Edible product

Abstract

The present invention provides an edible product. The method for producing cocoa pod shell powder comprises the steps of: making cocoa pod shells into sheets; incubating pieces of cocoa pod shells in water; in the wet milling process, 0.25 L to 1 L of water is added per kg of the cocoa pod shells, so that the cocoa pod shells become a paste, and slices of the cocoa pod shells are not dried after the incubation and before the cocoa pod shells become the paste in the wet milling process; and drying the paste at a temperature of at least 80 DEG C.

Description

[0001] This application is a divisional application of Chinese patent application No. 202180048416.9 entitled "Edible Products", which was filed on August 2, 2021, under the PCT international application PCT / US2021 / 044171 and entered the Chinese national phase on January 6, 2023. Technical Field

[0002] This invention relates to cocoa pod shell powder, edible products thereof, and methods for manufacturing the same. Specifically, this invention relates to cocoa pod shell powder, edible products containing cocoa pod shells, and methods for manufacturing cocoa pod shell powder for human consumption. Background Technology

[0003] Cocoa pod shell (“CPH”), also known as “cocoa pulp”, is the outer shell of a cocoa pod or cocoa fruit, surrounding the cocoa bean and pulp. Other names are also known, such as “cocoa pod skin,” “cocoa pod skin,” “cocoa pod shell,” “skin,” and “shell.” In the following text, the terms “cocoa pod shell” and “cocoa pulp” will be used interchangeably to refer to the outer shell of the cocoa fruit. Cocoa pod shells comprise approximately 52%–76% by weight of fresh, whole cocoa pods or cocoa fruits. During cocoa pod processing, approximately 10 tons of wet cocoa pod shells are produced for every tonne of dry cocoa beans extracted from the pods.

[0004] Cocoa pod shells are generally considered waste and disposed of through landfill, incineration, etc. There have been attempts to use cocoa pod shells, or at least a portion thereof, as products that can be incorporated into edible products. For example, in US4206245, cocoa pod shells (referred to as cocoa pulp in that patent) are first processed by peeling the outer skin off the shell, then removing the cocoa beans and pulp, leaving the peeled cocoa pod shells. The peeled shells are then processed to extract a pectin-containing juice, or ground to provide a powder that can be used in other products. Examples in US4206245 include the use of extracted shell juice in the manufacture of tobacco products and the use of peeled shell powder in various food products, including beverages, mayonnaise, pasta, pasta mixes, chocolate desserts, pizza bases, and animal feed.

[0005] Other methods for producing cocoa pod husk powder are discussed in B. Yapo, V. Besson, B. Benoit, and L. Kouassi, “Adding Value to Cacao Pod Husks as a Potential Antioxidant-Dietary Fiber Source,” *American Journal of Food and Nutrition*, Vol. 1, No. 3, pp. 38–46, 2013; R. Martínez, P. Torres, MA. Meneses, J.G. Figueroa, J.A. Pérez-Álvarez, and M. Viuda-Martos, “Chemical, technological, and in vitro antioxidant properties of cocoa (Theobroma cacao L.) co-products”; L. Vriesmann, R. Amboni, and C. Petkowicz, “Cacaopod husks (Theobroma cacao L.): Composition and hot-water-soluble pectins”; and P. Ozung, O. Oko, and E.A. Agiang, “Chemical Composition of Differently Treated The methods described in “Forms of Cocoa POD Husk Meal (CPHM)” and I. Amir, H. Hanida, and A. Syafiq, “Development and physical analysis of high fiber bread incorporated with cocoa (Theobromacacao sp.) pod husk powder,” *International Food Research Journal*, Vol. 20, No. 3, pp. 1301-1305, 2013, produce cocoa pod husk powder with different compositions and do not maximize the total dietary fiber or insoluble dietary fiber of the resulting product. Among existing CPH powders, the highest total fiber content in cocoa pod husk powder produced using the method described by Ozung et al. is 61.8% by weight, while the highest total insoluble dietary fiber content is described as 53% by weight in the literature by Martinez et al.

[0006] The use of cocoa pod shells in food and beverages is limited because the chemical composition of cocoa pod shells produced by known methods is unfavorable for their use in commercially useful products. Specifically, known technologies for producing cocoa pod shell products such as cocoa pod juice or ground powder result in products lacking high levels of fiber, particularly pectin, making them suboptimal as thickeners, gelling agents, or low-calorie, fiber-rich extenders. Furthermore, high levels of ash and / or sugar reduce the ability of known cocoa pod shell powder to function as an effective flour substitute or thickener in a variety of foods, including baked goods and confectionery.

[0007] Therefore, it is advantageous to provide cocoa pod shell powder and materials that can be used in a variety of edible products and to overcome one or more defects of existing cocoa pod shell products.

[0008] Furthermore, it is advantageous to provide cocoa pod powder that can be used effectively as a gelling agent, thickener, or extender in various foods or beverages without further processing. It is also advantageous to provide cocoa pod powder that does not have significant thickening ability, so that it can be effectively used in confectionery such as chocolate, where it can function similarly to cocoa powder.

[0009] It is also advantageous to provide an improved cocoa pod powder with a higher level of fiber, especially a higher level of insoluble fiber, compared to known cocoa pod powders. Furthermore, it is advantageous to provide a cocoa pod powder with an increased ratio of insoluble to soluble fiber.

[0010] Therefore, the purpose of the embodiments of the present invention is to overcome or mitigate at least one problem of the prior art. Summary of the Invention

[0011] According to a first aspect of the invention, cocoa pod shell powder is provided, having at least 55% by weight of insoluble dietary fiber and / or at least 68% by weight of total dietary fiber content of cocoa pod shell, and wherein the total ash content does not exceed 6.0% by weight.

[0012] The ash content of the cocoa pod powder of the first aspect of the invention may not exceed 5.5% by weight, 5.4% by weight, 5.3% by weight, 5.2% by weight, 5.1% by weight, 5.0% by weight, or not more than 4.5% by weight. Surprisingly, the cocoa pod powder of the invention containing less than 6.0% by weight of ash, especially not more than 5.5% by weight or not more than 5.0% by weight of ash, enables the CPH powder of the invention to be used in a wider range of foods, serving various functions, including as a non-sweetening extender, flour substitute, and / or thickener, without significantly impairing the taste or texture of the food.

[0013] In some embodiments, the insoluble dietary fiber (IDF) concentration is at least 56% by weight or at least 58% by weight. In a preferred embodiment, the amount of insoluble dietary fiber in the cocoa pod powder is at least 60% by weight, at least 65% by weight, at least 67% by weight, at least 68% by weight, or at least 70% by weight. In some embodiments, the total dietary fiber (TDF) is at least 70% by weight, at least 71% by weight, at least 72% by weight, at least 73% by weight, at least 74% by weight, or at least 75% by weight. In some embodiments, the insoluble dietary fiber content is at least 60% by weight of the total weight of the cocoa pods, and the total dietary fiber content is at least 70% by weight. In other embodiments, the TDF may be at least 72% by weight and the IDF may be at least 65% by weight, or the TDF may be at least 75% by weight and the IDF may be at least 67% by weight.

[0014] According to another aspect of the invention, cocoa pod shell powder is provided, having a content of at least 60% by weight of insoluble dietary fiber and at least 70% by weight of total dietary fiber, based on the total weight of the cocoa pod shells. In this aspect of the invention, although the total ash content may be relatively high, the very high levels of IDF and TDF enable the product to be used as a flour substitute, thickener, etc., in a variety of edible products. In a preferred embodiment, the amount of insoluble dietary fiber in the cocoa pod shell powder is at least 60% by weight, at least 65% by weight, at least 67% by weight, at least 68% by weight, or at least 70% by weight. In some embodiments, the total dietary fiber is at least 70% by weight, at least 71% by weight, at least 72% by weight, at least 73% by weight, at least 74% by weight, or at least 75% by weight. In other embodiments, the TDF may be at least 72% by weight and the IDF may be at least 65% by weight, or the TDF may be at least 75% by weight and the IDF may be at least 67% by weight.

[0015] Throughout this instruction manual, "cocoa pod shell" may refer to the skin of a cocoa pod, the flesh of a cocoa pod, or both; while the term "whole cocoa pod shell" refers to a combination of the flesh and skin of a cocoa pod.

[0016] It should also be noted that "cocoa pod shell" refers to the outer shell of the cocoa pod or fruit, surrounding the cocoa bean and the pulp inside. The term "cocoa pod shell" should not be confused with "cocoa shell," "cocoa bean pulp shell," or "cocoa bean pulp shell," which in this art refers to the skin or outer shell of the cocoa bean (pulp) inside the pod or fruit. "Edible product" means a food or beverage product or ingredient. "Ash content" can refer to the mineral content of the cocoa pod shell, including potassium, phosphorus, calcium, silicon, magnesium, sodium, and iron, as well as their oxides. Ash content can be determined using test method AOAC 942.05 (the official analytical method available online at AOAC INTERNATIONAL (OMA)).

[0017] Total dietary fiber and insoluble dietary fiber can be determined by any suitable method such as AOAC2009.01 and AOAC2011.25.

[0018] Surprisingly, cocoa pod powder has been found to have increased levels of fiber, particularly insoluble dietary fiber, compared to products from the prior art, and also surprisingly, reduced ash content. The higher fiber content, lower ash content, and ability to modulate fiber function enable the cocoa pods of this invention to be used in edible products for applications not currently commercially feasible or acceptable, such as thickening, gelling, and bulking filler applications in a wide range of products, without contributing significant amounts of calories. The high fiber and low ash levels allow cocoa pods to be used as a substitute ingredient in many foods without significantly affecting the taste, mouthfeel, or texture. In prior art cocoa pod products, lower fiber levels typically result in higher carbohydrate levels, which more significantly affect the taste, texture, and quality of the resulting product and contribute relatively more calories.

[0019] According to another aspect of the invention, cocoa pod shell powder with an ash content not exceeding 5.0% by weight is provided. Previously, it was thought that cocoa pod shell extracts and powders could only be obtained by processing cocoa pod shells in a manner that increased the ash content to unacceptable levels. The inventors have surprisingly discovered a method for producing cocoa pod shell powder (extract) in which the ash content can be reduced to levels previously unattainable in the prior art, thereby obtaining a product that can be used in a variety of edible products.

[0020] The following statements apply to all aspects of this invention.

[0021] Cocoa pod powder may include powdered cocoa pod skins and / or powdered cocoa pod meat. In some embodiments, cocoa pod powder includes peeled powdered cocoa pod meat, while in other embodiments, cocoa pod powder includes whole cocoa pod powder.

[0022] Cocoa pod powder may contain no more than 15% by weight, 14% by weight, 13% by weight, 12% by weight, 11% by weight, or no more than 10% by weight of protein.

[0023] Cocoa pod powder may contain no more than 5% by weight, 4% by weight, 3% by weight, 2% by weight, or no more than 1.5% by weight of fat.

[0024] In some embodiments, cocoa pod powder contains at least 55% by weight of insoluble dietary fiber, no more than 10% by weight of protein, and no more than 2% by weight of fat. An exemplary cocoa pod powder contains at least 65% by weight of insoluble dietary fiber, no more than 8.5% by weight of protein, and no more than 1.5% by weight of fat.

[0025] The moisture content of the cocoa pod powder may not exceed 10% by weight, 8.5% by weight, or especially 8% by weight. In some embodiments, the moisture content may be less than 8% by weight. The reduced moisture content in the cocoa pod powder of the present invention, combined with the high concentration of fiber, enables the product of the present invention to be used in applications where it is not possible using prior art CPH powders or products. Therefore, in a preferred embodiment, the cocoa pod powder of the present invention comprises at least 55% by weight of insoluble dietary fiber and less than 8% by weight of moisture.

[0026] The water activity (Aw) of cocoa pod powder is preferably less than 0.5, 0.4 or less than 0.3.

[0027] The sugar content of cocoa pod powder may not exceed 8% by weight of the powder, preferably not exceeding 7% by weight. According to another aspect of the invention, cocoa pod powder containing no more than 8% by weight of sugar is provided. It has been found that cocoa pod powder containing no more than 8% by weight, specifically no more than 7% by weight of sugar, enables CPH powder to be used in a wider range of foods, serving various functions, including as a non-sweetening extender, a flour substitute, and / or a thickener. In some embodiments, the cocoa pod powder contains no more than 8% by weight or 7% by weight of sugar, and contains no invert sugar or contains less than 1% by weight of invert sugar.

[0028] The fiber in cocoa pod powder may include lignin, cellulose, and / or pectin. In a preferred embodiment, the fiber includes all three of lignin, cellulose, and pectin. The ratio of lignin to cellulose in the powder may be between 2:1 and 1:2, preferably between 1.25:1 and 1:1.25. The ratio of the amount of pectin in the powder to the total amount of lignin and cellulose may be between 1:3 and 1:5 or between 1:3 and 1:4.

[0029] The ratio of insoluble dietary fiber to soluble dietary fiber can be between 4:1 and 10:1, and is preferably greater than 4:1, 4.5:1, or 5:1. In some applications of the cocoa pod powder of the present invention, such as its use as a low-calorie extender, the ratio of insoluble fiber to soluble fiber can be at least 5:1 or at least 6:1.

[0030] In some embodiments, the cocoa pod powder contains at least 5% by weight or at least 7.5% by weight of pectin. Surprisingly, it has been found that cocoa pod powder containing significant levels of functional pectin can be manufactured, enabling the use of cocoa pods in a variety of applications where pectin is particularly useful.

[0031] According to another aspect of the invention, an edible or palatable product comprising cocoa pod shell powder of any other aspect of the invention is provided.

[0032] When mixed with other ingredients in edible products, it should be understood that the cocoa pod shell powder of the present invention may or may not be in powder form in the final product, and therefore should be referred to as "cocoa pod shell" in edible products.

[0033] The edible or edible product can be any suitable food or beverage, selected from the group consisting of: beverages; confectionery; baked goods; edible fillers; and spreads. In other embodiments, the edible product can be a food or beverage ingredient. The food or beverage ingredient can be, for example, a extender, and in some embodiments, an extender for, for example, chocolate or other confectionery products. The food or beverage ingredient may include CPH powder and one or more other ingredients independently selected from the group consisting of: fiber, protein, milk powder, fat, emulsifiers, aqueous colloids, carbohydrates, minerals, vitamins, thickeners, flavorings, colorings, and sweeteners. The CPH powder can be tightly mixed with other ingredients at a CPH powder:other ingredient ratio of 25:75 to 99.5:0.5. The CPH powder and one or more other ingredients can be tightly mixed via agglomeration, spray drying, fluidized bed drying, extrusion, or any other suitable technique.

[0034] The beverage may include powdered beverages, which may be selected from fruit-flavored powdered beverages, cocoa powder, malt beverages, or any combination thereof. The cocoa pod shells in the powdered beverage may constitute the powder. The cocoa pod shell powder and the beverage powder may form a homogeneous mixture. The cocoa pod shell powder may be present in the beverage powder in an amount not exceeding 45%, 40%, 35%, 30%, 20%, 15%, or not exceeding 10% by weight of the total beverage powder.

[0035] Beverages may include liquid beverages, which may be derived from milk, milkshakes, chocolate milk, smoothies, malt-based beverages, chocolate beverages, soups, yogurt drinks, and coffee-based beverages. Cocoa pod shells may be present in the liquid beverage in amounts not exceeding 45%, 40%, 35%, 30%, 20%, 15%, or not exceeding 10% by weight of the total beverage powder.

[0036] In both powdered and liquid beverages, cocoa pod shells can act as a thickener or gelling agent in the resulting beverage. In other embodiments, cocoa pod shells can act as a caloric enhancer or filler, or as a spacer, where they can be used to separate sugars and aqueous colloidal particles to improve ease of dispersion.

[0037] Confectionery products may include chocolate. The term "chocolate" as used in this invention is not limited to the various definitions of chocolate provided by governments and regulatory agencies. "Chocolate" simply refers to a product containing a fat phase and comprising cocoa products and sweeteners. Other optional components of chocolate include dairy components (e.g., milk fat and milk powder).

[0038] The fat may be cocoa butter, milk fat, cocoa butter substitute (CBE), cocoa butter substitute (CBS), vegetable fat that is liquid at standard ambient temperature and pressure (SATP, 25°C and 100 kPa), or any combination thereof. In one specific embodiment, the chocolate contains cocoa butter.

[0039] CBE is defined in Directive 2000 / 36 / EC. Suitable CBEs include sage butter, Borneo butter, tengkawang (a type of sal tree), palm oil, salsa, shea butter, kokum gurgi (a type of fruit), and mango kernel. CBEs are typically used in combination with cocoa butter. In one embodiment, the chocolate contains no more than 5% by weight of CBEs.

[0040] Chocolate may contain cocoa butter substitutes (CBS) (sometimes called cocoa butter substitutes, CBR) to replace some or all of the cocoa butter. Such chocolate materials are sometimes called complex chocolate. Suitable CBSs include lauric CBSs and non-lauric CBSs. Lauric CBSs are short-chain fatty acid glycerides. They differ in physical properties, but they all have a triglyceride configuration, which makes them compatible with cocoa butter. Suitable CBSs include those based on palm kernel oil and coconut oil. Non-lauric CBSs consist of fractions obtained from hydrogenated oils. Selectively hydrogenating oils forms trans fatty acids, which increases the solid phase of the fat. Suitable sources of non-lauric CBSs include soybean oil, cottonseed oil, peanut oil, rapeseed oil, and corn (maize) oil.

[0041] Chocolate may contain at least one vegetable fat, which is liquid at standard ambient temperature and pressure (SATP, 25°C and 100 kPa). Suitable vegetable fats include corn oil, cottonseed oil, rapeseed oil, palm oil, safflower oil, and sunflower oil.

[0042] The invention also applies to chocolate products in which some or all of the fats are composed of partially or completely non-metabolizable fats, such as Caprenin.

[0043] Chocolate may contain at least one sweetener. This sweetener may be a modifier or a potent sweetener. Suitable modifiers include sucrose, invert sugar syrup, caramel, glucose, fructose, polydextrose, high-fructose corn syrup, maltodextrin, honey, maple syrup, stevia, and sugar alcohols such as glycerol, maltitol, isomaltitol, sorbitol, xylitol, lactitol, erythritol, galactitol, polyglucistol, mannitol, or optionally raffinose, inulin, FOS, GOS, IMO, XOS, HMO, soluble corn fiber, cyclodextrin, resistant maltodextrin, or other soluble fibers.

[0044] Chocolate products may contain more than one type of chocolate material. In one embodiment, the chocolate contains two different chocolate materials or two different chocolate materials with different appearances. For example, the chocolate may contain milk chocolate and white chocolate, or it may contain milk chocolate and dark chocolate with a swirl pattern.

[0045] Chocolate products can be chocolate bars, such as solid chocolate bars or filled chocolate bars or products. Chocolate products can also be molded chocolate products (i.e., chocolate products in which melted chocolate is solidified in a mold).

[0046] Cocoa pod shells can be evenly mixed with the chocolate ingredients in chocolate products.

[0047] Cocoa pod shells may be present in the chocolate in an amount not exceeding 30%, 20%, 15%, or 12% by weight of the total chocolate weight. In some embodiments, cocoa pod shells are present in an amount of 2% to 10% or 5% to 10% by weight of the total chocolate weight. Therefore, in some embodiments, the ratio of cocoa pod shells to other chocolate ingredients may be between, for example, 30:70 and 1:99.

[0048] The confectionery products can be non-chocolate confectionery, such as sugar foods or sugar substitutes or confectionery products. Confectionery products suitable for use in this invention include, for example, chewy candies such as caramel, toffee, fudge, marshmallows, and nougat; desserts; jellies; and gum bases. Confectionery products may contain at least one sweetener. This at least one sweetener may be a modifier or a potent sweetener. Suitable modifiers include sucrose, invert sugar syrup, caramel, glucose, fructose, polydextrose, high-fructose corn syrup, maltodextrin, honey, maple syrup, stevia, and sugar alcohols such as glycerol, maltitol, isomaltitol, sorbitol, xylitol, lactitol, erythritol, galactitol, polyglucistol, mannitol, or optionally raffinose, inulin, FOS, GOS, IMO, XOS, HMO, soluble corn fiber, cyclodextrin, resistant maltodextrin, or other soluble fibers.

[0049] In some embodiments, the confectionery product contains at least one gelling agent or thickener, particularly in chewy candies, gummies (or jelly candies), jellies (or jelly candies), and marshmallows.

[0050] As used herein, "chewable candy" refers in the art to a specific type of chewable candy containing fat and emulsifiers, and comprising crystalline sugars or sugar-free augmenting sweeteners in the bulk amorphous phase. It can also be aerated up to 20%.

[0051] Jelly and gummies are popular sweet treats because they combine a desired chewy texture with sweetness. Traditionally, jelly and gummies are made using sugar or sugar-free augmenting sweeteners along with gelling agents such as gelatin. The gelling agents suitable for the jelly or gummies of this invention comprise one or more soluble aqueous colloids selected from gelatin, xanthan gum, pectin, locust bean gum, psyllium husk, gum arabic, starch, and sodium alginate.

[0052] Cocoa pod shells can be used to replace some or all of the gelling agents or thickeners in chewy candies, gummy candies, or jelly candies. In some embodiments, at least 5%, 10%, 15%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, or up to 100% of the gelling agents or thickeners typically present in candies can be replaced by cocoa pod shells. Therefore, in embodiments of candies containing gelling agents or thickeners, the ratio of cocoa pod shells to gelling agents or thickeners (or the total amount of gelling agents or thickeners) can be between 1:9 and 99:1, such as between 1:4 and 50:1 or between 1:1 and 9:1. Specifically, cocoa pod shells can be used to replace pectin in chewy candies, jelly candies, or gummy candies.

[0053] When the product is a filler, the filler can be a confectionery filler. A variety of confectionery fillers will be apparent to those skilled in the art. The filler can be fat-based or water-based. Suitable fat-based fillers include truffles, custard, and chocolate. Suitable water-based fillers include caramel, frosting, jam, and gels such as Turkish delight. In one embodiment, the filler is a liquid or flowable material at room temperature. For example, the filler can be a viscous liquid, such as caramel, frosting, or a gel like Turkish delight.

[0054] Cocoa pod shells can be used to replace some or all of the gelling agents or thickeners in fillers. In some embodiments, at least 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, or up to 100% of the gelling agents or thickeners typically present in the filler can be replaced by cocoa pod shells. Therefore, in embodiments containing fillers or thickeners, the ratio of cocoa pod shells to gelling agents or thickeners (or the total amount of gelling agents or thickeners) can be between 1:9 and 99:1, such as between 1:4 and 50:1, or between 1:1 and 9:1. Specifically, cocoa pod shells can be used to replace pectin in fillers.

[0055] In an implementation where the edible product is a baked product, the baked product can be a flour-based product. The term "baked product" includes not only baked food products, but also products produced before baking, such as when the product comprises raw or partially cooked dough or batter. Flour-based food products can include dough-based or batter-based products such as cakes, biscuits, cookies, or pastries. The dough or batter may contain wheat, barley, rye, oat, or corn flour, or any other suitable grain or non-grain flour.

[0056] Cocoa pod shells can be included as a filler in baked goods. Cocoa pod shells can be used to replace at least a portion of the flour in baked goods. In some embodiments, at least 5%, 10%, 15%, 20%, 25%, or 33% of the flour typically present in baked goods can be replaced by cocoa pod shells. Therefore, in some embodiments, the ratio of cocoa pod shells to flour in baked goods can be between 5:95 and 35:65, or between 10:90 and 25:75.

[0057] According to another aspect of the invention, an edible product comprising whole cocoa pod shell powder is provided. This edible product may be as defined and described above with respect to other aspects of the invention. The whole cocoa pod powder may contain at least 55%, 56%, 57%, 58%, 59%, or at least 60% by weight of insoluble dietary fiber, in an amount equal to or greater than the total weight of the whole cocoa pod powder. In a preferred embodiment, the amount of insoluble dietary fiber in the cocoa pod shell powder is at least 65%, 66%, 67%, 68%, or at least 69% by weight.

[0058] Cocoa pod shell powder of any aspect of the present invention can be manufactured by a method comprising the following steps: a) Turn the cocoa pod shells into flakes; b) Optionally, cocoa pod shells are incubated in water at a temperature between 35°C and 85°C; c) Wet-grind cocoa pod shells to form a paste; d) dried paste; and e) Formed from a dried paste into powder.

[0059] Steps b) and c) can be performed in any order.

[0060] Therefore, another aspect of the present invention provides a method for manufacturing cocoa pod shell powder, the method comprising the following steps: a) Turn the cocoa pod shells into flakes; b) Optionally, cocoa pod shells are incubated in water at a temperature between 35°C and 85°C; c) Wet-grind cocoa pod shells to form a paste; d) dried paste; and e) Formed from a dried paste into powder.

[0061] Steps b) and c) can be performed in any order.

[0062] Surprisingly, the insoluble dietary fiber level of the cocoa pod powder produced using the above method is found to be higher than 55% or even 60% by weight of the total weight of the cocoa pod powder, which is far greater than the insoluble dietary fiber level achieved in the prior art. Furthermore, the total dietary fiber content exceeds 68% or even 70% by weight, which also far exceeds the levels in the prior art. The product produced by this method also has an ash content of no more than 6.0% by weight. As mentioned above, compared with prior art products, the cocoa pod powder produced by the above method retains the functionality of pectin, which makes the cocoa pod powder of the present invention usable in a wide range of edible products and various ingredient applications, such as replacing thickeners and gelling agents (e.g., in jelly candies, gummy candies or chewy candies, fillers or beverages), or as an additive filler (e.g., in confectionery products such as chocolate and flour-based products such as cookies, biscuits and pastries).

[0063] The step of distilling cocoa pod shells in warm water (instead of using the whole pod and neutralizing them in alkali and acid treatment steps, as is known in the art) helps to reduce the amount of insoluble fiber lost from the cocoa pod shell leaching, while allowing less desirable soluble fiber to leach out and retaining and concentrating the insoluble fiber.

[0064] Step a) may include chopping or cutting whole cocoa pod shells, cocoa pod meat, or cocoa pod skins, but preferably using whole cocoa pod shells. These pieces may have a maximum size between 0.05 cm and 10 cm or between 0.05 cm and 5 cm, preferably between 0.5 cm and 3 cm, and more preferably between 1 cm and 3 cm.

[0065] The cocoa pod shells used in step a) are preferably fresh cocoa pod shells that have not been previously processed (e.g., obtained after opening the pods and collecting the beans), or alternatively, vacuum-sealed and frozen cocoa pod shells, in which case there may be a step of thawing the freeze-dried cocoa pod shells before step a).

[0066] The cocoa pod shells used in step a) can also be cleaned and washed, preferably with water.

[0067] In some embodiments, the outer skin of the cocoa pod shell can be removed before step a), such as by peeling, but in a preferred embodiment, the outer skin remains on the cocoa pod shell.

[0068] Step b) may include incubating cocoa pod slices in water for at least 30 minutes, 45 minutes, 60 minutes, 90 minutes, 2 hours, 2.5 hours, or at least 3 hours. In some embodiments, the time period is at least 4 hours, 5 hours, or 6 hours.

[0069] Step b) may include incubating cocoa pod slices at a temperature of at least 40°C, 45°C, or at least 50°C and not exceeding 80°C, 75°C, 70°C, or 65°C. In some embodiments, the temperature of step b) is between 45°C and 65°C, or between 45°C and 60°C, or preferably between 50°C and 60°C. In some embodiments, the temperature is about 52°C-54°C.

[0070] Step b) is believed to involve soaking cocoa pod slices and extracting some water-soluble pectin, sugars, soluble fiber, polyphenols, and some proteins / peptides, leaving more desired insoluble fiber such as insoluble pectin, which would otherwise be removed in existing methods, such as by alkali or acid treatment. Additionally, it is believed that these slices are softened in a subsequent step c) to reduce their size (wet milling).

[0071] The amount of water used in step b) can be between 1L and 5L per kg of cocoa pod shells, preferably between 2L and 4L, such as about 2.5L-3.5L per kg of cocoa pod shells.

[0072] The preferred temperature, time, and water volume are believed to achieve a good balance between the yield of useful cocoa pod fiber and the reduction of mold, heavy metals, pesticides, and pests in and on the cocoa pods.

[0073] Step b) may include the use of one or more preservatives in the water. Suitable preservatives include sorbates, citric acid, antioxidants, essential oils, weak bases, or any combination thereof. Using preservatives in warm water ensures that any mold growth on the cocoa pods is minimized.

[0074] After step b), the incubation solution can be removed and discarded, and the wet cocoa pod shells can be collected.

[0075] Step c) may include wet grinding the slices in a suitable grinder or mill. The cocoa pod slices may be placed in a grinder or blender, for example, with 0.25 L to 1 L of water added per kg of cocoa pod slices, or without adding water. Alternatively, the cocoa pod slices may be mechanically extruded, for example using a screw press, to reduce the moisture content of the slices before grinding or milling. In another method, the cocoa pod slices may be homogenized by passing them through a shear mill or colloid mill, or other equipment designed to reduce the size of the wet pulp. However, it should be noted that the cocoa pod slices are not dried before grinding or milling (or mechanical extrusion).

[0076] The paste produced at the end of step c) is then dried during step d). Drying can be carried out by any suitable method, including but not limited to: oven drying, drum drying, sun drying, freeze drying, fluidized bed drying, and vacuum drying. The drying technology can be selected based on the scale of operation, the desired color, functionality, and water-binding capacity of the final powder product. The chosen drying method has a significant impact on the functionality of the final product, particularly its ability to form viscosity, which may be desirable in some applications but not in others.

[0077] In a preferred embodiment, drying is performed using freeze-drying or oven drying (with or without vacuum), as these drying techniques have been found to impart beneficial but distinct properties to the resulting powder. During freeze-drying, the paste loses 90% to 95% of its water content and forms a dry cake with a water activity (Aw) below 0.3 and, in most cases, below 0.2 or below 0.15. The lower the Aw (below 0.25, or most preferably below 0.2), the lower the chance of potential mycotoxin growth in the resulting powder.

[0078] Freeze-drying can be carried out for at least 6 hours, 12 hours, 18 hours, 24 hours, 3 days, 4 days, 5 days, 6 days or at least 7 days.

[0079] For vacuum drying, the paste can be placed in an 85°C vacuum oven and evacuated at <-20 mmHg to produce a dry cake that loses 90% to 95% of its water content and achieves the same Aw level as freeze drying. Alternative drying methods using heat treatment, such as oven drying, can also be employed to achieve the desired functionality.

[0080] Step e) may include grinding the dried product obtained after step d) by knife grinding, hammer grinding, or other milling methods. Step e) may include reducing the dried product to an average particle size between d90 > 5 micrometers and d90 < 70 micrometers, such as d90 < 26 micrometers.

[0081] According to another aspect of the present invention, a method for preparing cocoa pod shell powder is provided, the method comprising the steps of: turning cocoa pod shells into a paste during a wet milling process; and drying the paste at a temperature of at least 80°C to form powder from the paste.

[0082] The drying step may include vacuum drying. The drying step may include drying the paste at a temperature of at least 85°C.

[0083] It has been found that a heat treatment step of the paste at a temperature of at least 80°C and preferably at least 85°C during the drying process can produce cocoa pod fiber with increased levels of insoluble fiber and total dietary fiber and reduced moisture content.

[0084] This method can be used to produce cocoa pod powder for any other aspect of the invention described above.

[0085] According to another aspect of the invention, the use of the cocoa pod shell powder of the invention as a gelling agent, thickener or extender is provided.

[0086] According to another aspect of the invention, the application of cocoa shell powder as a substitute for egg solids in edible products is provided.

[0087] According to another aspect of the invention, the use of the cocoa shell powder of the invention as a flour substitute in dough or batter is provided. The cocoa shell powder can be used to replace 1% to 50% by weight or 5% to 33% by weight of flour in dough or batter.

[0088] According to another aspect of the invention, a cocoa pod powder comprising at least 68% by weight of insoluble dietary fiber is provided. In some embodiments, the amount of insoluble dietary fiber is at least 70% by weight of the total weight of the cocoa pod powder. The cocoa pod powder, the insoluble dietary fiber, and the method of manufacturing the powder are as described and defined above with respect to other aspects of the invention.

[0089] In some implementations, the cocoa pod powder contains no more than 8% by weight of total sugar.

[0090] In some implementations, the cocoa pod powder has an ash content of no more than 5.0% by weight.

[0091] In some embodiments, the cocoa pod powder has at least 60% by weight of insoluble dietary fiber and / or at least 70% by weight of total dietary fiber.

[0092] In some embodiments, the cocoa pod powder includes moisture in an amount not exceeding 12.5% ​​by weight of the total weight of the powder.

[0093] In some implementations, the water activity of the cocoa pod shell does not exceed Aw 0.4.

[0094] In some embodiments, the cocoa pod powder includes less than 2% by weight of fat and less than 10% by weight of protein of the total weight of the cocoa pods.

[0095] In some implementations, the cocoa pod shell includes cocoa pod meat and / or cocoa pod skin.

[0096] In some embodiments, the cocoa pod powder has an average particle size between 2 micrometers and 750 micrometers, preferably between 20 micrometers and 250 micrometers.

[0097] According to another aspect of the present invention, an edible product is provided, comprising cocoa pod shell powder.

[0098] In some implementations, edible products include those selected from confectionery, baked goods, fillings, spreads, and beverages.

[0099] According to another aspect of the present invention, the application of cocoa pod powder in edible products is provided.

[0100] According to another aspect of the present invention, a method for manufacturing an edible product is provided, comprising uniformly mixing cocoa pod powder with edible product ingredients and forming an edible product.

[0101] According to another aspect of the present invention, a method for manufacturing cocoa pod shell powder is provided, comprising: turning cocoa pod shells into a paste during a wet milling process; and drying the paste at a temperature of at least 80°C or at least 85°C. Attached Figure Description

[0102] This patent or application document contains at least one color-drawn drawing. A copy of the published patent or application with the color drawing will be provided by the Patent Office upon request and payment of the necessary fees.

[0103] To provide a clearer understanding of the present invention, embodiments are now described by way of example only with reference to the accompanying drawings, in which: Figure 1A This is a table listing the concentrations of fiber and other components in the CPH powder of the present invention, as well as various component parameters of the CPH powder of the present invention. Figure 1A (Tests Z3, Z11, B13-14 and B16-19). Figure 1B It is a table listing the fiber and other component concentrations and parameters of CPH products described in US4206425, other prior art CPH products, and defatted cocoa powder; Figure 2 This illustrates the thickening behavior of CPH materials treated differently compared to using RVA method 41.02 (Young NWG, Nonstarch Applications - Hydrocolloids. in: The RVA Handbook (Crosbie GB, Ross AS ed.), AACC International, St. Paul, MN, 2007, pp. 85-94), where a 1% w / w aqueous colloidal solution (or suspension) was held at 80°C for 5 minutes with a stirring rate of 160 RPM, and then cooled to 20°C at 1°C / min; Figure 3This is a series of photographs showing cookies made using freeze-dried CPH (“CPH-FD”) and vacuum-dried CPH (“CPH-Vac85C”) of the present invention as 25% substitutes for flour, compared to control cookies; Figure 4A These are photos of soft cakes made using eggs (control cake) and CPH-FD as substitutes for 30% and 100% egg solids; Figure 4B yes Figure 4A The photo shows a slice of soft cake. Figure 5A These are photographs of the refined paste of the experimental chocolate pellets described in Example 4 before their first pass through the refiner: control (left), CPH-Vac85C (middle), and CPH-FD (right). Figure 5B This is a table showing the particle size and viscosity measurement results of the experimental chocolate pellets described in Example 4; Figure 5C These are photographs of the experimental chocolate bars described in Example 4: control (left); bar with 9.2% CPH-Vac85C (middle); bar with 9.2% CPH-FD (right); Figure 5D This is a summary of informal sensory tasting comments on the experimental chocolate bars described in Example 4; Figure 6A This is a schematic diagram illustrating a Taiwanese method for incorporating CPH into milk chocolate dough in a scale of <200g. This method is used to prepare the chocolates described in Examples 5 and 6. Figure 6B The image shows a photograph of the experimental chocolate bar described in Comparative Example 5, which contains: (5i) 10% NFDM (Comparative Example), (5ii) 10% CPH (from Test #B19, sieve >230 mesh), (5iii) (from Test #B19, sieve <230 mesh), (5iv) 10% CPH (from Test #B19, sieve <325 mesh), and (5v) 10% CPH (from Test #B18, sieve <325 mesh); and Figure 7 The image shows a photograph of the experimental chocolate bar described in Comparative Example 6, which contains: (6i) 15% CPH (from Experiment #B19, sieve <230 mesh) and (6ii) 10% lactose (Comparative Example). Detailed Implementation

[0104] In the following embodiments and as indicated in the accompanying drawings, the following abbreviations are used: CPH - Cocoa pod shells CPH-FD - Freeze-dried cocoa pod shells prepared according to the present invention CPH-Vac85C – 85°C vacuum-dried cocoa pod shells prepared according to the present invention. FD - Freeze-drying according to the drying step of the method of the present invention Vac85C - According to the method of the present invention, the drying step involves vacuum drying at 85°C. CPHS - Cocoa pod shells according to the present invention CPHF - Cocoa pod kernels according to the present invention CPH (Mix) - Cocoa pod shells and flesh according to the present invention St - Incubation step b) distillation according to the method of the present invention Ml - according to the method of the present invention, step c) wet milling StMl and MISt- are distilled and wet-milled according to steps b) and c) of the method of the present invention, or vice versa. CBS-Whole - Whole cocoa pods not treated according to the invention TDF - Total Dietary Fiber IDF - Insoluble Dietary Fiber Edible products - food or beverage products Example 1 - Preparation of whole cocoa pod powder, cocoa pod pulp powder and cocoa pod skin powder The cocoa pod shells (hereinafter referred to as "CPH") are collected immediately after the pods open (the standard method where the beans are removed for chocolate processing and the CPH is typically discarded). The fresh CPH is then frozen or vacuum-sealed and transported from the cocoa farm for processing. In other embodiments, the freezing / vacuum-sealing step can be eliminated by placing the processing facility close to the pod opening.

[0105] The frozen / sealed CPH was then thawed / unsealed and washed with deionized water at room temperature to remove external dirt and debris. After washing, two types of cocoa pod shells were prepared: a) Remove the outer skin of CPH using a typical fruit peeling machine or other peeling mechanism. This yields cocoa pod skin and cocoa pod pulp, the cocoa pod skin being evaluated only for contaminants (see Figure 1), which are then used separately in further processing steps.

[0106] Samples #Z3 and Z11 in Figure 1 are merely examples of cocoa pod meat, with the skin removed using a peeling machine.

[0107] b) Some CPHs remain intact, with both skin and flesh intact (i.e., whole cocoa pod shells), and are used in subsequent processing steps (samples #B16, B17, B18 and B19 in Figure 1 are examples with both skin and flesh intact).

[0108] Next, each type of CPH was cut into small pieces approximately 1 cm in diameter and / or length and incubated in a warm, deionized water bath. In some embodiments, the bath temperature can range from 45°C to 85°C or vary between 45°C and 60°C. The bath temperatures for various samples are reported in Figure 1. This incubation or “soaking” step is partly designed to extract some water-soluble pectin, sugars, soluble fibers, some polyphenols, water-soluble proteins / peptides, and some small molecules that typically form during oxidation processes that occur during the ripening of cocoa pods, while retaining significant amounts of insoluble fibers such as lignin, cellulose, and insoluble pectin.

[0109] Typically, the incubation step uses 3.5 L of water to 1 kg of usable CPH (or CPH meat) for approximately 3.5 hours. Larger volumes of water, longer soaking times, and agitation during soaking can potentially be used to further reduce heavy metals and pesticides to desired levels, possibly at the cost of reduced yield. For applications requiring lower pectin concentrations in CPH tablets (such as foods requiring less gelling or thickening), using incubation bath temperatures above 60°C is expected to extract larger quantities of pectin at the cost of reduced yield.

[0110] Next, collect the soaked CPH blocks on a wire or porous basket (filter) and discard the soaking / incubation solution (which is now darker and stickier). Then place the wet CPH with approximately 0.5 L ( / kg CPH) of deionized water in a food processor and wet grind it into a fine paste. Optionally, the soaked CPH blocks can be mechanically extruded (e.g., through a screw press or other dehydration press) to reduce the moisture content, or homogenized by passing them through a shear mill.

[0111] The paste was then dried using freeze drying (samples #Z3, Z11, B13, B17) or in a vacuum oven at 85°C (samples #B14, B16, B19). In one embodiment (sample #B18), the paste was first briefly dried in a rotary (roll-up) oven at 190°C, and then further dried in a convection oven at 95°C.

[0112] For freeze-drying (samples #Z3, Z11, B13, B7), the paste was transferred to a freeze-drying tray and dried in a frozen state for 8 days. During freeze-drying, the paste lost approximately 93% by weight of water and formed a dry cake, which was then blast-ground into a dry powder with an Aw < 0.25. For oven drying with or without vacuum (samples #B14, B16, B19, B18), the paste was transferred to a disposable aluminum foil oven tray, which was placed in a preheated oven. For vacuum oven drying (samples #B14, B16, B19), the vacuum oven was set to 85°C and evacuated to < -20 mmHg for 4–6 days. For sample #B18, the paste was first dried in a rotary oven at 190°C for 45 hours, then further dried in a convection oven set to 95°C for 14 hours, and then dried at 65°C for 7 days. Some embodiments may use different ovens, such as impact ovens, infrared ovens, etc. Alternative industrial drying methods, such as fluidized bed drying, can be used, and in some embodiments, the drying time can be reduced to several hours.

[0113] In a preferred embodiment of chocolate preparation ( Figure 1A The frozen CPH (labeled B19) was washed in water for 1 hour (to thaw) and then cut into pieces with a knife. The pieces (9.9 kg) were then soaked in 38 liters of deionized water at 60°C in a jacketed multipurpose mixing container (Armfield FT140 CCT550) for 3 hours. The deionized water was changed once during soaking. The soaked pieces were then converted into a wet paste using a food processor. The paste was then dried in a vacuum oven at 85°C and -760 mmHg for 9 days. The material was then ground in a hammer mill (Bauermeister, USA) and passed through a 40-mesh sieve. The resulting powder was then separated into three particle size fractions: a) retained on a 230-mesh sieve (i.e., >64 microns), b) passed through a 230-mesh sieve (i.e., <64 microns), and c) passed through a 325-mesh sieve (i.e., <44 microns). In the preferred embodiment (B18) that provides the desired chocolate functionality, the wet paste from the previous embodiment (B19) is first dried in a rotary oven at 190°C for 45 minutes, then further dried in a convection oven at 95°C for 14 hours, followed by drying at 65°C for 7 days. It is then ground in a coffee grinder and passed through a 325-mesh (44-micron) sieve.

[0114] Various parameters of the product of the present invention obtained after the incubation and wet milling steps are shown in Figure 1A In the table, and Figure 1B The same parameters are shown for cocoa powder and cocoa pod shell products as described in US4206245 and other prior art.

[0115] In other embodiments, sorbic acid esters (E200 and E202) and citric acid (E330), along with other food-grade preservatives (antioxidants, essential oils, etc.), may be added to the washing and soaking steps to minimize the possibility of unwanted mold growth.

[0116] result Pollutant reduction The heavy metal levels in all samples remained below acceptable thresholds.

[0117] For cocoa components, the primary heavy metal of concern is typically cadmium (Cd); however, soaking treatment helps reduce Cd levels from 0.4 ppm in control test R1 (not of this invention) to 0.2 ppm or lower in tests conducted according to the invention (and to less than 0.1 ppm in test Z3, which involved soaking followed by wet milling according to the method of the invention). Thus, if the CPH from the field has a Cd level >0.4 ppm, the method of the invention can be used to reduce that level to <0.3 ppm and much lower.

[0118] The results also showed that the CPH components produced using the method of this invention have lower levels of lead and cadmium compared to existing cocoa bean "shells" and "cocoa bran" materials. Furthermore, pesticide and mycotoxin levels are well below the risk levels acceptable under global cocoa industry and food regulations in most countries.

[0119] After warming and wet grinding CPH composition As shown in Figure 1, for all dry powder products of various CPH raw materials, powdered CPH is obtained by the method of the present invention, which is a dry powder with a moisture content of up to 12% and an Aw < 0.4 (and in most cases not exceeding 0.2). The yield is typically in the range of 11%-16% of the available shell wet weight (note that the yield of CPH husk powder is about 3%, as the husk is a relatively minor component of the shell and therefore no evaluation other than contaminant determination is performed). The CPH produced at the end of the incubation and milling process consists mainly of carbohydrates (>70 wt%), most of which are in the form of insoluble fibers, typically exceeding 60 wt%, with about 15 wt%-25 wt% lignin.

[0120] As shown in Figure 1, the components of the present invention can be identified by the following characteristic compositions: - Insoluble dietary fiber (IDF) > 55% by weight, and preferably: - Total dietary fiber >68% by weight (usually greater than 70%); - Protein <10% by weight% - Fat <1.5% by weight Another identifiable feature of the CPH component of this invention is its low total sugar content of <8% by weight (typically <6% by weight).

[0121] The third identifiable characteristic of the CPH component of this invention is its low ash content of <6% by weight.

[0122] After incubation, wet grinding, drying and pulverization CPH characteristic like Figure 2 As shown, the thickening behavior of cocoa pod shells varies significantly with processing conditions and material source. Generally, the final viscosity values ​​are comparable to those observed with low-methoxyl pectin and high-methoxyl pectin, such as... Figure 2 As shown. Two samples, CPH(Mix) StMl FD (Experiment B13) and CPH(Mix) StMl Vac85C (Experiment B14), are of particular interest. Both samples were soaked and wet-milled together, and then separated only during drying. CPH(Mix) StMl FD was freeze-dried (hence labeled "FD"), while CPH(Mix) StMl Vac85C was dried in a vacuum oven at 85°C (hence labeled "Vac85C"). However, the final viscosity values, representing their thickening abilities, were completely different. While the freeze-dried material had a final viscosity comparable to high-methoxyl pectin, the vacuum-dried material had a lower viscosity than gum arabic. The results indicate that the thickening ability of the CPH component can be altered by changing processing conditions such as drying temperature (heat treatment).

[0123] The figures below show that CPH-FD and CPH-Vac85C have relatively high total dietary fiber (TDF), at 69% and 75%, respectively. However, the higher soluble fiber content (SDF) allows the freeze-dried sample (B13) to develop viscosity and be used effectively as a gelling / thickening agent. In contrast, the higher insoluble fiber content (IDF) of the vacuum oven-dried sample (B14) allows it to maintain low viscosity, which is preferred in applications such as chocolate confectionery. Effects of processing (freezing or heat treatment) on the composition Since heat treatment alters the functional behavior of CPH, its effects on composition and molecular weight were investigated. A comparative analysis of total nutritional content (approximate analysis) of CPH dried in a vacuum oven (CPH-Vac85C) and freeze-dried CPH (CPH-FD) is presented in Figure 1. The fiber composition was investigated in more detail by comparing total dietary fiber content, insoluble dietary fiber content, soluble dietary fiber content, lignin and uronic acid content, and the results are given in the table above.

[0124] Compositional analysis showed that CPH-FD had a slightly lower total dietary fiber (TDF). However, a larger portion of the fiber in CPH-FD was water-soluble (compared to a much higher SDF in CPH-FD). Consequently, CPH-FD exhibited a lower lignin content than CPH-Vac85C.

[0125] Interestingly, both treatments showed roughly the same uronic acid content, suggesting that the pectin in CPH-FD may have a higher methoxyl content than that in CPH-Vac85C. Heat treatment of CPH-Vac85C may have resulted in some degree of demethoxylation.

[0126] To investigate the effects of heat treatment at the molecular level, 1% aqueous slurries of CPH-Vac85C and CPH-FD were stirred for 24 hours. The supernatant (aqueous extract) was then passed through a size exclusion chromatography (SEC) column equipped with a refractive index (RI) detector. For comparison, commercially available high-methoxyl pectin powder and low-methoxyl pectin powder (containing sucrose as a dispersant) were used as reference materials.

[0127] SEC results showed that the aqueous extract of CPH-FD contained a high molecular weight fraction (approximately 1000 kDa), significantly larger than even commercial pectin. This fraction was absent in CPH-Vac-85C and was instead replaced by a very broad peak in the range of 22 kDa to 800 kDa.

[0128] The presence of this high molecular weight water-soluble fraction can explain the significantly higher viscosity and thickening ability of CPH-FD compared to CPH-Vac85C.

[0129] Example 2 - Cookie dough containing CPH powder from Example 1 CPH (CPH-StMl, incubated, milled, and dried according to the method of Example 1) was used instead of 25% by weight of flour in the cookie recipe. The cookie recipe (before replacing the flour with CPH) contained 13.54% shortening (palm oil-based, SansTrans™ 39 Cookie Shortening from Loders Croklaan), 27.51% sugar (granulated, Dominos), 0.44% salt, 0.53% sodium bicarbonate, 0.39% dextrose monohydrate (Staleydex 333 from Tate & Lyle), 9.98% deionized water, and 47.61% wheat flour (soft wheat blend, refined flour). The moisture content depends on the moisture content of the flour and is assumed to be on a 14% moisture basis. For other cookie embodiments, flours with different moisture contents were used, and the water was adjusted according to AACCI 10-50 method (http: / / methods.aaccnet.org / methods / 10-50.pdf). For the flour substitution experiment, 25% of the wheat flour was replaced with CPH, resulting in a formulation containing 11.9% CPH and 35.71% wheat flour. The moisture content of the formulation was adjusted to match that of a dry flour blend containing both CPH and wheat flour. All percentages are by weight (wt%). Two types of CPH were used: one was freeze-dried (CPH-FD), and the other was vacuum-dried at 85°C (CPH-Vac85C), as described above.

[0130] Mix CPH evenly with flour, and then mix flour-CPH with other cookie dough ingredients in the usual way.

[0131] A control dough was also prepared in which CPH (no flour substitute) was not used.

[0132] The resulting cookie dough was baked in a rotary oven set to 400℉ (204.4℃) for 11 minutes. During baking, the oven temperature varied between 381℉ and 420℉.

[0133] result A photograph of the cookies prepared by the method of Example 2 is shown. Figure 3 The results show that cookies made by replacing 25% of the flour in the control cookies with CPH-FD or CPH-Vac85C have a palatable texture, although they are slightly darker in color.

[0134] Compared to the control, CPH-FD showed a significant increase in dough viscosity and an LFRA value approximately nine times higher. Additionally, moisture loss during baking was significantly reduced, cookie diameter (extensibility) was greatly decreased, and cookie height (thickness / stack height) was significantly increased. All these behaviors can be attributed to the high water-holding capacity of the pectin in CPH. Furthermore, the CPH-containing variant provided an excellent "reddish-brown" color, and roundtable tasting results indicated a softer texture compared to the control cookies. Replacing 25% of the flour with vacuum-dried CPH (CPH-Vac85C) yielded a product that more closely resembled the control in behavior and geometry, but with a rich "reddish-brown" color, visually similar to chocolate chip cookies.

[0135] Thus, CPH, which has a significant fiber level (especially a significant pectin level) according to the present invention, can be used as a functional ingredient in cookie baking and / or as a partial flour substitute to promote cookie height increase, reduced extensibility, softened texture, darker color, etc.

[0136] Example 3 - Cake mixture containing CPH powder from Example 1 Compare soft cakes baked using eggs in the batter with soft cakes made using CPH-FD as a partial (30%) or complete (100%) egg substitute.

[0137] Specifically, the water and fat contributed by the eggs were calculated and replaced with deionized water and low-erucic acid rapeseed oil (weight to weight), while the egg "solids" (the remaining portion of the egg) were replaced with CPH-FD.

[0138] Figure 4A The images show soft pastry products made with eggs, with 30% of the egg solids replaced by CPH-FD, and with 100% of the egg solids replaced by CPH-FD.

[0139] Figure 4B It shows Figure 4A The photo shows slices of the three pastry products.

[0140] from Figure 4A and Figure 4BIt can be seen that for products made with CPH-FD replacing egg solids, replacing 30% of the eggs with CPH-FD had no significant effect on the cake volume, height, density, and texture. As can be seen from the photos, the 30% CPH-FD cake products appeared essentially similar to the control product in size and shape, and the total dough density and texture were also similar. In the round-table taste test, these cakes could not be distinguished from the control (with 100% eggs) by any of the evaluated sensory attributes, including color. However, on the other hand, completely (100%) replacing the eggs with CPH-FD produced a denser cake with a lower height, a firmer texture, and a much deeper color. No formula was optimized to further match the control cake. Although the 100% egg-replaced cake did not match the control cake, it still produced a palatable cake product with the desired different sensory characteristics, depending on the characteristics of the cake to be sold.

[0141] Thus, CPH, combined with water and low-erucic acid rapeseed oil, can be used to partially replace eggs in soft cake recipes without any detectable effect on the product. It can also be used to formulate completely cake-free cakes, although further work (e.g., including other ingredients in the formulation) will be required to match the characteristics of 100% sponge cakes if needed.

[0142] Example 4 - Chocolate containing CPH powder from Example 1 The effect of using CPH prepared by the method of Example 1 as an ingredient in chocolate formulations was evaluated. Freeze-dried cocoa pod shells (CPH-FD) and 85°C vacuum-dried cocoa pod shells (CPH-Vac85C) were incorporated into the experimental chocolates at a level of approximately 9.2% (by weight). The chocolates were prepared according to the formulations shown in the table below: The average particle size (d90, as measured by dry powder laser diffraction) of the dried CPH component is as follows: CPH-Vac85C = 411µm; CPH-FD = 400µm The control chocolate pellets were prepared into particles with a size of 26 micrometers (+ / - 2 micrometers) (d90), without altering the method for preparing the chocolate variant containing CPH.

[0143] The formula was modified to allow for reductions in premium ingredients (cocoa solids, milk solids, and sugar), while maintaining the same total fat as the control (by adjusting cocoa butter and anhydrous milk fat (AMF)). The ratio of cocoa butter to AMF remained constant.

[0144] All samples were made according to standard chocolate-making procedures. The total weight of each recipe produced was 1.5 kg. Figure 5APhotographs are provided of the refined paste-like consistency of the experimental chocolate pellets before their first pass through the refiner. Due to their greater oil-binding capacity compared to the sucrose, skim milk powder, and regular cocoa pellets they replaced, the CPH variants tend to produce a "drier" paste. The particle size and viscosity of the chocolate pellets are shown in [the image / photograph]. Figure 5B Provided in [the document]. Results showed that while freeze-dried CPH increased the viscosity of the chocolate dough, CPH dried in a vacuum oven at 85°C actually had a lower viscosity than the control chocolate dough, which could be advantageous in chocolate processing. All recipes were refined in a jacketed Hobart mixer (set to 40°C).

[0145] The finished material is manually tempered (tempered to 27°C, then heated to 29°C with untempered material) and molded in standard 40g strips.

[0146] The nutritional composition of the resulting chocolate bars is provided in the table below.

[0147] Including cocoa pod shells in chocolate bars significantly increases fiber content and reduces sugar and added sugar. Figure 5C Photographs of experimental chocolate bars containing CPH are provided. Informal sensory evaluations were conducted to obtain initial impressions of the effects of adding different forms of CPH on the sensory properties of the resulting chocolates. Figure 5D ).

[0148] Both CPH-FD and CPH-Vac85C chocolates achieved acceptable sensory properties, but each was denser and more clay-like than the control chocolate (as expected when making chocolate with unconventional ingredients). The fact that acceptable sensory properties were achieved suggests that the CPH powder of this invention can be used to increase the dietary fiber content of chocolate, which can lead to improved health benefits attributable to higher fiber intake.

[0149] This preliminary evaluation of CPH demonstrates the potential application opportunity as a non-premium additive in chocolate. It also shows that the method of processing CPH affects sensory properties.

[0150] Example 5 - CPH powder from Example 1, ground to various particle sizes, was incorporated into milk chocolate at 10% by weight. CPH variant (Experiment #B19 in Figure 1), skim milk powder, and NFDM (comparative example) were incorporated into the milk chocolate dough as extenders. Commercially available milk chocolate products were used as representative milk chocolate doughs for these experiments. As a typical procedure, according to... Figure 6A The schematic diagram shows that 20g of CPH powder from Example 1 was added to 180g of melted milk chocolate dough to obtain... Figure 6BThe experimental chocolate bars shown are (5i, 5ii, 5iii, 5iv, and 5v). Chocolate was prepared without fat regulation.

[0151] Figure 6B The effect of incorporating 10% by weight of heat-treated CPH of different particle sizes (from samples #B18 and B19) into milk chocolate dough is shown, in contrast to incorporating 10% by weight of NFDM as a comparative example. Figure 6B The results show that coarser CPH powder (5ii) with a mesh size greater than 230 produces a richer, deeper color compared to NFDM (5i). Fine CPH powder (5iv) with a mesh size <325 produces a deep brown with greater gloss (luster) and a lower undesirable frosting appearance. Among CPH powders with a mesh size <325, comparing vacuum oven-dried CPH (5iv) and oven-dried CPH (5v) shows that oven-dried CPH provides an even deeper brown, almost resembling the appearance of dark chocolate with increased commercial value.

[0152] Example 6 - The CPH powder from Example 1 was incorporated into milk chocolate at a weight of 15%. according to Figure 6A The schematic diagram shows the incorporation of a CPH variant (Experiment #B19) and lactose (Comparative Example) as extenders into a milk chocolate dough, with fat adjustment (0.25 g cocoa butter / g CPH). Figure 7 As shown, fine-grained (<325 mesh) CPH was incorporated into commercial milk chocolate products at 15% by weight (6i). As a comparative example (6ii), 10% by weight of lactose (lactose is the main component of whey powder and is commonly used as a expander in milk chocolate) was incorporated. Despite the increased level of use, CPH formed smoother chocolate bars with a richer brown color (6i), while the comparative example showed unevenness in the form of fat aggregates on the surface (6ii). Informal roundtable tasting results indicated that, compared to 6ii, 6i had a firmer texture, a gritty feel, reduced sweetness, a deeper color, and grassy off-flavors.

[0153] Example 7 - Recommended method for commercial-scale production of CPH ingredients Any method for commercially scaled production of CPH components must convert fresh cocoa pod shells, obtained after pod opening, into a stable intermediate (or final product) within a short period of time, free from the risk of microbial spoilage, which otherwise increases the risk of toxic contaminants (mycotoxins, etc.). To overcome the supply chain challenges posed by this time constraint after pod opening, the process of converting fresh shells into CPH preferably begins near the source of the shells, such as a cocoa fermentation plant (or farm, etc.). To eliminate the logistical challenges of setting up advanced industrial processing equipment and skilled operators near cocoa farms, the equipment used should preferably be "low-tech," requiring minimal capital investment and operator expertise. Preferably, such equipment can be obtained locally at low cost in cocoa-growing regions worldwide.

[0154] Farm workers open cocoa pods to obtain cocoa beans, producing approximately 130 kg of fresh cocoa pod shells per hour. The shells are then washed in commercial fruit / vegetable washing machines to remove external dirt, debris, pesticides, etc.

[0155] Next, the washed husks can be pre-cooked in steam / hot water / dilute acid (in a commercial fruit and vegetable steam pre-cooker / cooker) to sterilize the material and remove heavy metals, pesticides, and mycotoxins. This step also helps soften the husks. The pre-cooked husks are then drained of water using a press. While different types of presses such as screw presses, crushers, etc., can be used, low-tech, locally available solutions such as commercial sugarcane crushers are preferred. The primary purpose of this step is to drain water and bring the material to a solids content of approximately 50% or higher. Additionally, this step helps remove any residual contaminants, as well as sugars, soluble fibers, etc., thereby increasing the total insoluble fiber (IDF) content of the final product.

[0156] The next step involves drying the material to a water activity (aw) of at least 0.65, which is considered a critical threshold for achieving microbiological stability. Impact ovens, such as commercial-grade pizza ovens, or low-cost commercial drum dryers, or other locally available dryers and food dehydraters, can be used to achieve this (note that the polyaromatics, i.e., PAHs and acrylamides, generated during the drying step must be closely monitored to ensure food safety and compliance with local regulations). The resulting dried CPH intermediate with aw < 0.65 (preferably aw < 0.6, most preferably aw < 0.55) is now expected to be stable for transport and storage. The drying step also increases the brittleness of the CPH intermediate, which is beneficial for subsequent milling steps.

[0157] Microbiologically stable dried CPH intermediates can be stored and transported as needed to off-site grinding / milling facilities for grinding to the desired particle size. It must be noted that the ability to convert fresh cocoa pod shells into stable intermediates that can be stored and transported (with relatively low investment and simple equipment) overcomes the key issues of microbial spoilage and seasonality, which pose significant logistical challenges for supply chain considerations (one reason why cocoa pod shells remain underutilized as a waste stream).

[0158] In some cases, CPH intermediates received after storage and transportation may undergo further drying to reduce aw < 0.2 and decrease the total moisture content.

[0159] While size reduction can be achieved using commercially available hammer mills, jet mills, bore mills, and blade mills, planetary ball mills and air classifier mills with ceramic grinding media are expected to be particularly effective in achieving the fine particle size (d90 < 30 micrometers, preferably < 20 micrometers) required for chocolate.

[0160] In this way, the CPH ingredients optimally selected for chocolate applications can be commercially produced with relatively low capital investment and without significant supply chain and logistical constraints.

[0161] The above embodiments are described by way of example only. Many changes can be made without departing from the scope of the invention as defined in the appended claims.

Claims

1. A method for manufacturing cocoa pod powder, the method comprising the following steps: To turn cocoa pod shells into flakes; to incubate the cocoa pod shell flakes in water; During the wet milling process, 0.25L to 1L of water is added per kg of the cocoa pod shells to turn the cocoa pod shells into a paste, wherein the cocoa pod shells are not dried after incubation and before turning into a paste during the wet milling process; and the paste is dried at a temperature of at least 80°C.

2. Cocoa pod powder manufactured by the method according to claim 1, wherein the cocoa pod powder has at least 60% by weight of insoluble dietary fiber and / or at least 70% by weight of total dietary fiber, and wherein the total ash content of the powder does not exceed 6.0% by weight.

3. Cocoa pod powder manufactured by the method according to claim 1, wherein the cocoa pod powder has an ash content of not more than 4.5% by weight.

4. The cocoa pod powder according to claim 2 or 3, wherein the total sugar content of the cocoa pods does not exceed 8% by weight.

5. The cocoa pod powder according to claim 2 or 3, wherein the powder comprises moisture in an amount not exceeding 12.5% ​​by weight of the total weight of the powder.

6. The cocoa pod powder according to claim 2 or 3, wherein the water activity of the cocoa pod does not exceed Aw0.

4.

7. The cocoa pod powder according to claim 2 or 3, wherein the cocoa pod powder comprises less than 2% by weight of fat and less than 10% by weight of protein of the total weight of the cocoa pods.

8. The cocoa pod powder according to claim 2 or 3, wherein the cocoa pod includes cocoa pod meat and / or cocoa pod skin.

9. The cocoa pod shell powder according to claim 8, wherein the cocoa pod shell powder comprises whole cocoa pod shells.

10. The cocoa pod shell powder according to claim 2 or 3, wherein the cocoa pod shell powder has an average particle size between 2 micrometers and 750 micrometers, preferably between 20 micrometers and 250 micrometers.

11. An edible product comprising cocoa pod powder according to any one of claims 2 to 10.

12. The edible product according to claim 11, wherein the edible product includes products selected from confectionery, baked goods, fillers, spreads and beverages.

13. The use of cocoa pod powder according to any one of claims 2 to 10 as a gelling agent, thickener or extender.

14. The application according to claim 13, wherein the cocoa pod powder is used in the edible product according to claim 11 or 12.

15. The use of cocoa pod powder according to any one of claims 2 to 10 as a substitute for egg solids in edible products.

16. A method of manufacturing an edible product, the method comprising uniformly mixing cocoa pod powder according to any one of claims 2 to 10 with one or more edible product ingredients and forming the edible product.

Images