Process for producing a confectionery product

Abstract

The disclosure relates to a process for producing a confectionery product comprising heat resistant chocolate or a heat resistant compound mass and to the confectionery product, which is produced by this process. The process utilizes spraying water and/or a polyol (such as a sugar alcohol or a sugar) solution onto chocolate or a compound mass thereby inducing the formation of heat resistant chocolate or a heat resistant compound mass.

Claims

1. A process for producing a confectionery product comprising: spraying water and/or a polyol solution from a first spray nozzle onto a surface; spraying chocolate from a second spray nozzle onto the surface; wherein the water and/or the polyol solution sprayed from the first spray nozzle and the chocolate sprayed from the second spray nozzle mix prior to reaching the surface.

2. The process according to claim 1, wherein the chocolate comprises milk chocolate, dark chocolate or white chocolate.

3. The process according to claim 1, wherein the polyol comprises a sugar, sorbitol, mannitol, maltitol, erythritol, xylitol, lactitol, or glycerol.

4. The process according to claim 1, wherein the water and/or the polyol solution is sprayed from the first nozzle and the chocolate from the second nozzle is sprayed while the water and/or the polyol solution is at a temperature identical to the temperature of the chocolate.

5. The process according to claim 4, wherein the temperature is in the range of 29-31.5 C. when spraying the chocolate.

6. The process according to claim 1, wherein a pressure of a compressed air stream used for spraying the chocolate is from 0.5 bar to 1.5 bar.

7. The process according to claim 1, wherein a pressure of a compressed air stream used for spraying the water and/or the polyol solution is to 0 to about 0.5 bar.

8. The process according to claim 1, wherein the surface is a tray.

9. The process according to claim 8, wherein the surface is a confectionery substrate.

10. An apparatus for producing a confectionery product comprising: a first nozzle for spraying water and/or a polyol solution; and a second nozzle for spraying chocolate; wherein the first and second nozzles are configured such that the water and/or the polyol solution sprayed from the first spray nozzle and the chocolate sprayed from the second spray nozzle mix prior to reaching a surface.

11. A confectionery product obtainable by a process according to claim 1.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 shows one embodiment of a spraying apparatus for producing a confectionery product by the process provided herein.

(2) FIG. 2 shows a one fluid nozzle used in the process/apparatus provided herein.

(3) FIG. 3 schematically shows a spraying device used in the process described herein.

DETAILED DESCRIPTION

(4) There is provided a process for producing a confectionery product comprising heat resistant chocolate or a heat resistant compound mass, which allows for the formation of the heat resistant chocolate or the heat resistant compound mass during the production process.

(5) In a particular preferred embodiment, there is provided a process for producing a confectionery product comprising an interior enrobed with heat resistant chocolate or a heat resistant compound mass, which allows for the formation of the heat resistant chocolate or the heat resistant compound mass during the production process.

(6) The interior may be a wafer, a biscuit or the like.

(7) In accordance with the process provided herein, the heat resistant chocolate or the heat resistant compound mass are prepared by spraying water or a polyol solution onto the chocolate or a compound mass.

(8) In a preferred embodiment, the chocolate or the compound mass are provided by way of spray deposition.

(9) In another preferred embodiment, water or a polyol solution may simultaneously be sprayed with the chocolate or the compound mass, which results in one homogenous layer. Confectionery products may be prepared comprising 1, 2, 3 or more of these homogenous layers.

(10) In a further embodiment, water or a polyol solution are alternately sprayed with the chocolate or the compound mass, which results in at least two or more layers, for example 2 or 3 layers. Obtaining more than 3 layers is also feasible by applying the process described herein.

(11) Also, confectionery products comprising more than 6 layers of water or a polyol solution and chocolate or a compound mass may be produced by the process described herein.

(12) In a preferred embodiment, a confectionery product comprising a low number of up to 3 layers is prepared. However, depending on the overall thickness of the resulting heat resistant chocolate or the resulting heat resistant compound mass a higher number than 3 layers can be preferred.

(13) If water or a polyol solution are employed in the process described herein, they may each be sprayed onto separate chocolate layers or they may subsequently be sprayed onto one single chocolate layer.

(14) There is no specific sequence of the different layers of chocolate or a compound mass and water or a polyol solution required.

(15) In a preferred embodiment, water or a polyol solution are sprayed as outmost layer.

(16) In general, simultaneously spraying water or a polyol solution with the chocolate or the compound mass is most preferred, while alternately spraying water or a polyol solution with the chocolate or the compound mass is also preferred.

(17) During the process described herein, spraying of water or a polyol solution and chocolate or a compound mass is performed by applying atomizing spray nozzles.

(18) In a preferred embodiment, when alternately spraying, one single fluid nozzle system for spraying water or a polyol solution and one further single nozzle system for spraying chocolate or a compound mass are applied in the process described herein.

(19) In another embodiment, when simultaneously spraying, a two fluid nozzles system for spraying water or a polyol solution and chocolate or a compound mass is applied in the process described herein.

(20) In general, the spraying system applied in the process described herein comprises separate tanks, pipings and nozzles for each of the components to be sprayed, i.e. water or a polyol solution as well as chocolate or a compound mass. Hence, there is one tank, piping and nozzle, respectively, dedicated for each of the components to be sprayed.

(21) Atomization of water or a polyol solution and chocolate or a compound mass may be achieved by gas or by other means, e.g. by ultrasound or airless simply by high pump pressure (e.g. 50-150 bar).

(22) When gas atomization is applied, the nozzles used in the process described herein (both one fluid and two fluid nozzles) are additionally equipped with a gas inlet and a mixing chamber such as JAU-type nozzles from Spray Systems. Air/chocolate mixing may also take place outside the nozzle such as VAU-type nozzles from Spray Systems. In general, the nozzles may be different types requiring only the need to handle viscous suspensions like chocolate or sugar solutions.

(23) The gas applied for atomizing water or a polyol solution and chocolate or a compound mass may be air, oxygen or an inert gas, such as nitrogen gas.

(24) In case of gas atomization with a close chocolate or compound mass tank, the pressure of the chocolate or compound mass stream [applied inside the tank dedicated for chocolate or compound mass] for spraying chocolate or a compound mass by a one fluid nozzle is adjusted to 0-6 bar and preferably to 1-3 bar. The pressure controls the amount of the sprayed chocolate/compound mass, i.e. a high pressure provides for more chocolate/compound mass deposited.

(25) In case of gas atomization with an open chocolate or compound mass tank, the amount of the chocolate or the compound mass stream is controlled by an independent dosing pump.

(26) The pressure of the gas stream applied for atomizing chocolate or compound mass (e.g. an air or nitrogen stream) by a one fluid nozzle is adjusted to 0-2.5 bar and preferably to 0.5-1.5 bar. The pressure controls the distribution span/pattern of the sprayed matter.

(27) The pressure of the water or polyol solution stream [applied inside the tank dedicated for water or a polyol solution] for spraying water or a polyol solution by a one fluid nozzle is adjusted to 0-4 bar and preferably to 2.5 bar. The pressure controls the amount of the sprayed water or polyol solution, i.e. a high pressure provides for more water or polyol solution deposited.

(28) The pressure of the gas stream applied for atomizing water or a polyol solution (e.g. an air or nitrogen stream) by a one fluid nozzle is adjusted to 0-0.5 bar and preferably to 0.5 bar. The pressure controls the distribution span/pattern of the sprayed matter.

(29) When another atomization than gas atomization is performed and depending on the apparatus used different pressure settings than the above may be applied in the process described herein.

(30) By adjusting the spraying pressure and the length of the spraying intervals, the process described herein allows for precisely controlling the thickness of the layer of heat resistant chocolate or heat resistant compound mass, respectively.

(31) The preferred spraying intervals last from 2.5 sec for the water or polyol layer to 5 sec for the chocolate or compound mass layer.

(32) The chocolate or the compound mass may be sprayed in one or more strokes and preferably in three strokes, wherein each stroke preferably lasts 5 sec.

(33) When applied simultaneously with chocolate or a compound mass, water or a polyol solution are sprayed in parallel with the stroke(s) of the chocolate or the compound mass.

(34) In a further embodiment water or a polyol solution are sprayed just before the end of each stroke of the chocolate or the compound mass, preferably just before the end of some of the strokes of the chocolate or the compound mass and most preferably just before the end of the last stroke of the chocolate or the compound mass.

(35) Just before the end as used herein describes a period of 0.5-5 sec, preferably 2.5 sec.

(36) The resulting thickness of the layer of heat resistant chocolate or heat resistant compound mass, respectively, is in a range between 0 and 4 mm for enrobed products.

(37) In a preferred embodiment, the thickness is 1-2 mm for enrobed products.

(38) During the process described herein, the chocolate or the compound mass and the water or the polyol solution have the same temperature.

(39) The temperature is in a range, which provides for sufficiently low viscosity of the chocolate or the compound mass in order to ensure interaction of water or a polyol with the crystallization process of the chocolate or the compound mass, which is the necessary prerequisite for the formation of heat resistant chocolate or a heat resistant compound mass.

(40) That is, the temperature is adjusted and maintained during the process in a way that the crystalline state of the chocolate or the compound mass is relaxed to an extent, which allows for the interaction of water or polyol molecules with the crystallization process of the chocolate or the compound mass.

(41) The temperature of the chocolate and the water or the polyol solution applied in the process described herein is in a range between 29 and 35 C. and preferably in a range between 30 and 31.5 C. In case of chocolate this means that the temperature applied neither allows crystallization (hardening) nor loss of tempering, i.e. the presence of cocoa butter seed crystals. In essence, the temperature should be kept between 30 and 31.5 C. all the time.

(42) The temperature of the compound mass and the water or the polyol solution applied in the process described herein is in a range between 30 and 45 C. and preferably is 40 C.

(43) In the process described herein, sufficient time is provided during which the described temperatures are maintained to ensure mixing of the water or polyol phase and the chocolate or compound mass phase.

(44) That is, the hardening/drying intervals between each spraying step are adjusted in a way to ensure that the temperature of the chocolate or the compound mass and the water or the polyol solution does not fall below the above described desired value. Preferably, the hardening/drying intervals are shorter than 1 sec or last from 1 to 10 sec.

(45) Suitable viscosity values for both chocolate and compound mass are at most 35 Pa.Math.s. Also, viscosity values of <3 Pa.Math.s and ranging from 3-4 Pa.Math.s, 4-8 Pa.Math.s, 8-12 Pa.Math.s, 12-15 Pa.Math.s, 15-22 Pa.Math.s and preferably from 0.5-3 Pa.Math.s are suitable for the process described herein.

(46) Optionally, the confectionery product obtained by the process described herein may be subjected to a curing process. The curing step could either be applied to evaporate water or to increase the diffusion of the polyol phase into the chocolate phase. During the curing process a part of the water is evaporated to further solidify the structure of the heat resistant chocolate or the heat resistant compound mass of the confectionery product obtained by the process described herein.

(47) The solidification can be achieved by curing at ambient conditions as well as by curing under accelerated conditions such as temperature treatment or microwaving.

(48) The confectionery product produced by the process described herein may be any standard form of heat resistant chocolate or a heat resistant compound mass such as tablets bars and the like.

(49) In addition to solid tablets, the process described herein can dominantly be used for producing a compounded or enrobed confectionery product comprising an interior enrobed with heat resistant chocolate or a heat resistant compound mass, such as filled chocolate or chocolate with inclusion, e.g. chocolate coated wafers, biscuits or the like.

(50) The confectionery product produced by the process described herein may thus be a biscuit, a wafer, nuts, a caramel, or the like comprising heat resistant chocolate or a heat resistant compound mass.

(51) The confectionery product produced by the process described herein may also be a filled chocolate (or compound) tablet in which a heat resistant shell and/or bottom are/is prepared in the described way, while the filling is made of any state-of-the-art technology such as fat-based fillings, fondants, caramels or the like.

(52) No limitations are made concerning the three dimensional structure of the confectionery product.

(53) If the confectionery product produced by the process described herein is a biscuit, a wafer, nuts, a caramel, or the like comprising heat resistant chocolate or a heat resistant compound mass, the biscuit, the wafer, the nuts, the caramel, or the like used as centers and the chocolate or the compound mass and the water or the polyol solution have the same (or similar, meaning+/2 C.) temperature during the process described herein.

(54) In the same way if solid tablets or filled tablets comprising heat resistant chocolate or a heat resistant compound mass are produced, the moulds have the same (or similar, meaning+/2 C.) temperatures as the chocolate or the compound mass.

(55) As regards the particular temperature at which the process described herein is performed in this case, the same applies as set forth above.

(56) However, during the process described herein it is also possible that the centers exhibit a lower temperature than the chocolate or the compound mass and the water or the polyol solution, but their temperature should not be below room temperature (20 C.).

(57) In one embodiment, if the confectionery product produced by the process described herein is a compounded or enrobed product, it may fully be coated with heat resistant chocolate or a heat resistant compound mass. In this case, the coating is applied in two steps: in step 1 one side is coated and in step 2 the opposite side is coated.

(58) In another embodiment, if the confectionery product produced by the process described herein is a compounded or enrobed product, it may only partially be coated with heat resistant chocolate or a heat resistant compound mass.

(59) The term partially coated as used herein means that only a first portion of the confectionary product's surface is coated while at least a second portion remains uncoated.

(60) The partial coating may be applied in one or more steps. In case more than one step is accomplished, the sides to be coated may be subjected to the process described herein in an arbitrary sequence.

(61) Within the heat resistant chocolate or the heat resistant compound mass, the amount of the polyol is in a range of 5-35% by weight and preferably of 2-17% by weight.

(62) The chocolate, which may be used in the process described herein, may be milk chocolate, dark chocolate or white chocolate.

(63) In one embodiment the chocolate used in the process described herein contains a surfactant.

(64) In a preferred embodiment, the chocolates used in the process described herein always contain a surfactant.

(65) The surfactants, which may be contained in the chocolate, include, but are not limited to, polyglycerol polyricinoleate (PGPR) and lecithin. Also, any other surfactant may be used as long as the specifications for rheology are met. Preferably, PGPR is applied.

(66) In a preferred embodiment the chocolate contains a surfactant, preferably PGPR, in an amount of 0.1-0.5% by weight and preferably in an amount of 0.3-0.5% by weight.

(67) In a further embodiment the chocolate has a fat content in a range between 28 and 31% by weight. Preferably there is no restriction in the fat content.

(68) In another embodiment, the chocolate is tempered prior to spraying. For the tempering process conventional means can be applied.

(69) The compound mass, which may be used in the process described herein, may be based on different recipes and specifically on different fat systems such as CBR (Cocoa butter replacer), CBS (cocoa butter substitutes) or the like.

(70) The polyols, which may be used in the process described herein, include sugar alcohols such as sorbitol, mannitol, maltitol, erythritol, xylitol, lactitol or the like or any mixtures thereof and sugars such as glucose, fructose, sucrose, etc., as well as oligomeric or polymeric sugars or any mixtures thereof.

(71) In addition, liquid polyols such as glycerol can be used. Preferably, sorbitol is used.

(72) The polyol solutions employed in the process described herein are aqueous solutions and can be sprayed in any concentration.

(73) In a preferred embodiment, a saturated polyol solution in water is employed. Thus, depending on the type of the polyol(s), the water/polyol ratio may vary. For sorbitol, a saturated solution exhibits a water/sorbitol ratio of 30/70. Other polyols may exhibit different water/polyol ratios.

(74) It is also possible to use a less concentrated solution e.g. exhibiting a water/polyol ratio of 40/60, 50/50, 75/25 or 100/0.

(75) Also pure liquid polyols or aqueous solutions thereof in any concentration may be employed in the process described herein. Preferably, saturated aqueous solutions of liquid polyols are sprayed.

(76) Alternatively, the polyols can be incorporated in a carrier such as an emulsion.

(77) Any combinations of different polyols may be applied.

(78) There is also provided an apparatus for producing a confectionery product comprising a means for spraying water or a polyol solution onto chocolate or a compound mass

(79) The apparatus provided herein may further comprise a means for spraying chocolate or a compound mass.

(80) FIG. 1 shows one embodiment of an apparatus provided herein. Therein, the chocolate or the compound mass and the water or the polyol solution are each withdrawn from the pressurized tanks 10 and 20, respectively. Said tanks allow for adjusting the temperature of their content and are pressurized by an air, oxygen or an inert gas stream, such as nitrogen gas, which is supplied via the pipes 11 and 21. The chocolate or the compound mass and the water or the polyol solution are fed through the pipes 12 and 22, respectively, to the one fluid spray nozzles 13 and 23. The pipes 12 and 22 each comprise a tempering jacket. For spraying the chocolate or the compound mass and the water or the polyol solution with spray nozzles 13 and 23, an atomizing gas (air, oxygen or an inert gas, such as nitrogen gas) is supplied via the pipes 14 and 24 to the respective nozzle. The chocolate or the compound mass and the water or the polyol solution either may be sprayed in order to form a confectionary product 15 on the tray 16 or may be sprayed onto a substrate 17 placed on the tray 16.

(81) In the process/apparatus described herein, the means for spraying water or a polyol solution and the means for spraying chocolate or a compound mass is an atomizing spray nozzle. The atomizing spray nozzles applied in the process/apparatus may be one fluid or two fluid spray nozzles.

(82) An example of a one fluid spray nozzle is the nozzle 13 or the nozzle 23 of FIG. 1.

(83) FIG. 2 shows the nozzle 13. Chocolate, compound mass, water or a polyol solution is fed to the nozzle 13 through the jacketed pipe 12. Water for adjusting the temperature of the liquid fed through the pipe 12 is supplied via the inlet 18. Concurrent to the chocolate, the compound mass, the water or the polyol solution an atomizing gas (air, oxygen or an inert gas, such as nitrogen gas) is supplied via the pipe 14 to the nozzle 13. In the nozzle head 19, the atomizing gas expands thereby inducing the spray-cone 25 of chocolate, compound mass, water or a polyol solution.

(84) In addition, the disclosure relates to a confectionery product obtainable by the above described process.

EXAMPLES

Example 1Production of the Confectionery Base

(85) Ingredients for the chocolate confection of the Milk Chocolate Confection No. 1 or No. 2 were mixed and refined according to Table 1. Mixing of ingredients (with a certain amount of fat and no lecithin) was carried out in a double-jacketed blender (Stephan mixer, Hameln, Germany) at 50 C. (15 min., 1000 rpm) adjusting the total fat level at 24%. Refining was effected with a pilot plant 3-roll-refiner to a particle size of d90<30 m (Laser diffraction, Malvern). The base masses were couched with a pilot plant conche (60 kg). The remaining fat and lecithin were added during conching.

(86) TABLE-US-00001 TABLE 1 Confectionery Base Milk Chocolate Milk Chocolate Confection No. 1 Confection No. 2 Sugar 45.75% 45.75% Cocoa liquor 12.35% 17.50% Cocoa butter 23.3% 19.4% Skimmed milk powder 18.0% 16.75% Lactose Biscuitine 300 Lecithin 0.6% 0.6% Sum 100% .sup.100%

Example 2Spraying Trials

(87) Spraying Device 1Filled with Chocolate (Compound) Mass

(88) The above mass was mixed together with polyglycerol polyricinoleate (PGPR, high grade) in order to adjust the flow properties and to ensure a good distribution of the chocolate mass on the surface of the biscuit. Milk chocolate mass without PGPR has a viscosity at 2/s between 22 and 15 Pa.Math.s, whereas the presence of PGPR could lower the viscosity range down to 12-4 Pa.Math.s depending on the amount of PGPR.

(89) The particular viscosity values for the milk chocolate of the above Confection No. 1 containing various amounts of PGPR are as shown in the below table:

(90) TABLE-US-00002 PGPR content (% [w/w]) of Confection No. 1 Viscosity at 2/s .sup.0% PGPR 15-22 Pa .Math. s 0.1% PGPR 12 Pa .Math. s 0.2% PGPR 8 Pa .Math. s 0.3% PGPR 4 Pa .Math. s 0.5% PGPR <3 Pa .Math. s

(91) For this particular application, a good distribution is ensured at a viscosity range between 7 and 5 Pas. This corresponds to a PGPR amount between 0.2 and 0.5% and preferably an amount of 0.35%.

(92) Tempered chocolate is filled in the tank and the pressure is set to 1 bar, whereas the pressure of the air stream is set to 1.5 bar. These parameters ensure a good distribution of chocolate on the surface of a biscuit, which has a diameter between 4 and 6 cm. Furthermore, the distance of the nozzle to the surface of the biscuit is fixed to 8.5 cm for a biscuit with a diameter between 4 to 6 cm.

(93) Spraying Device 2Sorbitol Solution

(94) A sorbitol solution is used as a moisture carrier, which contains 30% of water.

(95) The chocolate and the sorbitol solution are sprayed simultaneously with the spraying device shown in FIG. 3.

(96) To spray the sorbitol solution and the chocolate simultaneously, the sorbitol solution is filled into another and separate pressurized tank and the pressure is set to 2.5 bar, whereas the air stream of this spraying system is set to 0.5 bar. All components, such as the chocolate, the sorbitol solution and the biscuit are set to a temperature of 30 C. Three strokes of the nozzle of the chocolate part will deliver about 1.6-1.8 g of chocolate on the surface of the biscuit. Each stroke takes about 5 sec and just before the end of the last stroke of chocolate the sorbitol solution is simultaneously sprayed with the chocolate for 2.5 sec. This will result in a product with 1.6-1.8 g of chocolate and 0.1-0.2 g of the sorbitol solution. After the spraying application, the product is either stored at 5 C. to allow crystallization or at 30 C. to induce the heat resistant character in a short period of time [1 wk].

Example 3Testing Heat Resistance

(97) Heat resistance of the chocolate layer is the main criteria. At temperatures <30 C., the chocolate should be hard, not sticky and not adhesive when touched with a finger.

(98) Sample Preparation and Storage

(99) A wrapped heat resistant chocolate coated product, which was prepared according to examples 1 and 2 by simultaneously spraying chocolate and a sorbitol solution, was stored in an oven at a temperature of 35 C. or higher (the maximum temperature was 50 C.) for about 2 hours prior to measurement in order to determine its heat resistance. The heat resistant properties were assessed via the product stickiness as analytical parameter.

(100) Analytical Method

(101) The attribute of stickiness is being determined by means of a texture analyzer. A plastic plate/sensor is forced to touch and penetrate the surface of the coated biscuit about 1 mm. The depth of penetration is strongly dependent on the thickness of the chocolate layer, i.e. the coated part of the biscuit. As soon as the plate touches and penetrates the chocolate, the positive force [g] is recorded. The positive force [g] determines the hardness of the coated part of the biscuit, i.e. the chocolate. Thereafter, the plate moves upwards and the negative force is recorded. The negative force determines the stickiness. As mentioned above, the product is placed at different temperatures for about 2 hours prior any measurement. If the chocolate layer is not heat resistant, then the heat treatment will force the chocolate to melt. The melted chocolate will stick to the plate/sensor while the latter starts moving upwards. If the chocolate layer is heat resistant, the coated biscuit will not stick to the sensor and the negative force will be zero. For a product which will not be sticky (and hence be a heat resistant product), the negative force will be zero. For a product which will stick to the plate/sensor (and hence is a non heat resistant product), the negative force will be below zero (negative values; unit: [g]).

(102) Procedure

(103) The product was placed on the measurement platform. A 6-fold determination was performed.

(104) Results

(105) Heat resistance of all tested products was proven at temperatures equal to 35 C. and up to 50 C.