Note: Descriptions are shown in the official language in which they were submitted.
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Method of tropicalizing chocolate
Field of the invention
The present invention relates to tropicalizing agent compositions, to methods
for the
preparation thereof, to methods of tropicalizing chocolate or analogues
thereof, and to
chocolate or analogues of chocolate containing the tropicalizing agents. In
particular, it relates
to the use of a novel combination of cocoa particles and the methods of the
invention and to
their incorporation into tropicalizing agent compositions and products of the
invention.
Background of the invention
Conventionally manufactured chocolate consists of sugars, cocoa solids and
protein (usually
from milk) homogeneously dispersed in fats and fatty substances originating
from cocoa butter.
Chocolate analogues contain other vegetable fats in partial/total replacement
of the cocoa
butter fat. Often the continuous fat phase also contains dairy fat.
Cocoa butter typically starts to soften at about 28 C, with consequent loss of
the mechanical
strength of the chocolate. This means that at the high ambient temperatures
frequently
encountered in tropical countries, chocolate becomes sticky or even runny. It
tends to stick to
the wrapper and fall apart when the wrapper is removed, leaving a semi-liquid
mass that can
often only be eaten with a spoon if cleanliness is desired. Enrobed chocolate
products typically
lose integrity under these conditions, with their contents often leaking and
individual units
tending to stick together in the packaging. Chocolate also loses the 'snap'
that is an important
(and pleasurable) textural characteristic of chocolate stored and eaten under
cooler conditions.
Attempts to produce a chocolate that is resistant to heat are numerous.
Persons skilled in the
art generally refer to methods to achieve chocolate or chocolate analogues
that are heat
resistant as to methods to tropicalize chocolate. The approaches most widely
used can be
divided two main groups: 1) incorporation of high-melting point fats; and 2)
creation of a three-
dimensional matrix or network of sugar crystals or protein particles that will
act as a sponge
and hold the fat ¨ thus maintaining the structure of the product even on
melting of the fat. Over
the last century many different methods have been reported.
There are two major drawbacks to the use of high-melting fats in chocolate.
Namely that food
regulations in many countries restrict the use of substitutes for cocoa butter
in chocolate.
Secondly, the high-melting point fats in chocolate-like products give an
unpleasant waxy
mouthfeel.
Many methods have been described for causing accretion of sugar crystals by
adding water
or a polyol to chocolate, as originally disclosed in DE 389127. CH 409603
describes the direct
incorporation of water into liquid chocolate mass during production causing a
rapid increase in
viscosity. As a result, it is impossible to pour the material into moulds or
use for enrobing.
EP0189469 describes the mixing of a liquid polyol with tempered conventional
chocolate mass
before depositing it into molds. Polyols that are liquid at ambient
temperatures (such as
glycerol) are preferred, though the patent teaches that higher melting polyols
(such as sorbitol)
can also be used. The mixture is held at slightly elevated temperatures (24 C
to 35 C) for a
short period of time during which the viscosity rises. This is stated to be
the result of a chemical
reaction between the fat and the polyol. The time and temperature of the
holding period are
critical parameters that control the viscosity increase ¨ the viscosity must
remain low enough
for the subsequent molding or enrobing operations.
In the method described by US5,445,843 a polyol (such as glycerol) is
encapsulated by
emulsifying it with a liquid fat (such as molten cocoa butter) and lecithin as
an emulsifier, then
spray-chilling the emulsion. The emulsion "capsules" (which have an average
diameter 100
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microns) are added to liquid chocolate mass to achieve a polyol content of
from 0.2 to 5% by
weight. The product was reported to have remained liquid for several minutes.
The use of emulsification to avoid too rapid an incorporation of water into
the chocolate mass
is described in US4,446,166. An oil-in-water emulsion (typically 50% water,
50% fat) is
prepared with cocoa butter using lecithin as the emulsifier. The emulsion is
cooled and milled
to give partially or entirely solid particles that are then added to the
chocolate mass at levels
of between 2 and 10%. Once incorporated in the warmer liquid chocolate mass,
the emulsion
particles will melt, releasing the water droplets. A disadvantage of this
method is the need to
guarantee a homogeneous distribution of the emulsion particles before they
melt. Premature
release of water causes a sudden increase in viscosity that renders the
chocolate unsuitable
for molding or enrobing.
EP0297054 describes a method for homogeneously dispersing water by using an
aqueous
foam. The foam is stabilized with an edible foaming agent (such as egg
albumin) and added
to conventionally prepared chocolate mass after tempering. The foam is added
at levels that
deliver from 0.5 to 2% of water, reportedly with no noticeable increase in
viscosity to provide a
treated chocolate usable for molding or enrobing. The trapped gases can be
removed from
the still liquid product by exposing it to reduced pressure. EP0407347
describes a similar
method.
EP0393327 discloses another variation in which the aqueous phase of the water-
in-oil
emulsion contains sugars (such as sucrose or glucose) or polyols (such as
sorbitol). The
emulsion is prepared with 30 to 60% fat using emulsifying agent at a level of
0.1 to 3%.
Described suitable emulsifying agents are lecithin, glycerol fatty acid ester,
polyglycerol fatty
acid ester, polyglycerol condensed ricinoleic acid ester and sucrose fatty
acid ester that has
an HLB not more than 7. The level of sugar or polyol in the aqueous phase of
the emulsion
can be between 20 and 60% and the level of water between 15 and 25%. The sugar
or polyol
in the aqueous phase is reported to provide smoother texture to the heat-
stable chocolate
mass. A storage period of about 20 days, however, is required for proper
development of
internal structure.
A similar method is disclosed in EP0442324, whereby an oil-in-water emulsion
is prepared by
mixing 30-80% of an oil or fat (for example, cocoa butter) in water containing
a small amount
of a suitable emulsifier. This emulsion is mixed at a level of about 5% with a
conventionally
manufactured and tempered chocolate mass that is then molded. It is stated to
be important
to control the temperature to be no higher than 90 F to keep the oil-in-water
emulsion stable.
The homogeneously dispersed water generates a viscosity increase of the
chocolate mass
during solidification of the finished product. However, it is still necessary
to store the molded
product for several days to establish heat stability.
US5,486,376 describes the use of water-in-oil microemulsions to introduce
finely dispersed
water into chocolate mass. Similarly, US6,159,526 describes addition of water
to the chocolate
as a water-in-oil emulsion stabilized by sucrose fatty acid esters (H LB <3).
US 6,159,526 is
concerned primarily with adding water-based flavors to chocolate.
WO 93/06737 describes methods for making gels/pastes by adding water to
"Raftiline" (inulin),
starches (potato and corn), "Splendid" (pectin), or Gum Arabic. The paste is
then mixed into
tempered chocolate that is molded.
US5,468,509 describes a method for adding up to 16% water to chocolate. The
chocolate
supposedly remains moldable. Two mixtures are prepared. (1) Cocoa is coated
with cocoa
butter in the presence of an emulsifier and (2) water, a sweetener and milk
solids are blended
to form an aqueous phase. The two are gently blended and the product molded.
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US5,965,179 aims to circumvent the problems of viscosity increase on the
addition of water to
chocolate by use of an extruder for processing the chocolate. The water is
added as an
aqueous gel with microcrystalline cellulose. This gel is injected into the
chocolate using a twin-
screw extruder so as to form a viscous product containing 3 to 20% of added
water.
US2005/0118327 describes the preparation of gel beads comprising 20-50% sugar
or polyol,
water, emulsifying agent and a gelling agent (hydrocolloids). The gel beads
are formed by
dispersing a hot aqueous sol (90 C-95 C) in a liquid fat in a high shear
mixer, to form an
emulsion, and then cooling to get gelification of the beads. The gel beads
dispersed in fat are
blended into molten chocolate mass. One drawback is that the release of the
sugar/polyol
syrup from the gel beads, requires activation. US2005/0118327 teaches the
activation of gel
bead degradation by freezing at temperatures of -5 C to -15 C. It is reported
that without this
cooling it is necessary to store the products for 10-14 days to develop shape
retention
properties.
In another approach, W091/19424 describes the preparation of gel beads
comprising alginate
or pectate, divalent metal ions and a sequestrant for the metal ions. The gel
beads are used
as fat substitutes.
EP0688506 describes the preparation of gels comprising polyol or polyol/water
with gelling
agents and alkali or alkali-earth metal salts. The gels are produced by
heating to temperatures
of 120 C and are then frozen in liquid nitrogen, before addition to liquid
chocolate. These prior
art references have drawbacks such as the release of water into the chocolate
mass, which
occurs early in the process and is not retarded for long enough for the
material to be used for
typical enrobing processes; the dispersion and release of water is not under
sufficiently fine
control to avoid development of unpleasantly gritty textures in the final
product; and/or
activation or an inconveniently long storage time is required for full
development of the
structures required to provide stability.
EP0393327 discloses making an emulsion out of a saccharide and an emulsifying
agent and
then maturing the chocolate. US5486376 discloses making an emulsion out of
monglyceride
(50-65%)/lecithin(0-10%)/chocolate fat (CBE/CBR/CB) (15-20%) and water (15-
20%).
W02011010105 relates to adding water and propylene glycol to molten chocolate.
US4446166
uses water in fat emulsion, where 20% of fat is in solid form.
Many of the processes are complex, or require additional steps in the
production procedure,
and/or require the use of emulsifiers and/or gelling agents.
The associated need to provide a tropicalizing agent that delays any
substantial increase in
viscosity so that the materials can be used for conventional moulding or
enrobing processes
and that provides a suitable texture and stability, or integrity, in a
chocolate product, has been
partially addressed by the tropicalizing agent and methods disclosed in the
international patent
publication W02013/045523.
However, this prior art method displays disadvantages in the time period
required for
maturation prior to the commercial release of the product, i.e., the product
must be stored
under certain conditions to ensure that the tropicalizing agent is able to act
effectively.
Additionally, the product requires the addition of additional fibrous
materials, which may
adversely impact organoleptic properties further.
Accordingly, the present invention is envisaged with the focus of solving the
above technical
problems.
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Summary of the invention
The inventors have developed a further improved route to introduce a humectant
into chocolate
or an analogue thereof to obtain a heat resistant (tropicalized) chocolate or
analogue thereof,
which displays improvements in respect of heat resistance without maturation
and adversely
impacting other properties of the chocolate.
According to one aspect of the invention, there is provided a tropicalizing
agent composition
comprising a fat component, a cocoa solids component and a humectant, wherein
the
composition comprises between Owt% and 60wt% of the cocoa solids component
based on
the weight of the composition.
In another aspect, the invention provides a process for preparing a
tropicalizing agent
composition according to the present invention comprising steps of (a) mixing
the cocoa solids
with the fat component, preferably at a temperature that the fat component is
liquid, (b)
optionally cooling the mixture, (c) adding the humectant to the mixture,
optionally at an elevated
temperature and (d) mixing the components..
In another aspect the invention encompasses the use of the tropicalizing agent
composition
according to the present invention for improving the heat stability of a
chocolate or chocolate
analogue product.
According to another aspect of the present invention, there is provided
chocolate or chocolate
analogue product comprising a tropicalizing agent composition according to the
present
invention.
In another aspect, the present invention provides a process for tropicalizing
chocolate, or an
analogue thereof, by combining a chocolate or a chocolate analogue mass,
optionally a
tempered chocolate mass or untempered chocolate analogue mass, with a
tropicalizing agent
composition according to the present invention so as to increase the structure
of the
tropicalized chocolate mass. Preferably, the amount of tropicalizing agent
composition is
sufficient to increase the shape retention of the tropicalized chocolate mass
compared to a
non-tropicalized mass.
Detailed description of the invention
Definitions
According to the present invention, the terms "chocolate product" and
"chocolate analogue
product" identify respectively chocolate or chocolate analogue based products
(also
conventionally known as "compound"). Chocolate and chocolate analogue products
of the
invention include but are not limited to: a chocolate product, a chocolate
analogue product (e.g.
comprising cocoa butter replacers, cocoa-butter equivalents or cocoa-butter
substitutes), a
chocolate coated product, a chocolate analogue coated product, a chocolate
coating for
biscuits, wafers or other confectionery items, a chocolate analogue coating
for biscuits, wafers
or other confectionery items and the like.
The term 'chocolate' as used herein denotes any product (and/or component
thereof if it would be
a product) that meets a legal definition of chocolate in any jurisdiction and
also include product
(and/or component thereof) in which all or part of the cocoa butter (CB) is
replaced by cocoa butter
equivalents (CBE) and/or cocoa butter replacers (CBR).
The term 'chocolate compound' as used herein (unless the context clearly
indicates otherwise)
denote chocolate-like 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.
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The term 'chocolate product' as used herein denote chocolate, compound and
other related
materials that comprise cocoa butter (CB), cocoa butter equivalents (CBE),
cocoa butter replacers
(CBR) and/or cocoa butter substitutes (CBS). Thus, chocolate product includes
products that are
based on chocolate and/or chocolate analogues, and thus for example may be
based on dark, milk
or white chocolate.
In an embodiment, the chocolate product, of the present invention comprises
cocoa butter (or
equivalent as described above) by weight of the confectionery material in at
least 5.0% by
weight, preferably at least 10.0% by weight, preferably at least 13.0% by
weight, more
preferably at least 15.0% by weight, for example at least 17.0% or at least
20%.
The preferred maximum amount of cocoa butter (or equivalent as described
above) present in
the chocolate product of the present invention is less than 35.0% by weight,
preferably not more
than 30.0% by weight, more preferably not more than 30.0% by weight, and most
preferably
not more than 25.0% cocoa butter by weight of the chocolate product. For
example, between
10.0wt% and 35.0wt% of the chocolate product.
In an embodiment, the chocolate product comprises between 0% and 95% by weight
of the
confectionery product of cocoa mass dependent on the end product, preferably
between 0%
and 85%, for example, between 45% and 80%, less than 5% or between 8% and 12%
by
weight of the chocolate product of cocoa mass.
Generally, the chocolate product of the present invention comprises at least
10.0% by weight,
preferably at least 13.0% by weight, more preferably at least 15.0% by weight,
and even more
preferably at least 17.0% cocoa mass by weight of the chocolate product.
The preferred maximum amount of cocoa mass present in the chocolate product of
the present
invention is less than 35.0% by weight, preferably not more than 30.0% by
weight, by weight,
and most preferably not more than 25.0% cocoa mass by weight. For example,
between
10.0wt% and 35.0wt% of the chocolate product.
If the chocolate product is a white chocolate product, the amount of cocoa
mass is lower than
that above, preferably not present.
In an embodiment of the present invention, the chocolate product comprises a
milk-based
component, preferably the milk-based component is selected from the group
consisting of non-
fat milk solids, milk powder (optionally full cream, skimmed or semi-skimmed)
and milk fat and
combinations thereof. This milk-based component may be present between Owt%
and 60wt%,
optionally between 10wt% and 50wt% of the chocolate product.
In an embodiment of the present invention, the chocolate product comprises a
sugar,
preferably in an amount of between 1 Owt% and 60wt% of the chocolate product.
A chocolate product of the present invention may include between:
5.0wt% and 35.0wt% cocoa butter,
10.wt% and 35.0wt% cocoa mass,
10wt% and 60wt% sugar,
Owt% and 60wt% milk-based component,
1.0wt% and 20%wt% of the tropicalizing agent composition.
In a preferred embodiment of the present invention, the cocoa butter, cocoa
mass, sugar and
milk-based component mentioned above provide between 75wtcY0 and 99.9wtcY0 of
the
chocolate product composition, preferably between 80wt% and 98wt% and
preferably between
90wt% and 95wt%.
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In a preferred embodiment, any cocoa butter and/or cocoa solids present in the
tropicalizing
agent composition contribute to the above-mentioned percentages of cocoa
butter and cocoa
mass, i.e. are not present in addition.
The chocolate or chocolate analogue product may be in form of a moulded
tablet, a moulded
bar, an aerated product, or a coating for confectionery products, wafer,
biscuits, among others.
It may also have inclusions, chocolate layers, chocolate nuggets, chocolate
pieces, chocolate
drops. The chocolate or chocolate analogue product may further contain crispy
inclusions e.g.
cereals, like expanded or toasted rice or dried fruit pieces.
The terms "tropicalization", "tropicalizing methods", and variations thereof
as used herein, refer
to methods and processes of the invention to achieve heat and shape resistance
in chocolate
or chocolate analogue products.
The term "tropicalized products", and variations thereof as used herein,
refers to chocolate and
chocolate analogue products of the invention which are endowed with heat and
shape
resistance.
The term "tropicalizing agent composition" as used herein, generally refers to
suitable
materials according to the invention. In particular, it refers to a
composition that increases the
stability, or structural integrity, in a tropicalized food product into which
it is incorporated. In a
preferred embodiment, the tropicalizing agent composition is not chocolate or
a chocolate
product.
The D90 value is a common method of describing a particle size distribution.
The D90 is the
diameter where 90% of the mass of the particles in the sample have a diameter
below that
value. In the context of the present invention, the D90 by mass is equivalent
to the D90 by
volume. The D90 value may be measured for example by a laser light scattering
particle size
analyser. A preferred method is given in the examples section.
Preferred Embodiments
As it will be apparent to the person skilled in the art, all embodiments and
preferred
embodiments here below described apply also to the different aspects of the
invention mutatis
mutandis and may all be combined between each other.
The present invention provides tropicalizing agent composition comprising a
fat component, a
cocoa solids component and a humectant, wherein the composition comprises
between 10wt%
and 60wt% of the cocoa solids component based on the weight of the
composition.
In a preferred embodiment, the cocoa solids are present in an amount of
preferably between
15wt% and 55wt% based on the weight of the composition, preferably between
20wt% and
45wt%, preferably between 25wt% and 40wt% and preferably between 30wt% and
40wt%.
In the present invention the term cocoa solids has the standard meaning in the
art, i.e. the
components of the cocoa beans remaining after the cocoa butter fat component
has been
removed. Cocoa liquor is pure cocoa mass, preferably in solid or semi-solid
form, which
contains both cocoa solids and cocoa butter. In a preferred embodiment, the
cocoa liquor
comprises between 40wt% and 60wt% cocoa solids and between 40wt% and 60wt%
cocoa
butter, preferably between 45wt% and 55wt% cocoa solids and between 45wt% and
50wt%
cocoa butter
In a preferred embodiment of the invention, the humectant is present in an
amount of between
2.5wt% and 40wt% based on the weight of the composition, preferably between
4.5wt% and
30wt%, preferably between 6.5wt% and 25wt%, preferably between 8.0wt% and
20wt% and
preferably between 10wt% and 18wt%. The above amounts relate to the total
amount of
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humectant present, i.e. if there is a mixture of humectants the total combined
weight is within
the above ranges.
Suitable humectants according to the present invention are food grade
humectants liquids.
Examples of humectants according to the invention include propylene glycol,
polyethylene
glycol, polyols such as glycerol and sugar alcohols such as sorbitol, xylitol,
maltitol, mannitol,
sugar solution such as fructose, dextrose, galactose, or any mixture thereof.
In some highly preferred embodiments, the humectant is a polyol. A preferred
polyol is glycerol.
However other polyols are envisaged such as sugar alcohols, e.g. sorbitol,
xylitol, erythitol,
maltitol, mannitol. According to certain embodiments, the polyol is selected
from glycerol,
sorbitol, xylitol or any mixture thereof. According to other embodiments, the
humectant liquid
is propylene glycol. According to some embodiments, the humectant is a mixture
of a polyol,
such as glycerol, together with another humectant liquid, such as another
polyol and/or
propylene glycol.
In a preferred embodiment, the humectant is a polyol and is present in an
amount of between
2.5wt% and 40wt% based on the weight of the composition, preferably the
humectant
comprises glycerol and the humectant is present in an amount of between 4.5wt%
and 30wt%.
According to one embodiment of the invention, water and liquid humectant may
be used in a
mixture ratio. According to one embodiment the tropicalizing agent composition
comprises
water and a humectant liquid in a water: humectant ratio of from 1:10 to 10:1
w/w, preferably in
a water:humectant ratio from 1:2 to 2:1 w/w, for instance in a water:
humectant ratio of about
1:1. According to one embodiment the tropicalizing agent composition comprises
water and a
polyol in a water:polyol ratio of from 1:10 to 10:1 w/w, preferably in a
water:polyol ratio from
1:2 to 2:1 w/w, for instance in a water:polyol ratio of about 1:1.
In a preferred embodiment of the invention, the fat component is present in an
amount of
between 20wt% and 80wt% based on the weight of the composition, preferably
between
25wt% and 75wt%, preferably between 30wt% and 70wt%, preferably between 35wt%
and
65wt% and preferably between 40wt% and 60wt%. The above amounts relate to the
total
amount of fat present, i.e. if there is a mixture of fats the total combined
weight is within the
above ranges.
The liquid fat component can be any vegetable fat or oil suitable for use in
edible foods. The
fat component should be compatible with the chocolate or chocolate analogue to
which it will
be added. Suitable fats include cocoa butter, cocoa butter equivalents (CBE),
cocoa butter
substitutes (CBS), vegetable oils and butter oils amongst others. Suitable CBE
and CBS are
widely commercially available. Examples of CBE include CoberineTM (Loders
Croklaan), and
lllexaoTM SC70 (AarhusKarlshamn). Examples of CBS include the PalkenaTM Range
and
MelanoTM Range (Fuji Oil).
Preferably, the liquid fat includes cocoa butter, particularly where the
tropicalizing agent or
tropicalizing agent composition will be used in chocolate products.
In one preferred
embodiment, the liquid fat is cocoa butter and tropicalizing agent
compositions are included in
regular chocolate, rather than chocolate analogues.
However, the liquid fat can include one or more cocoa butter substitutes,
particularly where the
tropicalizing agent or tropicalizing agent composition will be used in
chocolate analogues. In
another embodiment, the liquid fat preferably includes one or more vegetable
fats, e.g., non-
lauric vegetable fats. Where the tropicalizing agent or tropicalizing agent
composition will be
used in a chocolate analogue, the vegetable fat is preferably the same fat or
at least one of
the same fats, used in preparing the chocolate analogue mass so as to increase
the
compatibility and stability of the tropicalized chocolate mass.
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In a preferred embodiment of the invention, the fat component is selected from
the group
consisting of cocoa butter, cocoa butter equivalents (CBE), cocoa butter
substitutes (CBS),
vegetable oils and butter oils or any mixture thereof.
In one preferred embodiment the liquid fat is cocoa butter. The use of cocoa
butter as the
liquid fat component of the tropicalizing agent is particularly preferred for
the preparation of a
chocolate product, whereby food regulations in many countries restrict or
forbid the addition of
other fats to chocolate mass. In another preferred embodiment, the liquid fat
includes one or
more vegetable fats that are the same as a fat used in preparing a chocolate
analogue mass,
e.g. for a chocolate compound or compound coating product, so as to increase
the
compatibility and stability of the tropicalized chocolate analogue mass.
In a preferred embodiment, the tropicalizing agent composition comprises
between:
10wt% and 60wt% of the cocoa solids,
20wt% and 80wt% of the fat component, and
2.5wt% and 40wt% of the humectant.
In a preferred embodiment, the three components mentioned above provide
between 75wt%
and 100wt% of the tropicalizing agent composition, preferably between 80wt%
and 100wt%
and preferably between 90wt% and 100wt%.
In a preferred embodiment, the weight ratio of cocoa solids to humectant is
between 0.25:1
and 24:1, preferably between 0.5:1 and 20:1, preferably between 1:1 and 15:1
and preferably
between 1.5:1 and 10:1.
In a preferred embodiment, the weight ratio of cocoa solids to fat component
is between 0.4:1
and 2.4:1, preferably between 0.45:1 and 2.0:1, preferably between 0.5:1 and
1.5:1 and
preferably between 0.55:1 and 1.0:1.
In a preferred embodiment, the weight ratio of cocoa solids to humectant is
between 0.5:1 and
20:1 and the weight ratio of cocoa solids to fat component is between 0.45:1
and 2.0:1.
In a preferred embodiment, the tropicalizing agent composition comprises
between:
10wt% and 60wt% of the cocoa solids,
20wt% and 80wt% of the fat component, and
2.5wt% and 40wt% of the humectant, the weight ratio of cocoa solids to
humectant is
between 0.5:1 and 20:1 and the weight ratio of cocoa solids to fat component
is between 0.45:1
and 2.0:1 and three components mentioned above provide between 75wt% and
100wt% of the
tropicalizing agent composition.
Advantageously the tropicalizing agent composition of the present invention
can be prepared
from the above-described food ingredients and does not require the use of any
emulsifying
agent, gelling agent, nor other additive.
In a preferred embodiment, the tropicalizing agent is in the form of an
emulsion, preferably with
emulsion droplet sizes D90 of between 20 and 100 microns, preferably between
25 and 80
microns, preferably between 30 and 60 microns. As shown in the examples, these
ranges
provide advantageous properties in respect of heat resistance. The method set
out in the
examples may be used to measure this particle size.
The present invention provides a process for preparing a tropicalizing agent
composition
comprising steps of (a) mixing the cocoa solids with the fat component,
preferably at a
temperature that the fat component is liquid, (b) optionally cooling the
mixture, (c) adding the
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humectant to the mixture, optionally at an elevated temperature and (d) mixing
the
components.
In an embodiment of the process, the temperature of step (a) is greater than
40 degrees
Celsius, preferably greater than 45 degrees Celsius, preferably greater than
50 degrees
Celsius, and preferably greater than 55 degrees Celsius. In an embodiment, the
temperature
is less than 75 degrees Celsius, preferably less than 70 degrees Celsius, and
preferably less
than 65 degrees Celsius. For instance, where the fat component is cocoa butter
a temperature
of 40 C or above, such as around 50 C may be preferred. VVhere a fat
component, such as an
oil, which is liquid at room temperature, is used then the preparation of the
tropicalizing agent
can be carried out at room temperature, i.e. without any heating.
In an embodiment, the cooling in step (b) is to a temperature of between 45
and 65 degrees
Celsius. In a preferred embodiment, the elevated temperature in step (d) is
within the same
ranges as the temperature specified above for step (a).
In an embodiment of the process, the cocoa solids and at least a portion of
the fat component
are added in step (a) in the form of cocoa liquor. In a preferred embodiment,
the portion of the
fat in the form of cocoa liquor is between 25wt% and 90wt%, preferably between
45wt% and
80wt% relative to the total amount of fat added.
In an embodiment of the process, the cocoa liquor has a particle size D90 of
between 10
microns and 40 microns, preferably between 15 and 30 microns. The method set
out in the
examples may be used to measure this particle size.
An emulsion of the humectant component in fat component can be carried out by
simple mixing
of the components with agitation, for instance in conventional mixing/blending
apparatus.
Optionally an emulsifying agent may be added in order to facilitate emulsion
formation. The
emulsifier component can be any suitable emulsifier. Preferably, the
emulsifier component
includes lecithin, e.g. soy lecithin. The emulsifier, when used, is typically
present in the
tropicalizing agent composition in an amount from about 0.001 to 2 weight
percent, preferably
from about 0.10 to 1 weight percent, for example 0.10 to 0.5 weight percent
based on the total
weight of the tropicalizing agent composition.
Preferably, the prepared tropicalizing agent composition can be maintained
molten for later
addition to a liquid chocolate mass. Alternatively, the tropicalizing agent
composition can be
allowed to cool and solidify for storage and distribution, and can be re-
melted for addition to
liquid chocolate, or can be particulated or flaked for 'dry' addition to
liquid chocolate, upon
which the fat melts and the particles disperse.
Advantageously the tropicalizing agent composition is suitable for use in
chocolate, whereby
food regulations in many countries restrict or forbid the addition of
artificial additives to
chocolate.
Advantageously, the tropicalizing agent composition may be added to a
chocolate mass (or
chocolate analogue mass) without inducing any significant increase in
viscosity of the liquid
chocolate mass over time, such that the chocolate mass can be worked and
moulded, or used
for enrobing, in conventional industrial production processes, whilst at the
same time providing
a chocolate product that exhibits improved shape stability at elevated
temperatures above
room temperature, e.g. at temperatures up to 40 C, and even at higher
temperatures. By
"significant increase" it is meant a viscosity increase that would prohibit a
conventional
moulding or enrobing process. Preferably, the viscosity increase is less than
about 20 percent,
more preferably less than about 10 percent. The chocolate product is dry to
the touch and
does not stick to its wrapper, or adopt the shape of the wrapper, even when
exposed to
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temperatures above the melting range of the fat composition. Advantageously
good texture
and organoleptic properties of regular chocolate are retained.
The tropicalizing agent composition of the invention can be added to liquid
chocolate either
before, after, or in combination with tempering of the chocolate. Increase in
viscosity of the
chocolate following addition of the agent is delayed to such a degree as to
permit the tempering
process (manually or by machine, thermally/mechanically or by addition of
seeding agent or
pre-crystallised chocolate mass) without making the chocolate subsequently
unworkable and
without blocking the tempering machine and its associated pipes and pumps.
In a preferred embodiment, the addition of the tropicalizing agent composition
must be added
subsequent to conching of the chocolate or chocolate analogue. The conche
combination of
sustained temperature and high shear destroys some of the internal structures
of the
tropicalizing agent composition so that it can no longer provide heat
stability.
The tropicalizing agent composition of the invention can be added to liquid
chocolate or
chocolate analogue and dispersed by agitation, either manual agitation and/or
with use of
standard conventional mixing apparatus. Advantageously the fat-based
tropicalizing agent or
composition is readily dispersed in a liquid chocolate or chocolate analogue
to provide a
substantially uniform and homogeneous dispersion of the food particles through
the liquid
chocolate mass.
Advantageously tropicalization of chocolate or chocolate analogues according
to the present
invention uses simple and cost effective processes, suitable for industrial
application, requiring
no harsh conditions or expensive machinery. Advantageously the tropicalizing
agent
composition of the present invention requires only few ingredient components,
and can be
prepared with commercially available food ingredients. No expensive additives
are required.
According to a preferred embodiment of the present invention, the humectant
may be used in
an amount of between 0.1 and 5% by weight within the chocolate or chocolate
analogue based
on weight of the final chocolate or chocolate analogue product, preferably
between 0.2wt%
and 4.5wt%, preferably between 0.35 wt% and 3.5wt%, preferably between 0.40wt%
and
2.5wt%, preferably between 0.45wt% and 2.0wrk, preferably between 0.5wt% and
1.0wt%.
According to a preferred embodiment of the present invention, the
tropicalizing agent
composition may be added in an amount of between 1.0 and 20% by weight within
the
chocolate or chocolate analogue. Preferably, they are used in an amount of
between 2.0wt%
and 15wt%, preferably between 2.5wt% and 17.5wV/0, preferably between 2.75wt%
and
15.0wt%, preferably between 3.0wt% and 12.0wt%, and more preferably between
3.0wt% and
10wt%
In one variant of the process, the dispersion of cocoa solids in a portion of
the liquid fat
component is blended with an emulsion of the humectant component in a second
portion of
the liquid oil component.
Addition of too much tropicalizing agent or composition, or of tropicalizing
agent or composition
which contains a too high proportion of water and/or humectant liquid
component to particulate
carrier component, can tend to cause too rapid an increase in viscosity,
particularly if multiple
of these factors are present, for the product to be suitable for moulding,
enrobing, or both.
Addition of too little tropicalizing agent or composition can cause a delay in
the time over which
the desired heat shape stability properties are developed, or even failure to
produce the
desired heat stability properties.
According to one embodiment, the fat content, e.g. cocoa butter content of the
starting
chocolate mass, to which the tropicalizing agent composition is to be added,
is reduced
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compared to the desired final fat content, by an amount such that the fat
content, e.g. cocoa
butter, of the tropicalizing agent or composition provides the remaining fat
amount, to produce
a final chocolate product having the desired fat content.
Advantageously, the resultant chocolate products including the tropicalizing
agent composition
of the invention do not stick to a wrapper, or adopt the shape of the wrapper,
at elevated
temperatures, even at temperatures as high as 40 C, do not result in adverse
appearance or
mouthfeel, and in chocolate or analogues thereof do not have adverse effects
on bloom.
Moreover, the tropicalized chocolates and chocolate analogues have improved
shape
retention at elevated temperature, even at temperatures as high as 40 C
compared to
corresponding regular chocolate or chocolate analogue product without the
tropicalizing agent.
The tropicalizing agent composition of the invention can be added to any type
of chocolate e.g.
white, milk, dark chocolate or any intermediate, or any type of chocolate
analogue e.g.
compound coating. The heat resistance can be expected to develop most
effectively in masses
containing a high proportion of sugar and milk particulate solids of fine
granulometry and
relatively low fat content due to the loading and proximity of the building
blocks of the particle
network.
The tropicalized chocolate and chocolate analogues of the invention can
advantageously be
used in tropical countries where hot weather causes frequent or rapid melting
of chocolate,
chocolate analogues. For example, chocolate analogues including coatings and
covertures,
which are thin and tend to melt rapidly, can surprisingly and advantageously
be formed with
the tropicalizing agent of the invention. The tropicalized food products of
the invention remain
non-sticky so as to smoothly slide out of a wrapper and to avoid leaving food
product on the
consumer's fingers during consumption.
The term "about," as used herein, should generally be understood to refer to
both numbers in
a range of numerals. Moreover, all numerical ranges herein should be
understood to include
each whole integer within the range and the end points of the range, unless
otherwise
specified.
All patent and non-patent references cited in the present application, are
hereby incorporated
by reference in their entirety.
The invention will now be described in further details in the following non-
limiting examples.
Examples
Reference Example 1:
A reference composition was prepared with a composition as follows and using a
3 roll refiner
and Lipp Mischtechnichnik GmbH conchee:
Ingredient wt
Sugar 46
Cocoa Butter 19
Cocoa Mass 14
Full Cream Milk Powder 11
Milk Skimmed Powder 10
Sunflower Lecithin 0.5
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Vanilla flavour 0.03
Examples
In order to prepare the tropicalizing agent composition cocoa liquor is heated
to 60 C and
cocoa butter is added until liquid and cooled to about 50 C. Glycerol warmed
to approx. 50 C
is added under high shear (in Hobart planetary whisk) and the mixture is mixed
for 3 minutes.
The agent is combined with liquid chocolate post-temper, unless specified.
The chocolate compositions are stored for one week at ambient conditions (20 C
and 50
percent humidity).
Heat shock measurement. Placed in stove at a set temperature for 1 hour.
Removed from
stove and hit against flat surface twelve times to cause loss of shape.
Reference always
present on tray. Data given is in pixels, gives area increase. The larger the
figure the less heat
stable the mixture created is
Unwrapping measurement. Placed in stove at set temperature for 1 hour. Visual
assessment
performed based on mass stuck to wrapper and loss of logo definition when
wrapped in
standard foil.
Particle size analysis. Carried out using a Malvern Mastersizer 3000E,
Fraunhoffer Theory,
Hydro SM attachment, AAK Akomed R MCT oil dispersant (RI 1.45). In the wet
system the
sample is placed in the MCT oil and sonicated for 2 minutes with an ultrasonic
probe before
being run in the Malvern 3000E (in duplicate).
Mould size is 25mm by 25mm squares with a depth of 7mm. The pixel area of the
standard
square is 26228 for initial testing (Examples 1&2). From the conching trials
onward (including
particle size variation and the shelf-life/composition DoE), the camera was
adjusted and a new
standard was taken at 22000 pixels (all other examples in patent).
Examples 1 and 2
The following components were mixed by weight: Cocoa Butter: 1 part; Cocoa
Liquor: 4 parts
(2 parts Cocoa Butter 2 parts cocoa solids); Glycerol: 1 part. Therefore: 17%
Glycerol, 50%
Fat, 33% Cocoa Solids using the above method.
This mixture is then added at 6% to a tempered chocolate mass made using the
above recipe
with reduced cocoa liquor and butter to have the only recipe change be 1%
glycerol addition.
A portion of the agent is matured in a 45 C hot room for 24 hours and a
chocolate product is
prepared as above. Reference Example 2 uses the same base chocolate but uses a
commercially available cocoa butter improver, Illexao Sal, a previously used
tropicalization
agent.
Heat shock tests were carried out for a range of temperatures and the pixel
measurements
shown below:
Temperature Reference Reference Example 1 - matured Example 2 -
unmatured
(0C) Example 1 Example 2 tropicalization agent
tropicalization agent
33 37248 27566 27565 27887
35 45044 42017 26888 27985
37 50358 55073 27626 30938
39 49724 52576 27548 28406
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Hence, the sample containing matured tropicalization agent performs slightly
better but there
is a significant benefit provided for added complexity of process.
Accordingly, the present
invention offers advantages over known methods where maturation is needed to
ensure an
acceptable product.
Examples 3 to 5
The following trials were carried out based on the above recipes with the
position of addition
of the tropicalizing agent of the present invention being changed.
Temperature Reference Example 3 Start of Example 4 - End of
Example 5 - At
( C) Example 1 conche conche Tempering
33 37248 27011 25845.67 23712
35 45044 36275.67 28861.33 24516
37 50358 45587.33 33634.33 30698.33
39 49724 48806.67 34455.33 30619
Changing point of addition of tropicalization mixture greatly effects heat
stability. Reference
and 'start of conche' have similar heat stability profiles, indicating that
the conche combination
of sustained temperature and high shear damage the integrity of the
tropicalizing agent and its
subsequent effect. The sample at the end of the conche has a similar profile
to the tropicalized
chocolate where the agent was added at tempering.
Examples 6 to 9
The above processes were repeated with the mixing and shear rates controlled
to provide
emulsions of different particle sizes. The particle sizes were measured using
the above
parameters and chocolates prepared and heat shock tested at 37 C.
Emulsion D90/
microns Area of sample
Reference 1 50358
Example 6 38.4 24904
Example 7 39.3 25895
Example 8 44.3 27079
Example 9 52.1 29365
As can be seen, if emulsion particle size is smaller, greater heat stability
will be achieved.
Example 10
A study was carried out to compare the impact of the amount of lecithin,
amount of glycerol
and maturation time since moulding using heat shock tests at 37 C. The wt% are
based on the
chocolate composition weight.
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Amount of Amount of 2 3 4 6
glycerol/wt% lecithin/wt% weeks weeks weeks weeks
0 29958 26902 27556 23594
0.25 34460 32721 29618 25553
0.5 37283 34899 29444 27198
0.75 40023 37500 33676 29932
0 1 38291 34067 34522 31561
0.25 22874 22270 22709 22190
0.5 23931 24430 22821 22752
0.75 27509 27688 24945 24128
0.5 1 28466 26992 27500 24855
0.25 22672 22428 22300 22373
0.5 24333 23043 23059 22600
0.75 23546 23144 22785 22609
1 1 26263 25458 24050 23221
The p value for the interaction between Lecithin and Week is 0.576, which
indicates the
relationship between Lecithin and Week does not depend on the value of
Lecithin and Week
(i.e. no interaction). The p value for the interaction between Lecithin and
Glycerol is 0.01, which
indicates the relationship between Lecithin and Glycerol does depend of the
value of Lecithin
and Glycerol (i.e. .an interaction). The p value for the interaction between
Week and Glycerol
is 0.00, which indicates the relationship between Week and Glycerol does
depend of the value
of Week and Glycerol (i.e. an interaction).
The above data shows that the agent of the present invention works without the
need for
prolonged temperature controlled maturation unlike a number of known methods.
The quality
of the product does improve with maturation but is not an essential feature to
obtain the desired
product.
Example 11
The composition of Example 2 was wrapped in metallized foil and found to be
easy to unwrap
and not lose logo definition when kept at the temperatures set out in the
above tables.
Reference Example 1 was found to melt and become difficult to unwrap.
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