Methods and apparatus for molding chocolate

A method for removing flash from a chocolate product, comprising the steps of:

• providing a chocolate product having flash that has been cooled to a temperature less than that at which the chocolate sets;
• conveying a chocolate product having flash on a first surface of a conveyor belt, such that at least a portion of the flash contacts the conveyor belt, the conveyor belt having a second surface opposite the first surface;
• exposing the bottom of the chocolate product and the flash on the first surface of the conveyor belt at a first section to a temperature for a time sufficient to melt at least a portion of the flash without melting or detempering the bottom of the chocolate product, such that at least a portion of the flash adheres to the first surface of the conveyor belt;
• and
• passing the conveyor belt around a bull nose, thereby releasing the chocolate product from the conveyor belt, while retaining at least a portion of the flash on the conveyor belt.

An apparatus for continuously molding chocolate, comprising:

• a mold having an outer surface with at least one mold cavity;
• a mold configured for relative motion with respect to the manifold;
• the manifold contacting the outer surface of the mold and comprising a liquid chocolate supply conduit and a liquid chocolate return conduit and a manifold body comprising a port;
• wherein
• the liquid chocolate supply conduit is in fluid communication with the liquid chocolate return conduit and the at least one mold cavity.

A method for continuously molding chocolate, comprising:

• moving a mold having at least one mold cavity relative to a manifold, a surface of the manifold contacting a surface of the mold;
• flowing liquid chocolate into the manifold through a liquid chocolate supply conduit;
• directing at least a portion of the liquid chocolate into the at least one mold cavity through at least one port in the manifold;
• directing excess liquid chocolate from the manifold through a liquid chocolate return conduit;
• retaining the liquid chocolate within the mold cavity to prevent flow of the liquid chocolate from the mold cavities;
• cooling the mold to at least partially solidify the chocolate in the mold cavity;
• and
• removing the at least partially solidified chocolate from the mold.

An apparatus for continuously molding chocolate with inclusions, comprising:

• a substantially cylindrical rotary mold having an outer surface, at least one mold cavity on said outer surface, and an interior coolant cavity;
• conduits leading to and from said interior cavity for connecting said interior cavity with a coolant source;
• a liquid chocolate feeder for depositing liquid chocolate into said at least one mold cavity;
• a retaining/casting belt positioned to maintain said liquid chocolate in the mold cavity where the liquid chocolate solidifies;
• and
• an inclusion feeder adapted to transport inclusions and communicating with said at least one mold cavity, so that at least one inclusion is deposited in the at least one mold cavity before or after the liquid chocolate is deposited into the mold cavity and prior to the liquid chocolate solidifying.

A method for continuously molding chocolate pieces having inclusions, comprising the steps of:

• rotating a substantially cylindrical rotary mold having an outer surface, at least one mold cavity on said outer surface, and an interior coolant cavity;
• circulating coolant from a coolant source to said interior cavity;
• supplying liquid chocolate into said at least one mold cavity;
• placing inclusions in an inclusion feeder and moving the inclusion feeder in cooperation with the rotation of the mold;
• positioning inclusions transported by the inclusion feeder proximate said at least one mold cavity, so that an inclusion is deposited in the at least one mold cavity before or after the step of depositing liquid chocolate and prior to the liquid chocolate solidifying;
• and
• retaining the liquid chocolate in said mold cavity with a retaining/casting belt positioned against the mold cavity until the liquid chocolate at least partially solidifies.