New method for preparing fat-based candies

Abstract

The present invention relates to a novel process for the preparation of fat-based confectionery products.

Description

Background of the Invention

[0002] The preparation of fat-based confectionery products is a complex and labor-intensive process involving a large amount of equipment and materials.

[0003] Therefore, there is a need for a simplified alternative process for preparing fat-based compositions. Summary of the Invention

[0004] The present invention relates to a method for preparing fat-based confectionery compositions primarily or entirely in a spray dryer or similar system.

[0005] Traditional chocolate preparation methods are time and labor intensive and require the use of many different pieces of equipment. By eliminating the need for grinding, chonching, and / or other steps in the process, this new method enables the preparation of chocolate and other fat-based confectionery products in locations where setting up large production lines utilizing several pieces of equipment is impractical or economically unfeasible.

[0006] Theobroma cacao, the source of beans used to make chocolate, grows only in limited areas of the world, often in areas that are not easily accessible or where large-scale manufacturing facilities cannot be established. Among other benefits, using these new methods to prepare chocolate primarily in spray dryers will enable the production of small batches and specialty chocolates at origin.

[0007] In view of the disclosure herein and without limiting the disclosure in any way, in a first aspect of the invention, which may be combined with any other aspects listed herein unless otherwise stated, there is provided a method of preparing a confectionery composition, wherein the composition is prepared by creating a water-in-fat emulsion in a spray dryer.

[0008] In a second aspect of the invention, which may be combined with any other aspect listed herein unless otherwise stated, the method comprises spray drying the ingredients and centrifuging the resulting spray-dried material.

[0009] In a third aspect of the invention, which may be combined with any other aspect listed herein, unless otherwise stated, the composition does not comprise any added sugar.

[0010] In a fourth aspect of the invention, which may be combined with any other aspect listed herein unless otherwise stated, there is provided a method of making a food or confectionery ingredient, the method comprising spray drying a fruit or vegetable product with a carrier.

[0011] In a fifth aspect of the invention, which may be combined with any other aspect listed herein unless otherwise stated, there is provided a method of making a food or confectionery ingredient, the method comprising spray drying cocoa pulp with a carrier.

[0012] In a sixth aspect of the invention, which may be combined with any of the other aspects listed herein unless otherwise stated, the carrier is cocoa powder, cocoa pod fiber, cocoa butter, or other products obtained from cocoa pods. The cocoa powder may be fermented and roasted, or raw, dried, germinated, or malted.

[0013] In a seventh aspect of the present invention, which may be combined with any other aspect listed herein unless otherwise stated, the spray drying is carried out at an inlet temperature of 120°C to 180°C.

[0014] In an eighth aspect of the present invention, which may be combined with any other aspect listed herein unless otherwise stated, the spray drying is carried out at an outlet temperature of 60°C to 100°C.

[0015] In a ninth aspect of the present invention, which may be combined with any other aspect listed herein unless otherwise stated, the spray drying is carried out in a polytetrafluoroethylene-coated spray dryer.

[0016] In a tenth aspect of the present invention, which may be combined with any other aspect listed herein unless otherwise stated, the confectionery composition made by the method disclosed herein is a fat-based confectionery composition.

[0017] In an eleventh aspect of the present invention, which may be combined with any other aspect listed herein unless otherwise stated, the confectionery composition made by the method disclosed herein is a non-fat based confectionery composition.

[0018] In a twelfth aspect of the present invention, which may be combined with any other aspect listed herein unless otherwise stated, the confectionery composition made by the method disclosed herein is a coating.

[0019] In a thirteenth aspect of the invention, which may be combined with any other aspect listed herein unless otherwise stated, the confectionery composition made by the method disclosed herein is ice cream.

[0020] In a fourteenth aspect of the invention, which may be combined with the thirteenth aspect in combination with any other aspect listed herein unless otherwise stated, there is provided a method of making a fat-based confectionery composition without milling or grinding.

[0021] In a fifteenth aspect of the present invention, which may be combined with any other aspect listed herein unless otherwise stated, there is provided a method of making a fat-based confectionery composition with minimal grinding or milling.

[0022] In a sixteenth aspect of the invention, which may be combined with any other aspect listed herein unless otherwise stated, there is provided a fruit confectionery comprising fruit material dispersed with cocoa butter.

[0023] In a seventeenth aspect of the invention, which may be combined with any other aspect listed herein unless otherwise stated, dispersing the fruit material with cocoa butter is achieved by spray drying.

[0024] In an eighteenth aspect of the present invention, which may be combined with any other aspect listed herein unless otherwise stated, the fruit confectionery has a particle size of 30 microns or less.

[0025] In a nineteenth aspect of the invention, which may be combined with any other aspect listed herein unless otherwise stated, the fruit candies and cocoa butter are spray dried with cocoa liquor.

[0026] In a twentieth aspect of the present invention, which may be combined with any other aspect listed herein unless otherwise stated, a candy composition made by the method disclosed herein has a particle size of 30 microns or less.

[0027] In the twenty-first aspect of the present invention, which can be combined with any other aspect listed herein unless otherwise specified, the method disclosed herein can be used to prepare a fat-based candy incorporating the following materials: pressed or cold-pressed juice from fresh cocoa beans, pressed or cold-pressed juice from cocoa husks, or pressed or cold-pressed juice from cocoa placentas, all of which can be further concentrated by heating, evaporation, membrane filtration, or other concentration methods before being incorporated into the fat-based candy. Other materials that can be spray-dried into the fat-based candy of this method include cold-pressed or pressed cocoa pulp (together with juice and solid components processed together or separately), fermented cocoa pulp, and cocoa pulp vinegar. These materials can also be homogenized, filtered, pressed, or further concentrated by heating, evaporation, membrane filtration, or other concentration techniques. Fermented cocoa pulp can also be used to prepare molasses, which can then be spray-dried and used as an ingredient in the novel fat-based candy according to this method. Sweatings, i.e., pulp or gel that flows from cocoa beans during the fermentation process, can also be used in this method and product. The juice may also be homogenized, filtered, pressed, concentrated and / or reduced to molasses prior to spray drying.

[0028] In the twenty-second aspect of the present invention, in combination with Figures 1 to 5 Any structure and function disclosed can be combined with Figures 1 to 5Any other structural and functional combinations disclosed.

[0029] In view of the present invention and the above aspects, it is therefore an advantage of the present invention to provide a new method for preparing fat-based confectionery.

[0030] The advantages discussed herein may be found in one or several, but not all, aspects disclosed herein.Other features and advantages are described herein and will become apparent from the following detailed description and accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 Schematic representation of the composition of a cocoa seed pod from the Theobroma cacao plant.

[0032] Figure 2 Schematic diagram of the physical changes of droplets during the spray drying process (Dehydration I, II and III represent arbitrary stages of dehydration). g is the glass transition temperature, and T 表面 is the temperature of the drying particles.

[0033] Figure 3 A diagram of the spray drying process of a novel chocolate preparation method comprising spray drying a chocolate ingredient comprising cocoa pulp with a cocoa powder or non-fat milk powder carrier.

[0034] Figure 4 Particle size distribution of sprayed cocoa butter emulsion.

[0035] Figure 5 An image of crystallized sugar in a cocoa butter matrix. Detailed Description of the Invention

[0037] The present invention relates to a novel method for preparing fat-based confectionery compositions comprising chocolate and novel sugars and other ingredients suitable for use in confectionery and food products.

[0038] The method comprises producing a dispersion of a fat-based confectionery ingredient of a specific particle size. The dispersion can be further modified or processed, including adding other ingredients. In one aspect, the dispersion itself can be used as an ingredient in a food or confectionery composition.

[0039] Cocoa beans, derived from the pods of the Theobroma cacao fruit, are the primary raw material for chocolate production. The beans are surrounded by a sticky pulp within the pod. After the pods are harvested, the beans (usually including at least a portion of the surrounding pulp) are recovered from the pods, while much of the pulp may become waste.

[0040] In addition to providing an efficient new method for preparing small batches, fine flavors, or single-source chocolate and other confectionery products, the method is particularly suitable for preparing chocolate and other confectionery products that contain spray-dried cocoa pulp or other fruit or vegetable materials as ingredients. Patent application No. 62 / 961,562 is incorporated herein by reference in its entirety. Cocoa pulp can be a substitute for sugar or other sweeteners, can be added as a flavoring, or can be a filler or provide other benefits to the composition.

[0041] As used herein, the terms "cocoa" and "cacao" are considered synonyms.

[0042] As used herein, the term "confectionery product" or "fat-based confectionery product" is understood to refer to chocolate products that conform to applicable national standards of identity, including, but not limited to, the United States Standard of Identity (SOI), the European Standard of Identity, CODEX Alimentarius, and the like; and chocolate and chocolate-like products that do not conform (e.g., containing cocoa butter substitutes, cocoa butter equivalents, or substitutes), compound chocolates, coated chocolates, chocolate-like coated products, chocolate coatings for ice cream, chocolate-like coatings for ice cream, pralines, chocolate fillings, fondants, chocolate creams, extruded chocolate products, and the like. Fat-based confectionery products can be white chocolate, which contains sugar, milk powder, and cocoa butter without dark cocoa solids. The products can be in the form of aerated products, bars, or fillings, among others. The chocolate products or compositions can be used as coatings, fillings, encapsulating compositions, or other ingredients in finished or final food or confectionery products. The confectionery products of the present invention may also contain inclusions such as nuts, grains, and the like.

[0043] In another aspect, the method can be used to make certain other non-fat based confectionery products, such as traditional sugar confectionery such as ice cream, gummies, fruit candies, and the like.

[0044] In one aspect, the materials prepared using this method can be used as ingredients in other confectionery or savory foods.

[0045] According to the method of the present invention, a mixture of cocoa butter, cocoa pulp, lecithin is spray dried according to the invention herein. In another aspect, cocoa powder, cocoa liquor and / or milk powder are spray dried in combination with other ingredients or a subset of ingredients.

[0046] The ingredients are mixed together to form a fat emulsion, which is then spray-dried to remove the water. The fine suspension is kept warm to allow the sugar to crystallize, and then centrifuged to remove excess fat.

[0047] spray drying

[0048] Spray drying is a unit operation that atomizes or sprays a liquid product in hot air to obtain a powder instantly. The physicochemical properties of the final product depend mainly on the inlet temperature, air flow rate, liquid feed rate, droplet size distribution, nozzle pressure, carrier type and its concentration.

[0049] Spray-dried ingredients can be divided into two main categories: non-sticky and sticky. Non-sticky materials can be easily spray-dried using simple dryer designs, and the resulting powder remains free-flowing. However, sticky materials, such as those rich in sugars or acids, present technical challenges because they can stick to the dryer's interior walls or form undesirable clumps within the dryer chamber and conveying system. These issues lead to operational problems and low product yields.

[0050] Product yields are low due to poor powder recovery caused by the presence of low molecular weight sugars (glucose, fructose and sucrose) and organic acids such as those found in cocoa pulp (citric, malic and tartaric acids).

[0051] Without wishing to be bound by theory, the high hygroscopicity (a measure of a material's ability to absorb or release water as a function of humidity, i.e., water activity), thermoplasticity (a measure of a material's ability to soften when heated and harden when cooled without changing properties), and low glass transition temperature (Tg) of these low molecular weight materials contribute to the stickiness problem. The glass transition temperature is the primary characteristic transition temperature of the amorphous phase.

[0052] The glass transition occurs when a hard, solid, amorphous sugar changes to a soft, rubbery liquid phase. Figure 2 As shown, the first step in spray drying is atomization of the feed. Typically, a concentrate solution or emulsion is atomized or sprayed into fine droplets with diameters ranging from 20 to 50 microns. As the water evaporates, the solutes in the droplets become concentrated. The physical state of the product changes from solution to syrup to solid form as it passes through the dryer. The high molecular mobility of these substances, coupled with their low glass transition temperature, makes it difficult to achieve the temperatures typically used in spray drying.

[0053] In terms of surface energy, solid glass will have a low surface energy and will not stick to any other low-energy solid surface. Due to the transition from the glassy state to the rubbery state, the surface energy of the material increases, and the molecules begin to interact with the solid surface. During the drying operation of food or confectionery product ingredients, the product is in a liquid / rubbery state, and the ingredients are converted to a glassy state due to the removal of water (plasticizer). If the ingredients do not undergo the transition because the drying temperature is above the glass transition temperature, the product will remain in a high-energy, viscous state.

[0054] Certain chocolate and other fat-based confectionery ingredients are viscous materials. Cocoa pulp is one such example of a viscous material that can be used in the present method.

[0055] Table 1

[0056] sugar Hygroscopicity Melting point Approximate solubility in water Tg viscosity (Relative value) (℃) 60°C (% weight / weight) (℃) (Relative value) lactose h 223 35 101 s maltose hh 165 52 87 ss sucrose hhh 186 71 62 sss glucose hhhh 146 72 31 ssss fructose hhhhhh 105 89 5 sssss

[0057] In one aspect, the surface of the spray dryer used in the spray drying process of the present invention is coated with polytetrafluoroethylene (PTFE), commercially known as In one aspect, the spray dryer surface is coated with polychlorotrifluoroethylene, perfluoroalkoxy, tetrafluoroethylene-perfluoropropylene, or similar materials.

[0058] Ingredients used in the new method

[0059] In one aspect, any ingredient suitable for making chocolate or other fat-based confectionery can be used in the new method.

[0060] In one aspect, the ingredients include protein or fat. In one aspect, the protein or fat is derived from cocoa butter, cocoa powder, milk, milk substitutes, or a combination thereof. In one aspect, the protein is derived from a plant protein such as chickpea protein, pea protein, or other plant protein.

[0061] In one aspect, no dairy products are used in the preparation of the chocolate or fat-based confectionery of the new method.

[0062] Ingredients in fat-based confectionery may have a high moisture content. In one aspect, the particle size of the ingredients is reduced by reducing the feed rate, increasing the nozzle pressure, reducing the air flow rate, and / or extending the drying time. In another aspect, other processing methods are used to reduce the moisture content.

[0063] In one aspect, when a carrier is used, the liquid feed flow rate for the spray drying process is increased. Alternatively, the liquid feed flow rate is decreased.

[0064] Sugar rarely crystallizes during the spray drying process. In this process, sugar is dissolved in an aqueous solution and sprayed in droplets. When exposed to hot air, water rapidly leaves the solution, and although the solution becomes supersaturated, the crystallization kinetics are too slow for the sugar molecules to form crystals during the drying process. Because the mobility of sugar molecules decreases with the absence of water, an amorphous phase forms. When the sugar collects at the bottom of the dryer, its temperature is below its glass transition temperature (Tg), maintaining its amorphous state. Crystallization is further inhibited by impurities in the system (surfactants, stabilizers, film-forming agents, etc.). The presence of glucose and fructose in fruit pulp significantly inhibits the crystallization of sucrose. Subsequently, when exposed to higher temperatures (such as when processed in chocolate) or humidity, the amorphous sugar can crystallize. This uncontrolled crystallization results in large clumps, resulting in an undesirable texture.

[0065] To make crystallization possible, it is possible to slow down the drying process (which is difficult in a spray dryer) or to ensure that the particles are kept above the Tg for a sufficient time (e.g., several minutes) to allow the particles to crystallize. The risk is that residual moisture is released from the particles, which can cause stickiness. Crystallization of amorphous materials should be performed in a dry environment while keeping the particles separate and flowing individually.

[0066] In one aspect, the component particles are individually crystallized.

[0067] Spray drying parameters

[0068] In one aspect, the spray drying process comprises using an inlet temperature of about 100°C to about 205°C and an outlet temperature of about 40°C to about 105°C. In one aspect, the spray drying inlet temperature will be about 100°C to about 150°C. In another aspect, the inlet temperature will be about 110°C to about 200°C, or about 120°C to 180°C, or about 150°C to 180°C, or about 170°C to 190°C, or 120°C to 140°C, or 125°C to 135°C. In another aspect, the outlet temperature will be about 90°C to about 105°C, or 50°C to 100°C, or 50°C to about 80°C, or 80°C to 100°C, or 55°C to 75°C, or 70°C to 80°C, or 80°C to 90°C.

[0069] In one aspect, the air pressure used in the spray drying process is 10-60 PSI. In one aspect, the air pressure is 20-50 PSI. In one aspect, the air pressure used in the spray drying process is constant.

[0070] In one aspect, when a carrier is used, the air flow rate for the spray drying process is increased. In an alternative, the air flow rate is decreased.

[0071] In one aspect, a nozzle having a wide spray drying angle is used for the spray drying process. In an alternative aspect, a nozzle having a narrow spray drying angle is used.

[0072] In one aspect, after spray drying, the ingredient does not require grinding, milling, or other processing prior to use as an ingredient in a food or confectionery product.

[0073] In one aspect, the ingredients require less grinding, milling, refining or other processing after spray drying.

[0074] sugar

[0075] Traditionally, sugars used to prepare fat-based confectionery require extensive processing. Surprisingly, preparing sugar using the presently disclosed methods allows for less processing before use as an ingredient in standard fat-based confectionery recipes.

[0076] Surprisingly, preparing an emulsion according to the presently disclosed methods is important for producing fine sugars of appropriate particle size to make sweeteners useful in fat-based confections without requiring extensive additional processing.

[0077] In one aspect, about 40-90 brix of syrup is sprayed into the dryer while the molten cocoa butter flows down the walls of the dryer. The sediment is then collected and centrifuged.

[0078] In one aspect, sugar and cocoa butter are mixed using a high shear mixer. In another aspect, approximately 30% syrup, approximately 70% cocoa butter, and a small amount of lecithin are spray-dried. The material that accumulates at the bottom of the dryer is then centrifuged to produce a sugar and fat component for further use in confectionery products. In one aspect, the resulting particle size is less than 30 microns and can be used directly in chocolate processing without further grinding. In an alternative aspect, the ingredients are further ground to reduce the particle size.

[0079] The sugar may be any known sugar or other sweetener capable of forming a syrup.

[0080] The syrup and cocoa butter can be mixed into the emulsion with cocoa powder, milk powder or any other powdered ingredients.

[0081] The resulting composition can be used in coating applications or formulated for molding applications.

[0082] In one aspect, the prepared emulsion can be sprayed as a coating onto nuts, fruit, or other centers.

[0083] In one aspect, the material produced can be in bulk. In one aspect, the material produced by the novel method can be in bulk for use in fat-dissolving liquid applications.

[0084] Carriers and emulsifiers

[0085] In the presently disclosed methods, ingredients traditionally found in confectionery products are used as carriers. For example, if the desired product is a fat-based confectionery product, the ingredients can be spray-dried onto a cocoa powder carrier. In one aspect, the carrier can be cocoa butter or a component of cocoa butter. The carrier can also be prepared from another component of the cocoa pod, such as fibers from the cocoa husk.

[0086] The carrier may also be melted cocoa butter. In this case, a high shear mixer is used to form an emulsion of the pulp and melted cocoa butter. Figure 4 As shown, the emulsion is sprayed in very small droplets. The dry air removes the water from the droplets, and the solids remain in the fat matrix. Because the droplets are smaller than 30 microns, the solids are trapped in the fat matrix as very small particles. The suspension of sugar in fat will settle to the bottom of the dryer. Figure 5 The particles are kept separate while being kept warm to allow them to crystallize. The end result is fine crystalline sugar particles (less than 30 microns) in cocoa butter. This can be used directly in chocolate processing without refining and with minimal mixing.

[0087] For example, in a milk chocolate product, ingredients requiring a carrier can be spray-dried onto a dairy-derived or milk powder carrier, such as non-fat milk powder. The milk powder carrier can be skim milk, 1% milk, 2% milk, whole milk, or a combination thereof. The milk can be derived from any dairy animal. The milk powder carrier can be a milk substitute carrier, for example, made with milk substitute products such as soy milk, nut milks including cashew milk and almond milk, oat milk, or a combination thereof. Cocoa pulp can be spray-dried with a variety of carriers, such as cocoa powder and milk powder, or cocoa powder and cocoa butter, or milk powder and cocoa butter, or a combination thereof.

[0088] Alternatively, the material produced by the present method can be spray dried using cocoa butter as a carrier and the resulting material can then be used as an ingredient in milk chocolate and milk-based confectionery products.

[0089] The carrier may be a soft fat such as fractions of palm, palm kernel, coconut and shea butter and blends thereof.

[0090] The carrier can also be whey protein, sodium caseinate or oat protein. In one aspect, the carrier can be a sugar or multiple sugars. In one aspect, the carrier can be cocoa butter and sugar. In one aspect, the carrier can be cocoa powder and sugar.

[0091] In one aspect, the carrier can be combined with an emulsifier, such as polyglycerol polyricinoleate or any other commercially acceptable emulsifier. In preferred aspects, the emulsifier may include: lecithin obtained from plant sources such as soy, safflower, corn, etc.; fractionated lecithin enriched with phosphatidylcholine or phosphatidylethanolamine, or both; monoglycerides and diglycerides; diacetyl tartaric acid esters of monoglycerides and diglycerides (also known as DATEM); monosodium phosphate derivatives of monoglycerides and diglycerides of edible fats or oils; sorbitan; monostearate; hydroxylated lecithin; lactylated fatty acid esters of glycerol and propylene glycol; polyglycerol esters of fatty acids; propylene glycol monoesters and diesters of fats and fatty acids; or emulsifiers approved by the US FDA's soft candy catalog. In addition, other emulsifiers that can be used include ammonium salts of phosphatidic acid (e.g., YN), sucrose esters, oat extract, etc.; any emulsifier suitable for use in chocolate or similar fat / solid systems; or any blends thereof.

[0092] In one aspect, the carrier is a commercially acceptable ingredient included in fat-based confectionery products. For example, in one aspect, the carrier is a nut meat meal derived from any commercially acceptable nut. In another aspect, the carrier is an isolated solid or flour derived from a nut.

[0093] In one aspect, the ratio of the spray-dried ingredients other than the carrier to the carrier is about 40:60 by weight. In one aspect, the weight ratio is about 70:30. In one aspect, the ratio is about 80:20. In one aspect, the ratio is about 50:50 by weight.

[0094] In one aspect, the solids content of the spray-dried material is about 10% to 50% solids. In another aspect, the solids content of the spray-dried material is about 10% to 30% solids, or about 15% to 30% solids, or preferably about 15% to 25% solids.

[0095] In one aspect, the method is used to manufacture non-fat based confectionery products. In addition to the above-mentioned carrier, the carrier can also be gum arabic (e.g., gum arabic), starch, modified starch, maltodextrin, corn syrup solids, alginate, agar, gelatin, methylcellulose, cyclodextrin or other carriers or their combination. In one aspect, gum arabic is gum arabic (derived from Acacia Senegal). In yet another aspect, the carrier can be a vegetable protein, such as the protein of chickpea, pea or other plants.

[0096] In an alternative aspect, the carrier for non-fat based confectionery products can be used in fat based confectionery products.

[0097] In one aspect, the presently disclosed spray drying methods produce candy compositions having high levels of micronutrients, including antioxidants such as polyphenols. In one aspect, the presently disclosed methods can be used to make compositions having taste-masking properties to allow the use of spirits that would otherwise be unacceptable in candy.

[0098] In one aspect, the presently disclosed spray-drying method produces a spray-dried candy composition having less than about 10% moisture. In one aspect, the spray-dried candy composition has less than about 8% moisture. In yet another aspect, the candy composition has a moisture content of less than about 5%. In one aspect, the moisture content is less than 1.5%. In a preferred aspect, the moisture content is less than 1%.

[0099] Preparation of confectionery products

[0100] In one aspect, the new spray dryer process is used to make fat-based confectionery products such as chocolate products.

[0101] In one aspect, a fat-based confectionery product is prepared from cocoa beans. The roasted cocoa beans can be further roasted and air-selected to produce cocoa nibs, which are converted into cocoa liquor or cocoa butter. The cocoa nibs or cocoa liquor can be converted into cocoa powder. The liquor, cocoa butter, and cocoa nibs can be mixed with sugar or other natural or synthetic sweeteners, either alone or optionally with other ingredients suitable for fat-based confectionery. These ingredients are then added to a spray dryer, dried according to the parameters disclosed herein, and then centrifuged.

[0102] In such a spray dryer process, all of the above disclosed ingredients, carriers and other formulations can be specifically combined with the process. For example, in one aspect, cocoa liquor, cocoa butter and spray-dried cocoa pulp and optionally other ingredients can be combined in a spray dryer.

[0103] All ingredients in a standard chocolate recipe can be combined in a spray dryer and spray dried according to the parameters described herein. In a preferred aspect, cocoa liquor, cocoa butter, lecithin and cocoa pulp are spray dried.

[0104] In an alternative aspect of the spray dryer process, sugar can be added. The sugar can be added in the form of a syrup. In an alternative aspect, fruit other than cocoa pulp can be added to the spray dryer.

[0105] After forming the emulsion, the material is maintained at an appropriate temperature to allow the sugar present in the material to crystallize. The material is kept warm for a sufficient time to allow crystallization to occur. For example, in the presence of sucrose, the material is maintained at a temperature of at least 62°C for about 5-10 minutes until the material crystallizes.

[0106] The ingredients can then be centrifuged. The centrifuged material, i.e., the spray-dried product, can be identified as including, but not limited to, chocolate, compound chocolate, or chocolate-like substances. In alternative aspects, the final product is a non-fat-based confectionery product.

[0107] The material is formed into sticks, truffles, centers, lentils, sheets or other shapes suitable for fat-based confectionery. Alternatively, the centrifuged material can be used as an ingredient in other confectionery or food products.

[0108] In one aspect, the centrifuged material can be used to make fine flavored chocolate, premium chocolate, small batch chocolate, 100% cocoa chocolate, or single origin chocolate.

[0109] The centrifuged material can be further processed and used as an ingredient in other edible products.

[0110] In one aspect, the fat-based confectionery produced by the present method can have a high cocoa liquor to sugar ratio, i.e., comprise primarily cocoa liquor. In one aspect, the cocoa liquor to sugar ratio is 6:4 or 7:4 or 8:4 or higher.

[0111] In one aspect, the spray-dried product has a fat to particle ratio of 70:30 to 30:70. Preferably, the ratio is 50:50 to 60:40.

[0112] In one aspect, the spray-dried product comprises cocoa pulp to replace sugar in a fat-based confectionery product. In one aspect, the fat-based confectionery product does not include any other sugar. In one aspect, the product does not include any refined sugar.

[0113] The spray-dried cocoa pulp can also be used to replace all or part of the sugar in foods or non-fat based confectionery.

[0114] In one aspect, the product may include spray-dried cocoa pulp in place of texturizing agents such as gelatin, pectin, starch, and the like.

[0115] In one aspect, the fruit or vegetable material can be spray dried with cocoa butter.

[0116] Prior to spray drying the fruit or vegetable material, the material is ground so that any components that are not soluble in water or fat have a particle size of 30 microns or less.

[0117] The fruit or vegetable material spray-dried with cocoa butter may be subjected to further processing to reduce the particle size to less than 30 microns, such as 20 microns or 10 microns. The further processing may include a grinding step or a refining step.

[0118] In one aspect, the fruit material used in the spray drying process can replace some or all of the added sugar in the resulting candy composition. In one aspect, the fruit material can replace refined sugar.

[0119] In one aspect, the fruit or vegetable material can be strawberries, raspberries, blackberries, blueberries, guava, persimmon, pineapple, apple, mango, banana, beets, carrots, chayote, kale, pears, grapes, peas, boysenberries, cranberries, peppers, melons, potatoes, parsnips, yams, sweet potatoes, potatoes, tomatoes, papaya, citrus fruits, pumpkin, squash, nectarines, peaches, plums and other stone fruits, as well as other fruits and vegetables not listed here.

[0120] In one aspect, the fruit or vegetable material can also be derived from the pulp of any species of Theobroma or Herrania genus or its interspecific and intraspecific hybrids in these genera, more preferably derived from the pulp of species Theobroma cacao and large-flowered cocoa tree (Theobroma grandiflorum). Species Theobroma cacao as used herein includes all genotypes, particularly all commercially useful genotypes, including but not limited to Criollo, Forastero, Trinitario, Arriba, Amelonado, Contamana, Curaray, Guiana, Iquitos, Maranon, Nacional, Nanay and Purus and hybrids and hybrids thereof. The material can also be other pulps that are traditionally considered to be waste, such as the pulp of cashew apple and coffee cherry. DETAILED DESCRIPTION

[0121] The presently disclosed subject matter may be further understood by reference to the following examples, which are provided by way of illustration of the invention and not by way of limitation.

[0122] Example

[0123] Example 1 - Spray-dried chocolate containing spray-dried cocoa pulp

[0124] According to one aspect of the invention, chocolate comprising spray-dried cocoa pulp is prepared in a spray dryer.

[0125] The following materials are added to the spray dryer: 3000 grams of cocoa butter, 400 grams of cocoa liquor, 2000 grams of cocoa pulp, and additional cocoa butter is added to the spray dryer. Optionally, lecithin is added. The materials are mixed to produce a fine water-in-oil emulsion.

[0126] Prior to spraying, the material was kept at 50°C.

[0127] The material is spray dried at an inlet temperature of 130-160° C. The material is spray dried for less than ten seconds, preferably less than five seconds. The resulting suspension of fine particles in fat is maintained at a temperature above the glass transition temperature of the sugar for about ten minutes to allow crystallization to occur.

[0128] The resulting emulsion is centrifuged to remove excess fat. The resulting material has a moisture content of less than 1.0 and a fine particle size, resulting in a smooth chocolate.

[0129] Chocolate has the following composition:

[0130]

[0131]

[0132] The materials produced herein can be further processed by milling or other processing to achieve a smaller particle size distribution.

[0133] The manufactured material is suitable for consumption as a final product or alternatively may be used as an ingredient in the manufacture of confectionery products.

[0134] Example 2 - Spray-dried cocoa pulp with cocoa butter as an ingredient

[0135] Cocoa pulp is combined with melted cocoa butter and lecithin in a high-shear mixture to produce a water-in-oil emulsion. The emulsion is maintained at a temperature above 70°C and then spray-dried at 65°C to 140°C (air inlet temperature). After drying and water removal, the process yields a suspension of fine solids (sugar, pectin, and other pulp components) in melted cocoa butter. The suspension is incubated for 15 minutes to allow the sugar to crystallize and excess water to evaporate. The continuous matrix of fat separates the particles and eliminates clumping, resulting in fine crystals. The suspension is then centrifuged to remove excess cocoa butter. After most of the cocoa butter has been removed, the concentrated suspension is used in chocolate formulations.

[0136] As an ingredient, when combined with cocoa liquor, the material produced in this way can reduce the harsh taste of the cocoa liquor.

[0137] The material may alternatively be used as an ingredient in other confectionery products.

[0138] Other fruit pulps, such as the pulp of the Theobroma grandiflorum cacao tree, can be combined with cocoa butter as described herein. These products can also be added as ingredients to fat-based and non-fat-based confectionery and food products.

[0139] Example 3 - Ice Cream

[0140] According to one aspect of the invention, ice cream is prepared by spraying the ingredients of an ice cream composition under cooling conditions in a spray dryer to produce a water-in-fat emulsion.

[0141] The ingredients are sprayed in a spray dryer and then centrifuged. A stick or handle is inserted to make the ice cream ready for consumption.

[0142] Example 4 - Preparation of Fruit Candies Using the New Method

[0143] According to one aspect of the present invention, a fruit candy is prepared.

[0144] 1000 grams of strawberry material was added to a blender along with 1500 grams of cocoa butter. The material was added to a spray dryer and spray-dried to produce a water-in-fat emulsion. The resulting suspension of fine particles in fat was maintained at a temperature above the glass transition temperature of the fruit sugar to allow crystallization to occur.

[0145] The resulting material is then centrifuged to remove excess fat, resulting in a fruit candy with a particle size of less than 30 microns and a 2:1 fat to water base.

[0146] According to one aspect of the present invention, the same method as described for strawberries is used, but 1000 grams of bananas are used instead.

[0147] Example 5 - Preparation of Chocolate Fruit Candy Using the New Method

[0148] According to one aspect of the present invention, a chocolate fruit candy is prepared.

[0149] 1500-2000 grams of strawberry material is added to a blender along with 1500 grams of cocoa butter and 2500-3000 grams of cocoa liquor. This material is then added to a spray dryer and spray-dried to produce a water-in-fat emulsion. The resulting suspension of fine particles in fat is maintained at a temperature above the glass transition temperature of the fruit sugars to allow crystallization.

[0150] Despite no sugar being added to the fruit candies, sensory testing of the candies surprisingly demonstrated that the strawberry candies were perceived as sweeter than similar candies containing added sugar.

[0151] The resulting material is then centrifuged to remove excess fat, producing a fruit chocolate confectionery with a particle size of less than 30 microns.

[0152] This written description uses examples to disclose the invention, including the best mode, and to enable any person skilled in the art to practice the invention, including making and using any device or system and performing any incorporated method. The patentable scope of the invention is defined by the claims and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements that have substantially similar literal language to the claims.

Claims

1. A method for preparing a water-in-fat emulsion chocolate product, comprising: Cocoa pulp and a carrier are spray dried in a spray dryer to produce a water-in-fat emulsion, which is maintained at a temperature above the glass transition temperature of sugar to allow sugar crystallization and then centrifuged to produce a water-in-fat emulsion chocolate product having a particle size of 30 microns or less, wherein the carrier is cocoa powder, cocoa pod fiber, cocoa butter or other products derived from cocoa pods.

2. The method of claim 1, wherein the product does not contain any added sugars.

3. The method of claim 1, wherein the spray drying is performed at an inlet temperature of 120°C to 180°C.

4. The method of claim 1, wherein the spray drying is performed at an outlet temperature of 60°C to 100°C.

5. The method of claim 1, wherein the spray drying is performed in a spray dryer coated with polytetrafluoroethylene.

Images