Chocolate alternative product and method of preparing said

Abstract

The present invention relates to a chocolate alternative product comprising spent grains, edible fat and optionally sugar. The present invention also relates to a method of producing said chocolate alternative product and the use hereof.

Description

[0001] Chocolate alternative product and method of preparing said

[0002] Technical field of the invention

[0003] The present invention relates to a chocolate alternative product made without cocoa mass and cocoa butter. In particular, the present invention relates to a chocolate alternative product that comprises spent grains, brewer's spent grain or oat spent grain, and edible fat. The present invention also relates to the method of preparing such chocolate alternative product and the use thereof.

[0004] Background of the invention

[0005] Chocolate is a confectionary that is consumed all over the world with pleasure. However, preparing chocolate is a complex process that first includes harvesting cacao pods, comprising cacao beans embedded in a moist, fibrous, white pulp, from cacao trees. These cacao trees require a tropical climate to grow.

[0006] Then the cacao beans and pulp are fermented by exposure to oxygen. The fermentation breaks down the coat of the beans, kills germs and bacteria, and the fermentation is also crucial in developing the characteristic chocolate flavour of the beans.

[0007] After fermentation, the cocoa beans (as they are called after fermentation), is dried to reduce the moisture content and avoid over-fermentation.

[0008] After drying, the cocoa beans are roasted. Roasting cocoa beans is crucial in developing their flavour. It also loosens the outer shell of the bean (cacao husk), such that the cocoa bean can be separated into the bean kernel (cocoa nibs) and outer shell (cacao husk). The nibs are made of cocoa solids and cocoa butter and are ground or crushed (in a grinder) into a thick paste referred to as chocolate paste, chocolate mass, chocolate liquor or chocolate liquid. As the grinder continues to break down the nibs, the cocoa butter within the nibs begins to melt. The longer the chocolate is ground the smoother the liquor becomes.

[0009] During the grinding, additional ingredients can be added depending on the desired flavour of the chocolate. The ingredients may for example be sugar, emulsifier, milk powder, additional cocoa butter and spices. The chocolate is then subjected to conching, tempering, forming and cooling. Besides from the chocolate process is a complicated and complex process and cacao trees are only grown in tropical climates, the cacao yield is also dwindling and the cacao prices are increasing due to the climate changes. For example, the climate changes are affecting the cacao yields and this will have an effect on the prices, amounts available, and the energy necessary to produce cacao and chocolate products. Further, the production of chocolate involves high carbon dioxide emission. For example, the long transportation result in high carbon dioxide emission.

[0010] Hence, it is a desire to prepare an alternative to chocolate that has the same functional properties as chocolate along with a pleasant taste, i.e. similar flavour, texture, melting properties, snap when broken, strength, tempering properties, and shine / glossiness.

[0011] Summary of the invention

[0012] Thus, an object of the present invention relates to a chocolate alternative product prepared without the use of cocoa butter and cocoa mass, but with functional properties similar to chocolate, such as similar texture, melting properties, snap when broken, strength and glossiness.

[0013] Furthermore, an object of the present invention is to prepare a chocolate alternative product from by-products obtained from the production of other food products. The focus on avoiding food waste has increased over the past years and therefore the reuse of by-products from the preparation of various food products has increased.

[0014] In addition, an object of the present invention is to overcome the problems described above in relation to chocolate production.

[0015] Thus, one aspect of the invention relates to a chocolate alternative product comprising: i) dried and milled spent grains in an amount of 10% to 40% by weight, wherein the dried and milled spent grains are selected from the group consisting of brewer's spent grain and oat spent grain, and wherein the dried and milled spent grains have a moisture content of 12% by weight or less, ii) edible fat in an amount of 20% to 60% by weight, iii) sugar in an amount of 0% to 35% by weight and wherein the chocolate alternative product has a particle size of 40 micron or less. Another aspect of the present invention relates to a method of preparing a chocolate alternative product comprising the following steps: a) providing dried, spent grains selected from the group consisting of brewers spent grain and oat spent grain, and wherein the dried spent grains have a moisture content of 12% by weight or less; b) milling the dried spent grains to a particle size in the range of 60 to 500 micron; c) melting an edible fat by heating the edible fat to a temperature above the melting point of the edible fat used; d) mixing the dried and milled spent grains of step b), the melted edible fat of step c), optionally sugar and other ingredients, and conching the mixture to provide a homogenous mass, wherein the homogeneous mass comprises dried and milled spent grains in an amount of 10% to 40% by weight, edible fat in an amount of 20% to 60% by weight and sugar in an amount of 0% to 35% by weight and wherein the particle size of the homogenous mass is 40 micron or less; e) the homogenous mass of step d) is either used directly as a liquid chocolate alternative product or processed into a solid chocolate alternative product.

[0016] Yet another aspect of the present invention relates to the use of the chocolate alternative product according to the invention in a confectionary bar, a confectionary filling, a coating, a syrup, a cake, a cookie, a biscuit, a dessert mousse, a ganache, a doughnut, a bread or other baked item, an ice cream, a beverage, other liquid forms or in combination with chocolate products.

[0017] Brief description of the figures

[0018] Figure 1 shows a chocolate alternative product according to the present invention made with brewer's spent grains.

[0019] Figure 2 shows a top view of chocolate alternative product according to the present invention made with oat spent grains,

[0020] Figure 3 shows a side view of chocolate alternative product according to the present invention made with oat spent grains.

[0021] The present invention will now be described in more detail in the following. Detailed description of the invention

[0022] Definitions

[0023] Prior to discussing the present invention in further details, the following terms and conventions will first be defined:

[0024] All references to singular characteristics or limitations or the present invention shall include the corresponding plural characteristic or limitation, and vice versa, unless otherwise specified or clearly implied to the contrary by the context in which the reference is made.

[0025] All percentage referred to herein is percentage by weight unless otherwise stated. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art.

[0026] Chocolate alternative product:

[0027] In an aspect, the present invention relates to a chocolate alternative product comprising: i) dried and milled spent grains in an amount of 10% to 40% by weight, wherein the dried and milled spent grains are selected from the group consisting of brewer's spent grain and oat spent grain and wherein the dried and milled spent grains have a moisture content of 12% by weight or less, ii) edible fat in an amount of 20% to 60% by weight iii) sugar in an amount of 0% to 35% by weight and wherein the chocolate alternative product has a particle size of 40 micron or less.

[0028] In the context of the present invention, the term "chocolate alternative product" refers to a product that does not comprise cocoa butter or cocoa mass. Hence, the chocolate alternative product does not comprise any product obtained from the cocoa nibs.

[0029] However, the chocolate alternative product may comprise other ingredients that can be found in a traditional chocolate, such as sugar, emulsifiers and spices. Further, the chocolate alternative product may, in embodiments of the present invention, comprise cacao husk that is the outer shell of a cacao bean surrounding the cacao kernel. The cacao husk is typically not used in the methods of preparing traditional chocolate.

[0030] It was surprisingly found by the inventors of the present invention that a chocolate alternative product could be made without using cocoa butter and cocoa mass but made from spent grain and edible fat. The chocolate alternative product was surprisingly found to have texture, flavour, aroma, and functional properties similar to traditional chocolate.

[0031] The chocolate alternative product comprises dried and milled spent grains in an amount of 10% to 40% by weight, wherein the dried and milled spent grains are selected from the group consisting of brewer's spent grain and oat spent grain.

[0032] If the amount of spent grain is lower than 10% by weight, the texture of the obtained product is not similar to chocolate. Besides, if the amount of spent grain is lower than 10% by weight, the obtained product has a light flavour and not the intense flavour otherwise needed. If the amount of spent grains, on the contrary, is higher than 40% by weight, the product obtained will be hard to process, i.e., too thick to process in the conching step. Furthermore, a content of spent grains higher than 40% by weight will result in the product obtained being too difficult to set.

[0033] In an embodiment of the present invention, the chocolate alternative product comprises 15% to 35% of dried and milled spent grains selected from the group consisting of brewer's spent grain and oat spent grain.

[0034] Brewer's spent grain:

[0035] In the context of the present invention, the term "brewer's spent grain" (BSG) refers to a by-product obtained from the process of brewing beer and distilling liquor from grains, rice and corns, i.e., whiskey distillation. However, BSG may also come from the preparation of other types of liquor where grains, corn, rice or sugar canes is used as the starting material for preparing the liquor.

[0036] BSG is the insoluble solids obtained after malting and mashing in the brewing and distilling processes. Brewer's spent grain is a non-flowing product having a consistence similar to cooked oatmeal or wetted sawdust and may be referred to as a grain bed.

[0037] In the context of the present invention, the term "BSG" is an abbreviation of "brewer's spent grain", and "BSG" and "brewer's spent grain" therefore refer to the same and may be used interchangeable.

[0038] Brewing beer requires only a few ingredients and can typically be divided into four steps or phases, namely the malting step, the mashing step, the fermentation step and the post-fermentation step. However, the malting step can be excluded if there is a need for reduction of expenses or a need for an alternative flavour. Whiskey distillation also involves malting and mashing.

[0039] During the malting step in beer brewing, the barley grains are soaked in water and hence allowed to germinate or sprout until a certain point which allows development of a wide range of enzymes (malting enzymes). The enzymes developed are amylases, proteases, and other enzymes. These enzymes will modify the structure of the barley endosperm by breaking down the cell walls and the protein matrix. After germination and sprouting of the barley grains, barley grains are subjected to a kilning step that stops the germination and development of enzymes. The kilning step most often includes heat treatment. The kilning process provides roasting of the barley grains. During the mashing step, the enzymes are released and used for hydrolysis of large macromolecules such as starch and protein. In the mashing step, the malted barley is milled and mixed with water and followed by a step-wise heating in order to break down starch and proteins into subunits that will function as substrate in the following fermentation process.

[0040] At the end of the mashing step, a heat treatment is provided to inactivate the enzymes. Before fermentation, the insoluble solids from the mash is removed by filtration to obtain a mash liquid which is called the wort. The wort is used for the fermentation process in the beer production, where the insoluble solids removed is known as brewer's spent grain.

[0041] Brewer's spent grain (BSG) is thus the insoluble leftover obtained after wort production during brewing of beer and liquor distillation. BSG comprises grain solids, proteins, carbohydrates, and other materials, where the main solid components of BSG is the husk pericarp and seed coat of the malt, which are rich sources of lignin, cellulose, hemicellulose, lipids and protein. Of these components cellulose, hemicellulose and lignin comprise almost 50% of the dry matter content. The BSG also comprises a high amount of water, but the water content can vary a lot depending on the brewery delivering the BSG. In BSG, approximately 60-85% by weight is water, where approximately 15-40% by weight is solid materials. The water content in BSG comprises about 15% by weight free water, where the remaining water (about 85% by weight) is sucked into the grain material and thus not free flowing.

[0042] The chocolate alternative product comprising BSG will have a colour similar to the colour of dark chocolate. The BSG used for the present invention can be obtained from the brewing of different types of beer,

[0043] Oat spent grain:

[0044] In the context of the present invention, the term "oat spent grain" refers to the solid waste material obtained after preparing oat milk.

[0045] The preparation of oat milk involves mixing either whole, cut or rolled oat or oat flour with water. The mixture is blended to reduce the particle size, heated to about 60°C to gelatinize starch. Enzymes may be added to further break down the starch and the enzymes, if added, can be inactivated by a heat treatment step. Plant oil may be added to improve mouthfeel and stabilisers can be added to improve mouthfeel and stability. The resulting mixture is filtered to remove the solid waste material from the liquid phase known as the oat milk.

[0046] The solid waste material is sometimes referred to as oat pulp and the solid waste material is the oat spent grain used in the present invention.

[0047] The chocolate alternative product comprising oat spent grain may, contrary to the chocolate alternative product comprising BSG, be light in colour and resemble white chocolate. However, a dark chocolate may also be prepared from oat spent grains.

[0048] Dried and milled spent grains:

[0049] In the context of the present invention, the spent grains are a solid waste material obtained either from the brewery industry or the industry of making oat milk. The spent grains present in the chocolate alternative product are dried and milled into a smaller particle size than the raw BSG obtained from the brewery.

[0050] It is important to dry the spent grains before use in the chocolate alternative product in order to reduce the moisture content. If the moisture content is too high, the spent grains cannot be used to prepare a product that have functional properties similar to chocolate. Preferably, the moisture content in the dried spent grains is 12% by weight or less, more preferably 10% by weight or less, such as 5-12% by weight, for example 8-12% by weight. If the moisture content is higher than 12% by weight, the chocolate alternative product obtained will be grainy and not have the smooth texture of chocolate. In addition, if the water content is high, unwanted fermentation and unwanted bacterial and microbial growth will occur. Hence, unwanted flavour is developed, lactic acid is build-up and the product is contaminated with microorganisms and hence spoiled.

[0051] The spent grains may be dried by any process known by the skilled person and the type of drying is not a limitation to the present invention.

[0052] The spent grains present in the chocolate alternative product of the present invention are also milled.

[0053] The milled spent grains can for example be obtained by milling the dried spent grains that are used for the production of the chocolate alternative product in combination with conching of the mixture of the spent grains with edible fat. The conching step may in some embodiments of the invention be enough for obtaining milled spent grains having a desired particle size, but in other embodiments the spent grains are milled before mixed with edible fat and then further "milled" in the conching step.

[0054] Hence, in an aspect of the present invention, the chocolate alternative product has a particle size of 40 micron or less, such that 30 micron or less. Therefore, the dried and milled spent grains present in the chocolate alternative product has a particle size of 40 micron or less, such that 30 micron or less. More preferably, the particle size of the chocolate alternative product is 20 micron or less. The particle size of the chocolate alternative product is preferably 20 micron or less, since if the particle size is higher than 20 micron, a gritty texture will begin to be registered by the tongue when consuming the chocolate alternative product. A particle size of 20-40 micron is acceptable, since the product is relatively smooth and only having some minor texture. The chocolate alternative product should preferably have a smooth texture and not a gritty texture. Preferably, the chocolate alternative product and also the dried and milled spent grains have a particle size of 40 micron or less, such as 30 micron or less, preferably 20 micron or less. More preferably, the particle size of the chocolate alternative product and the dried and milled spent grains is 15 micron or less, such as 10 micron or less.

[0055] The term "milling" will in the context of the present invention cover all types of processes where the spent grains are particulated into a smaller particle size. Hence, the milled spent grains may be obtained by for example milling, blending, grinding, etc. The present invention should not be limited to the type of milling of the spent grains. The term "conching" refers in the context of the present invention to the same process as typically used during the preparation of chocolate. Conching is a process where the spent grains and edible fat are subjected to continuously mixing, grinding and kneading over a prolonged period to provide a homogenous mass. The conching is typically made by the use of a surface scraping mixer and agitator, known as a conche. During the conching, the particle size of the spent grain is further reduced and may be referred to as a "polisher" of the particles. After the conching step, the particle size of the chocolate alternative product and therefore also of the spent grains are 40 micron or less, such as 30 micron or less and preferably 20 micron or less. The conching process also promotes flavor development by allowing chemical reactions, such as acid-base reactions, oxidation, and reduction processes. Further, conching allows the volatile flavors to evaporate, which can eliminate any harsh or unwanted flavors.

[0056] Conching may also be referred to as wet milling and means in the context of the present invention the same.

[0057] In another embodiment of the present invention, the particle size of the chocolate alternative product and then also of the dried and milled spent grains present in the chocolate alternative product is less than 20 micron. For example, the particle size is in the range of 1 to 20 micron, such as 2 to 15 micron and more preferably 3 to 10 micron.

[0058] In a further embodiment, the dried and milled spent grains is BSG and comprises protein in an amount in the range of 15-25% by weight of dry matter. BSG also comprises a high amount of dietary fibre, such as about 40-65% by weight of dry matter content. In table 1 below, is an example of the nutrient content of a dried BSG given, based on the total solid content.

[0059] Table 1:

[0060] In the context of the present invention, the dried and milled spent grains comprises the BSG or oat spent grain as such that has been dried and milled into a smaller particle size. The dried and milled spent grains are therefore not a dried form of a protein extract from either BSG or oat.

[0061] Edible fat:

[0062] The chocolate alternative product according to the present invention comprises an edible fat in an amount of 20% to 60% by weight. The edible fat is necessary in order to obtain the melting properties coupled to chocolate, i.e. solid at room temperature, but melting in the mouth. The amount of fat should not be higher than 60%, because if higher than 60% the product obtained is too greasy and gives an unpleasant mouth feeling. Furthermore, the fat content should be higher than 20% by weight, because if lower, the product obtained will not have a texture similar to chocolate and hence the characteristic melting properties of chocolate.

[0063] Preferably, the chocolate alternative product comprises edible fat in an amount of 30% to 60% by weight, preferably 40 to 55% by weight.

[0064] In an embodiment of the present invention, the edible fat is at least one selected from the group consisting of illipe fat, shea butter, palm oil, palm kernel oil, kokum butter, mango butter, soybean oil, rapeseed oil, sunflower oil, coconut oil, coconut butter, mango kernel fat, olive oil, or fractionated and / or hydrogenated fat or oil thereof. The edible fat may also be a combination or two or more of the mentioned fats and oils. For example, the edible fat is at least one selected from the group consisting of the illipe fat, shea butter, palm oil, palm kernel oil, kokum butter, mango butter, coconut butter and fractionated and / or hydrogenated thereof.

[0065] Preferably, the edible fat used is having a melting point above room temperature. For example, shea butter has a melting point in the range of 36-38°C, while illipe fat has a melting point in the range of 30-40°C. More preferably, the edible fat is selected from the group consisting of illipe fat, shea butter and combinations thereof. In an embodiment of the present invention, the ratio between the dried and milled spent grains and the edible fat is in the ratio of 1:5 to 2: 1, preferably 1:3 to 2: 1 and more preferably about 1:2. It has been found by the inventors of the present invention that the ratio between the dried and milled spent grains and the edible fat should be in the ratio of 1: 5 to 2: 1 to obtain a suitable chocolate alternative product having properties similar to chocolate. If the content of fat as compared to the content of spent grains are higher, the product obtained will be too fat in consistence and lack intensity in flavour. Further, if the amount of spent grains becomes too high as compared to fat, the product obtained will be grainy, have a poor mouthfeel and be difficult to process.

[0066] Sugar:

[0067] The chocolate alternative product according to the present invention may comprise sugar, but it is optional. Hence, the chocolate alternative product may comprise sugar in an amount of 0% to 35% by weight. If sugar is used, it will provide texture to the chocolate alternative product as well as flavour and sweetening.

[0068] Preferably, the chocolate alternative product according to the present invention comprises sugar in an amount of 5% to 30% by weight, such as 10% to 25%, preferably 10% to 22%, and more preferably in an amount of 15% to 20% by weight.

[0069] The sugar used may for example be raw sugar or caramelised sugar. The type of sugar used is not a limitation to the present invention.

[0070] Further ingredients in the chocolate alternative product:

[0071] In some embodiments of the present invention, the chocolate alternative product comprises further ingredients beside from the dried and milled spent grains, the edible fat and optionally sugar.

[0072] In one embodiment of the present invention, the chocolate alternative product comprises cacao husk in an amount of 2% to 35% by weight. Cacao husk is the outer shell of the cacao bean surrounding the kernel. When the chocolate alternative product comprises cacao husk, the cacao husk is preferably milled into smaller particles. This milling may include crushing and grinding.

[0073] Even though cacao husk is a product obtained from the cacao bean, cacao husk is not typically used in the production of chocolate but is a waste product or by-product obtained from the chocolate production. The cacao husk will provide a deep and intense flavour of chocolate to the chocolate alternative product

[0074] In embodiments of the present invention, the chocolate alternative product comprises cacao husk in an amount of 3 to 30% by weight, such as 5% to 25% by weight, preferably 5% to 20% by weight and more preferably 5% to 15% by weight.

[0075] In a further embodiment of the present invention, the chocolate alternative product may comprise blackened, dried and milled spent grains in an amount of 0.5 to 15% by weight. The blackened, dried milled spent grain may be BSG, oat spent grains or a combination thereof. Preferably, the chocolate alternative product may comprise blackened, dried and milled spent grains in an amount of 2% to 10% by weight, more preferably 2% to 8% by weight, such as 2% to 5% by weight.

[0076] In the context of the present invention, the term "blackened" refers to that, the spent grains have been treated by placing the spent grains in warm, moist, controlled environment and thereby have obtained a darker colour. The blackening process of the spent grains is similar to the known process of blackening garlic. The term "blackened" may also be understood as caramelised spent grains. The blackening of the spent grains also provides a different taste to the spent grains, for example the blackening ads notes of dark fruit, such as prune, cherry and raisin. Further, the blackening adds acidic notes, caramelised and roasted taste to the spent grains.

[0077] Preferably, the blackening of the spent grains is made by placing the spent grains in a plastic bag with water and vacuum seal the package. The package is then placed in a dehydrator having a temperature of 55°C to 80°C for 14 to 60 days. After the dehydration / storage, the spent grains are blackened. After the spent grains are blackened, they are dried and stored for later use. Preferably, the humidity during the blackening process is up to 60%.

[0078] In embodiments of the present invention, the chocolate alternative product comprises blackened, dried and milled spent grains in an amount of 1 to 12% by weight, such as 1.5 to 10% by weight.

[0079] In a further embodiment of the present invention, the dried and milled spent grains in the chocolate alternative product may be roasted or unroasted or a combination thereof. If the spent grains are roasted, it may be roasted, dried milled spent grain of BSG, oat spent grains or a combination thereof. Using roasted spent grains may provide a different taste than using unroasted spent grains.

[0080] The roasted spent grains may for example be obtained by heating the spent grains to at least 140°C for at least 10 minutes, preferably around 175°C for 30 minutes. The roasting is for example to a temperature of 140°C to 200°C for 10 minutes to 45 minutes. The roasting of the spent grains may for example be by heating at 140°C for 45 minutes or by heating at 200°C for 10 minutes. The heating is preferably performed simultaneous to blowing air in the oven. The roasting could for example be in an oven with air circulation or in a heated extruder.

[0081] In embodiments of the present invention, the chocolate alternative product comprises roasted, dried and milled spent grains in an amount of 1 to 40% by weight, such as 5 to 35% by weight.

[0082] The chocolate alternative product of the present invention may also comprise one or more flavouring agents. The present invention should not be limited to the flavouring agent used and can in principle be any flavouring ingredient suitable for being added in chocolate. Examples of flavouring agents are extracts or powders of vanilla, fruit, berries, and spices. The extract or powder of berries may for example be of sea buckthorn, strawberry, raspberry, blueberry, blackberry, blackcurrant berry and cranberry.

[0083] The extract or powder of fruit may for examples be of a citrus fruit, such as orange, lemon, lime, pomelo, and of plum, cherry, mango and pear and apple.

[0084] Examples of spices to be used are chili, ginger, cinnamon, anise, clove, cayenne, saffron, curry, salt, bay leaf, cardamom, coffee and orange peel.

[0085] The chocolate alternative product may also in embodiments of the invention comprise one or more emulsifier. The emulsifier is used to "glue" the dry solids and edible fat together to obtain a homogenous mass. Further, the emulsifier is used to improve the flowing properties of the liquid chocolate alternative product. The emulsifier may be any emulsifier suitable for use in food products. Example of emulsifiers that can be used in the chocolate alternative product are lecithin, monoglycerides and diglycerides of fatty acids, esters of mono and diglycerides.

[0086] The chocolate alternative product preferably comprises emulsifier in an amount of 0- 1.0% by weight, such as 0.1-0.5% by weight.

[0087] The chocolate alternative product may also comprise a colouring agent. For example, red colour could be added to the light chocolate alternative product prepared from oat to give a pink colour. This could for example be if the taste of the product is fruity.

[0088] In a particularly preferred embodiment of the present invention, the chocolate alternative product does not comprise cocoa butter and / or cocoa mass.

[0089] In a further embodiment of the present invention, the chocolate alternative product does not comprise added water. Hence, the moisture provided in the product is derived from the brewer's spent grains or flavour extracts.

[0090] In an additional embodiment of the present invention, the chocolate alternative product does not comprise any isolated volatile organic compounds. In the chocolate alternative product according to the present invention, flavour is obtained from the spent grains and from extracts or powders of vanilla, fruit, berries, and spices, but not from adding an isolated volatile organic compound. Volatile organic compounds are not added since it is wished to prepare a "clean" product with natural ingredient from plant sources and not chemical produced isolated compounds.

[0091] In a further embodiment of the present invention, the chocolate alternative product may comprise milk powder. The chocolate alternative product may also comprise one or more edible acids, such as lactic acid, citric acid and acetic acid, preferably lactic acid.

[0092] Method of preparing the chocolate alternative product:

[0093] An aspect of the present invention relates to a method of preparing a chocolate alternative product wherein the method comprises the following steps: a) providing dried, spent grains selected from the group consisting of brewers spent grain and oat spent grain, and wherein the dried spent grains have a moisture content of 12% by weight or less; b) milling the dried spent grains to a particle size in the range of 60 to 500 micron; c) melting an edible fat by heating the edible fat to a temperature above the melting point of the edible fat used; d) mixing the dried and milled spent grains of step b), the melted edible fat of step c), optionally sugar and optionally other ingredients, and conching the mixture to provide a homogenous mass, wherein the homogeneous mass comprises dried and milled spent grains in an amount of 10% to 40% by weight, edible fat in an amount of 20% to 60% by weight and sugar in an amount of 0% to 35% by weight and wherein the particle size of the homogenous mass is 40 micron or less; e) the homogenous mass of step d) is either used directly as a liquid chocolate alternative product or processed into a solid chocolate alternative product.

[0094] In step a) is dried, spent grains provided where the spent grains are BSG and / or oat spent grain. The dried spent grains are provided in amounts as mentioned above under the description of the chocolate alternative product, i.e. in the broadest aspect in an amount of 10% to 40% by weight, preferably 15% to 35% by weight. The spent grains may be roasted or unroasted or a combination thereof.

[0095] The edible fat and sugar are also provided and mixed in the mixture of step d) in the amounts earlier disclosed under the description of the chocolate alternative product, i.e. the content of edible fat is 20% to 60% by weight and the amount of sugar is 0% to 35% by weight.

[0096] In an embodiment of the invention, the dried spent grains have a moisture content of 10% by weight or less, such as 5-12% by weight, for example 8-12% by weight. If the moisture content is higher than 12% by weight, the chocolate alternative product obtained will be grainy and not have the smooth texture of chocolate. In addition, if the water content is high, unwanted fermentation occur and therefore unwanted formation of flavour and aroma compounds. A high water content also causes bacterial and microbial contamination.

[0097] In an embodiment of the present invention, the method of preparing the chocolate alternative product does not involve addition of water.

[0098] Hence, the moisture provided to the product is derived from the brewer's spent grains or possible added flavour extracts. The method of preparing the chocolate alternative product further comprises addition of cacao husk in an amount of 2% to 35% by weight of the mixture in step d). The cacao husk is preferably milled into smaller particles. This milling may include crushing and grinding. The cacao husk will provide a deep and intense flavour of chocolate to the chocolate alternative product

[0099] In embodiments of the present invention, the method of preparing the chocolate alternative product comprises addition of cacao husk in an amount of 3 to 30% by weight of the mixture in step d), such as 5% to 25% by weight, preferably 5% to 20% by weight and more preferably 5% to 15% by weight. The amount given is based on the total composition, i.e. the total mixture in step d) provided to prepare the chocolate alternative.

[0100] In a further embodiment of the present invention, the method of preparing the chocolate alternative product comprises addition of blackened, dried and milled spent grains in an amount of 0.5 to 15% by weight of the mixture in step d). The blackened, dried milled spent grain may be BSG, oat spent grains or a combination thereof. Preferably, the method of preparing the chocolate alternative product comprises addition of blackened, dried and milled spent grains in an amount of 2% to 10% by weight of the mixture in step d), more preferably 2% to 8% by weight, such as 2% to 5% by weight. The amount given is based on the total composition, i.e. the total mixture provided to prepare the chocolate alternative.

[0101] In also an embodiment of the invention, the method comprises mixing dried and milled spent grains and melted edible fat in a ratio of 1:5 to 2: 1, preferably 1:3 to 2: 1 and more preferably about 1:2.

[0102] In an embodiment, the method of the invention does not comprise addition of any isolated volatile organic compounds.

[0103] The spent grains can be dried by any drying method known in the art, and the drying step is not to be seen as a limitation to the invention. One example of drying is drying by heat treatment to 55-85° for 3 to 20 hours.

[0104] The spent grains directly obtained from the brewery or from the oat milk production are after being dried preferably milled to a smaller particle size before mixed with edible fat and optionally other ingredients. At this stage, the dried spent grains have a particle size about 60 to 2000 micron. If the spent grains have not been milled, the particle size is typically 1000 to 2000 micron, but if they have been milled, the particle size may be in the range of 60 to 1000 micron, preferably 60 to 500 micron. After addition of fat and possible other ingredients, the mass is further being subjected to conching to provide a homogeneous mass. After conching, the particle size of the homogeneous mass and therefore also the spent grains become further reduced to 40 micron or less, such as 30 micro or less. Preferably, the particle size of the homogeneous mass is 20 micron or less, such as 15 micron or less, preferably 10 micron or less.

[0105] The dried spent grains is in step b) milled before the conching step. The dried spent grains can be milled by any method known to mill grains, for example by using a traditional mill, a blender or grinder. The present invention should not be limited to the device used for milling. Preferably, the milling is made to obtain a particle size of the spent grains in the range of 60 to 500 micron, preferably 100 to 500 micron.

[0106] In step c) of the method of the present invention is edible fat melted. The edible fat is preferably present in an amount of 20% to 60% by weight, such as 30% to 60% by weight, and more preferably 40 to 55% by weight. The edible fat is in step c) melted by heating to a temperature above the melting point of the edible fat used. The edible fat may be any of the edible fats and oils mention under the description of the chocolate alternative product. The melting of the edible fat, for example, could include heating to a temperature in the range of 35°C to 170°C. Preferably, 45°C to 150°C. The temperature during the melting step should not be above 170°C because then the edible fat will begin to burn and perform off-flavours. Further, the temperature should be above 45°C in order for the edible fats to melt.

[0107] When the edible fat is melted in step c), the melted fat is in step d) mixed with the dried spent grains, and optionally sugar and other ingredients, and the mixture is subjected to conching to provide a homogenous mass. Preferably, the melted edible fat and spent grain are mixed and conched for some time before for example sugar and other ingredients are added and conching is continued.

[0108] The mixture is preferably conched for at least 12 hours, such as for at least 20 hours and preferably at least 24 hours. The conching is in some embodiments preformed for 12 to 70 hours, such as for 20 to 60 hours. The conching is preferably performed while maintaining a temperature of the mixture of 36°C to 70°C, preferably 36°C to 60°C. such that the edible fat maintains melted.

[0109] The mixing in step d) is to provide a homogenous mass comprising 20-40% by weight dried and milled spent grains, 20-60% by weight edible fat and 0-35% by weight sugar. Hence, the mixing in step d) is mixing of at least 20-40% by weight dried and milled spent grains, 20-60% by weight edible fat and 0-35% by weight sugar.

[0110] In step e) of the method of the present invention, the homogenous mass of step d) is either used directly as a liquid chocolate alternative product or processed into a solid chocolate alternative product. Hence, in step e), a liquid chocolate alternative is obtained and / or homogenous mass is processed into a solid chocolate alternative product.

[0111] The liquid chocolate produced in step e) may be used as for example a coating, filling or syrup.

[0112] The homogenous mass of step d) may alternatively be processed into a solid chocolate alternative product comprises one of the following steps: a) tempering and cooling b) directly cooling.

[0113] Hence, the homogenous mass of step c) may for example be directly cooled such that the chocolate alternative product sets into a solid chocolate alternative product. Alternatively, the homogenous mass may be tempered before cooled.

[0114] Tempering of the chocolate alternative product is typically performed if it is desired to obtain a glossy or shiny surface of the chocolate alternative produce. If it is not necessary to obtain a shiny or glossy surface of the chocolate alternative product, it is not tempered. For example, if the chocolate alternative product is used in cakes, cookies, biscuits, doughnut, or bread, it is not necessary to temper the chocolate alternative product. If the homogenous mass is not tempered, the product obtained may have a dull appearance or has white streaks running through it. The term "white streaks" may also be referred to as "fat bloom" and refers to a situation where fats rise to the surface of the chocolate (also in conventional chocolate) and create a grey dull appearance.

[0115] In the context of the present invention, the tempering process is the same a typically understood from the chocolate production. Tempering involves slowly heating and cooling steps of the homogenous mass. The specific temperatures of these cooling and heating steps should not be seen as a limitation of the present invention However, in one example, the tempering involves a first heating of the homogenous mass to 45°C- 50°C, followed by cooling to 26°C to 28°C and subsequently heating again to about 31°C.

[0116] Use of the chocolate alternative product:

[0117] The present invention relates in a further aspect to the use of the chocolate alternative product in a confectionary bar, a confectionary filling, a coating, a syrup, a cake, a cookie, a biscuit, a dessert mousse, a ganache, a doughnut, a bread or other baked item, an ice cream, a beverage, other liquid forms or in combination with chocolate products.

[0118] The beverage can be a chocolate beverage that can include both hot chocolate beverages and cold chocolate milk beverages.

[0119] The liquid chocolate alternative product is typically used for some applications while the solid chocolate alternative product is used for other applications.

[0120] It should be noted that embodiments and features described in the context of one of the aspects of the present invention also apply to the other aspects of the invention. Hence, all embodiments relating to the spent grains, edible fat, sugar and other ingredients described in the context of the chocolate alternative product also applies to the method of preparing the chocolate alternative product. This means that the ranges of the different ingredients described in the context of the chocolate alternative product is the same amounts of ingredients used in the method of preparing the chocolate alternative product.

[0121] The invention will now be described in further details in the following non-limiting examples. Examples

[0122] Example 1: example of preparing the chocolate alternative product from BSG

[0123] This example gives an example on how to prepare the chocolate alternative product according to the present invention from BSG. The chocolate alternative product is made based on the amounts of ingredients (percentages are by weight) mentioned in table 2. The chocolate alternative product obtained has a dark brown colour similar to chocolate. The chocolate alternative product is disclosed in figure 1.

[0124] Table 2:

[0125] The chocolate alternative product is prepared by the following process steps:

[0126] 1. Fresh BSG is obtained from the brewery;

[0127] 2. The fresh BSG is dried by heating to about 60°C for 8-12 hours to obtain dried BSG having a moisture content of 5-10% by weight;

[0128] 3. A part of the dried BSG is roasted by placing the BSG on metal trays in an oven, 175°C for 30 minutes. After about 15 minutes the roasted BSG is mixed;

[0129] 4. Another part of the fresh BSG is mixed with water (25g water per 100g fresh BSG) and placed in a plastic bag. The plastic bag is sealed and subjected to vacuum to remove oxygen. The vacuum-sealed plastic bag is placed in a dehydrator at a temperature of 60°C for about 3 weeks to obtained blackened BSG.

[0130] 5. The dried, roasted BSG and the blackened BSG is blended in an industrial blender to obtain a particle size of the BSG about 100-500 micron. Hereby dried, roasted and milled BSG and dried, milled and blackened BSG is obtained;

[0131] 6. ipe fat was melted by heating to 70°C;

[0132] 7. Melted Wipe fat was melted with all the other ingredients (except lecithin) mentioned in table 2 and in the amounts mentioned in table 2. The ingredients are mixed for about 1 minute to incorporate all ingredients in the melted fat; 8. The mixture is added to a wet mill (conching) and subjected to conching for 24 to 36 hours (36-60°C), in the conching step the particle size was further reduced to below 20 micron;

[0133] 9. 1 hour before the conching was finalised, lecithin was added

[0134] 10. The conching was finalised and the liquid chocolate alternative product removed from the container

[0135] 11. The liquid chocolate alternative product can either be used directly, cooled down in a container or transferred to a tempering process.

[0136] The tempering process used was as follows:

[0137] 1. The liquid chocolate alternative product is heated to 45-50°C, followed by cooling down to 26-28°C for again to be heated to about 31°C

[0138] 2. The tempered chocolate alternative product is poured into moulds and set by cooling to 3°C for about 45 minutes to 1 hour.

[0139] 3. The chocolate alternative product can be stored for long time at 15-18°C.

[0140] The chocolate alternative product prepared with the ingredient of table 2 had a great snap, mouthfeel and the flavour were good.

[0141] Example 2: Example of preparing the chocolate alternative product from oat spent grain Example 2 shows an example of how to make a chocolate alternative product according to the present invention based on oat spent grains. The method of making this chocolate alternative product is the same method as disclosed in example 1.

[0142] The chocolate alternative product is made based on the amounts of ingredients (percentages are by weight) given in table 3. The chocolate alternative product obtained have a light cream colour similar to white chocolate. The chocolate alternative product based on oat spent grain is disclosed in figures 2 and 3.

[0143] Table 3: Percentages are per weight The chocolate alternative product has after cooling a great snap and melts well in the mouth. It has a taste resembling caramelised white chocolate. Example 3: Varying the amounts of fat and spent grains

[0144] An example was made to show that the chocolate alternative product could be made with different amounts of fat and spent grains.

[0145] Six samples was made that had different ratio between fat (illipe fat) and BSG. All other ingredients was the same. Hence, all samples was made with 3% blackened, dried, milled BSG, 12% cacao husk, 21% sugar, 3% oat spent grain, dried and milled, 0.04% vanilla powder and 0.06% sunflower lecithin.

[0146] The BSG had a moisture content of 5-10% by weight, and the chocolate alternative product was prepared as disclosed in example 1. The ratio between fat and BSG was as shown in table 4 below. Further, table 4 shows the properties of the different samples made.

[0147] Table 4:

[0148] In conclusion, the amount of BSG should be in the range of 10% to 40% by weight. Furthermore, the amount of fat should be in the range of 20% to 60% by weight.

[0149] Example 4: Using different particle size of BSG

[0150] An example was made to analyse the effect of using dried, milled spent grains having different particle size. BSG having a moisture content of 5-10% by weight was used as the spent grains. The ingredients used are the same for all samples, but the particle size of the dried and milled BSG was varying.

[0151] The chocolate alternative product was made with 40% illipe fat, 20% BSG, 3% blackened BSG, 12% cacao husk, 21% sugar, 3% oat spent grain, 0.04% vanilla powder, 0.06% sunflower lecithin.

[0152] The particle size of the dried, milled BSG that was combined with other ingredients before conching was: 60 micron, 100 micron, 500 micron, 1000 micron, 1500-2000 micron. A particle size of 1500-2000 micron corresponds to fresh BSG that has not been milled.

[0153] The chocolate alternative products were prepared by mixing of ingredients, conching, tempering and cooling as disclosed in example 1. After the conching step, the particle size of the samples is further reduced.

[0154] The result is shown in table 5 below. Table 5:

[0155] Hence, in order to obtain a chocolate alternative product that is not gritty and can be processed within a reasonable time period, it is necessary to mill the spent grains before the conching step to a particle size below 1000 micron. During the conching step, the particle size of the spent grains will be further reduced to be below 20 micron.

[0156] Example 5: Different particle size of the obtained chocolate alternative product

[0157] An example was made to test the different particle sizes in the obtained chocolate alternative product obtained after the conching step.

[0158] Four samples were made of chocolate alternative product having a particle size in the obtained chocolate alternative product of: 20 micron, 50 micron, 75 micron and 100 micron.

[0159] The chocolate alternative product was made with 40% illipe fat, 20% BSG, 3% blackened BSG, 12% cacao husk, 21% sugar, 3% oat spent grain, 0.04% vanilla powder, 0.06% sunflower lecithin.

[0160] The four chocolate alternative products were evaluated with regard to texture and the result is given in table 6 below:

[0161] Table 6:

[0162] Example 6: Using different amounts of sugar

[0163] An example was made to analyse the effect of using different amounts of sugar.

[0164] All samples included 18% dried milled BSG (moisture content was 5-10% by weight) (15.5% in sample f), 4% blackened BSG, 4% oat spent grains (samples e and f have 1.5%), 0.5% vanilla powder and 0.5% sunflower lecithin. The samples comprised varying amounts of illipe fat, cacao husk and sugar as disclosed in table 7 below.

[0165] Table 7:

[0166] Example 7: Using different amounts of cacao husk

[0167] An example was made to analyse the effect of using different amounts of cacao husk. All samples included 40% illipe fat, 25% sugar, 4% blackened BSG, 0.5% vanilla powder and 0.5% sunflower lecithin. The samples comprised varying amounts of cacao husk and BSG as disclosed in table 8 below.

[0168] The BSG used had a moisture content of 5-10% by weight and the chocolate alternative products were prepared as mentioned in example 1.

[0169] Table 8:

[0170] Example 8: Using different amounts of blackened spent grains

[0171] An example was made to analyse the effect of using different amounts of blackened spent grains.

[0172] All samples included 40% illipe fat, 30% sugar (sample 3, 4 and 5 had 20% sugar), 10% cacao husk, 0.5% vanilla powder and 0.5% sunflower lecithin. The samples comprised varying amounts of blackened brewer's spent grains and BSG (nonblackened) as disclosed in table 9 below. The BSG (blackened and non-blackened) used had a moisture content of about 5-10% by weight and the chocolate alternative products were prepared as mentioned in example 1

[0173] Table 9:

[0174] Example 9: Analysis of moisture content in BSG

[0175] An example was made to analyse the effect of using BSG having different moisture content.

[0176] The ingredients used are the same for all samples, but the moisture content in the BSG provided was variated. The chocolate alternative product was made with 45% illipe fat, 24% sugar, 15% BSG, 3% blackened BSG, 12% cacao husk, 0.5% vanilla powder, 0.5% sunflower lecithin.

[0177] The chocolate alternative products were prepared by mixing of ingredients, conching, tempering and cooling as disclosed in example 1. The moisture content of the BSG is disclosed in table 10 below ' . Table 10:

[0178] Example 10: Analysis of moisture content in oat spent grains

[0179] An example was made to analyse the effect of using oat spent grains having different moisture content.

[0180] The ingredients used are the same for all samples, but the moisture content in the oat spent grains provided was variated. The chocolate alternative product was made as disclosed in example 2 but where the oat spent grain had different moisture content. The moisture content of the oat spent grain is disclosed in table 11 below '. Table 11: Example 11: Varying the amounts of fat and oat spent grains

[0181] An example was made to show that the chocolate alternative product could be made with different amounts of fat and oat spent grains.

[0182] Six samples were made that had different ratio between fat (illipe fat) and oat spent grains. All other ingredients were the same. Hence, all samples were made with 24% sugar, 15% milk powder, 0.5% vanilla powder and 0.5% sunflower lecithin. The oat spent grains had a moisture content of about 5-10% by weight and the chocolate alternative product was prepared as disclosed in example 2.

[0183] The ratio between fat and oat spent grain was as shown in table 12 below. Further, table 12 shows the properties of the different samples made.

[0184] Table 12:

Claims

Claims1. A chocolate alternative product comprising: i) dried and milled spent grains in an amount of 10% to 40% by weight, wherein the dried and milled spent grains are selected from the group consisting of brewer's spent grain and oat spent grain, and wherein the dried and milled spent grains have a moisture content of 12% by weight or less, ii) edible fat in an amount of 20% to 60% by weight, iii) sugar in an amount of 0% to 35% by weight and wherein the chocolate alternative product has a particle size of 40 micron or less.

2. The chocolate alternative product according to claim 1, wherein the ratio between the dried and milled spent grains and the edible fat is in the ratio of 1: 5 to 2:

13. The chocolate alternative product according to any of the claims 1 or 2, wherein the dried and milled brewer's spent grain comprises protein in an amount in the range of 15-25% by weight of dry matter.

4. The chocolate alternative product according to any of the claims 1 to 3, wherein the chocolate alternative product comprises cacao husk in an amount in the range of to 2% to 35% by weight.

5. The chocolate alternative product according to any of the claims 1 or 4, wherein the edible fat is at least one selected from the group consisting of illipe fat, shea butter, palm oil, palm kernel oil, kokum butter, mango butter, soybean oil, rapeseed oil, sunflower oil, coconut oil, coconut butter, mango kernel fat, olive oil, and fractionated and / or hydrogenated fat or oil thereof.

6. The chocolate alternative product according to any of the claims 1 to 5, wherein the chocolate alternative product comprises blackened, dried and milled spent grains in an amount of 0.5 to 15% by weight.

7. The chocolate alternative product according to any of the claims 1 to 6, wherein the chocolate alternative product furthermore comprises one or more flavouring agents.

8. The chocolate alternative product according to any of the claims 1 to 7, wherein the chocolate alternative product furthermore comprises one or more emulsifier.

9. The chocolate alternative product according to any of the claims 1 to 8, wherein the chocolate alternative product does not comprise cocoa butter and / or cocoa mass.

10. A method of preparing a chocolate alternative product comprising the following steps: a) providing dried spent grains selected from the group consisting of brewers spent grain and oat spent grain, and wherein the dried spent grains have a moisture content of 12% by weight or less; b) milling the dried spent grains to a particle size in the range of 60 to 500 micron; c) melting an edible fat by heating the edible fat to a temperature above the melting point of the edible fat used; d) mixing the dried, and milled spent grains of step b), the melted edible fat of step c), optionally sugar and other ingredients, and conching the mixture to provide a homogenous mass, wherein the homogeneous mass comprises dried and milled spent grains in an amount of 10% to 40% by weight, edible fat in an amount of 20% to 60% by weight and sugar in an amount of 0% to 35% by weight and wherein the particle size of the homogenous mass is 40 micron or less; e) the homogenous mass of step d) is either used directly as a liquid chocolate alternative product or processed into a solid chocolate alternative product.

11. The method according to claim 10, wherein the ratio between the dried and milled spent grains and the melted edible fat is in the ratio of 1: 5 to 2: 1.

12. The method according to any of the claims 10 to 11, wherein the method in step d) further comprises addition of blackened, dried and milled spent grains in an amount of 0.5 to 15% by weight of the mixture.

13. The method according to any of the claims 10 to 12, wherein the method in step d) further comprises addition of cacao husk in an amount of 2% to 35% by weight of the mixture.

14. The method according to any of the claims 10 to 13, wherein the processing into a solid chocolate alternative product comprises one of the following steps: a) tempering and cooling b) directly cooling.

15. Use of the chocolate alternative product according to any of the claims 1 to 9 in a confectionary bar, a confectionary filling, a coating, a syrup, a cake, a cookie, a biscuit, a dessert mousse, a ganache, a doughnut, a bread or other baked item, a ice cream, a chocolate beverage, other liquid forms or in combination with chocolate products.

Images