Shelf-stable cookie dough confection, product, packaging apparatus and process

Abstract

An apparatus for metering and dispensing a compressible confection comprises: at least one metering pump having an intake port and a discharge port; at least one internal bottom shutoff nozzle; at least one product line interconnecting the metering pump and the internal bottom shutoff nozzle; and a control mechanism for cyclically operating the at least one metering pump and operating the at least one internal bottom shutoff nozzle in synchronization with the metering pump such that generally constant pressure is maintained between the metering pump and the internal bottom shutoff nozzle.

What is claimed is:  
     
         1 . A shelf-stable confection having a taste and a texture of raw cookie dough.  
     
     
         2 . The confection of  claim 1  having a water activity (A w ) level of 0.6 or less.  
     
     
         3 . The confection of  claim 1  comprising between about 10 and about 45 weight percent of an aerated fat.  
     
     
         4 . The confection of  claim 1  comprising between about 0.5 and about 10 weight percent of a food grade glycerine.  
     
     
         5 . The confection of  claim 4  wherein the glycerine has a percent solids level of between about 96 and about 99 percent solids.  
     
     
         6 . The confection of  claim 1  comprising between about 0.1 and about 2 weight percent of a food grade emulsifier.  
     
     
         7 . The confection of  claim 6  wherein the emulsifier is selected from the group consisting of mono- and di-glycerides and propylene glycol.  
     
     
         8 . The confection of  claim 1  comprising a fat and a food grade antioxidant at a level of about 0.02 percent by weight of the fat.  
     
     
         9 . The confection of  claim 1  comprising between about 0.05 and about 3.5 weight percent of a flavoring.  
     
     
         10 . The confection of  claim 1  comprising between about 5 and about 30 weight percent of a food grade starch.  
     
     
         11 . The confection of  claim 1  comprising between about 5 and about 30 weight percent corn syrup solids.  
     
     
         12 . The confection of  claim 1  comprising between about 5 and about 45 weight percent sugar.  
     
     
         13 . The confection of  claim 11  wherein the sugar is selected from the group consisting of brown sugar, brown sugar powder, granular sugar, powder sugar and mixtures thereof.  
     
     
         14 . The confection of  claim 12  comprising between about 5 and about 30 weight percent brown sugar powder.  
     
     
         15 . The confection of  claim 12  comprising between about 5 and about 30 weight percent granular sugar.  
     
     
         16 . The confection of  claim 12  comprising between about 5 and about 30 weight percent powder sugar.  
     
     
         17 . The confection of  claim 1  comprising a flavored chip content of between about 0.1 and about 20 weight percent.  
     
     
         18 . The confection of  claim 17  wherein the flavored chips are fat-based.  
     
     
         19 . The confection of  claim 18  wherein the flavored chips are coated.  
     
     
         20 . The confection of  claim 17  wherein the flavored chips are chocolate flavored.  
     
     
         21 . The confection of  claim 1  comprising between about 0.5 and about 4 weight percent of a cellulose-based gum.  
     
     
         22 . The confection of  claim 21  wherein the cellulose based gum comprises hydroxypropyl methylcellulose.  
     
     
         23 . The confection of  claim 1  comprising between about 0.1 and about 4 weight percent of a food grade salt.  
     
     
         24 . The confection of  claim 1  comprising: 
 a) between about 10 and about 45 weight percent of an aerated fat;  
 b) between about 0.5 and about 10 weight percent of a food grade glycerine;  
 c) between about 5 and about 30 weight percent of a food grade starch; and  
 d) between about 5 and about 45 weight percent sugar.  
 
     
     
         25 . The confection of  claim 1  having a water activity (A w ) level of 0.6 or less and comprising: 
 a) about 28 weight percent of an aerated fat,  
 b) about 1 weight percent of a food grade glycerine,  
 c) about 0.5 weight percent of a food grade emulsifier,  
 d) about 0.25 weight percent flavor,  
 e) about 0.0056 weight percent of a food grade antioxidant,  
 f) about 14.75 weight percent of a food grade starch,  
 g) about 13 weight percent brown sugar powder,  
 h) about 12.64 weight percent granular sugar,  
 i) about 10 weight percent corn syrup solids,  
 j) about 9.0 weight percent powder sugar,  
 k) about 7.75 weight percent chocolate chips,  
 l) about 2 weight percent cellulose-based gum and  
 m) about 1.1 weight percent of a food grade salt.  
 
     
     
         26 . The confection of  claim 1  wherein the confection is chocolate chip cookie dough flavor.  
     
     
         27 . The confection of  claim 1  wherein the confection is peanut butter cookie dough flavor.  
     
     
         28 . The confection of  claim 1  wherein the confection is sugar cookie dough flavor.  
     
     
         29 . The confection of  claim 1  wherein the confection is chocolate cream sandwich cookie flavor.  
     
     
         30 . The confection of  claim 1  wherein the confection is cookie and cream flavor.  
     
     
         31 . The confection of  claim 1  wherein the confection is chocolate mint chip flavor.  
     
     
         32 . The confection of  claim 1  wherein the confection is brownie flavor.  
     
     
         33 . A product comprising the confection of  claim 1  in a package.  
     
     
         34 . The product of  claim 33  wherein the package is resistant to oxygen and moisture.  
     
     
         35 . The product of  claim 34  wherein the package comprises a multi-layer laminate of polystyrene, ethylvinyl alcohol and polyethylene.  
     
     
         36 . The product of  claim 33  wherein the package comprises a cup.  
     
     
         37 . The product of  claim 36  wherein the package further comprises a lid.  
     
     
         38 . The product of  claim 37  wherein the lid comprises a multi-layer laminate of clay-coated paper, foil and a sealant layer, the sealant layer comprising high density polyethylene, ethyl acrylic acid and surlyn polymer.  
     
     
         39 . The product of  claim 33  wherein the package contains an eating implement.  
     
     
         40 . The product of  claim 39  wherein the package comprises a sanitary disk placed between the confection and the eating implement.  
     
     
         41 . The product of  claim 40  wherein the sanitary disk comprises a foam material; the foam material being impervious to fat.  
     
     
         42 . The product of  claim 39  wherein the eating implement is choke resistant.  
     
     
         43 . The product of  claim 42  wherein the eating implement is a spoon.  
     
     
         44 . The product of  claim 43  wherein the spoon has a 2½ inch length.  
     
     
         45 . An apparatus for metering and dispensing a compressible confection comprising: 
 a) at least one metering pump; the metering pump comprising an intake port and a discharge port;    b) at least one internal bottom shutoff nozzle;    c) at least one product line interconnecting the metering pump and the internal bottom shutoff nozzle; and    d) a control mechanism for cyclically operating the at least one metering pump and operating and the at least one internal bottom shutoff nozzle in synchronization with the metering pump such that generally constant pressure is maintained between the metering pump and the internal bottom shutoff nozzle.    
     
     
         46 . The apparatus of  claim 45  comprising at least one pulse regulator attached to the intake port of the metering pump.  
     
     
         47 . The apparatus of  claim 46  wherein the pulse regulator is sanitary.  
     
     
         48 . The apparatus of  claim 45  comprising a diving mechanism for lowering and elevating the at least one internal bottom shutoff nozzle, the control mechanism is capable of operating the diving mechanism in synchronization with the metering pump.  
     
     
         49 . The apparatus of  claim 48  comprising a bracket for supporting the at least one internal bottom shutoff nozzle and interconnecting the diving mechanism and the at least one internal bottom shutoff nozzle.  
     
     
         50 . The apparatus of  claim 48  wherein the diving mechanism comprises at least one air cylinder.  
     
     
         51 . The apparatus of  claim 45  wherein the control mechanism comprises a clutch breaking system.  
     
     
         52 . The apparatus of  claim 45  wherein the metering pump comprises a lobe-type positive displacement pump.  
     
     
         53 . The apparatus of  claim 52  wherein the lobe-type positive displacement pump has a maximum flow rate of 2.8 GPM at 20 PSI.  
     
     
         54 . The apparatus of  claim 45  comprising a motor to drive the metering pump.  
     
     
         55 . The apparatus of  claim 45  wherein the internal bottom shutoff nozzle comprises a nozzle tip collar for holding a cup in place as the cup is filled with the compressible confection.  
     
     
         56 . The apparatus of  claim 55  wherein the nozzle tip collar comprises a collar and at least one spring.  
     
     
         57 . The apparatus of  claim 45  wherein the internal bottom shutoff nozzle has an outlet with an inner diameter of about 1 inch.  
     
     
         58 . The apparatus of  claim 45  wherein the product line is sanitary.  
     
     
         59 . The apparatus of  claim 58  wherein the product line is flexible.  
     
     
         60 . The apparatus of  claim 59  wherein the product line is stainless steel braided pipe.  
     
     
         61 . The apparatus of  claim 45  comprising multiple metering pumps.  
     
     
         62 . The apparatus of  claim 61  comprising multiple internal bottom shutoff nozzles.  
     
     
         63 . The apparatus of  claim 61  comprising multiple product lines.  
     
     
         64 . The apparatus of  claim 45  wherein the control mechanism is capable of cyclically operating multiple metering pumps and operating multiple internal bottom shutoff nozzles in synchronization with the multiple metering pumps.  
     
     
         65 . The apparatus of  claim 45  comprising multiple pulse regulators.  
     
     
         66 . The apparatus of  claim 63  further comprising a manifold comprising at least one inlet port and multiple outlet ports, the manifold interconnecting the multiple outlet ports to the multiple product lines.  
     
     
         67 . The apparatus of  claim 66  wherein the manifold comprises multiple ball valves wherein each ball valve is attached to at least one outlet port of the manifold.  
     
     
         68 . The apparatus of  claim 67  wherein the multiple product lines interconnect the ball valves and the intake ports of the multiple metering pumps.  
     
     
         69 . The apparatus of  claim 66  comprising a supplemental surge accumulator.  
     
     
         70 . The apparatus of  claim 69  wherein the supplemental surge accumulator is attached adjacent the manifold inlet port for additional surge protection from air pockets in the compressible confection.  
     
     
         71 . An apparatus for metering and dispensing a compressible confection comprising: 
 a) at least one electrically operated rotary metering pump comprising: 
 i) an intake port,  
 ii) a discharge port, and  
 iii) a chain drive;  
   b) at least one pneumatically operated internal bottom shutoff nozzle controlled by at least one first electrical solenoid and supported by a bracket;    c) at least one nozzle tip collar comprising a collar and at least one spring for holding a cup in place as the cup is filled with the compressible confection dispensed from the internal bottom shutoff nozzle;    d) a diving mechanism comprising at least one pneumatically operated air cylinder controlled by at least one second electrical solenoid and attached to the bracket for lowering and elevating the at least one pneumatically operated internal bottom shutoff nozzle;    e) a product line interconnecting the electrically operated rotary metering pump and the pneumatically operated internal bottom shutoff nozzle;    f) a control mechanism for cyclically operating the at least one electrically operated rotary metering pump and operating the at least one pneumatically operated internal bottom shutoff nozzle in synchronization with the rotary metering pump such that constant pressure is maintained between the electrically operated rotary metering pump and the pneumatically operated internal bottom shutoff nozzle, the control mechanism being capable of operating the diving mechanism in synchronization with the electrically operated rotary metering pump;    g) a drive shaft comprising at least one sprocket engaging the chain drive of the electrically operated rotary metering pump; and    h) a motor driving the drive shaft.    
     
     
         72 . The apparatus of  claim 71  comprising at least one pulse regulator attached to the intake port of the rotary metering pump.  
     
     
         73 . The apparatus of  claim 71  wherein the pulse regulator is sanitary.  
     
     
         74 . The apparatus of  claim 71  wherein the control mechanism comprises: 
 a) a signal generating device controlled by a packaging conveyor; and  
 b) an electrically operated clutch breaking system comprising a clutch break engaging the drive shaft.  
 
     
     
         75 . The apparatus of  claim 74  wherein the control mechanism is capable of simultaneously sending a signal to at least one first electrical solenoid, at least one second electrical solenoid and the clutch breaking system.  
     
     
         76 . The apparatus of  claim 75  wherein the first electrical solenoid is capable of receiving the signal and opening the internal bottom shutoff nozzle.  
     
     
         77 . The apparatus of  claim 76  wherein the second electrical solenoid is capable of receiving the signal and lowering the at least one internal bottom shutoff nozzle to a fully lowered position.  
     
     
         78 . The apparatus of  claim 77  wherein the clutch breaking system is capable of receiving the signal and starting the rotary metering pump.  
     
     
         79 . The apparatus of  claim 78  wherein the clutch break is capable of disengaging the drive shaft to start the rotary metering pump.  
     
     
         80 . The apparatus of  claim 78  wherein the diving mechanism is capable of gradually elevating the at least one internal bottom shutoff nozzle as the rotary metering pump operates.  
     
     
         81 . The apparatus of  claim 75  wherein the first electrical solenoid is capable of receiving the signal and closing the internal bottom shutoff nozzle.  
     
     
         82 . The apparatus of  claim 81  wherein the second electrical solenoid is capable of receiving the signal and elevating the internal bottom shutoff nozzle to a fully upright position.  
     
     
         83 . The apparatus of  claim 81  wherein the clutch breaking system is capable of receiving the signal and stopping the rotary metering pump.  
     
     
         84 . The apparatus of  claim 82  wherein the clutch break is capable of engaging the drive shaft to stop the rotary metering pump.  
     
     
         85 . The apparatus of  claim 71  wherein the rotary metering pump comprises a lobe-type positive displacement pump.  
     
     
         86 . An apparatus for metering and dispensing a compressible confection comprising: 
 a) a pneumatically operated displacement drum pump which comprises a ram and a relief spout and is controlled by a third electrical solenoid;    b) a manifold which comprises: 
 i) at least one inlet port,  
 ii) multiple outlet ports,  
 iii) multiple ball valves wherein each ball valve is attached to at least one outlet port, and  
 iv) a supplemental surge accumulator for additional surge protection from air pockets in the compressible confection;  
   c) a product line connected at one end to the displacement drum pump and at the other end to the at least one manifold inlet port;    d) an accumulator attached to the product line between the displacement drum pump and the manifold;    e) multiple lobe-type positive displacement pumps each comprising an intake port and a discharge port, the pumps being driven by a motor driving a drive shaft having multiple sprockets thereon and chain drives between the drive shaft sprockets and the pumps;    f) multiple sanitary pulse regulators wherein each sanitary pulse regulator is attached to the intake port of at least one lobe-type positive displacement pump;    g) multiple first flex-lines wherein each first flex-line is connected at one end to one of said ball valves and at the other end to one of said pump intake ports;    h) multiple pneumatically operated internal bottom shutoff nozzles;    i) multiple nozzle-tip collars wherein each nozzle-tip collar comprises a collar and at least one spring mounted to the collar for holding a cup in place as the cup is filled with the compressible confection, the nozzle tip collar being attached to the pneumatically operated internal bottom shutoff nozzle;    j) multiple first electrical solenoids wherein each first electrical solenoid controls at least one pneumatically operated internal bottom shutoff nozzle;    k) a bracket for supporting and spacing the multiple pneumatically operated internal bottom shutoff nozzles;    l) a diving mechanism for lowering and elevating the multiple internal bottom shutoff nozzles comprising at least one pneumatically operated air cylinder controlled by at least one second electrical solenoid and is attached beneath the bracket;    m) multiple second flex-lines wherein each second flex-line is connected at one end to one of said pump discharge ports and at the other end to one of said internal bottom shutoff nozzles; and    n) a control mechanism for synchronously operating the displacement drum pump, the multiple lobe-type positive displacement pumps and the multiple internal bottom shutoff nozzles such that generally constant pressure is maintained between each multiple lobe-type positive displacement pump and shutoff nozzle, the control mechanism also being capable of operating the diving mechanism in synchronization with they rotary metering pump.    
     
     
         87 . The apparatus of  claim 86  wherein the control mechanism comprises: 
 a) a signal generating device controlled by a packaging conveyor; and  
 b) an electrically operated clutch breaking system comprising a clutch break engaging the drive shaft.  
 
     
     
         88 . The apparatus of  claim 87  wherein the control mechanism is capable of simultaneously sending a signal to the first electrical solenoids, the second electrical solenoids, the third electrical solenoid and the clutch breaking system.  
     
     
         89 . The apparatus of  claim 88  wherein the first electrical solenoid is capable of receiving the signal and opening the internal bottom shutoff nozzle.  
     
     
         90 . The apparatus of  claim 89  wherein the second electrical solenoid is capable of receiving the signal and lowering the at least one internal bottom shutoff nozzle to a fully lowered position.  
     
     
         91 . The apparatus of  claim 90  wherein third electrical solenoid is capable of receiving the signal and starting the pneumatically operated displacement drum pump.  
     
     
         92 . The apparatus of  claim 91  wherein the clutch breaking system is capable of receiving the signal and starting the rotary metering pump.  
     
     
         93 . The apparatus of  claim 92  wherein the clutch break is capable of disengaging the drive shaft to start the rotary metering pump.  
     
     
         94 . The apparatus of  claim 93  wherein the diving mechanism is capable of gradually elevating the at least one internal bottom shutoff nozzle as the rotary metering pump operates.  
     
     
         95 . The apparatus of  claim 88  wherein the first electrical solenoid is capable of receiving the signal and closing the internal bottom shutoff nozzle.  
     
     
         96 . The apparatus of  claim 95  wherein the second electrical solenoid is capable of receiving the signal and elevating the internal bottom shutoff nozzle to a fully upright position.  
     
     
         97 . The apparatus of  claim 96  wherein the third electrical solenoid is capable of receiving the signal and stopping the pneumatically operated displacement drum pump.  
     
     
         98 . The apparatus of  claim 97  wherein the clutch breaking system is capable of receiving the signal and stopping the rotary metering pump.  
     
     
         99 . The apparatus of  claim 98  wherein the clutch break is capable of engaging the drive shaft to stop the rotary metering pump.  
     
     
         100 . The apparatus of  claim 86  wherein the product line comprises 1 inch stainless steel pipe.  
     
     
         101 . The apparatus of  claim 86  wherein the manifold comprises 4 inch stainless steel pipe.  
     
     
         102 . The apparatus of  claim 86  wherein the first and second flex-lines comprise 1 inch stainless steel braided pipe.  
     
     
         103 . The apparatus of  claim 86  wherein the internal bottom shutoff nozzles comprise a 1 inch inner diameter outlet.  
     
     
         104 . The apparatus of  claim 86  wherein each of the lobe-type positive displacement pumps has a maximum output rate of 2.8 GPM at 20 PSI.  
     
     
         105 . The apparatus of  claim 86  wherein the motor comprises an electrical motor.  
     
     
         106 . A process for packaging the product of  claim 1  comprising the steps of: 
 a) loading at least one empty cup onto a packaging conveyor;  
 b) conveying the at least one empty cup to a filling station;  
 c) filling the at least one empty cup with the product of  claim 1  to form at least one filled cup;  
 d) conveying the filled cup to a lid placement station;  
 e) placing a lid on top of the filled cup;  
 f) conveying the filled cup to a lid sealing station; and  
 g) sealing the lid to the filled cup to form a packaged product.  
 
     
     
         107 . The process of  claim 106  further comprising between steps c) and d) the steps of: 
 a) conveying the filled cup to a disk insert station; and  
 b) inserting a disk.  
 
     
     
         108 . The process of  claim 107  further comprising the step of tapping the disk to settle the product of  claim 1  within the filled cup.  
     
     
         109 . The process of  claim 106  further comprising before steps d, the steps of: 
 a) conveying the filled cup to an eating implement placement station; and  
 b) placing an eating implement in the filled cup.  
 
     
     
         110 . The process of  claim 106  further comprising the steps of: 
 a) conveying the packaged product to a packaged product removal station; and  
 b) removing the packaged product from the packaging conveyor.  
 
     
     
         111 . The process of  claim 106  wherein the filling is performed using a lobe-type positive displacement pump feeding product to an internal bottom shutoff nozzle.  
     
     
         112 . The process of  claim 109  wherein the lid placement is performed by a pick and place machine inserting and tapping the disk.  
     
     
         113 . The process of  claim 106  wherein the lids are heat sealed at the lid sealing station.  
     
     
         114 . The process of  claim 106  wherein the packaging conveyor comprises at least one nesting tray; the nesting tray having an aperture into which the cup is loaded.  
     
     
         115 . The process of  claim 114  wherein the packaging conveyor comprises multiple nesting trays.  
     
     
         116 . The process of  claim 115  wherein the nesting tray comprises multiple apertures into which multiple cups are loaded.  
     
     
         117 . The process of  claim 116  wherein the multiple apertures comprise a configuration having two rows of three apertures.  
     
     
         118 . The process of  claim 106  wherein the packaging conveyer comprises a first magazine and a second magazine.  
     
     
         119 . The process of  claim 118  wherein the first magazine hold the cups to be loaded onto the packaging conveyor.  
     
     
         120 . The process of  claim 119  wherein the second magazine hold the lids to be placed on top of the filled cup.  
     
     
         121 . The process of  claim 120  wherein the packaging conveyor comprises a blister pack machine.  
     
     
         122 . The process of  claim 106  wherein the packaging conveyor operates intermittently.  
     
     
         123 . The process of  claim 122  wherein the packaging conveyor operates in synchronization with the apparatus of  claim 45 .  
     
     
         124 . The process of  claim 123  wherein the packaging conveyor conveys for about 1 second and stops for about 3 seconds.  
     
     
         125 . The process of  claim 124  wherein the apparatus of  claim 45  fills at least one empty cup at the cup filling station within about 3 seconds.