Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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PROCESS FOR PREPARING AND FORMULATION FOR
AERATED BAKED FOOD PRODUCTS AND CHOCOLATE
PRODUCTS
[0001] This application claims priority to US provisional application
61/493,263,
filed June 3, 2011, the entire contents of which are hereby incorporated by
reference.
Field of the Invention
[0002] In one aspect the invention relates to a process for preparing an
aerated
chocolate food product employing a refined chocolate crumb blend and an
aeration
agent. In another aspect, the invention relates to methods for refining
chocolate liquor
into a refined crumb blend, and the use this refined crumb blend in producing
novel and
advantageous food products and ingredients. One advantageous product of the
invention is an aerated, chocolate meringue-type product made with chocolate
liquor
containing cocoa butter or fat. Unlike similar fat-containing products of this
type, the
products of the invention hold their shape and texture despite the relatively
high levels
of fat, and they can be baked and formed into a final chocolate product that
contains up
to 15% chocolate liquor, one of the requirements for standard of identity
chocolate
under US FDA requirements.
Relevance of the Invention and Description of Related Art
[0003] Food and confectionery products and ingredients with sufficient
levels of fat
or having a fat-continuous phase, such as chocolate, butter, margarine, peanut
butter,
chocolate spread and the like, are generally unaerated products. Aeration can
be
desirable for variety of purposes, including modifying texture, softness or
spreadability,
and changing the visual appearance of the product. When it is an aerated
product,
chocolate is usually aerated by using pressurized conditions and gas, for
example
carbon dioxide, which is mixed into a molten chocolate. The pressure is then
released
and the gas bubbles expand within the chocolate, forming an aerated product
when
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cooled. Alternatively, vacuum-dependent steps can be used in a similar manner,
also
introducing bubbles during a phase of production.
[0004] A well-known example of an aerated chocolate is the AeroTM bar. The
production method is complex, however, and requires one or more chilled or
frozen
depositions and setting periods. Similarly, the firm-textured VolcanoTM
chocolate
product requires pressurized production steps.
[0005] Aerating using whipping agents is an alternative to pressurization.
In its
simplest form, a traditional chocolate mousse is prepared by melting chocolate
and
folding it into whipped egg whites. No pressurization steps or equipment are
required.
One can include low levels of fat, in the form of butter, cream or egg yolks.
However,
the chocolate mousse must be kept cooled to maintain its form. Heating or
baking
causes the mousse to collapse and lose its shape. Generally, however, the
water-
continuous products, such as mousse or ice cream, are much easier to aerate
than fat-
continuous food products by simply whipping in the presence of an emulsifier,
although
they require storage and serving at low temperatures.
[0006] Cocoa ingredients containing significant levels of cocoa butter
present real
problems in producing a stable aerated product that does not require
refrigeration.
Chocolate liquor is generally a low-melting solid that contains approximately
53-56% by
weight cocoa butter (fat). The high levels of fat make it difficult or
impossible to use in
most food production techniques, and that is especially the case when
considering
aerated products. Another consequence of the fat levels in chocolate liquor is
its
inability to be easily dispersed in water formulations. This effectively
prohibits its use in
dry mixes and other products where water is a major component. Furthermore,
and
also because of the fat content, producing a powder-like form of chocolate
liquor that
can be easily used as an ingredient for food products is difficult. Cocoa
powder, which
is pressed from chocolate liquor in a process that removes most of the cocoa
butter, is
thus the form of cocoa used in chocolate food products and particularly in
aerated
products.
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[0007] There are significant taste differences between chocolate liquor and
cocoa
powder, however, and most consumers prefer the taste profile of a chocolate-
liquor
based product as compared to cocoa powder. Thus, if products and ingredients
were
available that utilized chocolate liquor as an ingredient for an aerated
product, these
product would have an advantageous taste profile compared to others using only
cocoa
powder.
[0008] As described more fully below, the invention here involves in one
aspect the
production of a refined crumb blend of chocolate liquor. This refined crumb
blend can
be advantageously used in a number of food production processes, including
processes
to produce an aerated, baked chocolate meringue.
Brief Summary of the Invention
[0009] The object of the invention, in one aspect, is a method of
manufacturing a
fat- containing, yet light, aerated, and crispy meringue-type confection. The
final
product can contain concentrated levels of fat-containing ingredients, such as
a milk
powder or chocolate liquor. A fat-containing, baked meringue-type product is
not
currently available and the manufacture of such a product has been hampered by
the
inability to maintain a foam matrix in the presence of high levels of fat. As
one of
ordinary skill in the art understands, using high levels of fat or certain fat-
containing
ingredients, or even directly adding a fat, especially liquid fats and oils,
causes an
eventual if not immediate collapse of the foam matrix.
[0010] In contrast to the invention, the typical baked meringue products,
such as
cookies, are made with high levels of sugar and whipped egg whites and contain
very
little to no fat content. The present invention teaches a method that allows
addition of
fat and fat-containing ingredients to the recipe by applying a modification of
a refining
procedure similar to that used in chocolate making. The refining method
produces a
refined powder, or crumb blend, with a desired particle size range. In
addition, an
improved foam matrix to that of egg albumen alone can be formulated to help
maintain
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aeration once the refined powder is added. Application of the invention allows
for the
production of products that have excellent flavor and a crisp texture.
Advantageously,
under U.S. FDA guidelines or other guidelines for the SOI of chocolate,
properly
formulated aerated products of the invention can still be labeled as ,
"reduced fat
chocolate", "reduced fat milk chocolate", or "made with chocolate" as
examples. Other
options, not tied to a specific SOI labeling, are also possible.
[0011] In a particular aspect, the invention includes methods for producing
a baked
chocolate meringue food product, which can be a final product or an ingredient
in a food
product. In general, the methods encompasses the following steps: a) providing
a
cocoa product blend comprising chocolate liquor and cocoa powder and refining
the
blend by high pressure and low temperature rolling to an average particle size
of about
25 to about 50 microns, which produces a refined crumb blend having 15-30%
total fat
content by weight; b) mixing water and one or more suitable aeration agents,
and
mixing in a separate container from the blend; c) adding a sugar to the
mixture of b); d)
optionally adding vanilla to the mixture of c); e) then finally whipping the
mixture of b) -
d) into a stable foam matrix, where a stable foam matrix does not lose its
shape at room
temperature and prior to subsequent baking of deposited forms of the matrix.
Then, the
refined crumb blend of a) is mixed in the stable foam matrix. Optionally,
additional
coloring agents, texture, and/or flavor agents can be added. The resulting
product is
baked into a solid, stable meringue product. In preferred embodiments, the
total fat
content of the refined crumb blend is between 26-28%, or less than 30%.
[0012] The methods can use cocoa products in the refined crumb blend that
consist of 50% chocolate liquor by weight and 50% cocoa powder by weight. A
sugar
can also be added to the blend comprising chocolate liquor and cocoa powder to
make
the refined crumb blend. One or more of several sugars can be used, and
sucrose and
inulin are preferred.
[0013] The preferred aeration agent is a dairy-based albumin replacer. Any
aeration agent can be combined with a stabilizing hydrocolloid (gum Arabic is
preferred)
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in mixing to form the foam matrix. One or more egg white proteins can be used
as the
aeration agent, and, as noted, in combination with gum Arabic. Similarly, egg
white
albumin can be used. The methods of the invention can specifically exclude the
use of
pressurized containers to produce an aerated product, or specifically exclude
the use of
pressurized gas or CO2 to produce an aerated product.
[0014] The final baked product or ingredient can be a chocolate meringue-
type
product comprising approximately 15% chocolate liquor, approximately 0.01%
moisture,
one or more aeration agents, approximately 50% of one or more sugars, and
cocoa
powder. This final baked product can hold a stable form once it is deposited
for baking
and substantially retain that form through baking. This is in direct contrast
to other,
similar products, where the temperature of baking leads to a loss of shape or
form. As
noted from the methods described above, the baked chocolate can include
vanilla, gum
Arabic or other suitable hydrocolloid, soluble carbohydrates such as sucrose,
or other
sugars or combinations of sugars. In addition, ingredients such as sugar
alcohols,
inulin, or polydextrose can be used in place of sugar to contribute to calorie
and sugar
reduction. Thus, the invention also includes a baked, aerated chocolate- or
cocoa-
containing meringue-type product produced by any of the methods described
here.
[0015] Throughout this disclosure, applicants refer to journal articles,
patent
documents, published references, web pages, and other sources of information.
One
skilled in the art can use the entire contents of any of the cited sources of
information to
make and use aspects of this invention. Each and every cited source of
information is
specifically incorporated herein by reference in its entirety. Portions of
these sources
may be included in this document as allowed or required. However, the meaning
of any
term or phrase specifically defined or explained in this disclosure shall not
be modified
by the content of any of the sources. The description and examples that follow
are
merely exemplary of the scope of this invention and content of this disclosure
and do
not limit the scope of the invention. In fact, one skilled in the art can
devise and
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construct numerous modifications to the examples listed below without
departing from
the scope of this invention.
Brief Description of the Drawings
[0016] Preferred aspects, objects, and embodiments of the invention are
schematically represented in the exemplary drawings and flow charts, which in
no way
should be taken as a limitation on the scope or extent of the invention.
[0017] Figure 1 depicts a flow diagram showing an exemplary method for
producing an aerated baked food product of the invention
[0018] Figure 2 shows a graph of the antioxidant levels of baked as
compared to
pre-baked samples as measured by Folin-Ciocalteu assay of total polyphenols
(TPP
Values) known in the art. Samples A and B are prepared with alkalized cocoa
powder
in the refined crumb, resulting in lower TPP levels. Sample C contains natural
cocoa
powder that has not been alkali treated. In all samples, the levels of TPP
remain similar
in pre- and post-bale samples.
[0019] Figure 3 shows a graph of the antioxidant levels similar to those
shown for
the same Samples A, B, and C of Figure 2, but the assay for antioxidants is
the Oxygen
radical absorbance capacity (ORAC) assay known in the art.
Detailed Description of Exemplary Embodiments
[0020] In one aspect the invention encompasses a method that incorporates a
fat-
containing blend of ingredients that has been refined to a specific particle
size (about
20-55 micron average particle size) and fat content (15-30% by weight).
Specifically,
the fat-containing component is mixed with non-fat or low-fat solids
ingredients, such as
sugar, inulin, cocoa powder, or similar products, or other products consistent
with a
baking step, and then refined to produce a fine powder that can be slowly
added to a
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whipped, aerated foam matrix. The methods do not require pressurization,
vacuum
treatment, pressurized gas, or other complicated equipment and thus, the
method can
specifically exclude each of or any one of a pressurizing step, a vacuum step,
and a
pressurized gas introduction step. The fat content of the pre-refined mixture
or blend
should range between 15-30% and is optimally between about 26% and about 28%
fat.
Lower fat levels of this range are used (fore example 12% to about 15%),
however, if
the final product composition is a low fat product (from about 12% to about
16%).
[0021] Refining parameters, such as gap and roll temperatures, can be
manipulated to optimize the refined component. For example, a roll pressure of
above
15 psi, or approximately 18 psi, can be used, and a roll temperature of below
20
degrees C, or about 18 degrees C, can be used with these pressures. These are
higher
pressures and lower temperatures than for typical refining of chocolate. The
resulting
refined blend can comprise between 30-50% of the final product, which can be a
stable,
baked aerated product.
[0022] In addition and in another aspect, the invention employs an improved
foam
layer that allows a more stable matrix, a matrix that accepts the refined fat-
containing
materials without collapsing. Specifically, and in one example, the egg white
foaming
agent (or aeration agent) has been replaced with a more stable substitute
composed of
gum arabic and a dairy protein. Other combinations of hydrocolloid and protein
ingredients may be also be used as an egg white substitute. A preferred
example is the
Hyfoama product (Kerry, Beloit, WI) and similar dairy-based or vegetable-based
replacers of egg albumin. These ingredients can be resistant to heat and more
stable to
whipping procedures. Gum arabic, such as Instant Gum AA (Colloides NatureIs
International) can be used as a hydrocolloid, among others available.
[0023] In a general example of the method to produce a baked, chocolate
meringue-type product with a final fat content ranging from 7.5% to 16%, or
more
particularly between about 12% and about 16%, the non-fat components can first
be
batched by blending water, foaming protein (hydrolyzed whey dairy protein or
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alternative), and part of the sugar used. Separately, the remaining sugar is
dry blended
with a stabilizer. The foam and stabilizer blends are mixed, flavor is
optionally added,
followed by slow addition of the refined "fat-blend" (or crumb blend) so that
aeration is
preserved and maximized. This mixture is deposited on a bakery tray or similar
flat
surface and baked. Baking conditions can be 225 F for 120 minutes. The product
is
then cooled and stored in air-tight containers or packaging.
[0024] Piece and shape integrity can be maintained and the fat-based
ingredients
are incorporated into the final product without product collapse when these
general
parameters are followed. This process allows for a better tasting baked
meringue
product that mostly contains standard chocolate ingredients, and thus the
potential for
labeling as a modified chocolate under section 130.10 of the FDA regulations
for
standard chocolate, or other accepted standards for defining a chocolate
product.
Flavor variations can also be incorporated to help build uniqueness into the
products.
For instance, nuts and nut pastes, coconut, dark chocolate, fruit, peppermint,
and other
components used with chocolate can be incorporated into the product, with a
special
advantage for fat-based ingredients that would normally need to be excluded
due to de-
aeration issues.
[0025] While the foam or aeration agents noted above are preferred, other
egg
white (egg albumen) containing agents can be used as the foaming matrix. The
main
constituent proteins in egg whites are ovalbumin, conalbumin and ovomucoid.
The
effectiveness of egg white as a foaming agent in meringues arises from the
constituent
proteins and the glycoproteins present. Egg white is effective in forming a
stable foam
as opposed to a temporary foam, which is by its nature prone to collapse.
[0026] An acceptable and stable foam can be made with just ovalbumin,
although
the texture of the final product can be effected. The glycoprotein ovomucoid
generally
adds a higher viscosity than with egg albumen, which can improve foam
stability.
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Ovomucoid is extremely stable to heat. Combinations with other proteins or
enzymes
are also possible, but using lysozyme with other egg-white proteins,
especially
ovomucin, can lead to a reduction in foaming capacity. Once formed the foams
of these
combinations of egg proteins with other proteins or enzymes can have increased
strength and stability. However, lysozyme alone is a poor foaming agent.
[0027] Along
with egg components, the two other ingredients usually included in
traditional recipes for meringue cakes are sugar and lemon juice. Sugar is
added slowly
with continued beating, but only after the egg white has first been beaten
into a foam.
Fine grain sugar should be used in preference to ordinary granulated sugar,
since the
crystals of the latter are too large to dissolve properly in the aqueous phase
of the walls
surrounding the air bubbles. The lemon juice reduces the pH towards the
isoelectric
points of the acidic egg-white proteins and can enhance the surface properties
of the
foam and its stability. Surface properties of egg component-based foams are
increased
at the isoelectric point of the proteins. However, in one aspect of the
current invention it
is desirable to maintain neutral to basic pH in the product to preserve
flavanol
compounds and resulting ORAC values. ORAC content in cocoa, and especially
high
ORAC from cocoa antioxidant compounds and epicatechin, has been shown to
exhibit
favorable effects on blood pressure and blood circulation in favor of heart
healthy
nutrition. Other health effects have clinically been demonstrated, such as
improved
mental acuity and energy as a result of high cocoa flavanol content
demonstrating high
ORAC values. For this reason, gum arabic or another suitable foam stabilizing
agent is
used as an alternative to lowering pH of the food product. In this way pH is
kept neutral
to basic. Baked meringue products made with natural or dutched cocoa products
as
instructed in the current invention result in full preservation of ORAC values
in post
versus pre-baked products (see Fig. 2-3, where Sample C contains natural cocoa
powder, and Samples A and B contain dutched or alkalized cocoa powder). While
the
use of acids, bases or other pH adjusting agents (food approved acids, bases,
or
buffering compositions) is not required, they can optionally be included in
the invention,
especially if preserving or maintaining flavanol content or antioxidant
capacity is
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required or desired. One of skill in the art is familiar with various acid,
base, and
buffering or pH adjusting compounds or compositions for this purpose.
[0028] Whole egg based compositions can also be used. Non-fat milk solids,
starches and food gums can be added to improve the foams made from whole-egg
compositions.
[0029] Accordingly, a number of foam agents or aeration agents can be used
to
product a foam matrix of the invention, as well as various combinations of
these agents,
but the preferred embodiment employs the Hyfoama product. Consistent with the
composition of Hyfoama, other combinations of hydrocolloid and at least one
dairy
protein ingredient may also be used.
[0030] As noted above, the present invention utilizes a standard baked
meringue
cookie procedure that incorporates a fat-containing blend of ingredients that
has been
refined to a specific particle size (20-55 micron average) and fat content (15-
30%). A
smaller average particular size is used for higher levels of fat in the final
product.
Numerous specific averages and variations within the range of 20-55 microns
can be
selected and used. Similarly, numerous specific fat content levels and
variations within
the range 15-30% total fat content can be selected and used for the pre-mixed
blend of
fat-containing ingredients.
[0031] In specific examples of the methods to produce aerated chocolate
products,
the fat-containing component is mixed with non-fat or low-fat solids
ingredients (sugar,
inulin, cocoa powder, etc.) and refined to produce a fine powder. This fine
powder can
be slowly added to a whipped, aerated foam matrix. The total fat content of
the pre-
refined powder mixture should range between 15-30% and is optimal at 26-28%
fat.
Lower levels of this broader range are used, however, if the final product
composition
should be lower in fat. The resulting refined portion comprises between 30-50%
of the
final product.
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[0032] A chocolate meringue cookie-type product, using levels of chocolate
liquor
of up to 15% of the product, can be made according to the invention. The use
of
chocolate liquor provides a distinct taste advantage over processes employing
only
cocoa powder. The ability to produce a unique refining procedure that results
in a
powdered chocolate liquor led to successful aeration of the meringue cookie
product,
and that product maintains its shape during deposition and baking steps in
manufacturing. The addition of a powder blend, and not the free flowing
chocolate
liquor, also allowed air incorporation at standard pressures to form small
stable bubbles
and these bubbles do not collapse. In prior methods using chocolate liquor,
the free fat
available in the free flowing liquor collapsed the air bubbles over time,
leading to a
flawed product with poor appearance qualities and an inconsistent shape and
texture.
[0033] Specific Example - Product aerated very well and held shape
completely
during baking step. Crumb blend in this example is made from 50% chocolate
liquor
(Barry-Callebaut, Zurich, Switzerland) and 50% cocoa powder, which is then
refined to
17-20 micron average particle size using a refining approach with roller
pressures set to
18 psi and temperatures set to 18 degrees C.
[0034] Water (preferably cold water) and an aeration agent (HyfoamaO) are
mixed
in a bowl. In a separate container, sugar and Instant Gum AA (Colloides
NatureIs) are
blended. Optional flavors can be added.
[0035] In separate containers weigh and combine refined crumb blend
(composed
of 50% chocolate liquor and various levels of sugar and cocoa powder depending
on
specific formula). The water and aeration agent are whipped in a Hobart bowl
with wire
whip attachment on lowest speed for 1 minute to fully disperse aeration agent.
Mix on
slightly higher speed for 30 seconds. Begin slowly adding sugar/gum mixture at
30
seconds and mix for additional 2 minutes. Mix on higher speed for 30 seconds.
Add
vanilla extract or other flavors if desired. Mix on higher speed for 30
additional seconds.
A desired amount of this foam matrix can be optionally mixed with dry cocoa
powder
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(about 2.5%) for color. The result is a stable foam matrix that can be mixed
with a
chocolate liquor containing blend, or other fat-containing blend.
[0036] The
refined crumb blend is then gently mixed into the stable foam matrix.
The resulting mixture can be deposited into desired shapes and then baked for
120
minutes at 225 F.
TABLE 1
Wt %
grams/batch
Water 100
Hyfoama 12.20 18.1
Instant Gum AA 2.21 6.7
Sucrose 0.82 469
liquor/cocoa 57.20 220
refined blend 26.83 6.2
Vanilla Extract 0.76
100% 820
[0037] Table 1 above shows the ingredients used in an exemplary process as
described above. This recipe yields a post-baked percentage of 30.56% for the
refined
cocoa/liquor blend, which is equivalent to approximately 15% chocolate liquor
in the
final chocolate meringue product. A final product of 40 g total weight will
comprise
0.530 grams moisture, 2.559 grams protein, 4.043 grams fat, and 28.215 grams
carbohydrate., and 8.8 grams cocoa. The refined flake or crumb is 50% liquor
and 50
% cocoa powder. The
samples shown in the Figures are produced from the above
example, where for some samples alkalized cocoa powder is used exclusively as
the
cocoa powder (Sample A and B), or natural (non-alkali treated) cocoa powder is
used
exclusively as the cocoa powder (Sample C), or vanillin is optionally added
(Sample B).
[0038] In contrast to the stable chocolate meringue product produced from
the
process above, prior art methods using chocolate as a base failed to produce a
meringue product stable to baking in the oven. The prior art method involved
combining
cold water, egg white powder, and cream of tartar in a mixing bowl.
Separately, sugar
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and Fibregum B are mixed. In a bench-top mixer on low speed, mix the water/egg
white
for 1 minute. Increase to medium speed, mix for 0.5 minutes and begin to add
sugar
mixture, and mix for an additional 1 minute. Increase to high speed, mix for
0.5
minutes, add vanilla extract, mix for an additional 0.5 minutes. Reduce to
medium
speed, add cocoa powder, mix for 20 secs, scrape bowl, and mix for an
additional 20
secs. Add melted milk chocolate and gently fold in until uniform in color.
This
composition is deposited as 2 ¨ 3 cm circles on a parchment-lined baking sheet
and
baked at 225 F for 120 min. The resulting product fails to hold its shape and
texture.
Attempts with 25% milk chocolate, 50% milk chocolate, and 70% milk chocolate
similarly fail to hold shape and texture. These same mixing conditions and
baking
conditions can be used for the methods and compositions of the invention.
[0039] The
examples presented above and the contents of the application define
and describe examples of the many cocoa compositions, products, and methods
that
can be produced or used according to the invention. None of the examples and
no part
of the description should be taken as a limitation on the scope of the
invention as a
whole or of the meaning of the following claims.
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