamber. The chamber may optionally further comprise an aerating means (e.g. means to inject gas into the liquid optionally under high pressure) to aerate or further aeration the liquid content.

This apparatus is also referred to herein as a depositor and in a depositor of the present invention (which may optionally also be an aerator) comprises at least one nozzle of and/or capable of being used in a process of the present invention in conjunction with one or more of the other apparatus features described below.

In the example depositor the chamber is provided with an inlet and an outlet for supplying the food product to the chamber from a pump and suitable pumps and supply lines will be apparent to those skilled in the art. The pump is configured to supply the food product to the chamber at a rate of, for example, approximately 125% of the intended depositing rate.

Side walls of the chamber may be are provided as a unitary body formed of, for example, a stainless steel casting. Bottom and top walls of the chamber, which are substantially flat, may be formed of, for example, stainless steel plates bolted and sealed to the side walls. The bottom wall of the chamber may be provided with a plurality of apertures having a two dimensional arrangement for producing a desired depositing pattern, for example a two dimensional arrangement of apertures may be provided in a regular row and column array of say 64 apertures. Other arrangements are, however, possible. A nozzle is fitted into each of the apertures and defines an outlet orifice through which the food product is deposited. An inside surface of the nozzle may be provided with a conical surface, which surface serves as a first sealing surface. The apparatus may also comprises a plurality of valve spindles associated with respective outlet orifices and a plurality of linear pneumatic actuators associated with respective valve spindles.

Each valve spindle may be in the form of an elongate circular rod, or needle. A first (lower) end of the spindle may be provided with a conical surface which serves as a second sealing surface and is adapted for making sealing contact with the first sealing surface of a respective nozzle, as described above. The valve spindle may have a length slightly less than the internal height of the chamber (measured across the inner surfaces of the bottom and top plates of the chamber). A second (upper) end of the valve spindle may be attached to a respective actuator which is itself attached to the top plate of the chamber. The actuator may be attached to the top plate of the chamber such that it can be accessed for repair or replacement without significant disassembly of the apparatus.

The actuators and valve spindles may be arranged with their axes perpendicular to the bottom and top plates such that the actuators can be operated to longitudinally displace the valve spindles relative to the chamber walls with reciprocating movement. The valve spindles may be arranged such that, with the valve spindles in their upper position, the outlet orifices are open so the food product is deposited. With the valve spindles in their lower position, the sealing surfaces of the nozzle components and the valve spindles may be in sealing contact to thereby close the outlet orifices and prevent the flow of the food product.

The actuators may be operated independently so that the flow of food product can be varied between different outlet orifices, with a selectable number of the outlet orifices being open at any one time.

The actuators may be each connected to a pneumatic circuit (not shown) for providing linear movement and a controller (not shown) for controlling the pneumatic circuits. Suitable pneumatic circuits will be known to those skilled in the art. Suitable controllers include programmable logic controllers (PLCs) and suitably programmed computers.

In use of the apparatus the controller may be arranged to control the actuators to independently open and close the respective outlet orifices for starting and stopping the deposition of the food product. The flow rate of the food product through the outlet orifices may be controlled by opening and closing the outlet orifices in a cycle having a frequency of at least 2 Hz, and by varying the proportion of the cycle time in which the outlet orifice is open (i.e. varying the mark-space ratio).

The flow rate of the food product through the outlet orifices may also depend, at least in part, on the pressure of the food product in the chamber. The controller may therefore be provided with the output from a pressure sensor (not shown), which measures the pressure in the chamber. The controller may control the actuators based on the sensed pressure.

Rather than pneumatic actuators, the actuators may alternatively be other types of actuator, such as moving coil electrical actuators. Moving coil electrical actuators may be capable of accurate positional control so that the flow rate of the food product through the outlet orifices can be varied by adjusting the linear position of the valve spindles.

The apparatus may be provided with a spreader plate attached to the bottom plate. The spreader plate may connect the outlet orifices to a larger plurality of spreader plate outlets. The spreader plate outlets may be provided with a pressure operated valve, the pressure operated valve being arranged to close when a pressure drops below a predetermined pressure greater than atmospheric pressure.

The apparatus may be arranged in an intermittent motion (indexed) food product moulding line. When the line is stationary, the apparatus may be moved over a mould cavity at high speed to fill the mould cavity with the food product.

A conventional depositor as described above may be modified to be used to simultaneously deposit inclusions and aerated compositions as described herein. Such modification may comprise use of at least one nozzle as described herein have two conduits therein one for the fluid composition and another for the inclusions. The depositor may also comprise a second chamber for holding inclusions before they are deposited through the inner conduit. For example Figures 1 to 29 herein illustrates certain examples of prior art nozzles and nozzles of the invention (such as Nozzles 4 to 1 1 shown in Figures 12 to 27 herein), that may be used in a process of the invention as claimed herein and/or that are suitable for use with an apparatus as described and/or claimed herein (such as a depositor as described above) for example with reference to the Figures herein. It will be appreciated that a valve spindle (not necessarily shown in any of the Figures 1 to 29 herein) may optionally be used in conjunction with any nozzle of the invention (such as Nozzles 4 to 1 1 illustrated herein). The length of the spindle can be adjusted to suit the nozzle that is used and thus for example Nozzles 4 to 1 1 (which are non- limiting) do not have to have the same length. Although embodiments of a nozzle of and/or used in the invention described herein that could be used with the apparatus described herein and/or illustrated herein, other embodiments of a nozzle as claimed herein could be used with other apparatus. Accordingly, an embodiment of a nozzle as claimed herein could have other forms and other dimensions in other embodiments, whereby the form and the dimensions of the nozzles of Figures 1 to 29 to are by way of example only, and the claimed subject matter is not limited to the specific forms and dimensions described with reference to Figures 1 to 29.

General optional features of nozzles of the invention

Dual conduit nozzles of the invention (also referred to herein as dual nozzles or combination nozzles) comprise at least two channels or passages (also referred to herein as conduits and/or bores) which comprise an inner and outer conduit as described herein. Dual nozzles of the invention, may optionally have a generally cylindrical configuration, so for example the dual nozzles may usefully fit within conventional depositors that use using single bore nozzles of similar generally cylindrical configuration, size and shape with the minimal amount of modification.

For example in a dual nozzle of the invention the inner conduit may comprise a central cylindrical channel or bore surrounded by an outer conduit of substantially annular cross section when viewed in cross-section orthogonal to the axis of the central channel so that overall the dual nozzle is generally cylindrical. The nozzle may be manufactured as an integral unit using a food grade material, for example stainless steel. Although in a particular example described herein the nozzle may be manufactured from stainless steel, for example by machining a block of stainless steel, in alternative embodiments it could be manufactured from another food-grade material, from example from a food-grade metal or plastics material using any suitable manufacturing process, such as machining or moulding. Although the term bore may be used herein to describe a central inner channel or passage, it is to be understood that the channel or passage need not be manufactured by "boring" that channel or passage.

As used herein, the expression "food-grade" when referring to a material herein denotes that the material is permitted to be in contact with foodstuffs suitable for human consumption as defined under the relevant local legislation (also referred to herein as "suitable for food contact"). At the date of filing the present application in the European Union the relevant rules for materials that are suitable for food contact include the EU Regulation 1935/2004, entitled "Framework Regulation on materials and articles intended to come into contact with food" and EU regulation 2023/2006, entitled "Good Manufacturing Practice for materials and articles intended to come in contact with food". Also relevant are EU Regulations: 10/201 1 on food contact with plastic materials (as amended by 2015/174, 202/2014, 1 183/2012, 1 183/2012, 1282/201 1 , 321/201 1 , 284/201 1 ); 450/2009 on food contact with active and intelligent materials; 282/2008 on food contact with recycled plastic materials; 42/2007/42 on food contact with regenerated cellulose film; 1895/2005 on restrictions of food contact with certain epoxy materials; and EU Directives 500/1984 on national law of food contact with ceramic articles; and 1 1/1993 on release of N-nitrosamines and N-nitrosatable substances. Thus as used herein "food-grade material" denotes that said material is compliant with the aforementioned EU Regulations and Directives on suitability for food contact and preferably such food-grade materials will also those materials that will continue to be compliant with any updated rules and lists of materials issued under these and/or related EU Regulations or Directives.

The dual nozzle of and/or used in the present invention comprises a proximal end and a distal end. The proximal end may comprises the first (optionally outer) inlet for receiving the liquid, semi-liquid or semi-solid food product and the second inner inlet for receiving the inclusions, although in another embodiment the inlet the receives the food product may also be located elsewhere between the proximal and distal ends of the nozzle.

The distal end may comprise the first outer outlet for depositing the liquid, semi-liquid or semi-solid food product where the outer outlet may substantially form an annulus in cross- section. The distal end may also comprise a second inner inlet for dispensing the inclusions. The inner bore may extend from the inner inlet to the inner outlet. The outer conduit may extends from the first (optionally outer) inlet to the first outer outlet. The exterior of the nozzle may comprises various portions extending from the proximal end to the distal end.

A proximal portion at the proximal end of the nozzle may have a generally cylindrical external surface with an external diameter to be received within a nozzle-receiving aperture of the depositor. The cylindrical external surface of the proximal portion of the nozzle can typically have an external diameter in the range of, for example, 10 mm to 25 mm and a length of in the direction of an axis of the bore from the proximal end to the distal end of the nozzle (hereinafter referred to as the axial direction) of for example from 10 mm to 35 mm. The actual dimensions in any particular example will depend upon the apertures in the depositor into which the nozzle is to be inserted and the method of attachment. For example the cylindrical external surface of the proximal portion may be formed with an external screw thread to engage with an internal screw thread in a nozzle-receiving aperture of the depositor. However, in other examples, various attachment mechanisms, for example interlocking mechanisms, clips etc. can be provided for attaching the nozzle to a depositor as will be understood by the person skilled in the art.

In other example of an embodiment of the invention a nozzle of the invention (not shown) may be provided with distal portion that includes a boss with a hexagonal form to facilitate screwing of the nozzle into a receiving aperture of the depositor. The distal portion of the nozzle of the invention may be provided with a flange that presents a shoulder that can abut against a lower surface of the depositor when the nozzle is received with the nozzle- receiving aperture of the depositor. For example the boss may have a diameter of, for example, 10 mm to 25 mm and a length in the axial direction of for example from 8 mm to 20 mm. The flange may facilitate accurate location of the nozzle within the nozzle-receiving aperture. In another example embodiment, the flange could be omitted and instead, the boss could present the shoulder by being configured to have an external diameter larger than that of the cylindrical external surface of the proximal portion of the nozzle. In other example embodiments the boss could have other forms for example a cylindrical form. The form of the boss can be chosen, for example, based in part on the nature of the attachment mechanism for attaching the nozzle to the depositor.

The distal end of the boss may be formed with a conical external distal portion that extends from the hexagonal portion of the boss and may converge towards both outlets (outer and inner) from the nozzle. In one example nozzle may have a conical (frusto-conical) external distal portion that converges towards the outlets and terminates at a flat distal surface that surrounds the outlets of the nozzle. However, in other examples, the distal flat surface may not be present and the frusto-conical external distal surface may end at the outlets. The conical external distal portion can have a length of up to, for example, 20 mm in the axial direction according to a particular embodiment. The two conduits that may comprise the interior if the dual nozzle (through which inclusions and liquid may pass independently) may comprises various portions extending from at least one of the inlets at the proximal end of the nozzle to at least one of the outlets at the distal end of the nozzle.

The bore that may form the interior of the inner conduit of the dual nozzle through which inclusions pass may comprises various portions extending from the inner inlet at the proximal end of the nozzle to the inner outlet at the distal end of the nozzle. Thus for example in one embodiment a first conical portion may reduce the diameter of the inner bore of the inner conduit from its inlet to a valve-receiving portion of the bore. The conical surface of the first conical portion may have a length in the axial direction of, for example, from 1 mm to 10 mm. The cylindrical valve-receiving portion of the inner bore can have a diameter of, usefully from 5 mm to 20 mm, more usefully from 10 mm to 15 mm and a length in axial direction of, for example, 8 mm to 35 mm. An inner conical valve seat portion may extend from the valve-receiving portion to an inner outlet bore portion. The conical valve seat portion may forms a sealing portion against which a corresponding conical sealing portion of a valve (for example a conical surface of a valve spindle) can engage to close the outlet bore portion. The surface of the conical valve seat portion may extend at a constant angle of, for example, 45° to 70° (the angle chosen to match and angle of a corresponding conical surface of a valve spindle) from the valve-receiving portion which has a diameter of conveniently from 5 mm to 20 mm, more conveniently from 10 mm to 15 mm to the outlet bore portion having a diameter of preferably from 1 mm to 4 mm, more preferably from 1 .5 mm to 3 mm. The valve may be used to release portions of inclusions through the inner bore in co-ordination with operation of flow of liquid through the outer conduit. If the process is operated continuously flow of inclusions can be continuous as will be the flow of liquid from the outer conduit or if the process is used to deposit discrete amounts of aerated liquid the flow of inclusions can be temporarily interrupted so the amount of inclusions is matched to the amount of liquid deposited.

In another for example in an embodiment the inner bore may comprise a internal helical blades fitted so the blades rotate to abut the interior bore surface (or with a circumferential gap between blade and bore substantially less than the minimum size of the inclusions) and with the pitch and frequency of the helical blades being selected so that a defined portion of inclusions is entrapped between successive helical blades within the inner bore. On rotation of the blades within the inner bore the inclusion portions are moved in a distal direction within the bore (preferably from the proximal to distal end) to be deposited from the inner bore via the inner outlet. Usefully the internal screw is operated in co-ordination with the flow of liquid with the outer conduit so the portion of inclusions deposited is matched to the rate of deposition of the liquid.

In an embodiment of the nozzle as claimed herein, the outlet bore portion of the inner conduit does not extend all of the way from the conical valve seat portion to the inner outlet of the bore. In an embodiment a flared inner outlet portion is formed between a distal end of the inner outlet bore portion and the inner outlet of the bore. In the embodiment described above the outlet bore portion of the inner conduit may have a constant diameter of, usefully from 1 mm to 4 mm more usefully from 1 .5 mm to 3 mm and a length in axial (longitudinal) direction of conveniently from 4 mm to 25 mm. The flared outlet portion of the inner bore may have a length in the axial direction of, for example, 1.5 mm to 3 mm and the surface of the flared outlet portion may flare at a constant angle of preferably from 15° to 45° more preferably from 20° to 40° to the axis of the inner bore to provide an outlet having a diameter of, for example, from 3 mm to 8 mm. In another example a nozzle of the invention can be provided with an inner outlet that is at least twice the diameter, for example of the order of 2 to 3 times the diameter of the outlet bore portion of the inner conduit described previously. The inner outlet may be formed with a clean and sharp edge where it meets with the flat distal surface or the surface of the external conical distal portion depending on whether or not a flat distal surface is present as discussed above. Although in the example above the surface of the flared outlet portion flares at a constant angle to the axis of the inner bore in other examples the flared outlet portion of the inner conduit may have different configurations. For example, in other embodiments, the flared outlet portion of the inner conduit could for example have a parabolic shape or a shape that approximates a parabolic shape such as a series of different angles to approximate a parabolic shape. The resultant shape comprises a series of part conical surfaces where the angle, relative to the axis of successive part conical surfaces in the axial direction gradually approaches the axial direction of the axis.

For example, in the described examples and embodiments herein the various portions of the bore of the inner conduit (inner bore) are circular in cross-section perpendicular to the longitudinal axis (i.e. seen in a transverse plane) to facilitate manufacture. It is to be noted that the various portions of the inner bore may not be exactly circular and may deviate therefrom due, for example, to manufacturing tolerances. Indeed, it is to be noted that the various portions of the inner bore could have a different shape in cross-section on a transverse plane (transverse cross-section). For example, one or more portions of the inner bore could be elliptical or oval in transverse cross-section. In this regard, although in the described examples, the flared outlet portion of the inner bore has a surface that defines part of a right conical surface that has a circular transverse cross-section, in other examples the flared outlet portion may have a different shape in transverse cross-section. For example, in an alternative example, the flared outlet portion may define part of the surface of, for example, an elliptic or oval cone terminating in an outlet that has an elliptical or oval shape in transverse cross-section and/or an oblique cone that tends to an apex that is not aligned above the center of the inner outlet.

Examples

Non limiting examples of the invention will now be described.

Comp A to C (Nozzles A to C) and Examples 1 to 4 (resp. Nozzles 1 to 3)

Four different nozzles will now be described some according to the invention and some as comparisons.

Nozzle 1 of the invention is a nozzle of novel design comprising a screw therein and which was formed by additive manufacturing (3D printing). Nozzle 1 is used to mix the inclusions directly into the aerated chocolate.

Nozzles 2 and 3 of the invention are shown schematically in respective Figures 12 and 13 (Nozzle 2) and Figures 14 and 15 (Nozzle 3).

Nozzle A is a known nozzle designed for use with water available commercially from Festo.

Nozzle B is a known nozzle designed for use with air available commercially from Festo designed to be normally closed with a large 15 mm diameter

Nozzle C is a known nozzle designed for use to generate reduced pressure (vacuum) available commercially from Festo designed to be normally open with a smaller diameter less than that of Nozzle 3. In the tests below Nozzles A and 1 , 2 and 3 were used with a Novae™ gas injector in a first method (where the pressure after the exit of a Novae™ injector is atmospheric pressure). Nozzles B and C were used with a Novae™ injector in a second method (where the pressure after the exit of a Novae™ injector is higher than atmospheric pressure).

Referring to Figures 1 , 2 and 3 Nozzle A delivered a good micro-aeration quality of a finished chocolate bar without inclusions (see Figure 2). The aerated mass flowed out of the nozzle in a very controlled way and was easily adjustable (by simply screwing the black section to open of close the gap between the two sections, see Figure 1 ).

It was found best to deposit onto a substrate at a minimum distance from the nozzle.

Although inclusions can be fed into the stream of chocolate via Nozzle A to be incorporated therein, the feeding mechanism was inefficient and blocked easily as doses of inclusions was passed there through. The central orifice in Nozzle A was angled inwards, potentially impeding the flow of inclusions. It was found that whilst tapping the nozzle whilst depositing helped unblock the nozzle (and this effect could also be achieved using a vibrator feed system) the Nozzle A was unsatisfactory. Using smaller inclusions (such as fine almond pieces compared to the larger pecan pieces used for the majority of the trials) did not reduce the tendency of Nozzle A to block when dosing inclusions.

Nozzle 1

Refer to Figures 4 to 8;

Nozzle 1 (having a screw feeder therein) produces a micro-aerated product homogeneously dosed with inclusions throughout the chocolate mass. Without being bound by any theory it is believed this was assisted by automatically timing of the screw motor within the Nozzle 1 so each inclusion dose is added to each chocolate deposit at a consistent rate and time. Although there was a slightly destabilization of the micro-aeration and small but visible bubbles could be seen rising to the surface during depositing the resultant product contained homogeneously mixing inclusions in an aerated chocolate mass. Bubble coalescence resulting from the mechanical action of the screw feeder can be minimized by careful selection of the feeder parameters. It was also found that if inclusions are not fed through Nozzle 1 some chocolate worked its way back into the hopper.

Due to the potential destabilization of the aeration, Nozzle 1 is preferred for micro-aerated mass (where the bubbles are smaller) rather than macro-aerated masses (with larger bubbles).

Nozzle 2 is described below with reference to Figures 12 and 13 and may be tested in the first method at atmospheric pressure

Nozzle 3 is described below with reference to Figures 14 and 15 and may be tested in the first method at atmospheric pressure

Nozzles B and C Refer to Figures 9 to 1 1

Two nozzles B and C available commercially from Festo were tested as a comparison to deposit chocolate from the Novae. Nozzles B and C differed in terms of whether they were normally 'closed' (Nozzle B) or 'open' (Nozzle C). Nozzles B and C were used to deposit chocolate masses containing inclusions under pressure, i.e. using the second method described above.

Any a suitable apparatus can be used to feed suitable doses of inclusions into the Novae (such a fruit feeder, typically used in ice cream production). In the present examples Noozles B and C were first tested to ensure they can maintain optimal aeration quality in the absences and then presence of inclusions to determine whether the nozzles would bet blocked by the inclusions (independently of how the inclusions may be first introduced into the Novae).

No significant difference was seen in terms of the performance of Nozzles B and C. Although micro-aeration quality was satisfactory and slightly better than that seen with Nozzle 2 without inclusions, depositing with inclusions with either Nozzle B or C was challenging, with the mass 'swirling' as it left either Nozzle B or C. When these nozzles were used to deposit aerated chocolate at a distance from the mould and significant tailing was also noted. The physical size of each Nozzle B and C was found to be a challenge in terms of depositor block design.

The novel Nozzle 1 with screw feeder therein was found to be advantageous over known nozzles A, B or C. It was also found that using the first method (adding inclusions at atmospheric pressure) was preferred as opposed to the incorporation of inclusions into aerated chocolate under pressure

Nozzle 1 not only delivered the most promising results in terms of homogeneity of inclusion mixing but can be prepared in stainless steel using conventional machining methods (as well as by than 3D printing) and thus can be made more cheaply than a more complex design. Nozzle 1 can be used with suitable means that positively feed the inclusions into the mass, rather than rely on gravity alone. Nozzle 1 gave superior micro-aeration quality to the deposited chocolate compared to the Nozzles A, B and C tested. Nozzle 1 may be used to ensure homogeneous mixing of inclusions with aerated chocolate and/or may also be used in a secondary method to fine tune the amount of aerated chocolate deposited from a nozzle.

Experiments

Trials were conducted using a 'Mini' Novae to deposit the aerated chocolate, using a 3D printed nozzles of the invention. The inclusion used was rice crispies, in combination of the recipe of conventional chocolate used to prepare the product sold by the application in Mexico under the registered trade mark CRUNCH® chocolate bar. Two samples were successfully made (micro and macro).

Example 4 (Nozzle 4 and Figures 12 & 13)

One embodiment of the present invention is shown in Figures 12 and 13 and is also referred to herein as Nozzle 4. Aerated composition, preferably aerated chocolate, is passed from a proximal end through an outer conduit in the direction of arrows A to A' to exit the outer conduit at a distal end. The outer conduit is defined by its proximal end, the interior of an outer wall (1 ) and the exterior of an inside wall 3 and a flow director 5 at its distal end. As shown in Figure 2 the outer conduit flares outwardly towards an outer annular exit orifice at its distal end defined by the edge of the flow director 5 and the bottom of the outer wall 1. The outwardly flared conduit is achieved by a flow director which comprise a substantial flat circular plate shown in Figures 12 and 13. Particulate inclusions are passed from a proximal end through an inner conduit substantially circular in cross-section in the direction of arrows B to B' to exit the inner conduit at a distal end. The inner conduit is defined by its proximal end, the interior of the inside wall 3 and an inner circular exit orifice at its distal end.

The aerated chocolate passes through the outer annular exit orifice to form a stream of liquid aerated composition in the form of a substantially annular curtain deposed around the circumference of a circle defined by the outer annular exit orifice at its distal end as shown by arrows A'. The inclusions pass through the inner circular exit orifice to from a narrow inner stream of inclusion particles that flow inside the substantially annular stream of aerated composition at its distal end as shown by arrow B'. Thus inclusions are fed through the centre of the nozzle, with chocolate flowing around the outside, effectively encasing them in chocolate without any mechanical mixing element. The two streams of aerated composition A' and inclusions B' fall under the action of pressure and/or gravity from their respective distal ends towards a substrate (not shown) onto which the aerated composition is deposited together with the inclusions.

Usefully in this embodiment of Nozzle 4 as shown in Figures 12 and 13 deposition will typically occur so the major axis of the conduits is substantially vertical i.e. the proximal ends are vertically located above the distal ends. In this example the streams A and B' fall in mid-air from their distal ends at least partially under the influence of gravity.

Advantageously the inclusion stream B' and aerated composition stream A' do not come into contact whilst they are being deposited, once they have been deposited, i.e. are on the substrate. This minimizes loss of gas in the aerated composition due to mixing and/or turbulence caused by interaction with the inclusion stream which may leave the inner circular exit orifice at a different flow rate from the rate at which aerated composition stream leaves the outer annular exit orifice.

Example 5 (Nozzle 5 and Figures 14 & 15)

Another embodiment of the present invention is shown in Figures 14 and 15 and is also referred to herein as Nozzle 5. Aerated composition, preferably aerated chocolate, is passed from a proximal end through an outer conduit in the direction of arrow A" to exit the outer conduit 109 at a distal end. The outer conduit is defined by its proximal end, the interior of an outer wall (101 ) and the exterior of an inside wall 103 and a frusto-conical flow director

105 at its distal end. As shown in Figure 14 the outer conduit flares outwardly towards an outer annular exit orifice 108 at its distal end defined by the edge of the flow director 105 and the bottom of the outer wall 101 over a vertical distance .

The outwardly flared conduit may be achieved by a flow director than has a substantially frusto-conical surface deposed towards the direction of flow A in parallel with a matching surface in the inside of the outer wall 103 to define the conduit as shown in Figures 13 and 14. Without wishing to be bound by any theory it is believed that an outer conduit with an internal profile partially defined by a frusto-conical surface defines a smoother path for the composition to flow which is thus less prone to disrupt the aerated composition and/or cause turbulence which otherwise may result in loss of gas (de-aeration) of the composition. A splitter (1 13) is located across the annulus at its distal end, the splitter (1 13) being designed to split the stream of aerated material as it flows out of the outer annular exit orifice 108. The applicant has found that the splitter can improve the quality of micro-aeration by minimizing entrainment of atmospheric air in the final product.

According to particular embodiments therefore, where reference is made to a conical surface or a part thereof, or a frusto-conical surface, this may be a right conical surface or part thereof or it may be another type of conical surfaces or a part thereof.

This embodiment, Nozzle 5 also several other preferred optional features that may be advantageous. A short nozzle length, as defined by the average distance from proximal to distal end defined by arrows 1 1 1 . The distance 1 1 1 is a short as practical to prevent de- aeration as the aerated material passes through the outer conduit. The exit orifices 108 and

106 are also usefully lie along the same plane, preferably orthogonal to the plane passing through the central point at the proximal and distal ends of the nozzle. For a preferred nozzle which is deposed vertically the exit orifices will all lie in the same horizontal plane. In this embodiment the inclusions passing through the inner central conduit are still encased in the chocolate flow, but any entrained atmospheric air can be pushed out as it composition flows into the mould.

Particulate inclusions are passed from a proximal end through an inner conduit substantially circular in cross-section in the direction of arrows B to B' to exit the inner conduit at a distal end. The inner conduit is defined by its proximal end, the interior of the inside wall 103 and an inner circular exit orifice 109 at its distal end.

The aerated chocolate passes through the outer annular exit orifice 108 to from a stream of liquid aerated composition in the form of a substantially annular curtain deposed around the circumference of a circle defined by the outer annular exit orifice at its distal end as shown by arrow A" the curtain having a small gap in its circumference therein defined by the splitter 1 13. The inclusions pass through the inner circular exit orifice 106 to from a narrow inner stream of inclusion particles that flow inside the almost annular stream of aerated composition at its distal end as shown by arrow B". As with the previous embodiment shown in Figures 12 and 13 inclusions are fed through the centre of the nozzle, with chocolate flowing around the outside, effectively encasing them in chocolate without any mechanical mixing element. The two streams of aerated composition A" and inclusions B" may fall under the action of pressure and/or gravity from their respective distal ends towards a substrate (not shown) onto which the aerated composition is deposited together with the inclusions. However in this embodiment use of the splitter 1 13 creates a small gap in the annular curtain of aerated chocolate to allow atmospheric air that would otherwise be trapped inside the annulus to escape more easily. This reduces entrainment of atmospheric air in the product which might otherwise adversely effect the quality a micro-aeration in the final product (e.g. as measured by homogeneity and visibility of the bubbles).

Usefully in this embodiment of Nozzle 5 shown in Figures 14 and 15 deposition will typically occur so the major axis of the conduits is substantially vertical i.e. the proximal ends are vertically located above the distal ends. In this example the streams A" and B" fall in mid- air from their distal ends at least partially under the influence of gravity.

Advantageously the inclusion stream B" and aerated composition stream A" do not mix substantially during deposition rather they mix once they have been deposited, i.e. when on the substrate and/or in a mould. However this does not discount that the aerated chocolate may gently coat some or all of the inclusions as or after they leave the exit orifice. Minimising or avoiding mechanical mixing of the streams minimizes loss of gas in the aerated composition, which is subject to lower shear forces and/or turbulence that may otherwise be generated by over-energetic interactions between inclusion particles and the chocolate (e.g. when subject to vigorous mixing). For example the inclusions may leave the inner circular exit orifice at a different flow rate from the rate at which aerated composition stream leave the outer annular exit orifice and this relative motion between streams may cause undesired de-aeration if the streams mixed substantially during deposition. Where final mixing of inclusions and chocolate occurs in the mould, gentle vibration of the mould can be used to minimise bubble coalescence.

In other related embodiments a plurality of splitting elements may be used to provide gaps in the annular curtain of aerated chocolate to remove entrained air. The splitters can be of any useful shape or in any suitable location with the outer conduit (109) or near the outer orifice exit (108). Preferably the splitter(s) are as small as possible to provide only a small gap in the curtain wall (usefully smaller than the inclusions used, for example 1 mm wide or narrower), to prevent inclusions from passing there through and also to ensure the inclusions will be substantially coated in chocolate.

Example 6 (Nozzle 6 and Figures 16 to 18) Figures 16 to 18 are of another embodiment of a nozzle (Nozzle 6) for use in the invention where:

Figure 16 shows a cross section of Nozzle 6 in an up, open position.

Figure 17 shows a cross section of Nozzle 6 in a middle closed position.

Example 7 (Nozzle 7 and Figures 19 & 20)

Figures 19 to 20 are of yet other embodiment of a nozzle (Nozzle 7) for use in the invention having a screw to deliver the inclusions through the inner conduit of the invention.

Example 8 (Nozzle 8 and Figures 21 & 22) and

Figures 21 to 22 illustrate still another embodiment of a nozzle for use in the present invention, Nozzle 8, where the inclusions are initially fed substantially horizontally through the apparatus via a conduit that interrupts the path of deposition of chocolate fed through a vertical conduit, where there is a corresponding orifice in the bottom wall of the inclusion conduit (not shown) which allows both chocolate and inclusions to pass there through under gravity (via Nozzle 8 and conduits as described herein) to form during deposition an substantially annular curtain wall of chocolate within which the inclusions also fall. Nozzle 8 comprises a complete uninterrupted circumferential annulus (Figure 21 ) in the outer conduit so the fluid passing there through forms a complete annular curtain when exiting from Nozzle 8 as it is being deposited.

Example 9 (Nozzle 9 and Figures 23, 24 & 25)

Figures 23, 24 & 25 illustrate still another embodiment of a nozzle for use in the present invention Nozzle 9, which is similar to Nozzle 8 except Nozzle 9 comprises split pins (see Figures 23 to 25). In this embodiment Nozzle 9 is largely as described above for Example 8 (Nozzle 8) and operates in the same manner. However as Nozzle 9 comprises pins (Figures 23 to 25) deposed around the circumference of annulus they act to split the flow of fluid through the outer annular conduit so that there are small vertical slits in the annular curtain through which air can pass to and from the interior of the curtain during deposition.

Example 10 (Nozzle 10 and Figure 26)

Figure 28 shows in cross section of another embodiment of the invention Nozzle 10 with a central bore containing a screw feeder for the inclusions and where the chocolate mass enters the apparatus from a conduit orthogonal to the axis of the nozzle. The chocolate is allowed to bathe the central screw feeder and exits from below as shown.

Example 1 1 (Nozzle 1 1 and Figure 27)

Figure 29 shows in cross section of another embodiment of the invention Nozzle 1 1 in which there is a central bore containing screw feeder for the inclusions movable along the main axis of the bore relative to the outer conduit through which the chocolate flows towards the exit orifice, where the respective surfaces of the annular ends of the central bore walls and the annular ends of the walls of the outer conduit are shaped at an angular to the main bore axis so that in one (closed) position of the central bore the surfaces faces can abut each other face to face to form a seal and thus close the outer orifice and prevent chocolate flow there through. This provides better control of the chocolate flow that when embodiments (e.g. Nozzle 7) where the inner and outer tubes meet at an edge to close the orifice.

Comp D (Nozzle D and Figures 28 and 29) This shows a known Nozzle D incorporating a valve spindle shown in an open (Figure 28) and closed (Figure 29) positions as described previously. This value spindle may optionally be used in or incorporated into nozzles and/or apparatus of the present invention as a means to close either the inner conduit (or with modification) the outer conduit.

Density matching

In each of the examples of the invention described herein the gas (N2) flow rate was set once at the beginning of the process and was matched to the density of the inclusions added so for that example the inclusions did not substantially migrate within the liquid chocolate deposited into mould over the time taken for the chocolate to cool and solidfy and fix the inclusions in place. The gas flow rate was determined once each time by calculating the amount and rate of gas injection that is needed such that the density of the fluid would be comparable to the density given for the inclusions that were added and no further operator intervention was needed.

However analogous embodiments and examples can be envisaged where the inclusions added were changed during the process and/or the inclusion mixture has a wide variability in density and either the gas injection setting would be adjusted manually by an operator during the process. Optionally if mean density is measured from particle size, mass measurements and/or using other sensing means (such means shown schematically in the Figures by elements labelled 20 (or n20 where 'n' is a multiple of a hundred), input parameters can be generated which would then be readily used to generate control parameters that can be used manually or automatically and directly or indirectly to adjust the gas pressures, gas flow and/or other parameters used by Novae™ gas injector in the examples herein.

Clauses:

1 A process for preparing an [optionally aerated] edible food product having inclusions dispersed therein, the process comprising the steps of:

d) depositing the inner stream of inclusions and the outer stream of [optionally aerated] fluid onto a substrate at substantially the same time, where the streams exit the apparatus proximate to each other but remain substantially separate and where the outer fluid stream at least partially surrounding the inner inclusion stream as they travel towards the substrate; and where the streams mix on the substrate to form a mixture thereon; and

e) optionally solidifying the mixture on the substrate;

2. A process as defined in clause 1 , the process comprising the steps of:

characterized in that:

(e) generating at least one control parameter to control:

(i) operation of the density adjusting means in the processing chamber and/or

(e) adjusting the density of the fluid composition in the processing chamber using the at least one control parameter to control the density adjusting means, the control parameter being calculated from the at least one input parameter so that the density adjusting means will substantially match (preferably match) the density of inclusion(s) added and/or to be incorporated therein; and

3. A process as defined in either preceding clause, the process comprising the steps of: a) providing an apparatus for depositing edible inclusions simultaneously with an [optionally aerated] edible fluid on a substrate the apparatus having an exit orifice for inclusions and an exit orifice for the [optionally aerated] edible fluid;

e) optionally solidifying the mixture on the substrate;

4 A process as defined in any preceding clause, the process comprising the steps of: a) providing an apparatus for depositing edible inclusions simultaneously with an [optionally aerated] edible fluid on a substrate, the apparatus comprising a dual conduit nozzle comprising:

d) depositing the inner stream of inclusions and the outer stream of [optionally aerated] fluid onto a substrate at substantially the same time, where the outer fluid stream at least partially surrounding the inner inclusion stream as they travel towards the substrate and where the streams mix on the substrate to form a mixture thereon; and

e) optionally solidifying the mixture on the substrate;

5. A process as defined in any preceding clause, where the edible composition and fluid are aerated and the food composition is a food product.

6. A process as defined in clause 5, where before depositing step d) there is performed an aerating step of injecting gas into the fluid to form an aerated fluid.

7. A process as defined in clause 6, where the aerating step comprises injecting gas into the fluid to form bubbles having a mean size of less than 100 microns (micro-aerating).

8. A process as defined in any of clauses 5 to 7, where the fluid is aerated to the extent of having at least 5% of gas by volume (by total volume of the fluid) dispersed in the fluid as it leaves the outer exit orifice.

9. A process as defined in any preceding clause, where at the outer exit orifice the outer outlet surrounds or substantially surrounds the inner outlet and where during some or all of the depositing step d) the outer fluid forms an outer curtain that surrounds or substantially surrounds the inner inclusion stream as both streams travel towards the substrate.

10. A process as defined in clause 9, where the outer exit orifice has an annular or substantial annular cross-section, and the inner exit orifice has a rectangular, circular or ovoid cross section (each cross-section being viewed in a plane orthogonal to the main axis of their respective outlets) and where in depositing step d) the fluid forms an annular or substantially annular curtain that surrounds or substantially surrounds the inner inclusion stream.

1 1 . A process as defined in any preceding clause, where the fluid is a liquid, semi-liquid or semi-solid food composition.

12. A process as defined in clause 1 1 , where the fluid is a confectionery composition.

13. A process as defined in clause 12, where the confectionery composition is fat based.

14. A process as defined in clause 13, where the fat based confectionery composition is a choco-composition,

15. A process as defined in clause 14, where the choco-composition is compound or chocolate.

16. A process as defined in any preceding clause where the substrate is selected from a partially produced product to be coated with fluid and inclusions and/or a mould of food grade material and where obtained from the process is a food product selected from a coated product; moulded food product and/or part thereof.

17. A process as defined in any preceding clause, where the process is for preparing a moulded micro-aerated choco-product having inclusions dispersed therein, the process comprising the steps of

the process comprising the steps of:

e) solidifying the moulded composition from depositing step d); and

f) demoulding a solid moulded product from solidification step e);

to obtain a moulded micro-aerated choco-product having inclusions dispersed therein. 18. A process as defined in any preceding clause where during depositing step d) the nozzle is positioned relative to the substrate such that the distance over which the streams travel before deposit is the same or less than the length of the inner conduit.

19. A dual conduit nozzle for use in a process as defined in any preceding clause and/or an apparatus as described in any preceding clause for depositing an edible optionally aerated fluid together with inclusions and/or an apparatus as defined in clause 26;

the nozzle comprising:

a distal end and a proximal end: the distal end having respective outer and inner outlets for depositing the fluid and the inclusions

an inner conduit extending from an inner inlet at the proximal end to an inner outlet having an exit orifice at the distal end; and

an outer conduit extending from an outer inlet at the proximal end to an outer outlet at the distal end; where the outer outlet comprises a substantially annular exit orifice substantially surrounding the inner exit orifice of inner outlet at the distal end;

where the inner and outer outlets are proximate to each other being preferably within 10 mm of each other,

and where the internal surfaces of both the outer and inner conduits consist of food grade material. 20. A nozzle as defined in clause 19, in which in fluid connection with outer conduit there is located means to inject gas therein.

21 . A nozzle as defined in clause 19, in which no gas injection means is provided in the outer conduit as the nozzle is suitable for a fluid that is pre-aerated before it enters the outer conduit.

22. A nozzle as defined in any of clauses 19 to 21 where the exit orifices of the outer and inner conduits lie substantially in the same plane.

23. A nozzle as defined in any of clauses 19 to 22 where there is at least one splitter located in the outer conduit such that the fluid stream exiting the outer exit orifice forms an annular curtain having at least one circumferential gap therein.

24. The nozzle of any one of clauses 19 to 23, where a portion of the inner bore of the inner conduit is of a constant diameter of between 1 mm and 4 mm (preferably from 1.5 mm to 3 mm).

25. The nozzle of any one of clauses 19 to 24, wherein a proximal portion of the external surface of the nozzle is configured for attachment to the apparatus.

26. An apparatus for depositing a liquid, semi-liquid or semi-solid food composition and/or product, the apparatus comprising:

a fixed volume chamber for receiving the food product under a positive pressure, the chamber being defined by chamber walls, one of the chamber walls being provided with one or more outlet orifices for depositing the food product defined by a nozzle as defined in any of clauses 19 to 25 installed in the chamber wall; and

a valve spindle arranged for reciprocating movement within the chamber, a first end of the valve spindle being provided with a second sealing surface;

where the second sealing surface of the valve spindle is arranged for abutting the first sealing surface of the nozzle to thereby close the outlet orifice.

27. A method of depositing a liquid, semi-liquid or semi-solid food composition and/or product as described in any of process clauses 1 to 18, the method comprising operating an apparatus:

as described in any of clauses 1 to 18 for depositing an edible optionally aerated fluid together with inclusions and/or as defined in clause 26;

the method comprising the steps of:

providing the food product to the fixed volume chamber under a positive pressure, the chamber being defined by the chamber walls; and

reciprocating the valve spindle such that the second sealing surface of the valve spindle intermittently abuts first sealing surface of the nozzle to thereby open and close the outlet orifice.

28. A method of depositing a liquid, semi-liquid or semi-solid food composition and/or product comprising operating an apparatus as described in any of clauses 1 to 18 for depositing an edible optionally aerated fluid together with inclusions and/or operating an apparatus as defined in clause 26.

29. A food composition and/or food product obtained and/or obtained by a process as defined in any of clauses 1 to 18 and/or a method as defined in any of clauses 27 to 28, having inclusions dispersed therein.

30. A food composition and/or product as defined in clause 29 which comprises micro- aerated gas bubbles therein having a mean size of less than 100 microns.

31 . A composition and/or product as defined in either clause 29 or 30 which has inclusions substantially homogenously dispersed therein.

32. A product as defined in any of clauses 29 to 31 which is a confectionery product.

33. A product as defined in clause 32 which is a moulded product.

34. A composition and/or product as defined in any of clauses 29 to 33 which comprises micro-aerated chocolate and/or compound having inclusions dispersed therein.

Claims

1 A process for preparing an aerated edible food composition having inclusions dispersed therein, the process comprising the steps of:

a) providing an apparatus for depositing edible inclusions simultaneously with an aerated edible fluid on a substrate, the apparatus comprising a dual conduit nozzle comprising:

an inner conduit, extending from a second inlet to an inner outlet having an inner exit orifice; where during operation of the process the outer conduit is fluidly connected to a first source providing (optionally continuously) an aerated edible fluid; and

e) optionally solidifying the mixture on the substrate;

to form an aerated food composition having inclusions dispersed therein.

2. A process for preparing an edible aerated food composition having inclusions dispersed therein the process comprising the steps of:

b) aerating the fluid by injecting a gas therein (optionally through an injection orifice in the apparatus);

d) depositing the inclusions and the aerated fluid onto a substrate at substantially the same time, where the fluid exits the fluid exit orifice as a fluid stream and the inclusions exit the inclusion exit orifice as an inclusion stream and both stream travel towards the substrate substantially at the same time and where the streams mix on the substrate to form a mixture thereon; and

e) optionally solidifying the mixture on the substrate;

to form an aerated] food composition having inclusions dispersed therein.

3. A process comprising the steps of the processes of both claims 1 and 2 in combination.

4. A process as claimed in any preceding claim, where the aerating step comprises injecting gas into the fluid to form bubbles having a mean size of less than 100 microns (micro-aerating).

5. A process as claimed in any preceding claim, where the fluid is aerated to the extent of having at least 5% of gas by volume (by total volume of the fluid) dispersed in the fluid as it leaves the outer exit orifice.

6. A process as claimed in any preceding claim, where the fluid is a liquid, semi-liquid or semi-solid food composition, preferably a confectionery composition, preferably fat based, preferably where the fat based confectionery composition is a choco-composition,

7. A process as claimed in claim 6, where the choco-composition is compound or chocolate.

8. A process as claimed in any preceding claim, where at the outer exit orifice the outer outlet surrounds or substantially surrounds the inner outlet and where during some or all of the depositing step d) the outer fluid forms an outer curtain that surrounds or substantially surrounds the inner inclusion stream as both streams travel towards the substrate.

9. A process as claimed in claim 8, where the outer exit orifice has an annular or substantial annular cross-section, and the inner exit orifice has a rectangular, circular or ovoid cross section (each cross-section being viewed in a plane orthogonal to the main axis of their respective outlets) and where in depositing step d) the fluid forms an annular or substantially annular curtain that surrounds or substantially surrounds the inner inclusion stream.

10. A process as claimed in any preceding claim where the substrate is selected from a product to be coated and/or a mould of food grade material and the food product obtained from the process is selected from a coated product; moulded food product and/or part thereof.

1 1 . A process as claimed in any preceding claim, where the process is for preparing a moulded micro-aerated choco-product having inclusions dispersed therein, the process comprising the steps of

optionally where the outer exit orifice has a substantially annular shape surrounding the inner exit orifice outlet having a substantially circular shape;

the process comprising the steps of:

b) feeding a micro-aerated choco-liquid through the outer conduit to exit the outer orifice to form therefrom an outer stream of micro-aerated choco-liquid, optionally in the form of substantially annular curtain;

c) feeding edible particulate inclusions through the inner conduit to exit the inner exit orifice to form thereform an inner stream of the inclusions, optionally located within the outer curtain of choco-liquid;

d) depositing the inner stream of inclusions and the outer stream of micro-aerated choco-liquid into a mould at the same time, optionally where during depositing the inclusion stream remains within the outer curtain;

e) solidifying the moulded composition from depositing step d); and

f) demoulding a solid moulded product from solidification step e);

12. A process as claimed in any preceding claim where during depositing step d) the nozzle is positioned relative to the substrate such that the distance over which the streams travel before deposit is the same or less than the length of the inner conduit.

13. A dual conduit nozzle for use in a process as claimed in any preceding claim for depositing an edible optionally aerated fluid together with inclusions;

the nozzle comprising: a distal end and a proximal end: the distal end having respective outer and inner outlets for depositing the fluid and the inclusions

an outer conduit extending from an outer inlet at the proximal end to an outer outlet at the distal end; and where

the internal surfaces of both the outer and inner conduits consist of food grade material.

14. A nozzle as claimed in claim 13, in which in fluid connection with outer conduit there is located means to inject gas therein or in which no gas injection means is provided in the outer conduit, the nozzle being suitable for use with a fluid that is pre-aerated before it enters the outer conduit.

15. A nozzle as claimed in any of claims 13 to 14 where the exit orifices of the outer and inner conduits lie substantially in the same plane.

16 A nozzle as claimed in any of claims 13 to 15 where there is at least one splitter located in the outer conduit such that the fluid stream exiting the outer exit orifice forms an annular curtain having at least one circumferential gap therein.

17. A nozzle as claimed in any of claims 13 to 16 where the exit orifices are proximate to one another having a mean distance between the central or mid-point of each orifice of from 1 mm to 1 cm, optionally from 1 mm to 5 mm, optionally where the mean distance is from 1 mm to 3 mm.

18. The nozzle of any one of claims 13 to 17, where a portion of the inner bore of the inner conduit is of a constant diameter of between 1 mm and 4 mm, preferably is from 1 .5 mm to 3 mm.

19. The nozzle of any one of claims 13 to 18, wherein a proximal portion of the external surface of the nozzle is configured for attachment to the apparatus.

20. An apparatus for depositing a liquid, semi-liquid or semi-solid food composition, the apparatus comprising:

a fixed volume chamber for receiving the food composition under a positive pressure, the chamber being defined by chamber walls, one of the chamber walls being provided with one or more outlet orifices for depositing the food composition defined by a nozzle as claimed in any of claims 13 to 17 installed in the chamber wall; and

21 . A method of depositing a liquid, semi-liquid or semi-solid food composition as described in any of process claims 1 to 12, the method comprising depositing an edible optionally aerated fluid together with inclusions;

the method comprising the steps of:

providing the food composition to the fixed volume chamber under a positive pressure, the chamber being defined by the chamber walls; and

22. A food composition and/or product obtained and/or obtained by a process as claimed in any of claims 1 to 12 and/or a method as claimed in claim 21 , the food composition and/or product having inclusions dispersed therein, preferably which comprises micro-aerated gas bubbles therein having a mean size of less than 100 microns, preferably which has inclusions substantially homogenously dispersed therein, preferably which is a confectionery product or preferably which is a moulded product.

23. A food composition and/or product as claimed in claim 22, which comprises micro- aerated chocolate and/or compound having inclusions dispersed therein.