Cocoa extract, cocoa product and method for manufacturing thereof

Abstract

This invention discloses a method for processing cocoa beans or cocoa granules, comprising the steps of: (a) adding water to cocoa beans or cocoa granules to form a suspension; (b) wet milling the suspension; (c) subjecting the suspension to heat treatment at a temperature of 70°C or lower; (d) separating the suspension into: an aqueous phase (heavy phase), a lipid phase including cocoa oil (light phase), and a solid phase including cocoa powder and fluid components; (e) continuously separating the fluid components from the solid phase obtained in step (d) by supplying the solid phase to a mixing device to obtain cocoa aroma and cocoa powder; wherein the mixing device... The device includes: a cylindrical tubular body having a horizontal axis, the tubular body having an inlet opening for a solid phase, an outlet opening for a dried solid phase, and an optional outlet opening for a vapor phase including cocoa aroma; end plates closing the tubular body at opposite ends; a coaxial sleeve for heating or cooling the inner wall of the tubular body to a temperature of 55°C to 150°C; and a bladed rotor supported in the tubular body for rotation, the blades of the bladed rotor being arranged in a helical shape and oriented for centrifugally separating the solid phase and simultaneously transporting the solid phase toward the outlet opening.

Description

Cross-references to related applications

[0001] This application is a divisional application of the invention patent application (International Publication No. WO2017005372A1) entitled "Cocoa Extract, Cocoa Products and Methods of Manufacturing Thereof" with application number "201680053010.9", application date "July 8, 2016", and applicant "ODC Licensing Corporation". Technical Field

[0002] This invention relates to improved methods and techniques for producing cocoa extracts and chocolate or similar chocolate products. In some embodiments, the invention relates to a cocoa bean processing method for producing cocoa products, chocolate, or similar chocolate products with improved flavor characteristics and / or increased levels of antioxidants and / or vitamins. Background Technology

[0003] Cocoa (Theobroma cacao L.) is known as a healthy source of various nutrients, including minerals, vitamins, polyphenols (especially catechins, anthocyanins, and proanthocyanidins), and antioxidants such as flavonoids. Therefore, numerous methods have been developed to increase the yield of these nutrients. For example, EP2 071 961 A1 discloses a method for obtaining a polyphenol-rich cocoa powder extract.

[0004] The type and steps used in processing cocoa beans into food products (such as, for example, chocolate) have a profound impact on various aspects of the quality of the resulting cocoa products, such as flavor, strength, or the content and even yield of antioxidants or vitamins. For this reason, the methods used in processing cocoa beans into cocoa products (such as food) can be crucial to the economic viability, success, or acceptance of these products (in the market or in their use to enhance other products).

[0005] Traditionally, the processing of cocoa beans begins with harvesting the cocoa pods, opening the pods to extract the beans, followed by fermentation and drying. Afterward, the beans are cleaned, optionally shelled into cocoa nibs, and roasted, thus brittlening the shells. While the roasting conditions typically depend on the type of cocoa bean, roasting is usually achieved by subjecting the beans or nibs to temperatures ranging from about 100°C to 160°C for about 15 minutes (at higher temperatures) to several hours (at lower temperatures), for example, the method disclosed in EP 2 273 888 B1. Subsequently, the beans or nibs are subjected to grinding or mechanical extraction processes, such as, for example, the technique disclosed in WO 03 / 045159 A1. During these steps, high mechanical loads, shear stress, and / or frictional heat cause the cell septa of the unprocessed cocoa material to break down, leading to the liquefaction of cocoa butter and the emulsification of the oil fraction. Typically, the resulting cocoa liquor is then mixed with cocoa butter, sugar, milk, or further ingredients, depending on the individual manufacturer's recipe, and optionally refined to produce refined chocolate paste. From there, the refined chocolate paste is subjected to stirring, for example, by a continuous stirring method according to EP 0 711 505 A1. Here, the refined chocolate paste (typically comprising cocoa dry matter, but also cocoa butter, sugar, and / or lecithin) refined according to the aforementioned conventional method is supplied to a mixing apparatus including an outlet opening connected via a conduit to a separating device that separates air and moisture from the processed chocolate paste. The stirred blocks are then blended and molded under controlled conditions.

[0006] However, such technology is disadvantageous from the perspective of processability and the recovery of desired flavor and health components, because after emulsification during grinding or mechanical extraction, separating the oil phase without using undesirable solvents (such as hexanol, for example) while obtaining or maintaining the desired flavor and / or cocoa products (e.g., flavorings, antioxidants, and / or vitamins) is difficult, if not impossible. Furthermore, dry-roasting beans / cocoa kibbles involves compromises in flavor yield and quality because it is difficult to identify and monitor roasting conditions under which the flavors within the beans / kibbles are fully developed without being broken down and / or expelled from the beans, and without being lost with exhaust gases during roasting.

[0007] WO 2010 / 073117 A2 discloses an alternative method for processing cocoa beans to avoid the liquefaction of cocoa butter and the formation of chocolate liquid during mechanical processing. The method includes forming a suspension comprising cocoa beans or cocoa granules and water; wet-milling the suspended beans or cocoa granules in multiple steps; heating the suspension; and decanting the suspension to separate it into an aqueous phase, a lipid phase, and a solid phase. The process employs lower temperatures and lower shear forces to improve the retention of nutritious beneficial components and the flavor of the resulting cocoa product.

[0008] However, the use of water as an extraction solvent in the method of WO 2010 / 073117A2 presents several challenges. For example, the large amount of water added during cocoa bean processing must be removed again, which can consume significant energy, especially after decanting when drying and / or baking the solid phase. Furthermore, since this process is carried out at relatively low temperatures, the drying step should ideally be performed rapidly, continuously, and at a high throughput to inhibit microbial growth and / or spread without requiring extensive sterilization or intermittent sterilization processes.

[0009] In this respect, it has been found that using conventional drum dryers to dry and / or bake the solid phase obtained after phase separation presents problems, as it is difficult to minimize the heat load on the solid phase (which is advantageous when high levels of beneficial nutrients are required, such as, for example, polyphenols and vitamins) while simultaneously achieving rich roasted and grilled flavors as well as the development of secondary aromas. In particular, to obtain the desired level of roasted / secondary flavor, drying the decanted solid phase using a drum dryer may require processing times on the order of several hours, even if the processing is carried out under sub-atmospheric pressure conditions, which implies a high heat load on the solid phase.

[0010] Therefore, we hope to provide methods and products that overcome the above shortcomings. Summary of the Invention

[0011] This invention achieves this objective through the subject matter defined in the claims herein. The advantages of the invention will be described in further detail below, and further advantages will be apparent to those skilled in the art in light of the disclosure of this invention.

[0012] Generally, in one aspect, the present invention provides a method for processing cocoa beans or cocoa granules, comprising the steps of: (a) adding water to the cocoa beans or cocoa granules to form a suspension; (b) wet milling the suspension; (c) subjecting the suspension to heat treatment at a temperature of 70°C or lower; (d) separating the suspension into: an aqueous phase (heavy phase) comprising aromatic flavors, a lipid phase (light phase) comprising cocoa butter, and a solid phase comprising cocoa powder and fluid components; and a solid phase comprising cocoa powder and fluid components; (e) continuously separating the fluid components from the solid phase obtained in step (d) by supplying the stream of the solid phase to a mixing... An apparatus for obtaining cocoa aroma and cocoa powder, wherein the mixing apparatus comprises: a cylindrical tubular body having a horizontal axis, the body having an inlet opening for a solid phase, an outlet opening for a dried solid phase, and at least one outlet opening for a vapor phase; end plates of the tubular body closed at opposite ends; a coaxial sleeve for heating or cooling the inner wall of the tubular body to a temperature from 55°C to 150°C; and a bladed rotor supported inside the tubular body for rotation, the blades being arranged in a helical shape and oriented to centrifugally separate the solid phase while simultaneously transporting the solid phase toward the outlet opening.

[0013] A further aspect of the invention provides a method for producing cocoa products, chocolate, or similar chocolate products, comprising the steps of: processing cocoa beans or cocoa granules according to the method defined above, and mixing the obtained cocoa powder with at least one of cocoa flavoring, cocoa butter, or polyphenol powder.

[0014] Another aspect of the invention is a cocoa product, chocolate, or similar chocolate product obtained by the method described herein. Attached Figure Description

[0015] Figure 1 A method for processing cocoa beans or cocoa granules according to one embodiment of the subject invention is illustrated, showing up to optionally provide an extract obtained by separating the respective phases (dashed and dotted lines represent optional processing steps).

[0016] Figure 2 A method for processing cocoa beans or cocoa granules according to a preferred embodiment of the subject invention is illustrated schematically, showing an extract obtained by separating the phases (dashed and dotted lines indicate optional processing steps).

[0017] Figure 3 A mixing apparatus for the drying / separation step used in the method according to the invention is shown schematically.

[0018] Figure 4 An exemplary method for preparing dark chocolate is shown.

[0019] Figure 5 An exemplary method for preparing dark chocolate / milk chocolate using cocoa powder obtained after separating and processing the lipid phase, solid phase, and aqueous phase is illustrated. Detailed Implementation

[0020] To gain a more thorough understanding of the invention, reference is now made to the following description of exemplary embodiments: Methods for processing fermented cocoa beans and / or cocoa granules According to the present invention, a method for processing fermented cocoa beans or cocoa granules is characterized by generally the following steps: (a) adding water to the cocoa beans or cocoa granules to form a suspension; (b) wet milling the suspension; (c) subjecting the suspension to heat treatment at 70°C or lower; (d) separating the suspension into: an aqueous phase (heavy phase), a lipid phase including cocoa oil (light phase), and a solid phase including cocoa powder and fluid components; (e) By supplying the solid phase stream to a mixing device, fluid components are continuously separated from the solid phase obtained in step (d) to obtain cocoa aroma and cocoa powder; wherein the mixing device comprises: a cylindrical tubular body having a horizontal axis, the body having an inlet opening for the solid phase, an outlet opening for the dried solid phase, and an optional outlet opening for a vapor phase including the aroma agent; end plates of the tubular body closed at opposite ends; a coaxial sleeve for heating or cooling the inner wall of the tubular body to a temperature from 55°C to 150°C, preferably to a temperature above 65°C and below 140°C; and a bladed rotor supported in the tubular body for rotation, the blades of the bladed rotor being arranged in a helical shape and oriented to centrifugally separate the solid phase and simultaneously transport the solid phase toward the outlet opening. It has been found that the method provides enhanced heat transfer to the solid phase and allows for advantageously rapid, gentle, continuous, and high-throughput drying / roasting of cocoa powder.

[0021] Figure 1 A method for processing cocoa beans or cocoa granules is illustrated schematically, showing extracts obtained by separating the phases, up to an optional extent.

[0022] The pretreatment of cocoa beans or cocoa granules used in the processing method of the present invention is not particularly limited. Therefore, cocoa beans or cocoa granules may be unfermented, underfermented, fermented, and / or cultivated according to the prior art, or, after being separated from the pods, the beans with or without cocoa pulp / mucus may be used fresh.

[0023] The cocoa processing techniques of this subject typically begin either before grinding cocoa beans / cocoa granules, or during the grinding process, by adding water to form a suspension of cocoa beans or cocoa granules, according to step a).

[0024] Although there are no particular limitations, the weight ratio of water to cocoa beans / cocoa granules in the resulting suspension is preferably between 1:1 and 6:1, more preferably between 2:1 and 4:1, and particularly preferably about 3:1, which may advantageously affect the processability in subsequent steps (e.g., facilitated pumping, grinding, and easier phase separation).

[0025] If desired from the perspective of introducing additional flavors, alternative water-containing liquids can also be used as the water source, preferably selected from one or more of coffee, tea, and liquids having a water content of 60% to about 95% by weight (e.g., fruit juice, fruit juice concentrate, or milk). In such cases, preferably, the water content in the resulting suspension falls within the proportions defined above. Because the heat load is relatively low in the further process steps, the temperature-sensitive flavors originating from said liquid are preserved and advantageously interact with the primary and secondary flavors of the cocoa beans.

[0026] To obtain a coffee-flavored cocoa product, coffee beans (whole or broken, unroasted or roasted) can be mixed into the cocoa beans / cocoa granules when a suspension is formed in water, provided that the cocoa beans / cocoa granules form the main component of the bean mixture, and the coffee bean content does not hinder or negatively affect the wet milling and phase separation steps. Preferably, the coffee bean content in the bean mixture by weight is less than 20% by weight, more preferably, less than 10% by weight.

[0027] In step b), the cocoa beans / cocoa granules are subjected to one or more wet milling steps, resulting in a bean size preferably 50 μm or smaller, more preferably 40 μm or smaller, and even more preferably 20 μm or smaller. Reducing the bean size to such a range substantially increases the exposed surface area of ​​the bean material, thus allowing for more efficient wet milling (e.g., using water instead of chemical solvents) to obtain improved extraction results (e.g., improved extraction of lipids or oils, aromatic substances, and / or polyphenols). The reduction in bean size can be achieved by using, for example, a disc mill (e.g., a perforated disc mill), a gum mill (e.g., a toothed gum mill), or a diamond mill. Preferably, in at least one milling step, the cells of the cocoa beans are softened, and the increased usable surface area of ​​the softened cocoa beans allows the solution (water) to better wet the cocoa bean material. There are no particular limitations on the methods and equipment used for wet milling, as long as the product of the wet milling method is not emulsified. For example, when using multiple grinding steps, a perforated disc mill can be used for a coarse wet grinding step (e.g., water can also be used), and the suspension after coarse grinding can be pumped to a toothed colloid mill for a fine grinding step.

[0028] Following the wet milling step (b), to reduce the overall heat load and prevent emulsification, the suspension is subjected to heat treatment at a temperature not exceeding about 70°C (step (c)). A heating temperature of 43°C to 65°C is preferred from the perspective of a favorable balance between cocoa oil yield and maintaining desired flavors (e.g., flavorings, antioxidants, and / or vitamins). A heating temperature range of 45°C to 50°C is particularly preferred for the liquefaction of cocoa oil and / or improved mechanical phase separation. There are no limitations in this regard; the heating of the suspension after wet milling can be carried out using a plate heat exchanger or a tube heat exchanger.

[0029] Following this, phase separation is performed in step (d) to obtain three phases: an aqueous phase (heavy phase), a lipid phase (light phase), and a solid phase. The lipid phase comprises cocoa oil as the main component and solids and / or water as minor components. The aqueous phase comprises water and aromatic flavorings. The solid phase comprises cocoa powder and fluid components. The cocoa powder may include residual cocoa oil at a weight content of at least 30% relative to the total weight of the cocoa powder, preferably less than 27% by weight, more preferably less than 20% by weight. The term fluid component as used herein refers to the residue remaining in the solid phase after phase separation in step (d), which is fluid at room temperature, for example, the aqueous phase (e.g., may include hydrophilic polyphenols and aromatic flavorings) and volatile compounds.

[0030] Preferably, equipment employing centrifugal force can be used to achieve mechanical particle separation, such as a decanter or nozzle separator. For example, a suspension can be decanted to separate coarse, large, or bulky solids from the liquid, and then smaller and / or fine solid particles can be further separated from the liquid, and / or oil products can be separated from non-oil products.

[0031] Improved separation between the aqueous (heavy) phase, lipid (light) phase, and solid phase can be achieved through multiphase separation and recombination steps. For example, the lipid phase obtained through the initial decantation step can be filtered or centrifuged to separate residual fine particles or water from the lipid phase, and thus the obtained fine particles and water can be recombinated with the water and solid phase from the initial decantation in other containers, or in a later processing stage of said phases. The aqueous phase can also be subjected to further purification steps, for example, by filtration using a vacuum rotary filter to reduce liquid turbidity and remove fine particles (which can then be recombinated with the solid phase).

[0032] The three phases (i.e., the aqueous phase (heavy phase), the lipid phase (light phase), and the solid phase) can be separated and processed independently to separate cocoa butter (from the lipid phase) and polyphenol concentrate (from the aqueous phase), such as... Figure 1 As shown.

[0033] The cocoa bean / cocoa nut processing method described herein also has the advantage that unwanted acids that cause sourness or bitterness in the final product (e.g., acetic acid formed during fermentation, or formed or added before or during cocoa bean incubation) or further hydrophilic components (e.g., bitter and / or astringent low-molecular-weight polyphenols (e.g., catechins)) can be removed via the aqueous phase. There are no particular limitations on the method for removing these unwanted components, and any suitable method in the prior art can be used. For example, acids can be removed from the aqueous phase by, for example, distillation (e.g., extractive distillation or reactive distillation), extraction (e.g., liquid-liquid extraction), emulsion-type liquid membrane processes, salting out, or a combination of these methods. Removing unwanted hydrophilic components before subjecting the solid phase to a drying / roasting step is advantageous over conventional processing in the prior art because it eliminates the need for prolonged drying / roasting of the fermented cocoa beans (especially during roasting and stirring) and high heat loads for evaporating or decomposing components, thus preserving high levels of aromatic flavors, antioxidants, and vitamins. Cocoa beans with relatively high acetic acid content and / or in a changing stage of fermentation can be used to produce high-quality cocoa products, such as chocolate. Furthermore, the resulting products have less bitterness, eliminating the need for large amounts of sugar or sweeteners to mask or compensate for the bitterness.

[0034] In step (e) of the method of the claims of the present invention, dried cocoa powder is obtained from the solid phase exiting the separator. Cocoa aromatic extracts can be obtained from the vapor phase exiting the separator in step (e) by processing (e.g., concentration) the aqueous phase.

[0035] As noted above, the lipid phase (light phase) can be filtered (e.g., by using a vibrating screen) and / or conveyed to a three-phase separator (e.g., a centrifuge) to remove fine particles (optionally, these fine particles can be added to the solid phase before or during the drying / roasting step) and residual water (optionally, residual water can be added to the aqueous phase before aroma recovery). Cocoa butter is obtained by filtering the purified lipid phase.

[0036] Optionally, the (wet) solid phase obtained after three-phase separation can be processed by a heated roll mill to reduce particle size and begin pre-drying. During step (e), prior to drying to improve flavor development, sugar, sugar solution, and / or fruit juice may optionally be added to the separated cocoa solids.

[0037] According to the invention, by continuously separating the fluid components from the solid phase obtained in step (d), which is achieved by supplying the flow of the solid phase to one (or more) mixing devices, the (wet) solid phase obtained after three-phase separation is dried and / or baked in parallel or serial (preferably serial) in one or more steps. The mixing devices (schematically represented in…) Figure 3 The tube (shown in the figure) includes: a cylindrical tubular body (1) having a horizontal axis (2), the tubular body (1) having: an inlet opening (3) for the solid phase, an outlet opening (4) for the dried solid phase, and an optional outlet opening (10) for the vapor phase; end plates (5, 5') closing the tubular body at opposite ends; a coaxial sleeve (6) for heating or cooling the inner wall (7) of the tubular body to a temperature of 55°C to 150°C, preferably to a temperature greater than 65°C and less than 140°C; and a bladed rotor (8) supported in the tubular body (1) for rotation, the blades (9) of the bladed rotor (8) being arranged in a helical shape and oriented for centrifugal separation of the solid phase and simultaneously transporting the solid phase toward the outlet opening (4). Although not particularly limited, in order to maintain the inner wall (7) of the body at a predetermined temperature, it is preferable to use a heat-permeable oil or other fluid as the heat medium inside the coaxial sleeve (6).

[0038] During the rotation of the bladed rotor (8), centrifugal force causes a thin and dynamic tubular layer of solid phase to form on the inner wall (7) of the tubular body, while the interaction between the solid phase and the blades (9) simultaneously mixes and promotes the thin layer of solid phase toward the outlet opening (4). Thus, effective heat exchange is achieved between the heated inner wall and the solid phase, which, combined with mixing, requires a relatively low heating temperature, resulting in rapid and gentle drying and baking of the solid phase. Consequently, the solid phase retains a higher concentration of polyphenols (especially catechins, anthocyanins, and proanthocyanidins), antioxidants, and / or aromatic flavors compared to conventional drum dryers that operate continuously or in batches. Furthermore, it has been surprisingly found that after drying and baking in step (e) using a mixing device for less than 10 minutes, typically less than 5 minutes, at a product temperature not exceeding 90°C, the overall concentration of roasted and grilled flavors (e.g., furan-2-carboxaldehyde, 1-(2-furanyl)acetone, benzaldehyde, 5-methylfurfural, 2-furanethanol, benzyl alcohol, and / or 4-methylcresol) in the resulting cocoa powder and cocoa aroma is higher than that after drying using a conventional drum dryer at sub-atmospheric pressure with a linear temperature gradient from approximately 65°C to 100°C for several hours (typically approximately 10 hours). Therefore, in addition to accelerating the drying / baking process, the currently claimed method reduces thermal stress on the solid phase, thereby (as opposed to conventional drying / baking) simultaneously maintaining a higher concentration of roasted flavors and a higher overall content of key flavors, polyphenols, antioxidants, and / or vitamins in the resulting extract and final product.

[0039] Using the equipment described above allows the drying / roasting steps and the separation of roasted flavors from other aromatics to be carried out continuously, and also greatly accelerates the processing of cocoa beans up to the preparation of cocoa powder (dry cocoa matter), resulting in a total processing time of less than 20 minutes from step (a) to (e), typically less than 15 minutes, which is a significant improvement over existing technologies and has an economic advantage when compared with conventional methods used to prepare cocoa products.

[0040] Generally, if microbial damage is present in cocoa extracts (i.e., cocoa butter, cocoa powder, cocoa flavorings, and polyphenol concentrates), these materials can be deodorized using a vacuum deaerator, or subjected to high-pressure treatment such as Pascalisation. However, because the method according to the invention allows for advantageously rapid processing of cocoa beans / cocoa granules, microbial contamination and growth can be eliminated or minimized.

[0041] As described above, the mixing device includes an outlet (10) for the vapor phase (i.e., the vapor generated during the drying of the solid phase), which can serve multiple purposes depending on its composition and temperature.

[0042] Preferably, in order to enhance heat distribution and drying of the solid phase inside the tubular body (1), and to drive the vapor phase toward the outlet (10), hot air is supplied to the mixing device simultaneously and in parallel with the flow of the solid phase to be dried via an optional inlet (11).

[0043] In a preferred embodiment, the vapor phase leaving the mixing apparatus is injected into the suspension before or during step (b) or (c), more preferably before or during step (b). Accordingly, the re-injection of the hot vapor phase facilitates or enables the (pre)heating of the suspension to the desired temperature via heat exchange in step (c). Therefore, the energy consumption required in step (c) can be effectively reduced, resulting in improved energy efficiency in the cocoa bean processing method. Furthermore, phase separation in step (c) is improved. A further advantage is that the aromatic flavors contained in the vapor phase are retained in the system and can also be incorporated into each of the three phases in step (d), thereby ensuring optimal yields of those components in the final extract or product. This embodiment is generally preferred if the vapor phase contains a relatively low amount of aromatic flavors, for example, roasted aromas.

[0044] In a further preferred embodiment, this embodiment is particularly advantageous if the vapor phase comprises a relatively high number of aromatic flavors, especially roasted and grilled flavors, in which the vapor phase leaving the mixing device in step (e) is collected as the aromatic phase. Optionally, the aromatic phase can be further processed by separating the flavor components to obtain cocoa aroma.

[0045] While not strictly necessary, it is practical to combine the collected aromatic phase with the water obtained in phase separation step (d), as the latter also contains the desired flavor, and it is also feasible to subject the combined liquid to a first concentration step to obtain the cocoa aroma. In another embodiment, the recovered cocoa flavor can be enhanced by reflux distillation (e.g., separating the flavor components from the water), preferably at low pressure (less than 300 mbar) and room temperature to minimize heat load. After separating the cocoa flavor / aroma from the combined liquid, excess water can be evaporated in an optional second concentration step to obtain polyphenol powder. Unwanted water can be removed using evaporation techniques, which, when employed, can desirablely separate the flavor compounds suspended in water from the concentrated polyphenol powder.

[0046] Based on the above description, by using multiple mixing devices in parallel, it is possible to combine these advantages, such that the vapor phase exiting one mixing device (preferably operating at a relatively low inner wall heating temperature) can be injected into the suspension before or during step (b) or (c), more preferably before or during step (b), and the vapor phase exiting another device (preferably operating at a relatively high inner wall heating temperature) can be collected as an aromatic phase for aroma recovery.

[0047] In a preferred embodiment of the present invention (in...) Figure 2 In the schematic diagram shown below, step (e) comprises two sub-steps: (e1) continuously pre-drying the solid phase obtained from step (d) by supplying a stream of the solid phase to a first mixing device; and (e2) continuously drying the pre-dried solid phase obtained from step (e1) by supplying a continuous stream of the pre-dried solid phase to a second mixing device; wherein each of the first and second mixing devices comprises: a cylindrical tubular body (1) having a horizontal axis (2) and an inlet opening (3) for the solid phase. An outlet opening (4) for the dried solid phase and at least one outlet opening (10) for venting; end plates (5, 5') closing the tubular body at opposite ends; a coaxial sleeve (6) for heating or cooling the inner wall (7) of the tubular body to a temperature from 55°C to 150°C; and a bladed rotor (8) supported in the tubular body (1) for rotation, the blades (9) of the bladed rotor (8) being arranged in a helical shape and oriented for centrifugal separation of the solid phase while simultaneously conveying the solid phase toward the outlet opening (4). In other words, both the first and second mixing devices exhibit the characteristics of the mixing device initially described above. The drying / baking process in this manner results in an excellent balance between drying performance, processing and energy efficiency, development of baked flavor, and high yields of key flavors, polyphenols, antioxidants, and / or vitamins.

[0048] Preferably, the first mixing device and the second mixing device are operated under different conditions (e.g., heating temperature of the inner wall, vapor phase outlet connection) or exhibit different dimensions. More preferably, the heating temperature of the inner wall of the first mixing device is lower than that of the inner wall of the second mixing device.

[0049] Preferably, the inner wall of the tubular body of the first mixing device is heated to a temperature between 70°C and 110°C, more preferably between 80°C and 100°C. In a more preferred embodiment, the temperature of the inner wall (7) of the tubular body of the first mixing device is heated in the pre-drying step (e1) so that the temperature of the preheated solid phase leaving the outlet (4) is between 70°C and 100°C, more preferably between 80°C and 90°C.

[0050] In a preferred embodiment, the first mixing device is operated under the following conditions: the pre-dried solid phase obtained after step (e1) has a water content of 3% to 7% by weight, more preferably 4% to 6% by weight.

[0051] More preferably, before or during step (b) or (c), or more preferably, before or during step (b), the vapor phase leaving the first mixing device is injected into the suspension.

[0052] Preferably, the inner wall of the tubular body of the second mixing device is heated to a temperature between 100°C and 150°C, more preferably, between 120°C and 145°C. More preferably, in the drying step (e2), the temperature of the inner wall (7) of the tubular body of the second mixing device is heated so that the temperature of the solid phase leaving the outlet (4) is between 110°C and 145°C, more preferably, between 120°C and 135°C.

[0053] More preferably, the vapor phase leaving the second mixing device in step (e2) is collected as the aromatic phase for aroma recovery.

[0054] In a preferred embodiment, the second mixing device is operated under the following conditions: the solid phase obtained after step (e2) has a water content of less than 3% by weight, more preferably less than 2% by weight, and even more preferably less than 1% by weight.

[0055] In summary, preferably, in the mixing device used in step (e) or in any of the sub-steps (e1) and (e2), the bladed rotor is driven at a speed from 300 rpm to 1300 rpm, more preferably from 700 rpm to 1100 rpm, and even more preferably from 800 rpm to 1000 rpm.

[0056] In a preferred embodiment, in order to prevent the (pre-dried) solid phase from being exposed to rising temperatures for an extended period of time, the duration of step (e) (or the total duration of the sub-steps of step (e)) is less than 15 minutes, more preferably less than 10 minutes.

[0057] Cocoa powder extract In a second embodiment, the present invention relates to cocoa powder manufactured according to the method steps described in the first embodiment outlined above. This extract represents a raw material for a wide variety of high-quality chocolate products, wherein high concentrations of water-soluble aromatic components, polyphenolic components, and vitamins from cocoa beans / cocoa granules are preserved at high concentrations due to low heat burden, while optionally, unwanted water-soluble hydrophilic components (e.g., acidic or bitter and / or astringent low-molecular-weight polyphenols (e.g., catechins)) are removed.

[0058] The dried cocoa powder prepared by the method of the present invention typically exhibits a water content of less than 2% by weight, usually less than 1.5% by weight, and a fat content of typically 30% or less by weight, preferably less than 27% or less by weight, more preferably less than 20% by weight, each calculated based on the total weight of the dried cocoa powder.

[0059] GC-MS analysis of flavor components has revealed that, compared to commercially available cocoa powder, dried cocoa powder obtained according to the currently claimed method includes a higher total concentration of raw / earthy, fruity / floral, malty / oily, and roasted / baked aromas, as well as a lower concentration of pungent / sour flavors.

[0060] For the purpose of quantifying the aromatic profile, it has been based on Figure 4 The exemplary scheme shown produces cocoa powder, cocoa flavoring, polyphenol powder, and cocoa butter extract, wherein a drying / baking step has been achieved using the mixing equipment described above. Overall, Figure 4 An exemplary method is shown for processing cocoa beans from unroasted beans into chocolate products.

[0061] The aforementioned flavor profiles have been quantified in extracts obtained according to the currently claimed methods, as well as in commercially available cocoa powder. Specifically, raw / earthy flavors have been quantified by GC-MS through the total concentration of pyrazine derivatives (i.e., 2-acetylpyrazine, methylpyrazine, tetramethylpyrazine, 2,3-dimethylpyrazine, 2,6-dimethylpyrazine, 2,5-dimethylpyrazine, trimethylpyrazine, ethylpyrazine, 2-ethyl-3-methylpyrazine, 2-ethyl-6-methylpyrazine, 2-ethyl-5-methylpyrazine, 2-ethyl-3,6-dimethylpyrazine, 2-ethyl-3,4-dimethylpyrazine, 2,3-diethyl-5-methylpyrazine, 2-isopropyl-3-methoxypyrazine, 2-isobutyl-3-methoxypyrazine); fruity / floral flavors have been quantified by 1-methylpyrazine. The total concentrations of -1H-pyrrole, ethyl 2-methylbutyrate, 3-methyl-1-butanol acetate, 2-heptanone, hexyl acetate, linalool, benzyl alcohol, 2-phenylethanol, ethyl cinnamate, and 2-phenylethyl acetate were quantified; the malty / oily flavor was quantified by the total concentrations of vanillin, isobutyraldehyde, dimethyl-n-butyraldehyde, isovaleraldehyde, acetoin, and 2,3-butanedione; the smoky / baked flavor was quantified by the total concentrations of furfural, 2-acetylfuran, benzaldehyde, 5-methylfurfural, 2-furanethanol, benzyl alcohol, and 4-methylphenol; and the tingling / sour flavor was quantified by the total concentrations of acetic acid, propionic acid, isobutyric acid, 2-methylbutyric acid, 3-methylbutyric acid, and valeric acid. The measurement results are shown in Table 1.

[0062] Table 1

[0063] Table 1 shows that, compared with conventional cocoa powder (7.504 mg / kg), the cocoa powder obtained by the method of the present invention has a substantially higher total content of perceived pleasant flavors (10.180 mg / kg), while the concentration of pungent / sour flavors is significantly lower, since most of them have been extracted via the aqueous phase.

[0064] The total polyphenol content of defatted cocoa solids is typically at least 40 mg ECE (epicatechin equivalent) per gram of defatted dry matter, preferably more than 50 mg ECE per gram of defatted dry matter, and more preferably more than 55 mg ECE per gram of defatted dry matter. The total polyphenol content can be determined using the Folin-Ciocalteu assay with (-)-epicatechin as a standard, according to the methods disclosed in Off. J. Eur. Communities 1990, 41, 178-179 and Cooper et al., J. Agric. Food Chem 2008, 56, 260-265.

[0065] It has been found that the combination of the above properties cannot be achieved by using a conventional drum dryer instead of the mixing equipment described above, because the extended heating time required to develop the same concentration of grill / baked flavor results in a significant loss or decomposition of polyphenols, antioxidants, and / or vitamins.

[0066] In the cocoa aroma produced according to the method steps described in the first embodiment outlined above, the pungent / sour flavor (i.e., the total concentration of acetic acid, propionic acid, isobutyric acid, 2-methylbutyric acid, 3-methylbutyric acid, and valeric acid) generally comprises less than 7% by weight, preferably less than 5%, of the total weight of the raw / earthy, fruity / floral, malty / oily, roasted / baked, and pungent / sour flavors indicated by the marker compounds described above.

[0067] In a preferred embodiment, preferably, the vapor phase obtained in step (e2) is collected as the aromatic phase, and the aromatic phase is combined with water, and the combined liquid undergoes one or more concentration steps to obtain cocoa aroma.

[0068] Exemplary methods for manufacturing chocolate and chocolate-like products based on the extract obtained according to the method of the first embodiment will be described below respectively.

[0069] Method for manufacturing cocoa products, chocolate or chocolate-like products The cocoa powder produced according to the method steps described in the first embodiment can be used to prepare a wide variety of cocoa products, chocolates, or similar chocolate products, as described in the following third embodiment.

[0070] The method for producing chocolate or similar chocolate products according to the present invention generally includes the following steps: processing cocoa beans or cocoa granules according to the first embodiment described above; mixing the obtained cocoa powder with at least one of cocoa flavoring, cocoa butter or polyphenol powder; and stirring the mixture.

[0071] The term “chocolate-like products”, as used herein, refers to products that fall within the legal definition of “chocolate” in at least one country, but not all countries, because they deviate from the legally defined chocolate in terms of the type and / or range of the components.

[0072] Figure 5Examples of methods for preparing dark and milk chocolate are shown, wherein the cocoa aroma obtained from step (e) or (e2) (optionally, along with the product obtained by aqueous dearomatization) is first added to the cocoa butter. Before undergoing a stirring step, the dried and roasted cocoa powder obtained from step (e) or (e2) is mixed with the aroma-added cocoa butter and finely ground. Polyphenol powder may be added to the mixture as needed to provide a stronger flavor and even higher levels of antioxidants in the final product. Flavor customization or development may be achieved by adding one or more of sugar, sweeteners, cocoa mass, and / or juice. For the preparation of milk chocolate, milk powder is also added, preferably before the mixing step. Optionally, an emulsifier (e.g., lecithin) may be added before stirring to reduce viscosity, control sugar crystallization and the flow properties of the chocolate, and help to mix the ingredients evenly. Additional ingredients and flavors, such as vanilla, rum, etc., may also be added before or during the stirring step.

[0073] The stirring process redistributes flavor-producing substances from the dried cocoa into the lipid phase, while removing unwanted acetic acid, propionic acid, and butyric acid from the chocolate, reducing moisture, and softening the flavor of the product. The stirring temperature is controlled and varies depending on the type of chocolate (from approximately 49°C for milk chocolate to 82°C for dark chocolate). For good results, although temperature-dependent, the stirring duration in conventional chocolate making generally ranges from 16 to 72 hours. In the method according to the invention, preferably, the stirring duration is less than 16 hours, more preferably less than 12 hours, and typically 10 hours or less. Therefore, the loss of desired aromatic qualities observed with prolonged stirring is not observed. Furthermore, because unwanted acids can be removed from the product via the aqueous phase, a shorter stirring duration allows for a smoother flavor.

[0074] Overall, chocolate or similar chocolate products obtained by the method of the present invention exhibit pleasant sensory characteristics and include a high concentration of baked flavor and higher total content of main flavors, polyphenols, antioxidants and / or vitamins.

[0075] As an example, cocoa beans, (wet) solid phase, and through Figure 4The polyphenol content of the dark chocolate obtained by the method shown has been analyzed by spectrophotometric methods. Specifically, the total polyphenol content can be determined by using the Folin-Ciocalteu index, Off. J. Eur. Communities 1990, 41, 178-179 and Cooper et al., J. Agric. Food Chem 2008, 56, 260-265, using the Folin-Ciocalteu assay with (-)-epicatechin as a standard. The total flavonoid content has been determined by aluminum chloride colorimetric assay using (-)-epicatechin as a standard, according to Emelda et al. Int. J. ChemTech Res. 2014, 6(4), 2363-2367. The butyric acid method (e.g., Bates-Smith assay or Porter method) using proanthocyanidin B2 as a standard has been adopted to determine the proanthocyanidin content by spectrophotometric methods. The results are shown in Table 2.

[0076] Table 2

[0077] *ECE=(-)epicate acid equivalent **PCE = Proanthocyanidin B2 equivalent** As shown, the method of the present invention ensures that, among other substances, the high levels of polyphenols, flavonoids and / or proanthocyanidins present in cocoa beans are preserved via solid-phase / cocoa powder so as to achieve optimal yields of healthy components in the final chocolate product, in addition to a pleasant aroma profile.

[0078] The chocolate or similar chocolate product obtained by the method of the present invention can take any suitable form and can, for example, be packaged and sold as blocks or bars, filled, used as a coating, or used in other confectionery and bakery applications (e.g., as a cake coating or filler, cookie coating or filler, sponge coating or filler, or for use as a coating in ice cream). Optionally, the obtained chocolate or similar chocolate product may also have added additives before final use.

[0079] Once the above disclosure has been given, many other features, modifications, and improvements will be apparent to those skilled in the art.

[0080] Reference number 1. Cylindrical tubular body 2 Horizontal axis 3 Solid phase inlet opening 4. Opening of the solid phase outlet after drying 5,5' end plate 6 coaxial sleeves 7. Inner wall of the tubular body 8. Bladed rotor 9 blades 10 Vapor phase outlet opening 11 Hot air inlet opening 12 Heating / Cooling Medium Inlet Opening 13 Heating / cooling medium outlet opening 14 engines

Claims

1. A method for processing cocoa beans or cocoa granules, comprising the following steps: (a) Add water to cocoa beans or cocoa granules to form a suspension; (b) Wet milling of the suspension; (c) subject the suspension to heat treatment at 70°C or lower; (d) Separate the suspension into: Aqueous phase (heavy phase) Including the lipid phase (light phase) of cocoa butter, and Solid phase including cocoa powder and fluid components; (e) The fluid components are continuously separated from the solid phase obtained in step (d) by supplying a stream of the solid phase to a mixing device to obtain cocoa aroma and cocoa powder; wherein The mixing device includes: a cylindrical tubular body (1) having a horizontal axis (2), the tubular body (1) having an inlet opening (3) for a solid phase, an outlet opening (4) for a dried solid phase, and an optional outlet opening (10) for a vapor phase including cocoa aroma; end plates (5, 5') closing the tubular body (1) at opposite ends; a coaxial sleeve (6) for heating or cooling the inner wall (7) of the tubular body (1) to a temperature of 55°C to 150°C; and a bladed rotor (8) supported in the tubular body (1) for rotation, the blades of the bladed rotor (8) being arranged in a helical shape and oriented for centrifugally separating the solid phase and simultaneously transporting the solid phase toward the outlet opening.

2. The method for processing cocoa beans or nibs according to claim 1, wherein, Before or during step (b) or (c), the vapor phase leaving the mixing device is injected into the suspension.

3. The method for processing cocoa beans or nibs according to claim 1 or 2, wherein, The inner wall (7) of the tubular body (1) of the mixing device is heated to a temperature between 65°C and 140°C.

4. A method for processing cocoa beans or nibs according to any preceding claim, wherein, The solid phase obtained after step (d) has a water content of 50% to 75% by weight.

5. The method for processing cocoa beans or cocoa granules according to any one of the preceding claims, wherein, Step (e) includes the following steps: (e1) The solid phase obtained in step (d) is continuously pre-dried by supplying a stream of the solid phase to the first mixing device; and (e2) The pre-dried solid phase obtained in step (e1) is continuously dried by supplying a continuous flow of the pre-dried solid phase to the second mixing device; Each of the first mixing device and the second mixing device includes: a cylindrical tubular body (1) having a horizontal axis (2), the tubular body (1) having an inlet opening (3) for the solid phase, an outlet opening (4) for the dried solid phase, and an optional outlet opening (10) for a vapor phase including cocoa aroma; end plates (5, 5') closing the tubular body (1) at opposite ends; a coaxial sleeve (6) for heating or cooling the inner wall (7) of the tubular body (1) to a temperature of 55°C to 150°C; and a bladed rotor (8) supported in the tubular body (1) for rotation, the blades of the bladed rotor (8) being arranged in a spiral shape and oriented for centrifugally separating the solid phase and simultaneously transporting the solid phase toward the outlet opening.

6. The method according to claim 5, wherein, The inner wall (7) of the tubular body (1) of the first mixing device is heated to a temperature between 70°C and 110°C, preferably between 80°C and 100°C, and / or wherein, The inner wall (7) of the tubular body (1) of the second mixing device is heated to a temperature between 100°C and 150°C, preferably between 120°C and 140°C.

7. The method for processing cocoa beans or cocoa granules according to any one of the preceding claims, wherein, The hot air stream and the stream of solid phase to be dried are supplied to the mixing device simultaneously and in parallel through the inlet opening (11).

8. The method for processing cocoa beans or cocoa granules according to any one of the preceding claims, wherein, The bladed rotor (8) of the mixing device is driven at a speed from 600 rpm to 1100 rpm, preferably between 750 rpm and 1050 rpm.

9. The method for processing cocoa beans or cocoa granules according to claims 5 to 8, wherein, Before or during steps (b) and (c), the first vapor phase that leaves the first mixing device in step (e1) is injected into the suspension.

10. The method for processing cocoa beans or cocoa granules according to claims 5 to 9, wherein, The pre-dried solid phase obtained after step (e1) has a water content of 3% to 7% by weight, and / or the cocoa powder obtained after step (e2) has a water content of less than 3% by weight.

11. The method for processing cocoa beans or cocoa granules according to claims 5 to 10, wherein the vapor phase obtained in step (e2) is collected as an aromatic phase, the aromatic phase is combined with water, and the combined liquid undergoes one or more concentration steps to obtain a cocoa aromatic extract.

12. Cocoa powder prepared by the method according to any one of claims 1 to 11.

13. A method for manufacturing chocolate or similar chocolate products, comprising the following steps: Process cocoa beans or cocoa granules according to any one of claims 1 to 11. The obtained cocoa powder is mixed with at least one of cocoa flavoring, cocoa butter, or polyphenol powder; and Stir the mixture.

14. A chocolate or similar chocolate product obtained by the method according to claim 13.

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